Manual Códigos Cabina

SERVICE MANUAL
DIAGNOSTIC/TROUBLESHOOTING MANUAL
ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — DuraStar®,

TerraStar®, TranStar®, and WorkStar® Models Built May 2010 and Later
Model: DuraStar®
Model: TerraStar®
Model: TranStar®
Model: WorkStar®
S08361
2012
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© 2012 Navistar, Inc. All rights reserved
All other trademarks are the property of their respective owners.
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 MANUAL INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 ELECTRONIC GAUGE CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 SWITCH PACKS (J1708 DATA LINK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4 LIGHTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5 CAB FEATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6 CHASSIS FEATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
7 TRANSMISSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
8 MULTIPLEXING (DATA LINKS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
9 12-VOLT POWER DISTRIBUTION AND GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
10 FANS AND ENGINE ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
11 BATTERY, CHARGING, AND CRANKING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
12 VEHICLE AND DRIVER INFORMATION DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
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TABLE OF CONTENTS
ii S08361
SAFETY INFORMATION
SAFETY INFORMATION
The information contained in this International® Electrical System Troubleshooting Guide 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.
Navistar, Inc 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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SAFETY INFORMATION
2 S08361
TABLE OF CONTENTS
MANUAL INTRODUCTION
Table of Contents
1. MANUAL INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. VEHICLE ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. ELECTRICAL CIRCUIT DIAGRAM BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1. CIRCUIT DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Circuit Diagram Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2. CONNECTOR BODY COMPOSITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1. VERIFY THE PROBLEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2. IMPORTANT STEPS BEFORE PERFORMING CIRCUIT TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3. REVIEW FEATURE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4. CHECK THE CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5. PERFORMING CIRCUIT AND SYSTEM TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.6. PERFORM THE REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7. VERIFY THE REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. ELECTRICAL TEST EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.1. EZ-TECH® ELECTRONIC SERVICE TOOL (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2. BODY CONTROLLER BREAKOUT BOX (ZTSE4477). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3. FLUKE 88 DIGITAL MULTIMETER (DMM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4. MIDTRONICS EXP-1000HD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5. JUMPER WIRES, TEST LEADS, AND TEST LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Jumper Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Test Leads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.6. OHM'S LAW REVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.7. VOLTMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Measuring Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.8. AMMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Measuring Amperage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.9. OHMMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Measuring Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Checking For Open Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Checking For Short Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6. BENCH TESTING RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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TABLE OF CONTENTS
4 S08361
MANUAL INTRODUCTION
1. MANUAL INTRODUCTION
This manual covers the vehicle's body electrical system.
Detailed information on engines, transmissions, and Anti-Lock Brake Systems (ABS) can be found in vendor
and International Truck manuals. These systems are addressed in this manual as they apply to the vehicle's
Body Controller (BC) and are not addressed in other manuals.
This manual is intended to be used in conjunction with the Circuit Diagram manual hat applies to the specific
vehicle requiring repair. There are variations between specific models and periods of manufacture that may
only be addressed in the applicable Circuit Diagram manual.
The applicable Circuit Diagram manual has information that can be helpful in diagnosing the problem.
Beyond circuit diagrams, the book provides information on connector composites, connector location, circuit
identification, schematic symbol chart, relay function and wiring guide, and a lamp bulb chart.
The strategy used in this manual focuses on starting with general diagnostics and progressing toward more
specific information to guide a technician to the cause of an electrical failure. The manual is grouped into major
areas. These major areas are divided into sections covering each feature. Each feature section is further
divided into the following areas:
• System Description includes a general feature overview and operation. The feature operation section
provides in more detail, how circuits are used to operate the feature and how the feature interacts with
the vehicle's BC.
• Feature Codes contain information and definition related to a specific feature and how the BC is
programmed to control the inputs and outputs.
• User Programmable Parameters provide the parameters in which a feature operates and the adjustable
values that can be programmed for a specific feature.
• Diagnostic Trouble Codes provide detailed information that can assist in locating a fault in a feature's
electrical circuits. The Diagnostic Trouble Code (DTC) list contains a DTC's SPN number, the BC's
description of the fault, connector and pin if available, the BC's message, probable causes, and a logical
signal. The DTC section will refer the technician to a more specific circuit or system test to pinpoint the fault.
• Troubleshooting provides a preliminary check that will pinpoint the fault to a specific circuit or system if no
DTCs are present. The preliminary check can also assist in locating faulty circuits that are shared with
other features. The Troubleshooting section contains feature-specific tests in which circuit measurements
are performed to locate open circuits, short circuits, sources of high resistance, and other common
electrical faults. The Troubleshooting section will also provide detailed diagnostic steps to test the BC input
and output processing using the Diamond Logic® Builder (DLB) to view signals as well as actuate outputs.
• Some features require brief descriptions of Programming or Body Controller Signals that may help
in the diagnostic procedure.
Operator observation and warning lights may be used to determine when there is a problem with the vehicle
electrical system.
Technicians must still rely on observation of failed components or malfunctioning features. Once the
technician has identified a failure, he may go to the Table of Contents and refer to the applicable section
for troubleshooting information.
Another way a feature failure may become evident is through the vehicle's on-board diagnostics.
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VEHICLE ELECTRICAL SYSTEM OVERVIEW CIRCUIT DIAGRAMS
A warning lamp will illuminate when a detectable fault has occurred. The lamp may illuminate either
continuously or for 5 seconds depending on the fault. When a fault occurs and the BC is able to communicate
with the Electronic Gauge Cluster (EGC), the lamp will illuminate for 5 seconds. Each time the ignition is cycled
and the EGC completes a gauge sweep, the lamp will illuminate for 5 seconds if an active fault is present. If
the light remains on consistently, there is a communication problem between the BC and EGC. The technician
may retrieve the DTCs through the EGC odometer display. The technician may then look up the DTC to
locate the applicable troubleshooting information.
BC diagnostics are not capable of identifying all possible system faults. This is why problem identification
through observation and preliminary checks is still important.
DTC retrieval procedures for engines, transmissions, and ABS vary from the procedure for retrieving DTC
produced by the BC.
An Electronic Service Tool (EST) such as the EZ-Tech along with the Diamond Logic® Builder (DLB) software
can be used to list vehicle DTCs, monitor inputs to the BC, and actuate outputs controlled by the BC.
This manual will require using the DLB as well as basic electrical troubleshooting procedures. The EZ-Tech and
appropriate software can also be used to troubleshoot the engine, transmission, and ABS electrical systems.
2. VEHICLE ELECTRICAL SYSTEM OVERVIEW

The body electrical system provides a means to distribute electrical power, monitor vehicle performance, and
control multiple body features. Unlike previous electrical system designs, this approach uses multiplexed
wiring technologies for interfacing major functional areas of the vehicle. Furthermore, the system relies on
software algorithms to accomplish logic functions instead of implementing similar features using complex
wire harness designs with relays and switches. Multiplexing greatly reduces the amount of wiring used on
a vehicle, as multiplexing can communicate large amounts of information using a pair of insulated wires.
Multiplexing allows the vehicle's electronic controllers to communicate on a data link that is shared on the
vehicle's Controller Area Network (CAN).
A benefit of this system is increased diagnostic capability in terms on-line, off-line, and off-board testing.
On-line or on-board diagnostics are performed on the vehicle while it is in operation. If a detectable fault
occurs, the CHECK ELECTRICAL SYSTEM lamp will illuminate for 5 seconds. If a communication failure
between the BC and EGC occurs, the lamp will stay illuminated until communications are restored.
Off-line diagnostics are enabled when the system is put in diagnostic mode. While the system is in the
diagnostic mode, diagnostic trouble codes will be displayed on the vehicle's LCD display or if equipped, a
Driver Information Display (DID) and Vehicle Information Display (VID).
Off-board diagnostics require the use of an EST, such as the EZ-Tech and the DLB diagnostic software. The
EST is connected to the vehicle diagnostic connector. The DLB software will allow the technician to view
DTCs, monitor input signals to the BC, and actuate output signals controlled by the BC.
3. ELECTRICAL CIRCUIT DIAGRAM BOOK

Electrical circuit diagrams can be found in GROUP 08-ELECTRICAL of the Master Service Manual.
3.1. CIRCUIT DIAGRAMS

Circuit Diagrams provide an overview of a feature circuits, power, ground, fuses, and components.
6 S08361
CIRCUIT DIAGRAMS ELECTRICAL CIRCUIT DIAGRAM BOOK
Figure 1 Sample Circuit Diagram
In most cases, a circuit diagram will provide specific information regarding fuse ratings, wire gauges, connector
location, and circuit identifications. The circuit components are named, using capital letters (See Sample
Circuit Diagram) (See Figure 1, page 7), and abbreviations may be used (See Sample Circuit Diagram
Instructions and Abbreviations) (See Figure 3, page 9). Circuit diagrams are a direct representation of the
system circuits, and it is important to note when a cavity or pin is used, a relay is normally open or closed,
ground studs or adapters are used, and if power and ground circuits are shared from one feature to another.
NOTE – Switch, relay, and solenoid positions, as shown on circuit diagrams, indicate NORMAL position
with the key switch in the OFF position, unless otherwise noted.
On more complex features, it will be necessary to refer to other circuit diagrams to view a feature's power
supply and how it operates with other features. For example, many features are provided voltage through an
ignition or accessory relay, and referencing the 12–VOLT POWER DISTRIBUTION AND GROUNDS circuit
diagrams will be necessary to diagnose circuits powering the relays.
Circuit Diagram Instructions
Examples of the circuit diagram instructions, abbreviations, and symbols are included in the Sample Circuit
Diagram Instructions (See Figure 2, page 8), Sample Circuit Diagram Instructions and Abbreviations (See
Figure 3, page 9), and Sample Schematic Symbol Chart (See Figure 4, page 10).
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ELECTRICAL CIRCUIT DIAGRAM BOOK CIRCUIT DIAGRAMS
Figure 2 Sample Circuit Diagram Instructions
8 S08361
CIRCUIT DIAGRAMS ELECTRICAL CIRCUIT DIAGRAM BOOK
Figure 3 Sample Circuit Diagram Instructions and Abbreviations
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ELECTRICAL CIRCUIT DIAGRAM BOOK CONNECTOR BODY COMPOSITE
Figure 4 Sample Schematic Symbol Chart
3.2. CONNECTOR BODY COMPOSITE

The CONNECTOR COMPOSITE section is located in the back of the Group 08 - Electrical Circuit Diagrams .
The composites show the pin configuration of the connector and which circuits are attached to the pins as
shown in the Sample Pin Configuration (See Figure 5, page 11).
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VERIFY THE PROBLEM TROUBLESHOOTING
Figure 5 Sample Pin Configuration
4. TROUBLESHOOTING
Before intrusive circuit tests are performed, there are several important steps to be taken:
4.1. VERIFY THE PROBLEM

Operate the system and list all symptoms in order to:
1. Check the accuracy and completeness of the concern.
2. Learn more that might give a clue to the nature and location of the problem.
3. Analyze what parts of the system are inoperative and how it is affecting other features.
NOTE – It may be necessary to perform a vehicle road test to completely test the functionality and
rationality of a feature or system.
4.2. IMPORTANT STEPS BEFORE PERFORMING CIRCUIT TESTS

1. GATHER INFORMATION
Discuss the concern with the vehicle operator if possible. Try to determine the exact symptoms by
gathering relevant information:
A. What happened and when?

B. Under what conditions?
C. When did the symptoms begin?
D. What else occurred at that time?
2. VERIFY THE CUSTOMER'S CONCERN
Operate the faulty system and verify the customer's concern. It may be necessary to road test a vehicle
to duplicate conditions.
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TROUBLESHOOTING REVIEW FEATURE OPERATION
3. CHECK FOR ACTIVE OR STORED DIAGNOSTIC TROUBLE CODES
Ensure DTCs relate to the customer's concern and are not erroneous or DTCs not set by the faulty system.
It is important to record any erroneous or residual DTCs as they might be helpful in the diagnostic process.
4. Were the DTCs set about the same time as the symptoms appeared?
5. Do the DTCs relate to other symptoms?
6. Eliminate the possibility that a physical or mechanical fault has occurred, such as contaminated fuel,
clogged air filters, damaged air lines, or a mechanical brake failure.
7. PERFORM THE FOLLOWING PRELIMINARY STEPS:
A. Before beginning these test procedures, make sure the vehicle batteries are at 75% state of
charge (SOC) or higher. This represents an open circuit voltage (OCV) of 12.4 volts. Batteries
with an OCV of 12 volts or less are either completely discharged or have a dead cell.
B. Before beginning these test procedures, check any light or indicator lamp filaments that are
suspected of being open (burned out). This is done to avoid unnecessary extensive circuit
checks. A blown bulb will lower circuit resistance and increase the amperage in a circuit,
causing other features to malfunction.
C. Before beginning these test procedures, visually inspect connectors for loose, damaged, or
corroded terminals. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in
GROUP 08 ELECTRICAL in the Master Service Manual.
D. When a blown fuse is located, it will be necessary to continue the troubleshooting process to
pinpoint the fault resulting in a blown fuse.
E. Switches sticking in the ON or OFF position are generally not covered in detail. It is assumed
that the technician knows to check for a malfunctioning switch, relay, or solenoid.
NOTE – Measuring continuity between two terminals of a switch while operating the switch will determine
its functionality.
4.3. REVIEW FEATURE OPERATION

Always review the feature's operation section and circuit diagram prior to troubleshooting. Enough information
about the feature operation must be learned to narrow the cause of the problem to one component or portion of
the circuit. It is also important to become familiar with the feature operation due to complexity of a multiplexed
system. A multiplexed system can recognize functionality and rationality faults which result in residual DTCs.
A functionality fault occurs when a specific component is inoperative. This is most commonly caused by an
open circuit or a damaged sensor. A rationality fault occurs when the information gathered by a specific
component is shared on the vehicle's data link and, when interpreted by the BC or other control module, a fault
is recognized. Rationality faults can occur when a short to voltage, short to ground, or an operational but faulty
sensor exists. It will require further diagnostics to determine if a rationality fault has occurred as a result of a
faulty sensor or if the system that a sensor or component is monitoring is not within specifications.
4.4. CHECK THE CIRCUIT DIAGRAM

Refer to the circuit diagram for possible clues to the problem. Location and identification of circuit components
may give some idea of where the problem is located.
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PERFORMING CIRCUIT AND SYSTEM TESTS ELECTRICAL TEST EQUIPMENT
The circuit diagrams are designed to make it easy to identify common points in circuits. This can help narrow
the problem to a specific area. For example, if several circuits fail at the same time, check for a common power
source or common ground connection. Refer to the 12–VOLT POWER DISTRIBUTION AND GROUNDS
section for further diagnostic information when multiple features are inoperative.
4.5. PERFORMING CIRCUIT AND SYSTEM TESTS

Circuit tests and system tests are provided for many common faults that occur. Refer to these tests in each
section. Follow the procedures in the test until the cause of the problem is located.
If a fault is discovered, perform the appropriate repairs and retest the system. Multiple faults may occur, and
performing a circuit test again will be necessary.
If the particular symptom found in the problem circuit is not covered in the diagnostics, refer to the general
electrical troubleshooting information provided under ELECTRICAL TEST EQUIPMENT.
4.6. PERFORM THE REPAIR

Repair the problem circuit or replace the faulty component as directed in the diagnostic steps. When
performing component replacement, it will be necessary to refer to appropriate service manuals for remove
and install procedures.
4.7. VERIFY THE REPAIR

Clear all active and stored DTCs. Operate the system or feature to its full capacity; a vehicle road test may be
required to duplicate conditions that had set the fault. If the system is operating correctly, check for new DTCs
that might have set during the repair or road test.
5. ELECTRICAL TEST EQUIPMENT

5.1. EZ-TECH® ELECTRONIC SERVICE TOOL (EST)
The EZ-Tech® EST is a ruggedized laptop computer capable of running various software programs to perform
vehicle diagnostics.
The EZ-Tech® is connected to the vehicle diagnostic connector through an interface connector.
Once connected, the software on the EZ-Tech® can be used to monitor certain vehicle parameters, list active
and inactive DTCs, and in some cases override inputs and outputs of electrical controllers.
The Diamond Logic® Builder (DLB) software can be used to diagnose the Body Controller (BC). Refer to the
Diamond Logic® Builder Software User's Manual for detailed instructions.
When performing advanced programming, using Ladder Logic, or creating and editing Logic Blocks refer to the
Diamond Logic® Builder Software User's Manual Volume II – Advanced Programming.
Other software programs are available for other electrical systems on the vehicle.
5.2. BODY CONTROLLER BREAKOUT BOX (ZTSE4477)

The Breakout Box allows the technician to perform wire intrusive circuit tests and input and output checks
at the BC's connectors. This will prevent damaging connector cavities with test probes (See BC Breakout
Box) (See Figure 6, page 14).
S08361 13
ELECTRICAL TEST EQUIPMENT FLUKE 88 DIGITAL MULTIMETER (DMM)
NOTE – Always inspect BC connectors for loose, damaged, or corroded connections each time it is
disconnected.
Figure 6 BC Breakout Box
The breakout box can be connected to the BC connectors in the engine compartment or the connectors
in the cab.
The breakout box can be used to provide pinouts to a single connector (out of circuit), to test individual wires
for shorts or opens, to test output signals from the BC, or to test input circuits to the BC.
The breakout box can also be connected in circuit to allow technicians to monitor signals with the BC in
operation.
5.3. FLUKE 88 DIGITAL MULTIMETER (DMM)

CAUTION
When probing connectors, always take care not to force probe tips into cavities. Use
the appropriate tip adapters to prevent damage to the connector. Expanded cavities will
cause increased circuit resistance.
14 S08361
MIDTRONICS EXP-1000HD ELECTRICAL TEST EQUIPMENT
The Fluke 88 Digital Multimeter (DMM) is the meter recommended by International Truck, and discussions of
meter use in this manual will refer to this meter Digital and Analog Meters (See Figure 7, page 15).
The Fluke 88 Multimeter is a digital meter and is recommended because it uses very little current when
performing tests. Digital meters have high impedance (resistance), 10 Mega ohms. Thus they do not damage
components or give misleading readings.
1. DIGITAL MULTIMETER 2. ANALOG VOLTMETER

Figure 7 Digital and Analog Meters
5.4. MIDTRONICS EXP-1000HD

The vehicle battery, charging, and starting systems will require the use of the Midtronics EXP-1000HD
diagnostic equipment.
Refer to the Midtronics EXP-1000HD Expandable Electrical Diagnostic Platform Instruction Manual for specific
instructions and diagnostic steps.
S08361 15
ELECTRICAL TEST EQUIPMENT JUMPER WIRES, TEST LEADS, AND TEST LIGHTS
Figure 8 Midtronics EXP-1000HD Diagnostic Equipment
5.5. JUMPER WIRES, TEST LEADS, AND TEST LIGHTS

Jumper Wires
CAUTION
When using jumpers and test leads, always take care not to force probe tips into cavities.
Use the appropriate tip adapters to prevent damage to connectors. Expanded cavities
will cause increased circuit resistance.
Jumper wires allow a technician to bypass or jump across a suspected open or break in a circuit.
1. If the circuit works properly with the jumper wire in place, but does not work when the jumper wire is
removed, the circuit has an open spot (See Figure 9, page 17).
16 S08361
JUMPER WIRES, TEST LEADS, AND TEST LIGHTS ELECTRICAL TEST EQUIPMENT
Figure 9 Jumpers in Circuits
2. A circuit without any opens or breaks has continuity (is continuous), and a DMM can be used to measure
the continuity (resistance of a few ohms) of the circuit with the battery removed.
Jumper wires are fitted with several types of tips or ends. It will be helpful to have several jumper wires
available with different tips.
If bypassing the switch with a jumper wire causes the light to illuminate, but closing the switch does not, it
indicates the switch has failed.
If, when the switch is closed, the light does not illuminate, and bypassing the switch does not cause the light to
operate, but bypassing the light to ground causes the light to operate, then there is an open in the ground circuit.
The jumper wire can be used to check for such things as open relay contacts, wire breaks, and poor ground
connections.
Test Leads
CAUTION
When using jumpers and test leads, always take care not to force probe tips into cavities.
Use the appropriate tip adapters to prevent damage to connectors. Expanded cavities
will cause increased circuit resistance.
Construct test leads using a mating terminal, a short lead and an alligator clip. Insert the mating terminal into
the connector and attach the alligator clip to the meter lead.
S08361 17
ELECTRICAL TEST EQUIPMENT OHM'S LAW REVIEW
Test Lights
Test lights can be used when quick voltage or ground checks are necessary. Many features operate on
switched 12 ± 1.5V (Volts, direct current), and using a test light as a load device may be helpful. The test light
may also be used to verify continuity to ground. Discretion should be used when using a test light, as the
light may illuminate even though there may be an excessive amount of resistance on the ground circuit or
less than 12V is present.
5.6. OHM'S LAW REVIEW

Ohm's Law describes the relationship of voltage, current, and resistance, and provides a formula to make
calculations.
Table 1 Ohm's Law
OHM'S LAW
Ohm's Law states that the current through a conductor between two points is directly
proportional to the potential difference or voltage across two points, and inversely
proportional to the resistance between them.
The mathematical equation that describes this relationship is:
I = V / R
I = Current (Amperes)
E = Electromotive Force (Volts)
R = Resistance (Ohms)
I=E/R This formula states that current flow (I) = voltage (E) applied
to a circuit divided by total resistance (R) in the circuit. This
shows that an increase in voltage or a decrease in resistance
increases current flow.
R=E/I This formula states that resistance (R) = voltage (E) applied to
a circuit divided by current flow (I) in the circuit. This allows us
to calculate resistance needed for a specific current flow with a
specific voltage applied.
18 S08361
OHM'S LAW REVIEW ELECTRICAL TEST EQUIPMENT
Table 1 Ohm's Law (cont.)

OHM'S LAW
E = IR (I multiplied by R) This formula provides the voltage drop across a particular load
device (resistance) that is part of a series of load devices.
Memorize the formula in the circle. You only have to cover the
letter that you wish to calculate, with your finger, and you have
the formula. For example: If you cover the letter I, the formula is
I = E / R.
If any two of the values are known for a given circuit, the missing one can be found by substituting the values
in amperes, volts, or ohms and solving for the missing value.
In a typical circuit, battery voltage is applied to a bulb through a 10 amp fuse and a switch. Closing the
switch turns on the bulb (See Figure 10, page 19).
Figure 10 Typical Circuit
To find the current flow, use the Ohm's Law formula (See Table 1, page 18):
I=E/R
Filling in the numbers for the circuit in the Typical Circuit figure (See Figure 10, page 19), we have:
I = 12V / 2 ohms or I = 12 divided by 2 = 6 amperes of current flow.
The bulb in this circuit operates at 6 amps and is rated to operate at this level. With 12 volts applied, the bulb
will glow at the rated output level (candlepower rating). However:
1. If the voltage applied is low (low battery), then (the value of E is lower). Current flow will be less, and
the bulb will glow less brightly.
S08361 19
ELECTRICAL TEST EQUIPMENT VOLTMETER
2. Or if the connections are loose, or the switch corroded, the circuit resistance will be greater (value of R will
be larger). The current flow will be reduced, and the bulb will glow less brightly.
Being able to determine voltage drops is important because it provides the following information:
• Too high a voltage drop indicates excessive resistance. If, for instance, a blower motor runs too slowly
or a light glows too dimly, one can be sure that there is excessive resistance in the circuit. By taking
voltage drop readings in various parts of the circuit, the problem can be isolated (corroded or loose
terminals, for example).
• Too low of a voltage drop, likewise, indicates low resistance. If for instance, a blower motor ran too fast,
the problem could be isolated to a low resistance in a resistor pack by taking voltage drop readings.
• Maximum allowable voltage drop under load is critical, especially if there is more than one high resistance
problem in a circuit. It is important because all voltage drops in a circuit are cumulative. Corroded
terminals, loose connections, damaged wires, or other similar conditions create undesirable voltage drops
that decrease the voltage available across the key circuit components.
The increased resistance from the undesirable conditions will also decrease the current flow in the circuit, and
all the affected components will operate at less than peak efficiency.
A small drop across wires (conductors), connectors, and switches is normal. This is because all conductors
have some resistance, but the total should be less than 10% of the total voltage drop in the circuit.
5.7. VOLTMETER
Voltage is an electrical pressure or force that pushes the current through a circuit. The pressure is measured in
Volts and the symbol V (as in 12V) is used in the circuit diagrams. The letter E is also used for voltage and
stands for Electromotive Force.
Low voltage to a lamp will cause the lamp to glow dimly. This can be caused by low source voltage (battery
discharged or low alternator output), or by high circuit resistance in the circuit due to a poor connection.
The resistance of the poor connection or poor ground acts as an additional load in the circuit, causing less
voltage to be available to push current through the load device. Before making any meter measurements, it is
important to briefly review the relationship between voltage, current, and resistance (See Table 1, page 18).
Measuring Voltage
In electrical diagnosis, the voltmeter is used to perform the following:
1. Presence of voltage
2. Measurement or force of voltage
3. Voltage drop or voltage used across a given point
When using a voltmeter to determine if voltage is present to power a device, connect the positive meter
lead to input connection of the device (positive side) and connect the negative meter lead to good vehicle
ground. A good ground would be any metallic bracket, body panel, or fastener that is free of paint, rust, or
corrosion and is connected to the frame, engine, or body. The Voltmeter Lead Connections Diagram shows
how much of the source voltage is available to the device (See Figure 11, page 21). Note that the meter
is connected in parallel to the device.
20 S08361
VOLTMETER ELECTRICAL TEST EQUIPMENT
Figure 11 Voltmeter Lead Connections Diagram
To determine if voltage is available at a connector that is not accessible, connect the meter in series between
ground and the connector (voltage source) as shown in the Connecting the Meter in Series Diagram (See
Figure 12, page 22). The meter's internal resistance is very high, resulting in little to no current flowing through
the internal circuit, and the voltage can be read accurately.
S08361 21
ELECTRICAL TEST EQUIPMENT VOLTMETER
Figure 12 Connecting the Meter in Series Diagram
To measure the voltage drop across a load device, connect the positive lead of the voltmeter to the positive
side of the device and the negative meter lead to the negative side of the device. With the device operating,
measure the voltage drop across the device. Notice in the Checking Voltage Drop Across a Load Device
Diagram (See Figure 13, page 23), with only a single load device, all of the voltage is dropped at the device. In
any circuit, the voltage applied will equal the voltage dropped in the circuit. If in this circuit a 9V voltage drop is
recorded across the load, that would indicate that the wires and connections. were dropping the other 3V,
which would indicate excessive circuit resistance.
22 S08361
AMMETER ELECTRICAL TEST EQUIPMENT
Figure 13 Checking Voltage Drop Across a Load Device Diagram
5.8. AMMETER
An ammeter is used to measure current flow or amperage in a circuit. Amperes are units of electron flow,
which indicate how many electrons are passing through the circuit. Ohm's Law indicates that current flow in
a circuit is equal to the circuit voltage divided by total circuit resistance, known as the potential difference.
Since amps is the current in the circuit, increasing voltage also increases the current level. Also, any decrease
in resistance will increase current flow.
At normal operating voltage, most circuits have a characteristic amount of current flow, referred to as amperage
draw, which can be measured with an ammeter. Referring to a specified amperage draw rating for a electrical
device, measuring the current flow in the circuit, and comparing the two (the rated versus the actual measured)
can provide valuable diagnostic information.
Measuring Amperage
An ammeter is ALWAYS connected in series with switches, resistors, and load devices. (Measuring Current
Flow Diagram). This causes all of the current to flow through the meter. The meter will measure current flow
only when the circuit is powered and operating. The DMM is fused to measure up 10 amps using the 10A
connection point. Never measure amperage draw on high amperage circuits as this will result in damage to
the meter.
S08361 23
ELECTRICAL TEST EQUIPMENT AMMETER
CAUTION
To prevent damage to vehicle circuits or the DMM, always measure amperage in series.
1. DMM SET TO MEASURE DC 4. METER LEAD CONNECTED TO

CURRENT 10A METER JACK
2. FUSE SHOWN REMOVED
3. LIGHT BULB (2 OHMS
RESISTANCE)
Figure 14 Measuring Current Flow Diagram
The estimate of current flow can easily be calculated. In the Measuring Current Flow Diagram (See Figure 14,
page 24), the resistance of the light bulb is 2 ohms. Applying Ohm's Law, the current flow is 6 amps (6A = 12V
/ 2 ohms). If the fuse is removed, and an ammeter installed as shown, with the switch closed, a measurement
of 6 amperes of current flows in the circuit. Notice that the ammeter is installed so that all the current in the
circuit flows through it. The ammeter is installed in series.
24 S08361
OHMMETER ELECTRICAL TEST EQUIPMENT
CAUTION
To prevent damage to vehicle circuits or the DMM, never attempt a voltage measurement
with the test lead in the amperage terminal (10A or 300mA).
Excessive current draw means that more current is flowing in a circuit than the fuse and circuit were designed
for. Excessive current will damage fuses and circuit breakers. Excessive current draw can also quickly
discharge batteries. An ammeter is useful to help diagnose these conditions.
A reduced current draw will cause a device (electric window motor, for example) to operate poorly. Remember
that increased circuit resistance causes lower current to be available to the device. Loose, damaged, or
corroded connections can frequently cause this problem.
5.9. OHMMETER
The ohmmeter is used to measure resistance (ohms) in a circuit. Like the ammeter and voltmeter, there are
both analog and digital meters available. It is recommended that the digital meter (Fluke 88 DMM) be used.
CAUTION
To prevent damage to vehicle circuits or the DMM, the ohmmeter can only be used on
circuits that have been isolated, and power has been removed. The meter contains its
own low voltage power supply, and the power from 12–volt systems may damage the
meter.
Ohmmeters use a small battery to supply the voltage and current that flow through the circuit being tested.
The voltage of the meter battery and the amount of current flow in the circuit are used with Ohm's Law, and
the meter calculates the circuit resistance which is displayed by the meter. With the Fluke 88 DMM, range
selection and meter adjustment are not necessary.
Measuring Resistance
Resistance measurements determine:
1. Resistance of a load
2. Resistance of conductors
3. Value of resistors
4. Operation of variable resistors
To measure the resistance of a component or a circuit, power must first be removed from the circuit.
NOTE – To prevent an inaccurate resistance measurement, avoid contact with the metal part of the test
lead as the human body presents resistance to current and can provide a false reading.
The component or circuit that is to be measured must be isolated from all other components or circuits so that
meter current (from probe to probe) only flows through the desired circuit or component, or the reading will
not be accurate.
Notice in the Measuring Resistance Diagram (See Figure 15, page 26), that to measure the resistance of
the load, most of the current flow from the meter would flow through the indicator lamp because it has less
resistance. To measure the load, one connector to the load should be removed. It is not always apparent
S08361 25
ELECTRICAL TEST EQUIPMENT OHMMETER
when a component must be isolated in such a manner, so it is usually a good practice to isolate the circuit or
component by physically disconnecting one circuit.
Figure 15 Measuring Resistance Diagram
The ohmmeter leads are then placed across the component or circuit and the resistance will be displayed
in ohms (See Figure 16, page 27). When checking a sensor or variable resistor such as fuel level gauge,
heating the element or moving the arm should move the meter through a range of resistance that can be
compared to a specification.
26 S08361
OHMMETER ELECTRICAL TEST EQUIPMENT
Figure 16 Placing Ohmmeter Leads Across a Component or Circuit Diagram
Checking For Open Circuits
Electrical circuits can be checked for opens using an ohmmeter. The circuit must first be disconnected from
the power supply. The circuit to be checked must also be isolated from other circuits. Connect the meter to the
open ends of the circuit as shown in the Checking For Open Circuits diagram (See Figure 17, page 28). A high
reading (infinity) indicates there is an open in the circuit. A near zero reading is an indication of a continuous
circuit. Disconnecting the circuit between the light and the ground prevents reading a circuit as complete that
may be open at the load (light) and shorted to ground ahead of the load device.
S08361 27
ELECTRICAL TEST EQUIPMENT OHMMETER
A. DISCONNECTED CONNECTOR
Figure 17 Checking For Open Circuits
Checking For Short Circuits
Measurements for short circuits are made in a similar manner to that used to check for open circuits, except
that the circuit to be checked must be isolated from both the power source and the ground point.
Connecting the ohmmeter, as shown in the Checking For Short Circuits diagram (See Figure 18, page 29),
between an isolated circuit and a good ground point will allow checking the circuit for a short to ground. A
short to ground will be indicated by a near zero reading, while a circuit not shorted to ground will cause the
meter to read very high (near infinity). With the Fluke 88 DMM, an open circuit will read out of limits (OL) on
the meter display.
28 S08361
OHMMETER BENCH TESTING RELAYS
Figure 18 Checking For Short Circuits
6. BENCH TESTING RELAYS

International® circuits use suppressed relays for controlling power to load devices. The suppression feature (a
resistor circuit parallel to the relay coil) prevents voltage spikes from damaging electronic components such as
control modules.These relays must be replaced with approved International® parts. The part number and
relay circuit diagram are embossed on the relay body. The terminals are numbered on the relay in the same
manner as in the circuit diagrams Relay Schematic (See Figure 19, page 30).
S08361 29
BENCH TESTING RELAYS OHMMETER
Figure 19 Relay Schematic
30 S08361
OHMMETER BENCH TESTING RELAYS
Table 2 Relay Bench Test
STEP TEST POINT SPEC. IN SPEC. NOT IN SPEC.

1. Remove relay. <1 ohm Go to next step. Replace relay.
Measure resistance
between terminals 30
and 87A.
2. Measure resistance No continuity. Go to next step. Replace relay.
and 87.
3. Use a 12-volt battery Relay coil Go to next step. Replace relay.
source and test leads energizes and
in the follow test: switch operates.
Connect (+) test lead to

terminal 85 and (-) test
lead to terminal 86.
4. Relay energized. <1 ohm Go to next step. Replace relay.
Measure resistance
and 87.
5. Relay energized. No continuity. No relay fault present. Replace relay.
Measure resistance
and 87A.
S08361 31
BENCH TESTING RELAYS OHMMETER
32 S08361
TABLE OF CONTENTS
ELECTRONIC GAUGE CLUSTER

Table of Contents
1. ELECTRONIC GAUGE CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1. SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3. USER PROGRAMMABLE PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.4. DIAGNOSTIC TROUBLE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.5. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electronic Gauge Cluster Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
EGC Backlight Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
EGC Gauge Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Warning Lamp Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel Level Gauge Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Transmission Oil Temperature Circuit Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Front Rear and Rear Rear Axle Temperature Circuit Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Air Pressure Transducer Circuit Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Park Brake Switch Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Air Restriction Gauge Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Engine Coolant Level Monitor Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.6. ELECTRONIC GAUGE CLUSTER PROGRAMMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
S08361 33
TABLE OF CONTENTS
34 S08361
SYSTEM DESCRIPTION ELECTRONIC GAUGE CLUSTER
1. ELECTRONIC GAUGE CLUSTER

1.1. SYSTEM DESCRIPTION
This section contains a general overview and operation of the Electronic Gauge Cluster (EGC).
Overview
The EGC consists of one electronic assembly that provides ten gauge locations, eight serviceable warning
lights, and 25 individual Light Emitting Diode (LED) warning lamp positions.
Other EGC features include:
• Audible alarm
• Digital display with control
• Transmission gear display
• Headlights / park light switch
• Panel dimmer switch
• Two push button switches (variable configurations)
• Two rocker switches (variable configurations)
• Four analog inputs: axle load input 1, axle load input 2, outside temperature, and twilight sensor
• Four digital inputs
The digital display is capable of providing the driver with the following Instrument Panel (IP) Text
Messages:
• Load Shedding
• Washer Fluid Low
• Electrical Fault
• Check Air Conditioning
• Air Filter Restriction
• Exterior Lamp Check Active
• HVAC Temp Setting
• Activate HVAC Front Blower
• HVAC Sleeper Blower Speed
• Air Pressure Diagnostics
• Cruise
• Fuel Filter
Operation
The EGC communicates with the Body Controller (BC), Engine Control Module (ECM), Transmission Control
Module (TCM), and Anti-lock Brake System (ABS).
NOTE – Warning Indicators are part of the gauges and are located within the gauge.
S08361 35
ELECTRONIC GAUGE CLUSTER SYSTEM DESCRIPTION
Table 3 Gauges and Signal Paths
GAUGE DATA LINK COMMUNICATION SENSOR WARNING

LOCATION INDICATOR
Voltmeter The BC provides J1939 data link BC internal Yes
communication to the EGC.
Water Temperature The ECM provides J1939 data link Engine Yes
Engine Oil The ECM provides J1939 data link Engine Yes
Temperature communication to the EGC.
Engine Oil Pressure The ECM provides J1939 data link Engine Yes
Speedometer The ECM provides J1939 data link Transmission No
Tachometer The ECM provides J1939 data link Engine No
Fuel Level The BC provides J1939 data link Fuel tank Yes
Air Pressure 1 The BC provides J1939 data link Inside cab / Yes
communication to the EGC. dash panel
Air Pressure 2 The BC provides J1939 data link Steering Yes
communication to the EGC. column area
Transmission The BC provides J1939 data link Transmission Yes
Temperature communication to the EGC.
Air Application The BC provides J1939 data link Forward No
communication to the EGC. chassis
Rear Axle Temperature The BC provides J1939 data link Axle Yes
Warning Lamps
The EGC displays warning lamps for conditions not displayed by gauges. There are also direct drive warning
lamps that are wired directly to a particular control module output. When the ignition key is turned to the ON
position, the EGC will perform a lamp check by illuminating the individual warning lamps for a few seconds.
During normal operation, the state of the warning lamps will be controlled based on information being sent from
a particular control module to the EGC on the SAE J1939 data link. The EGC is also equipped with 25 Light
Emitting Diode (LED) warning lamps integrated into the cluster, and eight serviceable warning lamp bulbs.
NOTE – The warning lamp trip points are the factory default settings. Some trip points may be changed
by the service tool utilizing the Diamond Logic® Builder (DLB).
36 S08361
Table 4 Warning Lamp and Signal Path
WARNING LAMP DATA LINK COMMUNICATION SENSOR

LOCATION
Range Inhibited The TCM provides J1939 data link communication to TCM internal
the EGC.
Retard Over Heat The TCM provides J1939 data link communication to Transmission
the EGC.
Engine Amber Warning The ECM provides J1939 data link communication to ECM internal
the EGC.
Engine Red Stop The ECM provides J1939 data link communication to ECM internal
the EGC.
Brake Pressure The BC provides J1939 data link communication to Switch
the EGC.
Park Brake The BC provides J1939 data link communication to Switch
the EGC.
Wait to Start The ECM provides J1939 data link communication to ECM internal
the EGC.
Traction Control The ABS provides J1939 data link communication to ABS internal
the EGC.
PTO / Throttle The BC provides J1939 data link communication to BC internal
the EGC.
Fasten Seat Belt The BC provides J1939 data link communication to BC internal
the EGC.
Brake Fluid The BC provides J1939 data link communication to Brake reservoir
the EGC.
Vehicle ABS The ABS provides J1939 data link communication to ABS internal
the EGC.
Trailer ABS The ABS provides J1939 data link communication to ABS internal
the EGC.
Left Turn The BC provides J1939 data link communication to BC internal
the EGC.
Right Turn The BC provides J1939 data link communication to BC internal
the EGC.
High Beam The BC provides J1939 data link communication to BC internal
the EGC.
Check Transmission The TCM provides J1939 data link communication to TCM internal
the EGC.
Fuel Filter The BC provides J1939 data link communication to Fuel filter
the EGC.
Washer Fluid The BC provides J1939 data link communication to Washer bottle
the EGC.
Water In Fuel The BC provides J1939 data link communication to Fuel filter
the EGC.
S08361 37
ELECTRONIC GAUGE CLUSTER SYSTEM DESCRIPTION
Table 4 Warning Lamp and Signal Path (cont.)

WARNING LAMP DATA LINK COMMUNICATION SENSOR
LOCATION
Coolant Level The ECM provides J1939 data link communication to Surge tank
the EGC.
Check Electrical System The BC provides J1939 data link communication to BC internal
the EGC.
Cruise The BC provides J1939 data link communication to BC internal
the EGC.
Cold Ambient Protection The BC provides J1939 data link communication to BC internal
(CAP) the EGC.
Check A/C The BC provides J1939 data link communication to BC internal
the EGC.
The EGC also provides warning lamp capabilities for features that are not communicated over the J1939 data
link. These discrete signals can be hardwired inputs or J1708 data link communication.
• Auto Neutral
• Alternator
• Optimized Idle
• Snow Valve
• Front Axle Differential Lock
• Rear Axle Differential Lock
• Message Wait
• PTO Enable
• Converter Temperature
• Touch Lock Release
• Front Rear Axle Engaged
• Air Bag
Audible Alarm
The EGC generates an audible alarm from a selection of several alarm types whenever a particular gauge
value represents a hazardous condition. The alarm will not sound when the key switch is turned off except
when requested to sound by another electronic module.
Pressing and holding the display control and either the panel dimmer up or panel down switch for 5 seconds
will disable the audible alarm for all warning conditions until the engine speed reaches 325 RPM or the ignition
is cycled. This can be useful during troubleshooting to avoid the alarm constantly being on.
38 S08361
Table 5 Audible Alarms
AUDIBLE ALARM DESCRIPTION GAUGE / COMPONENT

One time, An out-of-range value in • Fuel level
five-short-beeps any of the following gauges
alarm will trigger a one time, • Voltmeter
five-short-beeps, audible
alarm and visual indicator • Engine Oil Pressure
light in the corresponding
gauge. The alarm shall • Engine Coolant Temperature
sound only once per gauge
during each ignition cycle. • Transmission Oil Temperature
• Engine Oil Temperature
• Rear Axle Oil Temperature
• Front Axle Oil Temperature
• Boost Pressure
• Auxiliary Air Pressure

Repetitive, An out-of-range value in • Primary Air Pressure
one-short-beep any of the following gauges
alarm will trigger a repetitive, • Secondary Air Pressure
one-short-beep, audible
alarm and visual indicator • BC, Loss of Data Communication
light in the corresponding
gauge. The alarm shall stop • Sensor fault
as soon as normal conditions
are reestablished. • Red Stop Lamp Illumination Request
• ABS Request
One time, Loss of SAE J1939 drive train ECM to EGC communication
ten-short-beeps data link communication to
alarm the EGC from the engine
controller will trigger a one
time, ten-short-beeps audible
alarm.
One time, A sensor fault error will result All gauges
three-long-beeps in the gauge pointer being
alarm driven clockwise to the 6:00
position and (if configured)
a three-long-beeps audible
alarm.
S08361 39
ELECTRONIC GAUGE CLUSTER FEATURE CODES
Switches
The EGC has locations for the following switches:
• Headlight / Park Lamp Switch

• Panel Dimmer
• Right Side Optional Switch #1
• Right Side Optional Switch #2
• Left Side Optional Switch #1
• Left Side Optional Switch #2
NOTE – The optional switch locations will require a switch blank if there is no configured function for
that switch.
Diagnostic Mode
The EGC is capable of performing self diagnostics. When enabled, the EGC will perform a gauge sweep,
warning lamp check, and operate gauge backlighting. When in diagnostic mode, the EGC digital display
can display DTCs.
To place the EGC in diagnostic mode, perform the following procedure:
• Set parking brake.

• Key is in ON position.
• Simultaneously press the CRUISE ON and CRUISE RESUME / ACCEL buttons located on the steering
wheel.
1.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the Electronic
Gauge Cluster.
NOTE – Refer to the FEATURES tab in the Diamond Logic® Builder (DLB) for a list of feature codes
equipped on a particular vehicle.
Table 6 Electronic Gauge Cluster Feature Codes
FEATURE CODE FEATURE DESCRIPTION

0595ABP VOLTMETER
0595ABN SPEEDOMETER
0595AAZ PARK BRAKE INDICATOR
0595HGG ENGINE OIL TEMP GAUGE
0595ABB AIR PRESSURE GAUGES
0595ALJ BC PROG, FUEL WARNING low fuel warning light and audible alarm activated
separately
40 S08361
USER PROGRAMMABLE PARAMETERS ELECTRONIC GAUGE CLUSTER
Table 6 Electronic Gauge Cluster Feature Codes (cont.)

0595AZW BC PROG, SPECIAL FUEL WARNING SINGLE TANK low fuel warning light
and audible alarm activated separately
0595ALT BC PROG, FUEL TANK GAUGE single, left side

0595ABD FUEL TANK GAUGE single, right side
0595ABK ENGINE COOLANT TEMP
0595ABL ENGINE OIL PRESSURE GAUGE
0595ABM TACHOMETER 2500 RPM
0595ADH COMPASS DISPLAY
0595ABA SEATBELT INDICATOR
0595ABV BC PROG, ABS INDICATOR full power hydraulic or air brake systems
0595ABW BC PROG, TRAILER ABS INDICATOR
0595ACG BC PROG, OUTSIDE TEMP MONITOR
0595ANW BC PROG, DIAGNOSTICS LOCATION display in gauge cluster
0595BMS BC PROG, TRACTION CONTROL IND Bendix® ATC enable / disable with
traction warning light for air brakes with 2010 cluster
1.3. USER PROGRAMMABLE PARAMETERS

This section contains all user programmable parameters directly related to the Electronic Gauge Cluster.
Name: Fuel_Level_Min_WL
• ID: 1958
• Description: Minimum set point for fuel level in-gauge warning light
• Access Level: Fleet
• Unit of Measurement: Percent (%)
• Default Value: 12.8
• Minimum Value: 0
• Maximum Value: 100
Name: Eng_Oil_Press_Min_WL
• Description: Minimum set point for engine oil pressure in-gauge warning light
• ID: 1948
S08361 41
ELECTRONIC GAUGE CLUSTER USER PROGRAMMABLE PARAMETERS
• Unit of Measurement: PSI (kPa)
• Default Value: 12 (83)
• Minimum Value: 0.0001 (0.001)
• Maximum Value: 100 (689)
Name: Eng_Water_Temp_Max_WL
• ID: 2292
• Description: Maximum set point for water temperature in-gauge warning light
• Unit of Measurement: °F (°C)
• Minimum Value: 140 (60)
Name: Eng_Oil_Temp_Max_WL
• ID: 2274
• Description: Maximum set point for engine oil temperature in-gauge warning light
Name: Trans_Oil_Temp_Max_WL
• ID: 2272
• Description: Maximum set point for transmission oil temperature in-gauge warning light
42 S08361
S08361 43
ELECTRONIC GAUGE CLUSTER USER PROGRAMMABLE PARAMETERS
Name: Battery_Voltage_Min_WL
• ID: 1944
• Description: Minimum set point for voltmeter in-gauge warning light
• Unit of Measurement: Volts
• Default Value: 12
• Minimum Value: 10
Name: Prim_Air_Press_Min_WL
• ID: 2316
• Description: Minimum set point for air pressure in-gauge warning light
• Unit of Measurement: PSI (kPa)
• Minimum Value: 0.0001 (0.001)
Name: Park_Brake_Reminder
• ID: 2349
• Description: Park Brake reminder ON / OFF
• Unit of Measurement: ON / OFF
• Default Value: 0 (OFF)
44 S08361
Name: Work_Light_Timeout_Enable
• ID: 640
• Description: Work Light time duration
• Unit of Measurement: Minutes
• Default Value: 12
• Minimum Value: 0.16667
S08361 45
ELECTRONIC GAUGE CLUSTER DIAGNOSTIC TROUBLE CODES
1.4. DIAGNOSTIC TROUBLE CODES

This section provides details of the Diagnostic Trouble Codes (DTC) set by the Electronic Gauge Cluster.
The EGC is able to set DTCs when a fault occurs. Information given by the DTC can aid in the diagnosis of
the problem.
NOTE – Always check for DTCs before performing intrusive wire tests or parts replacement.
Table 7 Diagnostic Trouble Codes
SPN DESCRIPTION FMI CONN. PIN MESSAGE PROBABLE LOGICAL

CAUSE SIGNAL
2023 Gauge Cluster 9 N/A N/A EGC Data Link • Faulty J1939DT_Rcv_
Communication Electronic 61184_
Failure Gauge Cluster 033_040_Timer
• J1939 Data
Link failure
Proceed to the Electronic Gauge Cluster Circuit Test (See Table 9, page 56).
2023 Gauge Cluster 12 N/A N/A Failure Of Defective N/A
Non Volatile Electronic
Memory Or Gauge Cluster
Checksum
Fault
2023 Gauge Cluster 6 1500 4 Short Detected EGC Detects N/A
and In The Panel That Current
5 Dimmer On The Panel
Dimmer Circuit
Is Above
Normal
Refer to the LIGHTING SYSTEMS section for more information.
NOTE – If this DTC is set, the EGC backlighting will be ON at full intensity. All other panel dimming
controlled by the EGC will be OFF.
46 S08361
DIAGNOSTIC TROUBLE CODES ELECTRONIC GAUGE CLUSTER
Table 7 Diagnostic Trouble Codes (cont.)

CAUSE SIGNAL
2023 Message 11 1500 7 This DTC • Open N/A
Ignition And Occurs If Circuit On
Switched The EGC The Ignition
Ignition Do Not And The BC Voltage Circuit
Match Have Different To The BC
Interpretations
Of The Ignition • Open
Key Switch Circuit On
State The Ignition
Voltage Circuit
To The EGC
• Faulty BC
• Faulty EGC
520605 Gauge Cluster 13 N/A N/A EGC Faulty EGC Cluster_cal_
Checksum status
Error
DTC Occurs If
The EGC Fails
Calibration
2000 Loss Of 9 Data link Loss Of Data • J1939 Data N/A
Communication Link From ECM Link Failure
• Faulty EGC
• Faulty ECM
NOTE – If this DTC is set, the speedometer, tachometer, water temperature, and oil pressure gauges
will also be inoperative.
2003 Source 9 Data Link Loss Of Data • J1939 Data N/A
Address 3 Link From Link Failure
Transmission
Controller • Faulty TCM
• Faulty EGC
NOTE – If this DTC is set, the transmission gear display on the EGC will not function.
S08361 47

CAUSE SIGNAL
Address 11 Link From ABS Link Failure
Controller
• Faulty ABS
Controller
• Faulty EGC
Address 33 Link From BC Link Failure
• Faulty BC
• Faulty EGC
NOTE – When this DTC is set, all displays that are BC controlled will be inoperative. Fuel level,
voltmeter, air brake gauges, turn signal indicators, high beam indicator are inoperative, and a
repetitive single tone alarm will sound.
2023 Gauge Cluster 3 and 1505 1 See below for N/A N/A
4 details.
Refer to the LIGHTING SYSTEMS section for diagnostic information associated with
the Ambient Light Sensor (if equipped).
520606 AGSP Gauge 13 N/A N/A Defective N/A AGSP_cal_status
Calibration AGSP
171 Ambient Air 3 1501 9 See below for N/A N/A
Temperature details.
Refer to Ambient Temperature Sensor Circuit Test (See Table 99, page 161) for diagnostic
information associated with the Outside Air Temperature Sensor.
829 Left Fuel Level 0 1600 B8 Fuel Tank • Faulty Fuel Fuel_
Sensor 1 Sensor Level Sensor Sensor1_
Reading Above Or Circuits Raw_Signal
Normal
• Faulty Body
Controller (BC)
Proceed to the Fuel Level Gauge Circuit Test (See Table 13, page 61).
829 Left Fuel Level 1 1600 B8 Fuel Tank • Faulty Fuel Fuel_
Sensor 1 Sensor Level Sensor Sensor1_
Reading Below Or Circuits Raw_Signal
Normal Range
• Faulty Body
Controller (BC)
48 S08361

CAUSE SIGNAL
830 Right Fuel 0 1600 B9 Fuel Tank Fuel Tank Fuel_Sensor2_
Level Sensor 2 Sensor 2 Sensor Raw_Signal
Reading Above Shorted High
Normal Range Or Open
Circuit Or
Faulty Sensor
System
830 Right Fuel 1 1600 B9 Fuel Tank Fuel Tank 2 Fuel_Sensor2_
Level Sensor 2 Sensor Sensor Short Raw_Signal
Reading Below To Ground Or
Normal Range Faulty Sensor
System
177 Transmission 0 1600 B7 Transmission • Faulty Trans_Oil_
Oil Oil Transmission Temp_
Temperature Temperature Oil Raw_Signal
Sensor Temperature
Reading Above Sensor Or
Normal Range Circuits
• Faulty Body
Controller (BC)
Proceed to the Transmission Oil Temperature Circuit Test (See Table 14, page 62).
NOTE – In order to diagnose input electrical issues, refer to specific engine or transmission manuals.
177 Transmission 1 1600 B7 Transmission • Faulty Trans_Oil_
Oil Oil Transmission Temp_
Temperature Temperature Oil Raw_Signal
Sensor Temperature
Reading Below Sensor Or
• Faulty Body
Controller (BC)
Proceed to the Transmission Oil Temperature Circuit Test (See Table 14, page 62).
NOTE – In order to diagnose input electrical issues, refer to specific engine or transmission manuals.
S08361 49

CAUSE SIGNAL
77 Forward Rear 0 1600 B10 Front Rear Axle • Faulty Frw_RR_
Drive Axle Temperature Forward Rear Axle_Oil_
Temperature Sensor Axle Sensor Temp_Raw_
Reading Above Or Circuits Signal
Normal Range
• Faulty Body
Controller (BC)
Proceed to the Front Axle Temperature Circuit Test (See Table 16, page 64).
77 Forward Rear 1 1600 B10 Front Rear Axle • Faulty Frw_RR_
Drive Axle Temperature Forward Rear Axle_Oil_
Temperature Sensor Axle Sensor Temp_Raw_
Reading Below Or Circuits Signal
Normal Range
• Faulty Body
Controller (BC)
Proceed to the Front Axle Temperature Circuit Test (See Table 16, page 64).
78 Rear Rear 0 1600 B11 Rear Rear Axle • Faulty Rear_RR_
Drive Axle Temperature Rear-Rear Axle_ Oil_Temp_
Temperature Sensor Axle Sensor Raw_ Signal
Reading Above Or Circuits
Normal Range
• Faulty Body
Controller (BC)
Proceed to the Rear Axle Temperature Circuit Test (See Table 15, page 63).
78 Rear Rear 1 1600 B11 Rear Rear Axle • Faulty Rear_RR_
Drive Axle Temperature Rear-Rear Axle_ Oil_Temp_
Temperature Sensor Axle Sensor Raw_ Signal
Reading Below Or Circuits
Normal Range
• Faulty Body
Controller (BC)
Proceed to the Rear Axle Temperature Circuit Test (See Table 15, page 63).
116 Brake 0 1600 B14 Brake • Faulty Air Brake_App_
Application Application Pressure Air_ Sensor_
Pressure Pressure Transducer Or Raw_ Signal
Sensor Circuits
Reading Above
Normal Range • Faulty Body
Controller (BC)
Proceed to the Air Pressure Transducer Circuit Test (See Table 17, page 65).
50 S08361

CAUSE SIGNAL
116 Brake 1 1600 B14 Brake • Faulty Air Brake_App_Air_
Application Application Pressure Sensor_Raw_
Pressure Pressure Transducer Or Signal
Sensor Circuits
Reading Below
Normal Range • Faulty Body
Controller (BC)
1089 Auxiliary 1 1600 B2 Auxiliary Air • Faulty Air Auxiliary_
Equipment Tank Sensor Pressure Air_ Sensor_
Supply Reading Above Transducer Or Raw_ Signal
Pressure Normal Circuits
• Faulty Body
Controller (BC)
1089 Auxiliary 1 1600 B2 Auxiliary Air • Faulty Air Auxiliary_
Equipment Tank Sensor Pressure Air_ Sensor_
Supply Reading Below Transducer Or Raw_ Signal
Pressure Normal Circuits
• Faulty Body
Controller (BC)
1088 Service Brake 0 1600 B3 Secondary Air • Faulty Air Secondary_
Air Pressure Tank Sensor Pressure Air_ Sensor_
Circuit #2 Reading Above Transducer Or Raw_ Signal
• Faulty Body
Controller (BC)
1088 Service Brake 0 1600 B3 Secondary Air • Faulty Air Secondary_
Circuit #2 Reading Below Transducer Or Raw_ Signal
• Faulty Body
Controller (BC)
S08361 51

CAUSE SIGNAL
1087 Service Brake 0 1600 B2 Primary Air • Faulty Air Primary_
Circuit #1 Reading Above Transducer Or Raw_ Signal
• Faulty Body
Controller (BC)
1087 Service Brake 0 1600 B2 Primary Air • Faulty Air Primary_
Circuit #1 Reading Below Transducer Or Raw_ Signal
• Faulty Body
Controller (BC)
171 Ambient Air 3 1501 9 Fault On • Defective N/A
Temperature Analog Input 3 Ambient Air
Above Normal Temperature
When Used Sensor Or
For Outside Circuit
Temperature
• Defective
Gauge Cluster
Refer to the Ambient Temperature Sensor Circuit Test (See Table 99, page 161) for diagnostic
NOTE – If the EGC determines there is a short or open in the sensor, it will display “—“ in place of a
temperature value.
171 Ambient Air 4 1501 9 Fault On • Defective N/A
Temperature Analog Input Ambient Air
3 Below Normal Temperature
When Used Sensor Or
For Outside Circuit
Temperature
• Defective
Gauge Cluster
Refer to the Ambient Temperature Sensor Circuit Test (See Table 99, page 161) for diagnostic
NOTE – If the EGC determines there is a short or open in the sensor, it will display “—“ in place of a
temperature value.
52 S08361

CAUSE SIGNAL
623 Red Stop Lamp 5 N/A N/A Red Stop Light • Current N/A
Malfunction Below Normal
• Open Circuit
Proceed to the Warning Lamp Test (See Table 12, page 60).
624 Amber Warning 5 N/A N/A Amber • Current N/A
Light Warning Light Below Normal
Malfunction
• Open Circuit
1213 Malfunction 5 N/A N/A MIL Warning • Current N/A
Indicator Lamp Light Below Normal
Malfunction
• Open Circuit
1438 ABS / EBS 5 N/A N/A ABS Warning • Current N/A
Amber Warning Light Below Normal
Lamp State Malfunction
(Powered • Open Circuit
Vehicle)
987 Protect Lamp 5 N/A N/A Protect • Current N/A
Warning Light Below Normal
Malfunction
• Open Circuit
1081 Wait To Start 4 N/A N/A Wait To Start Output N/A
Lamp Lamp Shorted To
Ground
1081 Wait To Start 6 N/A N/A Wait To Start Output N/A
Lamp Lamp Overheat
1792 Tractor-Mounted 5 N/A N/A Trailer ABS • Current N/A
Trailer ABS Warning Light Below Normal
Warning Signal Malfunction
• Open Circuit
1793 ATC / ASR 5 N/A N/A Traction Control • Current N/A
Information Warning Light Below Normal
Signal Malfunction
• Open Circuit
S08361 53
ELECTRONIC GAUGE CLUSTER TROUBLESHOOTING

CAUSE SIGNAL
3697 Diesel 5 N/A N/A Particulate Trap • Current N/A
Particulate Lamp Relay Below Normal
Filter Lamp Under Current
or Open Circuit • Open Circuit
1.5. TROUBLESHOOTING
This section contains troubleshooting procedures for specific Electronic Gauge Cluster (EGC) components.
CAUTION
Static electricity can cause permanent damage to the cluster. Before working with the
EGC, be sure to remove all static electricity from your body by touching the metal part
of the dash.
NOTE – Always refer to the applicable Circuit Diagram manual for latest circuit information.
The Engine Oil Pressure, Engine Oil Temperature, Speedometer, Tachometer, and Coolant Temperature
Gauge are driven by the J1939 data link. Information is directly communicated to the EGC from the Engine
Control Module (ECM) and is not interrupted by the Body Controller (BC). Refer to specific engine manuals
and appropriate circuit diagrams for information regarding input circuitry and communication wiring.
Preliminary Checks
EGC preliminary checks should be performed prior to specific system tests. Preliminary checks will lead to
a general area to begin more specific troubleshooting as well as locate common circuits such as shared
power and grounds.
Table 8 EGC Preliminary Checks
STEP ACTION SPEC. IN SPEC. NOT IN SPEC.

1. Switch Ignition to ON EGC responds to key Go to next Refer to the EGC Circuit
position and observe ON, gauges move to step. Test (See Table 9, page
EGC. appropriate positions, and 56).
warning lights illuminate.
Visually observe cluster
response to ignition
voltage.
2. Inspect for warning lamps Warning lamps perform Go to next Refer to the Warning
remaining illuminated. self-check then turn off. step. Lamp Test (See Table
12, page 60).
Visually observe EGC NOTE – The PARK light
warning lights. may remain illuminated. NOTE –
Communication
loss with any of the
modules will result in
54 S08361
TROUBLESHOOTING ELECTRONIC GAUGE CLUSTER
Table 8 EGC Preliminary Checks (cont.)

an audible warning
alarm and an electrical
fault text message.
3. Ensure proper EGC Backlighting operational Go to next Refer to the EGC
backlighting operation. and dimmer switch step. Backlighting Circuit
functioning properly. Test (See Table 10,
Turn on headlights and page 58).
verify display backlight
operation.
Operate panel dimmer

switch.
4. Road test vehicle. All applicable gauges are Go to next Refer to the EGC Gauge
functioning properly. step. Test (See Table 11, page
Observe all gauge 59).
operation.
Verify gauges are

representing vehicle
conditions such as engine
speed, vehicle speed,
engine temperature, and
other applicable gauges.
5. Ensure compass and Compass and outside See below for Refer to the Ambient
outside temperature temperature gauge are details. Temperature Sensor
displays are accurate. functioning properly. Circuit Test (See Table
99, page 161) table.
Compare outside air
temperature reading
to actual ambient
temperatures.
Verify compass is working

accurately.
• Utilizing the DLB, check for DTCs set in the Electronic Gauge Cluster.
• Refer to the Diagnostic Trouble Codes table (See Table 7, page 46) for specific cause.
S08361 55
Electronic Gauge Cluster Circuit Test
Table 9 Electronic Gauge Cluster Circuit Test

1. Disconnect the gauge 12 ± 1.5V Go to next step. • Inspect 15A Fuse F2-G
cluster connector (1011).
(1500).
• Inspect circuit A28 for
Measure voltage open or short.
between the gauge
cluster connector
(1500), cavity 2 and
ground.
2. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect 10A Fuse F4-L
(1013).
Measure voltage
between the gauge • Inspect circuit A28A for
cluster connector open or short.
ground.
3. Measure resistance <1 ohm Go to next step. Inspect ground circuits
between the gauge A28-G and A11-GS for
cluster connector open or source of high
(1500), cavity 1 and resistance.
ground.
4. Measure voltage Approximately 2.5V Go to next step. • If voltage is 0 volts, the
between the gauge J1939 circuit is shorted to
cluster connector NOTE – Voltage ground or open.
(1501), cavity 12 and may vary due to
ground. communication on • If voltage is above 5
the J1939 data link. volts, the J1939 circuit is
shorted to voltage.
Refer to the
MULTIPLEXING NOTE – The combined
(DATA LINKS) section voltage of cavities 12
for further diagnostic and 11 is 5 volts.
information.
56 S08361
Table 9 Electronic Gauge Cluster Circuit Test (cont.)

5. Measure voltage Approximately 2.5V Go to next step. • If voltage is 0 volts, the
between the gauge J1939 circuit is shorted to
cluster connector NOTE – Voltage ground or open.
(1501), cavity 11 and may vary due to
ground. communication on • If voltage is above 5
the J1939 data link. volts, the J1939 circuit is
shorted to voltage.
Refer to the
MULTIPLEXING NOTE – The combined
(DATA LINKS) section voltage of cavities 12
for further diagnostic and 11 is 5 volts.
information.
6. Measure resistance 60 ± 6 ohms Electronic Gauge • If resistance is 120
between the gauge Cluster has power ohms, the J1939 data link
cluster connector and ground and has an open or a missing
(1501), cavities 12 is communicating terminating resistor.
and 11. on the J1939 data
link. • If resistance is 0 ohms,
the J1939 data link circuits
are shorted together.
S08361 57
EGC Backlight Circuit Test
NOTE – Ensure the Lighting System is operating properly prior to diagnosing the Electronic Gauge
Cluster.
NOTE – Refer to the LIGHTING SYSTEMS section to assist in diagnosis.
Table 10 EGC Backlighting Circuit Test

1. Set DMM to the diode Voltage present. Go to next step. Replace EGC.
setting.
NOTE – Many NOTE – The EGC has
Place positive test lead common light eight serviceable
on pin 1 of the gauge emitting diodes warning lamp
cluster #1 connection measure 0.7 volts. bulbs. LEDs are
and place the negative not serviceable and
test lead on pin 5 require replacement
of the gauge cluster of the EGC.
connection (1500).
2. Set DMM to the diode DMM should read • No internal EGC Replace EGC.
setting. open. Light Emitting Diode
(LED) fault. NOTE – The EGC has
Place positive test lead eight serviceable
on pin 5 of the gauge • Proceed to the warning lamp
cluster #1 connection Electronic Gauge bulbs. LEDs are
and place the negative Cluster Circuit Test not serviceable and
test lead on pin 1 (See Table 9, page require replacement
of the gauge cluster 56). of the EGC.
connection (1500).
EGC Gauge Test
A gauge with an incorrect reading is a result of the following:
• Faulty gauge
• Fault on the sensor circuit
• Faulty sensor
• Faulty control module, including Anti-lock Brake System (ABS), Transmission Control Module (TCM),
Electronic Gauge Cluster (EGC), Engine Control Module (ECM), or Body Controller (BC)
NOTE – Utilize the appropriate engine manual for sensor and sensor circuit information to assist in
diagnosis.
NOTE – It is necessary to utilize the Diamond Logic® Builder (DLB) while performing the EGC Gauge
Test. Connect the DLB prior to beginning test.
58 S08361
Table 11 EGC Gauge Test

1. Utilizing the DLB, check for No DTCs present. Go to next step. • SPN 2023, FMI
the following DTCs: 12: An internal fault
is present, replace
• SPN 2023, FMI 12: EGC.
Failure of non-volatile
memory or checksum • Communication
fault. DTCs: Perform the
Electronic Gauge
• Loss of communication
Cluster Circuit Test
DTCs.
to verify J1939
• DTCs relating to communication (See
individual control Table 9, page 56).
modules or sensor
faults. • Sensor or Module
specific DTCs:
Refer to diagnostic
troubleshooting
information for
specific module
and sensor faults.
2. Viewing the DLB The Electronic Go to next step. If information is
CLUSTER tab, ensure Gauge Cluster incorrect, replace
that the input signal value is interpreting EGC.
being displayed in the DLB information
for a specific gauge or correctly from the
warning lamp matches the BC, TCM, ABS, and
position that the cluster is ECM.
actually commanding.
3. Select the appropriate Gauge value Gauge working If value differs,
malfunctioning gauge. represents input correctly. replace EGC or
value from DLB. defective gauge if
Manually input valid value serviceable.
other than that currently
displayed by the gauge.
Verify the EGC gauge
position has responded
correctly and matches the
input value.
S08361 59
Warning Lamp Test
Warning lamp information in the EGC is provided on the SAE J1939 drive train data link from various control
module sources.
A problem on the data link will demonstrate several problems on the EGC as well as a Diagnostic Trouble Code.
If other warning lamps are not operating correctly, the problem is not isolated to a single warning lamp input.
A malfunctioning warning lamp may be the result of any of the following:
• Faulty gauge
• Fault on the sensor circuit
• Faulty sensor
• Faulty control module, including ABS, TCM, EGC, ECM, and BC
NOTE – The following diagnostic test only applies to the warning lamps / indicators that are attached to
the EGC center circuit board. The test is not valid for the ABS, trailer ABS, or the Traction Control Lamp.
NOTE – Utilize the appropriate engine manual for sensor and sensor circuit information to assist in
diagnosis.
NOTE – It is necessary to utilize the DLB while performing the Warning Lamp Test.
Table 12 Warning Lamp Test

1. Key is in OFF position. Warning lamps Go to next step. • Perform diagnostics for
and indicators specific warning lamp
Observe current warning in the vehicle indicator.
lamp status. configuration turn
on momentarily • If no warning lamps
Turn key to ON position. during the warning operate, perform the EGC
lamp self test. Preliminary Checks (See
Table 8, page 54).
2. Check for the following No DTCs present. Go to next step. • SPN 2023, FMI 12:
DTCs: Replace faulty EGC.
• SPN 2023, FMI 12: • Communication DTCs:

Failure of non-volatile Perform the Electronic
memory or checksum Gauge Cluster Circuit
fault. Test to verify J1939
communication. (See
• Loss of communication
Table 9, page 56).
DTCs.
• DTCs relating to • Sensor or Module
individual control specific DTCs: Refer to
modules or sensor diagnostic troubleshooting
faults. information for specific
module and sensor faults.
60 S08361
Table 12 Warning Lamp Test (cont.)

3. While viewing the DLB The Electronic Go to next step. If information is incorrect,
CLUSTER tab, ensure that Gauge Cluster replace EGC center circuit
the input signal value being is interpreting board.
displayed in the DLB for information
a specific warning lamp correctly from the
or indicator matches the BC, TCM, ABS,
position that the cluster is and ECM.
actually commanding.
4. Select the appropriate Lamp responds No fault at this Replace the EGC.
malfunctioning warning or to command time.
indicator lamp to initiate actuation.
manual lamp actuation.
Single click the

malfunctioning warning
lamp or indicator. It should
turn on or off each time the
lamp is clicked. Verify that
the actual EGC warning
lamp or indicator has
responded correctly and
matches the state of the
lamp shown in DLB.
Setting a gauge outside

of its parameters will also
illuminate the warning
indicator.
Fuel Level Gauge Circuit Test
NOTE – The Fuel Level Gauge Circuit Test can be performed on the left and right draw and storage tanks.
Table 13 Fuel Level Gauge Circuit Test

1. Disconnect the 10 ± 1.0V Go to next step. • Check for open or short on
fuel level sensor appropriate fuel level signal circuit
connector. (draw or storage tank) between
sensor and the Body Controller (BC).
Measure voltage
between the • Inspect IP / Chassis connector
fuel level sensor (1701) pin 29 / 27 for loose, damaged,
connector, cavity or corroded terminals.
A and ground.
2. Measure voltage 10 ± 1.0V Go to next step. • Inspect for an open in appropriate
between the ZVR circuit.
fuel level sensor
S08361 61
Table 13 Fuel Level Gauge Circuit Test (cont.)

connector, cavity
A and cavity B. • Inspect electronic ground adapter
(8802).
• Verify BC operation.
3. Measure Full: 27 to No fault at this time. Replace appropriate fuel level sensor.
resistance 37 ohms
between the fuel Reconnect fuel level
level sensor, pins Half: 142 to sensor connector.
A and B. 156 ohms
Empty: 234
to 246 ohms
Transmission Oil Temperature Circuit Tests
NOTE – Refer to specific transmission service manual for service information related to the Transmission
Oil Temperature Sensor.
Table 14 Transmission Oil Temperature Circuit Test

1. Utilizing the Signal • Suspect faulty Go to next step.
Diamond Logic® matches gauge.
Builder (DLB), actual
select the temperature. • Refer to the
CONNECTORS Warning Lamp
tab. Test (See Table
12, page 60).
Select the BC #J3
(1600) connector.
Locate and observe

the following signal:
Trans_Oil_
Temp_Signal
Does signal value

agree with actual
transmission oil
temperature?
2. Disconnect the 5 ± 0.5V Go to next step. • Inspect BC 5-volt reference signal
transmission oil circuit for open or short.
temperature sensor.
• Inspect the engine / IP connector
Key is in ON (1702) for damaged, loose, or
position. corroded connections.
62 S08361
Table 14 Transmission Oil Temperature Circuit Test (cont.)

Measure voltage
between the
transmission oil
temperature sensor
connector, cavity 1
and ground.
3. Key is in ON 5 ± 0.5V Replace faulty • Inspect Zero Volt Reference (ZVR)
position. transmission circuit for open or short.
oil temperature
Measure voltage sensor. • Inspect ZVR connector (6702
between the / 6747) for loose, damaged, or
transmission corroded terminals.
oil temperature
connector, cavity 1
and cavity 2.
Front Rear and Rear Rear Axle Temperature Circuit Tests
NOTE – Refer to specific axle service manual for further diagnostic information related to the front and
rear axle temperature sensor.
• Rear Axle Temperature Sensor Circuit Test
NOTE – Check with ignition ON and axle temperature sensor disconnected.
Table 15 Rear Rear Axle Temperature Circuit Test

1. Measure voltage 5 ± 0.5V Go to next step. • Inspect circuit R32 for open or short.
between the
appropriate rear • Inspect the IP / Chassis Connector
axle temperature (1701), pin 6 for loose, damaged, or
connector (9812), corroded terminals.
cavity 1 and ground.
• Inspect circuits N32 and A32 for open
or short.
S08361 63
Table 15 Rear Rear Axle Temperature Circuit Test (cont.)

2. Measure voltage 5 ± 0.5V Replace • Inspect ZVR circuit to the Chassis
between the faulty axle Center connector (9800) for open or
appropriate rear temperature short.
axle temperature sensor.
connector (9812), • Inspect ZVR circuits N9BF and N9BC
cavity 1 and cavity 2. for open or short.
• Inspect the electronic ground adapter

(8802) for loose, damaged, or corroded
terminals.
• Inspect IP / Chassis Connector

terminals.
• Front Rear Axle Temperature Sensor Circuit Test
NOTE – Check with ignition ON and axle temperature sensor disconnected.
Table 16 Front Rear Axle Temperature Circuit Test

1. Disconnect the front axle 5 ± 0.5V Go to next • Inspect circuit R32A for open or short.
temperature sensor. step.
• Inspect circuits N32A and A32A for
Measure voltage between the open or short.
front axle temperature sensor
connector (9811), cavity 1 • Inspect the chassis center / chassis
and ground. rear connector (9800), pin 5 for loose,
damaged, or corroded terminals.
2. Measure voltage between the 5 ± 0.5V Replace • Inspect ZVR circuits R9A and R9B for
front axle temperature sensor faulty axle open or short.
connector (9811), cavity 1 to temperature
cavity 2. sensor. • Inspect the chassis center / chassis
rear connector (9800) for loose,
• Inspect the isolated ground adapter

terminals.
Air Pressure Transducer Circuit Tests
This test covers Primary Air Transducer and the Secondary Air Transducer. Refer to latest circuit diagram for
specific circuits and component information.
64 S08361
NOTE – Transducers share a common 5-volt supply and Zero Volt Reference (ZVR) circuits from Body
Controller (BC).
NOTE – Check with ignition ON and appropriate air pressure transducer disconnected.
NOTE – Always use a Breakout Box (ZTSE4477) to take measurements at BC connectors.
Table 17 Air Pressure Transducer Circuit Test

1. Utilizing the Diamond Logic® Signal • Suspect faulty Go to next step.
Builder (DLB), select the matches gauge.
CONNECTORS tab. actual
pressure. • Refer to the
Select the BC #J3 (1600) Warning Lamp
connector. Test (See Table
12, page 60).
Locate and view the following
signals: • Refer to the
EGC Gauge Test
Primary_Air_Pressure (See Table 11,
page 59).
Secondary_Air_Pressure
Does signal value match

actual air pressure?
2. Disconnect the air pressure 5.0 ± 0.5V Go to next step. • Inspect appropriate 5-volt
transducer connector. supply circuit for open and
short.
Measure voltage between
the appropriate air pressure • Inspect the IP / DCM
transducer harness connector, connector (1800) for loose,
cavity B and ground. damaged, or corroded
connections.
NOTE – All air transducers

share common 5-volt
supply circuit A6/A6H from
BC connector #J5 (1602),
pin E4.
S08361 65
Table 17 Air Pressure Transducer Circuit Test (cont.)

3. Measure voltage between 5.0 ± 0.5V Go to next step. • Inspect appropriate Zero
the appropriate air pressure Volt Reference (ZVR) circuit
transducer harness connector, for open or short.
cavity A and cavity B.
• Inspect the IP / DCM
connector (1800) for loose,
damaged, or corroded
connections.
NOTE – All air transducers

share common ZVR circuits
A9AA and A9V from the BC
connector #J5 (1602), pin
E5.
4. Key is in OFF position. <1 ohm Replace faulty Inspect appropriate signal
transducer. circuit for open or source of
Disconnect Body Controller high resistance.
(BC) Connector #J5 (1602).
Measure continuity between

the following circuits:
Primary air transducer:
Body Controller (BC) #J5

(1602), cavity B2 and the
primary air transducer (1811),
cavity C.
Secondary air transducer:
Body Controller (BC) #J5

(1602), cavity B3 and the
secondary air transducer
(1812), cavity C.
66 S08361
Park Brake Switch Circuit Test
Table 18 Park Brake Switch Circuit Test

1. Using Diamond Logic® Signal No faults present at Go to next step.
Builder, select the follows this time.
CONNECTORS tab. switch
Select the BC #J3 (1600) command. Inspect brake
connector. Locate and system for
observe the following mechanical failures.
signal:
Park_Brake_Switch_
Signal signal.
Apply and release the

park brake.
2. Key is in ON position. 12 ± 1.5V Connect Body Suspect faulty BC.
Controller #J3
Measure voltage connector.
between the BC #J3
connector (1600), pin Go to next step.
A12 and ground.
3. Disconnect park brake 12 ± 1.5V Connect the park Hydraulic Brakes:
switch connector. brake switch.
• Inspect circuit B44BB, A44A,
Key is in ON position. Go to next step. and white wire to park brake
switch (1815) for open or short.
Measure voltage
between the hydraulic • Inspect the DCM / IP connector
park brake switch (1800) for loose, damaged, or
(1815), terminal A, corroded terminals.
or air park brake (1813),
terminal C, and ground. Air Brakes:
• Inspect circuit B44BB and

A44A to park brake switch
(1813) for open or short.
• Inspect the DCM / IP connector

(1800) for loose, damaged, or
corroded terminals.
S08361 67
Table 18 Park Brake Switch Circuit Test (cont.)

4. Key is in ON position. <1 ohm Parking brake • Replace faulty Park Brake
switch (1813/1815) switch (1813/1815).
Measure resistance is operating
between the hydraulic properly. • Inspect Zero Volt Reference
park brake switch (ZVR) circuits B9V, A9V, and
(1815), terminal A A9AA for open.
and B, or air park brake
(1813), terminal C and • Inspect the DCM / IP connector
D. (1800) for loose, damaged, or
corroded terminals.
Air Restriction Gauge Circuit Test
Table 19 Air Restriction Gauge Circuit Test

1. Measure voltage 12 ± 1.5V Go to next • Inspect circuit A28 and K28 for open or
between the air step. short.
restriction indicator
switch (6703A), • Inspect the IP / Engine connector
cavity B and (1702) for loose, damaged, or corroded
ground. connections.
2. Measure voltage 12 ± 1.5V Replace • Inspect appropriate Zero Volt Reference
between the air faulty air (ZVR) circuit K9AAB for open.
restriction indicator restriction
switch (6703A), indicator • Inspect the ground adapter (6702) for
cavity B and cavity switch. loose, damaged, or corroded terminals.
A.
Engine Coolant Level Monitor Circuit Test
NOTE – Verify J1939 data link communication from the ECM prior to performing the Low Coolant Sensor
Circuit Test.
Refer to the specific engine manual for further diagnostics related to the coolant level monitor.
Table 20 Low Coolant Sensor Circuit Test

1. Disconnect the 5 ± 0.5V Go to next step. • Inspect circuit K34AA for open or
low coolant sensor short.
connector (6400).
• Inspect ECM connector (6020M)
Measure voltage for loose, damaged, or corroded
between the low terminals.
coolant sensor
(6400), cavity A
and ground.
68 S08361
ELECTRONIC GAUGE CLUSTER PROGRAMMING ELECTRONIC GAUGE CLUSTER
Table 20 Low Coolant Sensor Circuit Test (cont.)

2. Measure voltage 5 ± 0.5V Replace faulty • Inspect ground circuit K34-GG for
between cavity A low coolant open.
and cavity B of the sensor.
low coolant sensor • Inspect Zero Volt Reference (ZVR)
(6400). adapter (6747) for loose, damaged, or
corroded terminals.
NOTE – The coolant module, low

coolant sensor, and idle control
temperature sensor share common
ground circuit K34A1.
1.6. ELECTRONIC GAUGE CLUSTER PROGRAMMING

When gauge configurations are changed or the Body Controller is replaced, the Body Controller must be
programmed using Diamond Logic® Builder (DLB) programming software. The Body Controller will store the
current configuration and update the configuration after changes are made. The new configuration will have to
be uploaded to Navistar. This is accomplished by dialing in and uploading the updated programming. A copy
of the programming is stored at Navistar and updated each time there is a change. This is required in case
there is a need to download the programming for Body Controller replacement.
S08361 69
ELECTRONIC GAUGE CLUSTER ELECTRONIC GAUGE CLUSTER PROGRAMMING
70 S08361
TABLE OF CONTENTS
SWITCH PACKS (J1708 DATA LINK)

Table of Contents
1. SWITCH PACKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Switch Pack Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Switch Pack Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
J1708 Data Link Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
S08361 71
TABLE OF CONTENTS
72 S08361
DESCRIPTION SWITCH PACKS
1. SWITCH PACKS
1.1. DESCRIPTION
This section contains a general overview of switch packs.
Overview
The switch pack provides a module in which switches can be mounted and monitored on the data link.
Switch data link is a private J1708 style data link. The data link is a pair of twisted insulated wires that
interconnect all of the associated control modules on the network.
Private data link means aftermarket J1708 devices cannot be added to this data link.
Operation
The information transmitted on the network is done in a digital encoded format.
Switch packs are daisy chained together. The first switch pack connects directly to the vehicle harness, and
each remaining switch pack connects to the previous switch pack.
Each switch pack is addressed by the Body Controller (BC). Addressing is accomplished by a hard wired
ground side address line. The cab harness for switch pack #1 will be missing a wire, with no ground present.
Because of the missing wire, the switch pack is designated #1. Switch pack #1 supplies the ground for
switch pack #2 when installed.
Ignition key must be in the ON or Accessory position for switch pack operation.

The switch packs are able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given
by the DTC can aid in the diagnosis of the problem.
Always check for any DTCs before doing any intrusive wire tests or parts replacement.

CAUSE SIGNAL
520461 Switch 6-Pack 9 N/A N/A Switch Faulty Switch SwitchPack_1_

#1 Data Link 6-Pack #1 Pack #1 Or N_Timer
Data Link Switch Data
Commu- Link
nication
Failure
Proceed to the Switch Pack Circuit Test (See Table 23, page 75) and the J1708 Data
Link Circuit Test (See Table 24, page 76).
S08361 73
SWITCH PACKS TROUBLESHOOTING

CAUSE SIGNAL

#2 Data Link 6-Pack #2 Pack #2 Or IN_Timer
Commu- Link
nication
Failure
#3 Data Link 6-Pack #3 Pack #3 Or IN_Timer
Commu- Link
nication
Failure
NOTE – Always check for Diagnostic Trouble Codes when a switch pack fault is suspected.
In most cases, the switch pack will notify the Body Controller (BC) if one of the individual switches has failed.
The BC continuously monitors the switch pack communication on the switch data link. If a switch pack fails to
communicate with the BC within the expected period of time, a fault will be logged.
Switch packs send a periodic address message. If the switch packs are not installed in the correct order,
the BC can set a fault for a missing switch pack.
The BC continuously monitors the switch pack communication on the switch data link. If a switch pack fails to
communicate with the BC within the expected period of time, a fault can be logged.
Depending on the feature, some switch indicators have four modes of illumination that can aid in diagnosis,
they are as follows:
• Indicator ON - switch and corresponding feature is activated.

• Indicator OFF - switch and corresponding feature is deactivated.
• Indicator flashes fast (twice per second) - there is a problem in the switch or corresponding circuit.
• Indicator flashes slowly (once per second) - this indicates that all the interlocks have not been met to
operate the selected feature.
74 S08361
TROUBLESHOOTING SWITCH PACKS
Switch Pack Preliminary Check
Table 22 Switch Pack Preliminary Check
STEP ACTION YES NO

1. Are other features Refer to the applicable Circuit Go to next step.
malfunctioning that may Diagram manual Power
have common circuits? Distribution and Ground
section.
2. Are there any Diagnostic Refer to the Diagnostic Trouble Go to next step.
Trouble Codes stored in the Codes for specific cause(See
BC? Table 21, page 73).
3. Does the switch indicator Go to next step. Proceed to the Switch Pack
illuminate when feature is Circuit Test (See Table 23,
activated? page 75).
4. Ignition key is in ON or ACC Switch indicator flashes fast: • Switch indicator remains ON
position. or OFF depending on switch
There is a problem in the command.
Operate switch pack switches switch or corresponding
while monitoring switch pack feature circuit. • Refer to failed feature
indicator. troubleshooting in this manual.
Switch indicator flashes
Do switch indicators flash? slowly:
The interlocks have not been

met to operate the selected
feature. Review feature
operation and ensure no
interlock faults exist.
Switch Pack Circuit Test
Table 23 Switch Pack Circuit Test

1. Disconnect the switch pack 12 ± 1.5V Go to next • Inspect 10A Fuse F4-K (1013).
connector (1101M). step.
• Inspect circuit A12F for open or
Key is in ON position. short.

the switch pack connector
(1101M), cavity B and
ground.
2. Key is in ON position. 12 ± 1.5V Go to next • Inspect ground circuit A11-GKD and
step. A11-GCA for open.
cavity B and cavity A of
S08361 75
SWITCH PACKS TROUBLESHOOTING
Table 23 Switch Pack Circuit Test (cont.)

(1101M). • Inspect left side ground plate
for loose, damaged, or corroded
connections.
3. Headlight switch is in ON 12 ± 1.5V Replace • Inspect circuit A62DB for open or
position. faulty short.
switch
Measure voltage between pack.
(1101M), cavity C and
ground.
J1708 Data Link Circuit Test
Table 24 J1708 Data Link Circuit Test

1. Disconnect the switch pack Approximately Go to next • If voltage is 0 volts, the J1708 circuit
connector (1101M). 4.5V step. is shorted to ground or open.
Measure voltage between • If voltage is ABOVE 5 volts, the

the switch pack (1101M), J1708 circuit is shorted to voltage.
cavity D and ground.
2. Measure voltage between Approximately The switch • If voltage is 0 volts, the J1708 circuit
the switch pack (1101M), 0.5V pack J1708 is shorted to ground or open.
cavity E and ground. data link is
functional • If voltage is above 5 volts, the J1708
and circuit is shorted to voltage.
commu-
nicating.
Connect
the switch
pack
connector
(1101M).
76 S08361
TABLE OF CONTENTS
LIGHTING SYSTEM
Table of Contents
1. BACKUP LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Backup Lights Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Backup Light Circuit Test (Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Backup Light Switch Test (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2. DOME AND COURTESY LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.5. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Dome and Courtesy Lights Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Door Switch Circuit Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cab Dome Light Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Courtesy Lights Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3. FOG LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.3. USER PROGRAMMABLE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Fog Light System Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Fog Light Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Fog Light Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4. HEADLIGHTS AND DAYTIME RUNNING LIGHTS (DTRL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.5. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Headlight System Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Headlight Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Turn Signal Switch Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Right Headlight Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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TABLE OF CONTENTS
Left Headlight Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5. STOP, TURN, AND HAZARD LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.1. SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.3. USER PROGRAMMABLE PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.4. DIAGNOSTIC TROUBLE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.5. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Stop, Turn, and Hazards System Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Turn Signal Switch Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Brake Switch Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Left Front Turn Signal Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Right Front Turn Signal Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Left Rear Turn Signal Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Right Rear Turn Signal Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6. TAIL, MARKER, PARK, AND CLEARANCE LIGHTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6.1. SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.5. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Tail, Marker, Park, and Clearance Lighting Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Headlight Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Tail Light Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Park, Marker, Clearance, and Identification Lights Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7. WORK LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Work Light System Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Work Light Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Work Light Circuit Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8. ROOF AUXILIARY LOAD AND AIR SHIELD LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Roof Auxiliary Load Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Air Shield Light Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
8.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Roof Auxiliary Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Lighted Air Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
78 S08361
TABLE OF CONTENTS

Roof Auxiliary Load Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Lighted Air Shield Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Roof Auxiliary Load Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Roof Auxiliary Load Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Lighted Air Shield Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
9. TRAILER LIGHTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Trailer Lights Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Trailer Socket Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Trailer Left Turn Relay Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Trailer Right Turn Relay Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Trailer Marker Light Relay Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Trailer Tail Light Relay Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Trailer Stop Light Relay Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Trailer ABS ECU Relay Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
10. AUXILIARY SNOWPLOW LIGHTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

10.1. SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
10.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.3. USER PROGRAMMABLE PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.4. DIAGNOSTIC TROUBLE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.5. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Auxiliary Snowplow Lights Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Snowplow Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Snowplow Lights Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
S08361 79
TABLE OF CONTENTS
80 S08361
SYSTEM DESCRIPTION BACKUP LIGHTS
1. BACKUP LIGHTS
This section contains a general overview of the backup lights.
Overview
Backup lights are provided for illumination behind the vehicle when operating it in reverse. The lights also
provide a visual warning, alerting external persons that the vehicle is backing up or is about to do so. Circuit
operation will vary depending on vehicle configuration and transmission application.
Operation
Manual Transmissions: The Body Controller (BC) does not govern backup light illumination when equipped
with a manual transmission. A conventional ball-type switch is used to illuminate the backup lights. The
backup lights ball switch is located on the transmission and mechanically closes the circuit anytime the
transmission is placed in reverse. Power for the backup light switch is supplied by Ignition Relay #3, through
10A Fuse F5-M (1014).
Automatic Transmissions: The Body Controller (BC) does not govern backup light illumination. When the
vehicle is configured with an automatic transmission, the Transmission Control Module (TCM) will activate the
backup light relay, and illuminate the backup lights. The backup light relay (1010) is located in the PDC and
is supplied power through 10A Fuse F5-M (1014).
When the automatic transmission is placed in REVERSE, the following occur:
• TCM provides ground to the backup light relay (1010).

• The backup light relay (1010) energizes, closing the switch.
• Voltage is provided to the turn signal adapter (400).
• The turn signal adapter (400) provides voltage to the left backup light, right backup light, and backup alarm.
• The backup lights are provided ground by the chassis ground adapter (8807).
• A J1939 data link message indicating Current_Gear is sent from the TCM to the Electronic Gauge Cluster
(EGC) for the EGC gear display.
• When the TCM activates the backup lights, an input signal is sent to the BC (work light ON in reverse
feature).
• A 12-volt charge is supplied to the backup monitor (if equipped).
• A 12-volt charge is supplied to the lift axle relay coil (if equipped).
1.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the backup light
feature.
Table 25 Feature Code

0595ABS BC PROG, WORK LIGHT ON WITH BACKUP
S08361 81
BACKUP LIGHTS USER PROGRAMMABLE PARAMETERS

There are no user Body Controller (BC) programmable parameters associated with the backup lights.

The backup lights are able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information
given by the DTC can aid in the diagnosis of the problem.

CAUSE SIGNAL
2392 Back Up Light 5 1601 4 Reverse • Current Below Ext_Lamp_
And Alarm Lights Relay Normal Or Test_Reverse_
Horn Under Current Open Circuit Lamp
Or Open
Circuit • Faulty Relay
Proceed to Backup Light Circuit Test (See Table 28, page 83).
2392 Back Up Light 6 1601 4 Reverse • Current Above Ext_Lamp_
And Alarm Lights Relay Normal Or Test_Reverse_
Horn Over Current Grounded Lamp
Circuit
• Faulty Relay
Proceed to Backup Light Circuit Test (See Table 28, page 83).
Always refer to the specific electrical diagram for the individual vehicle or system being serviced.
Manual Transmission: Should the backup lights fail to operate, the problem could be attributed to a faulty ball
switch in the transmission, open circuits to the tail lights, or faulty backup bulbs.
Automatic Transmission: Should the backup lights fail to operate, the problem could be attributed to an
issue within the TCM , a problem with the backup lights relay, faulty backup light bulbs, or problems in the
associated circuits. For backup light concerns related to TCM circuits and functionality, refer to the appropriate
service information.
82 S08361
TROUBLESHOOTING BACKUP LIGHTS
Backup Lights Preliminary Checks
Table 27 Backup Lights Preliminary Checks
STEP ACTION YES NO

1. Turn ignition switch ON. Place Backup lights are functioning Go to next step.
transmission in REVERSE. as designed. Problem may be
intermittent.
Visually check backup light
operation.
Are backup lights working

correctly?
2. Are individual backup lights Inspect specific bulb and related Go to next step.
malfunctioning? (Example: circuits for open or short.
left light working, right light
inoperative.)
3. Are other features Utilize circuit diagrams to Go to next step.
malfunctioning that may locate shared circuits for further
have common circuits? diagnosis.
4. Are there any Diagnostic Refer to the Diagnostic Trouble • Proceed to the Backup Light
Trouble Codes stored? Codes for specific cause (See Circuit Test (See Table 28,
Table 26, page 82). page 83).
• Proceed to the Backup Light

Switch Test (See Table 29,
page 85).
Backup Light Circuit Test (Automatic Transmission)
NOTE – The Transmission Control Module (TCM) controls the backup light operation. The Body
Controller receives input from the backup light relay and will operate the work lights when the backup
lights are illuminated.
Table 28 Backup Light Circuit Test

1. Using the Diamond Signal follows Proceed to step 6. Go to next step.
Logic® Builder (DLB), transmission
locate and observe request. • Refer to the specific transmission
the Backup_Light_ manual for further diagnostic
State signal. information.
Place transmission in
reverse.
2. Remove the backup 12 ± 1.5V Go to next step. • Inspect 10A Fuse F5-M (1014).
light relay (1010).
• Inspect circuit A71 for open or
Key is in ON position. short.
S08361 83
BACKUP LIGHTS TROUBLESHOOTING
Table 28 Backup Light Circuit Test (cont.)

Measure voltage
between the backup
light relay (1010),
3. Key is in ON position. 12 ± 1.5V Go to next step. Inspect circuit A71C for open or
short.
Measure voltage
between the backup
light relay (1010),
4. Measure continuity Continuity Install the backup Inspect ground circuit A92 for
between the backup present light relay (1010). open.
light relay (1010),
cavity 85 and ground. Go to next step.
Transmission in
reverse.
5. Disconnect the turn 12 ± 1.5V Go to next step. • Inspect circuit A71AB for open
signal adapter (400). or short.
Key is in ON position. • Replace faulty backup light relay

(1010).
Transmission in
reverse.
Measure voltage
at the turn signal
adapter (400), pin J
and ground.
6. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect circuits R71, N71A, and
A71A for open or short.
Transmission in
reverse. • Inspect the center chassis /
rear chassis (9800) for loose,
Measure voltage damaged, or corroded terminals.
between the tail light
connector (9303), • Inspect the IP / center chassis
cavity A to ground. (1701) for loose, damaged, or
corroded terminals.
84 S08361
TROUBLESHOOTING BACKUP LIGHTS
Table 28 Backup Light Circuit Test (cont.)

7. Key is in ON position. 12 ± 1.5V • No faults evident at • Inspect ground circuits R10-G,
this time. N10-G, and N11-GA for open.
Transmission in
reverse. • Make sure correct • Inspect the center chassis /
bulbs are used and rear chassis (9800) for loose,
Measure voltage connectors are not damaged, or corroded terminals.
between cavity A and loose, damaged, or
cavity E of the tail light corroded. • Inspect ground adapter (8807)
connector (9303). for loose, damaged, or corroded
terminals.
Backup Light Switch Test (Manual Transmission)
Table 29 Backup Light Switch Test

1. Disconnect the backup 12 ± 1.5V Connect the • Inspect 10A Fuse F5-M
light switch. backup switch (1014).
connector.
Key is in ON position. • Inspect circuit A71A for
Go to next step. open or short.
Measure voltage
between the backup
switch connector
(7502M/7500M/
7500MA/7500W), cavity
6 and ground.
2. Disconnect the turn 12 ± 1.5V Go to next step. • Inspect circuit A71AB for
signal adapter (400). open or short.
Measure voltage • Replace faulty switch.

between the turn signal
adapter (400), cavity J
and ground.
Transmission is in
reverse.
S08361 85
DOME AND COURTESY LIGHTS SYSTEM DESCRIPTION
Table 29 Backup Light Switch Test (cont.)

3. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect circuits R71,
N71A, and A71A for open
Transmission in reverse. or short.
Measure voltage • Inspect the center chassis

between the tail light / rear chassis (9800)
connector (9303), cavity for loose, damaged, or
A to ground. corroded terminals.
• Inspect the IP / center

chassis (1701) for loose,
terminals.
4. Key is in ON position. 12 ± 1.5V • No faults evident • Inspect ground circuits
at this time. R10-G, N10-G, and N11-GA
Transmission is in for open.
reverse. • Make sure correct
bulbs are used and • Inspect the center chassis
Measure voltage connectors are not / rear chassis (9800)
between cavity A and loose, damaged, or for loose, damaged, or
cavity E of the tail light corroded. corroded terminals.
connector (9303).
• Inspect ground adapter
(8807) for loose, damaged,
or corroded terminals.
2. DOME AND COURTESY LIGHTS

This section contains a general overview of the dome and courtesy lighting system.
Overview
The dome lights provide interior cab lighting and are controlled by an input switch assembly located in each
cab door.
The courtesy lights are located in both the driver and passenger doors and are provided to illuminate the steps
and floors while entering and exiting the vehicle.
Operation
Dome Lights: The Body Controller (BC) monitors inputs from the Electronic Gauge Cluster (EGC) for
dome light switch operation and door switch input. When a door switch closes, the input circuit is grounded
through the individual door switch to a cab ground point. The BC then will respond by energizing the dome
light output circuit.
Courtesy Lights: The Body Controller (BC) dome light output circuit also provides current to illuminate the
courtesy lights. When a door is opened or closed, the courtesy lights will operate in the same manner as
86 S08361
FEATURE CODE DOME AND COURTESY LIGHTS
the dome lights. Courtesy lights are supplied current from the dome light output circuit, and are grounded
through the left side cab ground (4081).
2.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the dome and
courtesy lights.

0595AKY BC PROG, DOME LIGHT

This section contains all user programmable features directly related to the dome light system.
Name: Dome_Light_Wait_Time
• ID: 2395
• Description: Delays theater timing
• Maximum Value: 60 seconds
• Minimum Value: 0 seconds
• Default Value: 15 seconds

The dome and courtesy lights are able to set Diagnostic Trouble Codes (DTC) when specific faults occur.
Information given by the DTC can aid in the diagnosis of the problem.

CAUSE SIGNAL
3976 Cab Dome 5 1604 J Cab Dome Open In Cab Dome_Light_Cmd
Light 1 Light Dome Light
Open Circuit
Circuit
Proceed to the Cab Dome Light Circuit Test (See Table 34, page 90).
S08361 87
DOME AND COURTESY LIGHTS TROUBLESHOOTING

CAUSE SIGNAL
3976 Cab Dome 6 1604 J Cab Dome Short To Ground Dome_Light_Cmd
Light 1 Light In Cab Dome
Short To Light Circuit
Ground
Proceed to the Cab Dome Light Circuit Test (See Table 34, page 90).
NOTE – Always utilize the Breakout Box (ZTSE4477) when circuit testing is being performed at the Body
Controller (BC).
Dome and Courtesy Lights Preliminary Checks
NOTE – The key switch must be in the OFF position and park brake must be ON.
NOTE – Dome light power will be cut back to 1% after 10 minutes.
NOTE – Cycle the door ajar or key switch to reset the dome lights.
Table 32 Dome and Courtesy Lights Preliminary Checks
STEP ACTION YES NO

1. Are dome and courtesy lights Go to step 3. Go to next step.
working correctly using driver
door?
Close all cab doors. Open

driver door ONLY.
Are all dome lights functioning

properly?
2. Are individual dome and • Inspect specific inoperative Go to next step.
courtesy lights inoperative? bulb and electrical circuits for
(Example: dome lights damage or open. NOTE – Dome light control
working, single courtesy light switch (if equipped) on
inoperative.) • Proceed to the Dome Light EGC will disable dome and
Circuit Test (See Table 34, page courtesy light functions
Open driver door and visually 90). when in OFF position.
check if individual dome or
courtesy lights are inoperative.
Are specific dome lights

inoperative?
88 S08361
TROUBLESHOOTING DOME AND COURTESY LIGHTS
Table 32 Dome and Courtesy Lights Preliminary Checks (cont.)

STEP ACTION YES NO
3. Do dome and courtesy lights Go to next step. Proceed to the Door Switch
operate when each door is Circuit Test (See Table 33,
opened? page 89).
Starting with all doors closed,

open each door, one at a time,
while observing dome and
courtesy light operation.
Are dome lights functioning

correctly with each door
switch?
4. Are there any Diagnostic Refer to the Diagnostic Trouble • No problem found.
Trouble Codes stored in Body Codes for specific cause (See
Controller? Table 31, page 87). • Refer to Body Controller
Signal States and monitor for
Using Diamond Logic® Builder, intermittent input signals.
check for diagnostic trouble
codes related to headlight
system.
Door Switch Circuit Tests
NOTE – The key switch must be in the OFF position and park brake should be ON.
NOTE – Dome light power will be cut back to 1% after 10 minutes of dome light activation.
NOTE – Cycling the door proximity switch or the key switch will reactivate the dome lights.
Table 33 Door Switch Circuit Test

1. Utilizing the Diamond Value should follow • No faults evident Go to next step.
Logic Builder (DLB), actual door switch with door switch
locate and view the position. or Body Controller
Door_Switch signal. operation.
Open and close the • Proceed to the

driver door. Cab Dome Light
Circuit Test (See
Open and close the Table 34, page 90).
passenger door.
S08361 89
DOME AND COURTESY LIGHTS TROUBLESHOOTING
Table 33 Door Switch Circuit Test (cont.)

2. Measure continuity All doors open, Suspect faulty • If continuity exists when
between cavity E5 of continuity is Body Controller. doors are closed, disconnect
the BC #J5 connector present. driver door switch and retest
(1602), and A13 of for continuity.
the BC #J3 connector All doors closed,
(1600). circuit is open. • If continuity exists,
disconnect remaining door
Open and close doors switches, one at a time, and
while observing circuit retest for each switch.
continuity.
• If continuity exists when all
switches are disconnected,
inspect dome light door
switch input circuit for
damage or short to ground.
Cab Dome Light Circuit Test
The Cab Dome Light Circuit Test provides diagnostics for dome lights when controlled by the Body Controller
(BC). The BC will provide voltage to the dome light circuits when a door is ajar or the EGC mounted dome
light switch is operated.
NOTE – The key switch must be in the OFF position and park brake should be ON.
NOTE – Ensure a door is open or dome light switch is in the ON position, allowing the BC to provide
voltage to appropriate dome or courtesy light.
Table 34 Cab Dome Light Circuit Test

1. Utilizing the Diamond Logic Signal Go to next • BC not receiving request.
Builder (DLB), locate and follows switch step.
observe the Dome_Light command. • Refer to the EGC section for
signal. further diagnostic information
related to the dome light switch.
Operate the Electronic
Gauge Cluster (EGC)
mounted dome switch.
90 S08361
TROUBLESHOOTING DOME AND COURTESY LIGHTS
Table 34 Cab Dome Light Circuit Test (cont.)

2. Disconnect the dome lamp 12 ± 1.5V Go to next • Inspect BC output circuits A63A
connector (2117M) for step. and A63DA for open or short.
premium trim or dome
lamp connector (2116M) for • Inspect the console / roof
standard trim. connector (2502) for loose,
Door open or dome light
switch is in ON position.
Premium Trim:

the dome lamp connector
(2117M), cavity E and
ground.
Standard Trim:

(2116M), cavity D and
ground.
3. Door open or dome light 12 ± 1.5V Inspect dome • Inspect ground circuits D11-GF,
switch is in ON position. light connector A11-GF, and A11-GS for open.
for loose,
Premium Trim: damaged, • Inspect the console / roof
or corroded connector (2502) for loose,
Measure voltage between terminals and damaged, or corroded terminals.
the dome lamp connector for correct
(2117M), cavity E and cavity bulb. • Inspect the left side cab ground.
B.
Standard Trim:

(2116M), cavity D and cavity
B.
S08361 91
FOG LIGHTS SYSTEM DESCRIPTION
Courtesy Lights Circuit Test
Table 35 Courtesy Lights Circuit Test

1. Disconnect appropriate 12 ± 1.5V Go to next • Inspect BC output circuits A63A,
courtesy light. step. A63DB/DC, and A63DA for open
or short.
Door is open.
• Inspect the door / IP or IP / roof
Measure voltage between connector for loose, damaged, or
the courtesy light corroded terminals.
connector, pin A and
ground.
2. Measure voltage between 12 ± 1.5V Replace Front Courtesy Lights:
the courtesy light courtesy light. Inspect ground circuits E63-G,
connector, pin A and A63-GDW/GDV, and A63-GD for
pin B. open.
Inspect ground adapter (1006)

terminals.
Rear Courtesy Lights: Inspect

ground circuits D63-GA, A63-GA,
and A11-GT for open.
Inspect the left side ground post

terminals.
3. FOG LIGHTS
This section contains a general overview of the fog light feature.
Overview
The fog lights are controllable by the operator from the driver position using the fog light switch. The fog
light switch is a two-position (OFF / ON) rocker type switch located in a center switch pack location or a
push button switch located below the Electronic Gauge Cluster (EGC). Fog lights are only functional when
the key is ON, and the low beam headlights are ON. The fog lights are deactivated by the BC during high
beam headlight operation.
The BC fog light output consists of two 10A circuits, which are used to power the left fog light connector and the
right fog light connector individually. The left and right fog light is provided ground by ground adapter (8800).
Operation
EGC Mounted Switch: The fog light switch is located below the EGC, and is monitored by the EGC using
the EGC switch data link. When the key is in the ON position and the fog light switch is ON, the EGC will
communicate with the BC over the J1939 data link. As the BC receives the fog light request message, the
92 S08361
FEATURE CODES FOG LIGHTS
BC will check first for high beam activation. If high beams are not being requested, the BC will then supply
voltage to the fog light output circuits.
Center Switch Pack Mounted Switch: The fog light switch is mounted in a center switch pack position, and is
monitored by the switch pack assembly in which it is located. When the key is in the ON position and the fog
light switch is ON, the switch pack will communicate with the BC using the J1708 switch data link. As the BC
receives the fog light request message, the BC will check first for high beam activation. If high beams are not
being requested, the BC will then supply voltage to the fog light output circuits.
3.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the fog lights.
Table 36 Feature Codes

0595ACE BC PROG, FOG LIGHTS rocker switch
0595AMS BC PROG, FOG LIGHTS push button location A
0595AMT BC PROG, FOG LIGHTS push button location B

There are no user programmable parameters associated with this feature.

The fog lights are able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given by
the DTC can aid in the diagnosis of the problem.

CAUSE SIGNAL
4008 Fog Light 2 5 1603 K Right Fog Light • Blown Fog Light Right_Gen2_
Under Current Bulb Fog_Light_Cmd
• Open In Right
Fog Light Circuit
Proceed to the Fog Light Circuit Test (See Table 40, page 96).
4008 Fog Light 2 6 1603 K Right Fog Light Short To Ground Right_Gen2_
Over Current In Right Fog Light Fog_Light_Cmd
Output Circuit
Proceed to the Fog Light Circuit Test (See Table 40, page 96).
S08361 93
FOG LIGHTS TROUBLESHOOTING

CAUSE SIGNAL
2388 Fog Light 1 5 1603 F Fog Light Relay Fog Light Relay Fog_Light_Cmd
Command Under Current Or
Open Circuit • Fog Light Relay
Under Current Or
Open Circuit
• Current Below
Normal Or Open
Circuit
Proceed to the Fog Light Switch Test (See Table 39, page 95).
2388 Fog Light 1 6 1603 F Fog Light Relay • Fog Light Relay Fog_Light_Cmd
Command Over Current
• Shorted Circuit
2387 Tractor Front 2 N/A N/A Fog Light Switch • Faulty Switch Fog_Light
Fog Light Error Actuator _Switch,
Command
• Faulty Front_Fog_
Microswitch Light
_Switch
NOTE – Fog light functions are disabled by the Body Controller when the headlights are placed in the
high beam mode.
Fog Light System Preliminary Check
Table 38 Fog Light System Preliminary Check
STEP ACTION YES NO

1. Turn headlight and fog light switch Problem may be intermittent. Go to next step.
is ON.
Visually check fog lights.
NOTE – Headlights must be in low

beam mode.
94 S08361
TROUBLESHOOTING FOG LIGHTS
Table 38 Fog Light System Preliminary Check (cont.)

STEP ACTION YES NO
Are fog lights working correctly?

2. Are individual fog lights • Inspect appropriate bulb and Go to next step.
malfunctioning? (Example: left light electrical circuits for faults.
working, right light inoperative.)
• Proceed to the Fog Light Circuit
Test (See Table 40, page 96).
• If bulb and circuits OK, go to step

4.
3. Are other features malfunctioning Refer to other inoperative feature’s Go to next step.
that may have common circuits? specific diagnostic section.
NOTE – Refer to Body Controller

Functions to verify if fog light
function is being disabled by
other Body Controller features.
4. Are there any Diagnostic Trouble Refer to the Diagnostic Trouble Proceed to the Fog
Codes stored in Body Controller? Codes for specific cause (See Table Light Switch Test
37, page 93). (See Table 39, page
Using Diamond Logic® Builder 95).
(DLB), check for active and inactive
diagnostic trouble codes related to
fog light system.
Fog Light Switch Test
NOTE – The key switch, headlight switch, and fog light switch must all be in the ON position.
Table 39 Fog Light Switch Test

1. Using the Diamond Signal follows switch Go to next Refer to the SWITCH
Logic® Builder (DLB), command. step. PACK (J1708) section
locate and observe the for further diagnostic
Fog_Light_Switch signal. information.
Operate fog light switch.
S08361 95
FOG LIGHTS TROUBLESHOOTING
Table 39 Fog Light Switch Test (cont.)

2. Fog light switch in ON Left_Fog_Light_Req: Proceed to • Verify all interlocks have
position. Checked the Fog Light been met.
Circuit Test
Using the DLB, locate and Right_Fog_Light_Req: (See Table • Suspect faulty BC.
observe the following signals: Checked 40, page 96).
Left_Fog_Light_Req
Right_Fog_Light_Req
Monitor signals for correct

values.
Fog Light Circuit Test
Table 40 Fog Light Circuit Test

1. Using the Diamond Logic® Fog lights • BC output Go to next step.
Builder (DLB), select the illuminate. signals are
CONNECTORS tab. functioning
properly.
Select the BC #J1 (1603)
connector. • Proceed to the
Fog Light Switch
Actuate both right and left Test (See Table
fog lights. 39, page 95).
96 S08361
SYSTEM DESCRIPTION HEADLIGHTS AND DAYTIME RUNNING LIGHTS (DTRL)
Table 40 Fog Light Circuit Test (cont.)

2. Ensure headlight low 12 ± 1.5V Go to next step. Left fog light:
beams are ON and fog
light switch is ON. • Inspect circuits M64A and A64A
for open or short.
Perform the following test
at the appropriate fog light: • Inspect the IP / forward chassis
Measure voltage between damaged, or corroded terminals.
the fog light connector
(8201/8200), cavity A and • Inspect the BC #J1 connector
ground. (1603) for loose, damaged, or
corroded terminals.
Right fog light:
• Inspect circuits M64B and A64B

for open or short.
• Inspect the IP / forward chassis

• Inspect the BC #J1 connector

corroded terminals.
3. Perform the following test 12 ± 1.5V Inspect fog light Left fog light:
at the appropriate fog light: connector for
damage and • Inspect ground circuit M64-GA to
Measure voltage between inspect fog light ground adapter #1 (8800) for open
the left fog light connector bulbs. or short.
(8201/8200), cavity A and
cavity B. Right fog light:
• Inspect ground circuit M64-GB to

ground adapter #1 (8800) for open
or short.
NOTE – Ground adapter #1 (8800)

is grounded through circuits
11-GD and M11-G to the left side
cab ground.
4. HEADLIGHTS AND DAYTIME RUNNING LIGHTS (DTRL)

This section contains a general overview of the headlight system.
S08361 97
HEADLIGHTS AND DAYTIME RUNNING LIGHTS (DTRL) FEATURE CODES
Overview
Headlights : Headlights provide lighting for operator forward visibility during low-light conditions. Headlights
are capable of being turned ON or OFF regardless of key state.
Daytime Running Lights (DTRL): Feature provides forward illumination meant to make the vehicle more
visible to oncoming traffic during daylight hours. DTRL will function whenever the key is in the ON position, the
headlight switch is OFF, and the park brake is not set.
Operation
Headlights: When the key is in the ON position and the headlight switch is ON, the Electronic Gauge Cluster
(EGC) will communicate with the Body Controller (BC) on the J1939 data link. The BC will then supply
voltage to the headlights as requested by the J1939 data message. Key OFF operation is enabled by a single
circuit routed directly from the EGC to the BC, which is not dependent on the J1939 data link. Identified as
the headlight enable circuit, it also acts as a fail-safe circuit that will activate the low beam headlights if
communication on the J1939 data link is interrupted. The BC will disable high beam operation when the park
brake is set, or the fog lights are turned on. The flash-to-pass feature will function as normal regardless of the
state of the park brake or fog light inputs.
DTRL: Daytime Running Lights (DTRL) operation is a programmed function of the BC. When the DTRL option
is enabled in Diamond Logic® Builder (DLB), the system will activate DTRL any time the key switch is ON
and the headlight switch is OFF. During DTRL operation, the BC will operate the low beam headlights at a
reduced intensity using Pulse Width Modulation (PWM). DTRL will be disabled when the park brake is set, or
the key switch is turned OFF.
4.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the headlights and
daytime running lights.

0595ALB BC PROG, HEADLIGHTS WITH DRL less auto
0595BLN BC PROG, HEADLIGHTS WIG WAG with high beam flash
0595BLP BC PROG, HEADLIGHTS WIG WAG with low beam or high beam flash
0595AAH BC PROG, LIGHTS ON WITH WIPERS

There are no Body Controller related user programmable parameters associated with this feature.

The headlights are able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given
98 S08361
DIAGNOSTIC TROUBLE CODES HEADLIGHTS AND DAYTIME RUNNING LIGHTS (DTRL)

CAUSE SIGNAL
2653 Headlamp Low 5 1604 B Left Low • Left Low Left_
Beam Left #1 Beam Under Beam Bulb Lowbeam_
Current Cmd
• Open In Left
Low Beam
Circuit
Proceed to the Left Headlight Circuit Test (See Table 47, page 106).
2653 Headlamp Low 6 1604 B Left Low • Left Low Left_
Beam Left #1 Beam Short Beam Bulb Lowbeam_
To Ground Cmd
• Short To
Ground Or
Overload
In Left Low
Beam Circuit
2655 Headlamp Low 5 1604 H Right Low • Right Low Right_
Beam Right #1 Beam Open Beam Bulb Lowbeam_
Circuit Cmd
• Open In
Right Low
Beam Circuit
Proceed to the Right Headlight Circuit Test (See Table 46, page 104).
S08361 99
HEADLIGHTS AND DAYTIME RUNNING LIGHTS (DTRL) TROUBLESHOOTING

CAUSE SIGNAL
2655 Headlamp Low 6 1604 H Right Low • Right Low Right_
Beam Right #1 Beam Short Beam Bulb Lowbeam_
To Ground Cmd
• Right Low
Beam Short
To Ground
4011 Headlamp 1 5 1604 C Left High • Left High Left_
High Beam Beam Open Beam Bulb Highbeam_
Circuit Cmd
• Open In Left
High Beam
Circuit
4011 Headlamp 1 6 1604 C Left High • Left High Left_
High Beam Beam Short Beam Bulb Highbeam_
To Ground Cmd
• Short To
Ground In Left
High Beam
Circuit
4012 Headlamp 2 5 1604 K Right High • Right High Right_
High Beam Beam Open Beam Bulb Highbeam_
Circuit Cmd
• Open In
Right High
Beam Circuit
4012 Headlamp 2 6 1604 K Right High • Right High Right_
High Beam Beam Short Beam Bulb Highbeam_
To Ground Cmd
• Short To
Ground In
Right High
Beam Circuit
100 S08361
TROUBLESHOOTING HEADLIGHTS AND DAYTIME RUNNING LIGHTS (DTRL)
Headlight System Preliminary Check
Table 43 Headlight System Preliminary Check
STEP ACTION YES NO

1. Are headlights working No fault evident at this time. Go to next step.
correctly?
Operate headlight switch.
Visually check headlight

operation.
2. Are both high and low beam Go to next step. • Proceed to the Headlight
headlights operational? Switch Test (See Table 44,
page 102).
• If high beam operation is

inoperative, suspect faulty turn
signal switch.
3. Are both headlights operational Go to next step. • Proceed to the specific
when illuminated? Headlight Circuit Test.
• Proceed to the Left Headlight

Circuit Test (See Table 47,
page 106).
• Proceed to the Right

Headlight Circuit Test (See
Table 46, page 104).
4. Are there any Diagnostic Refer to the Diagnostic Trouble Proceed to the Headlight
Trouble Codes stored in Body Codes for specific cause (See Switch Test (See Table 44,
Controller? Table 42, page 99). page 102).
S08361 101
Headlight Switch Test
Table 44 Headlight Switch Test

1. Using Diamond EGC_ If equipped with Auto Refer to the ELECTRONIC
Logic® Builder Headlight_ Headlights, go to GAUGE CLUSTER section for
(DLB), locate Request: next step. further diagnostic information
and observe the related to the headlight switch.
EGC_Headlight_ Headlight Switch If not equipped with
Request signal. Position: Auto Headlights, go
to step 3.
Operate headlight ON position
switch. value: checked
PARK position
value:
unchecked
OFF position
value:
unchecked
2. Using the DLB, Signal follows Go to next step. Refer to the ELECTRONIC
observe the switch command. GAUGE CLUSTER section for
following signal: further diagnostic information
related to the headlight switch.
EGC_Auto_
Headlight_
Request
Operate headlight
switch in AUTO
position.
3. Using the DLB, Signal follows Go to next step. Refer to the ELECTRONIC
observe the switch command. GAUGE CLUSTER section for
following signal: further diagnostic information
related to the headlight switch.
Headlight_Enable
_Signal
Operate headlight
switch.
102 S08361
Table 44 Headlight Switch Test (cont.)

4. Using the DLB, Value displays Go to next step. Refer to the ELECTRONIC
observe the low beam ON. GAUGE CLUSTER section for
Headlight_Output further diagnostic information
signal. related to the headlight switch.
Operate the
headlight switch
in the low beam
position.
5. Using the DLB, Value displays • Proceed to specific • Refer to the ELECTRONIC
observe the high beam ON. Headlight Circuit GAUGE CLUSTER section for
Headlight_Output Test. further diagnostic information
signal. related to the headlight switch.
• Left Headlight
Operate the Circuit Test (See • If high beam operation is
headlight switch Table 47, page 106). inoperative, suspect faulty turn
in the high beam signal switch.
position. • Right Headlight
Circuit Test (See
Turn Signal Switch Circuit Test
Table 45 Turn Signal Switch Circuit Test

1. Disconnect the 12 ± 1.5V Go to next step. • Inspect circuit B52A and circuit
turn signal switch A52A for open or short.
connector (1810).
• Inspect the IP / DCM connector
Key is in ON (1800) for loose, damaged, or
position. corroded terminals.
Headlight switch is
in ON position.
Measure voltage
between the turn
signal switch
connector (1810),
2. Key is in ON 12 ± 1.5V Go to next step. • Inspect circuit B102A and circuit
position. A102A for open or short.
Headlight switch in • Inspect the IP / DCM connector

ON position. (1800) for loose, damaged, or
corroded terminals.
Measure voltage
between the turn
S08361 103
Table 45 Turn Signal Switch Circuit Test (cont.)

signal switch
connector (1810),
3. Key is in ON 12 ± 1.5V Go to next step. • Inspect Zero Volt Reference
position. (ZVR) circuits B9S, B9V, A9V,
and A9AA for open.
Headlight switch in
ON position. • Inspect the IP / DCM connector
Measure voltage corroded terminals.
between the turn
signal switch
connector (1810),
cavity 4 and cavity
7.
4. Measure continuity Continuity Go to next step. Replace faulty turn signal switch.
between the turn present
signal switch
connector (1810),
pin 7 and pin 4.
Operate the
flash-to-pass
switch.
5. Measure continuity Continuity Proceed to Replace faulty turn signal switch.
between the turn present the appropriate
signal switch headlight circuit test.
connector (1810),
pin 7 and pin 3.
Operate the high

beam switch.
Right Headlight Circuit Test
Table 46 Right Headlight Circuit Test

1. Disconnect the right 12 ± 1.5V Go to next step. • Inspect circuit M53B for open or
headlight / turn signal short.
harness connector
(8000). • Inspect the IP / forward chassis
Headlight switch in low damaged, or corroded terminals.
beam position.
• Proceed to the Headlight Switch
Measure voltage Test (See Table 44, page 102).
between the right
headlight / turn signal
104 S08361
Table 46 Right Headlight Circuit Test (cont.)

harness connector
(8000), cavity C and
ground.
2. Headlight switch in low 12 ± 1.5V Replace faulty Inspect ground circuit M11-GA for
beam position. low beam bulb. open.
Measure voltage NOTE – All headlight bulbs share

between the right ground circuit M11-G.
headlight / turn signal
harness connector
cavity B.
3. Headlight switch high 12 ± 1.5V Replace faulty • Inspect circuit M52D for open or
beam position. high beam bulb. short.
Measure voltage • Inspect the IP / forward chassis

between the right connector (1700) for loose,
headlight / turn signal damaged, or corroded terminals.
harness connector
(8000), cavity A and • Proceed to the Headlight Switch
ground. Test (See Table 44, page 102).
S08361 105
STOP, TURN, AND HAZARD LIGHTS SYSTEM DESCRIPTION
Left Headlight Circuit Test
Table 47 Left Headlight Circuit Test

1. Disconnect the left 12 ± 1.5V Go to next step. • Inspect circuit M53 for open or short.
headlight / turn
signal harness • Inspect the IP / forward chassis
connector (8001). connector (1700) for loose, damaged, or
corroded terminals.
Headlight switch in
low beam position. • Proceed to the Headlight Switch Test
(See Table 44, page 102).
Measure voltage
between the left
headlight / turn
signal harness
connector (8001),
cavity C and
ground.
2. Headlight switch in 12 ± 1.5V Replace faulty low Inspect ground circuit M11-GB for open.
low beam position. beam bulb.
NOTE – All headlight bulbs share
Measure voltage ground circuit M11-G.
between the left
headlight / turn
signal harness
connector (8001),
cavity C and cavity
B.
3. Headlight switch 12 ± 1.5V Replace faulty high • Inspect circuit M52 for open or short.
high beam position. beam bulb.
Measure voltage connector (1700) for loose, damaged, or
between the left corroded terminals.
headlight / turn
signal harness • Proceed to Headlight Switch Test (See
connector (8001), Table 44, page 102).
cavity A and ground.
5. STOP, TURN, AND HAZARD LIGHTS

This section contains a general overview of the stop, turn, and hazard lights.
Overview
The turn signals are located in the front and rear of the vehicle: one set on the left side of the vehicle and one
set on the right side of the vehicle. Through normal operation, the turn signals flash on / off when activated.
When the left and right turn signals flash at the same time, they are known as hazards. Depending on which
106 S08361
FEATURE CODES STOP, TURN, AND HAZARD LIGHTS
type of stop / turn / hazard circuitry the vehicle may utilize, the rear turn signals may also be used to indicate
when the brake is being applied, also acting as brake lights.
Operation
This system utilizes the Body Controller (BC) to illuminate the turn signal lamps, brake lights, and hazard
flashers. Brake light, turn signal, and hazard activation is accomplished using switched inputs sent directly to
the BC. As the BC monitors the brake switch and turn signal switch inputs, it will also provide direct control of
the turn, stop, and hazard lamp output circuits. Therefore, conventional mechanical type flasher units are
not necessary. The BC contains software parameters that provide for a circuit output cycling timer, which will
control flashing of the turn signal and hazard lamps. Flashing of the individual lamps is timer controlled and
maintains a cycle rate of 90 times per minute anytime a turn or hazard switch request signal is received. The
software timer is activated any time the turn signal lamps or hazards are to be illuminated, and it will provide a
timed ON / OFF output cycle that is used to illuminate and extinguish the individual turn signals or hazard lights.
5.2. FEATURE CODES

This section contains the available Body Controller feature code definition related to the stop, turn, and
hazards system.

0595AAL BC PROG, TURN SIGNALS / BRAKE combined stop and turn
0595ALW BC PROG, STOP / TURN / PARK / MARKER DIAGNOSTICS OMIT


This feature is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given by

CAUSE SIGNAL
2368 Left Turn Signal 5 1603 B Left Front Turn • Left Front LT_FT_
Lights Lamp Under Turn Signal Turn_Cmd
Current Bulb
• Open In Left
Front Turn
Signal Circuit
Proceed to the Left Front Turn Signal Circuit Test (See Table 53, page 115).
S08361 107
STOP, TURN, AND HAZARD LIGHTS DIAGNOSTIC TROUBLE CODES

CAUSE SIGNAL
2368 Left Turn Signal 6 1603 B Left Front Turn • Left Front LT_FT_
Lights Lamp Over Turn Signal Turn_Cmd
Current Bulb
• Short To
Ground Or
Overload In
Left Front
Turn Signal
Circuit
Proceed to the Left Front Turn Signal Circuit Test (See Table 53, page 115).
2370 Right Turn 5 1603 A Right Front • Right Front RT_FT_
Signal Lights Turn Lamp Turn Signal Turn_Cmd
Under Current Bulb
• Open In
Right Front
Turn Signal
Circuit
Proceed to the Right Front Turn Signal Circuit Test (See Table 54, page 116).
2370 Right Turn 6 1603 A Right Front • Right Front RT_FT_
Signal Lights Turn Lamp Turn Signal Turn_Cmd
Over Current Bulb
• Short To
Ground Or
Overload In
Right Front
Turn Signal
Circuit
Proceed to the Right Front Turn Signal Circuit Test (See Table 54, page 116).
2372 Left Stop Light 5 1603 D Left Rear Turn Open In Left LT_RR_
Lamp Under Rear Turn Turn_Cmd
Current Signal Circuit
Proceed to the Left Rear Turn Signal Circuit Test (See Table 55, page 116).
2372 Left Stop Light 6 1603 D Left Rear Turn Short To LT_RR_
Lamp Over Ground Or Turn_Cmd
Current Overload In
Left Rear Turn
Signal Circuit
Proceed to the Left Rear Turn Signal Circuit Test (See Table 55, page 116).
2374 Right Stop Light 5 1603 M Right Rear Open In Right RT_RR_
Turn Lamp Rear Turn Turn_Cmd
Under Current Signal Circuit
108 S08361
DIAGNOSTIC TROUBLE CODES STOP, TURN, AND HAZARD LIGHTS

CAUSE SIGNAL
Proceed to the Right Rear Turn Signal Circuit Test (See Table 56, page 117).
2374 Right Stop Light 6 1603 M Right Rear Short To RT_RR_
Turn Lamp Ground Or Turn_Cmd
Over Current Overload In
Right Rear
Turn Signal
Circuit
Proceed to the Right Rear Turn Signal Circuit Test (See Table 56, page 117).
597 Brake Switch 0 1602 E14 Brake Switch Brake Switch Brake_
and Reading Short To Analog_
E15 Above Normal Ground Or Switch_ Raw_
Range Faulty Sensor Signal
System
Proceed to the Brake Switch Test (See Table 52, page 113).
597 Brake Switch 1 1602 E14 Brake Switch Brake Switch Brake_
and Reading Short To Analog_
E15 Below Normal Ground Or Switch_ Raw_
Range Faulty Sensor Signal
System
597 Brake Switch 2 1602 E14 Brake Switch High Brake_
and Inputs Do Not Resistance Switch_
E15 Match In The Wire Signal
Harness
Defective
Brake
Switch Or
A Defective
Body
Controller
Or Defective
ABS
Controller Or
Data Link
597 Brake Switch 7 1602 E14 Brake Switch Defective Brake_
and Stuck Open Brake Switch Switch_
E15 Or Closed Signal
597 Brake Switch 14 N/A N/A Brake Switch Defective Brake_
Stuck Open Brake Switch Switch_
Or Closed Signal
S08361 109
STOP, TURN, AND HAZARD LIGHTS TROUBLESHOOTING

CAUSE SIGNAL
597 Brake Switch 14 N/A N/A Brake Switch Occurs If Brake_
Inputs Do Not There Is Switch_
Match A High Signal
Resistance
In The Wire
Harness
Defective
Brake
Switch Or
A Defective
Body
Controller
(BC)
NOTE – When diagnosing brake system electrical components, maintain air pressure at or above 90 PSI
(621 kPa).
NOTE – It is necessary to bench test appropriate stop, turn, or hazard relays prior to circuit testing.
Stop, Turn, and Hazards System Preliminary Check
Table 50 Stop, Turn, and Hazards System Preliminary Check
STEP ACTION YES NO

1. Operate turn signal switch Go to step 3. Go to next step.
lever to each position.
Visually check operation of all

left and right turn signals.
Are all turn signals working

correctly?
110 S08361
TROUBLESHOOTING STOP, TURN, AND HAZARD LIGHTS
Table 50 Stop, Turn, and Hazards System Preliminary Check (cont.)

STEP ACTION YES NO
2. Activate turn signal switch to • Proceed to appropriate Proceed to the Turn Signal
malfunctioning side. circuit test. Switch Test (See Table 51,
page 111).
Visually check if all left turn • Right Rear Turn Signal
or all right turn lights are Circuit Test (See Table 56,
malfunctioning. page 117).
Are individual turn lights • Left Rear Turn Signal Circuit

malfunctioning? (Example: Test (See Table 55, page 116).
front light working, rear light
inoperative.) • Right Front Turn Signal
page 116).
• Left Front Turn Signal Circuit

• If circuit OK, go to step 4.

3. Are brake lights working • Inspect brake light bulb and Proceed to the Brake Switch
correctly? inspect circuit for open or Test (See Table 52, page 113).
short.
Operate brake pedal.
• If circuit OK, go to step 4.
Visually check if brake lights
are malfunctioning.
4. Are there any Diagnostic Refer to the Diagnostic No problem found. Problem
Trouble Codes stored in Body Trouble Codes for specific may be intermittent.
Controller? cause (See Table 49, page
107).
Turn Signal Switch Circuit Test
Table 51 Turn Signal Switch Circuit Test

1. Using Diamond Logic® Turn Signal Switch Go to next step. Suspect faulty turn
Builder, locate and Position: Left signal switch.
observe the following
signals: Left_Turn_Signal_
Switch: checked
Left_Turn_Signal_
Switch Turn Signal Switch
Position: Right
Right_Turn_Signal_
Switch
S08361 111

Operate turn signal Right_Turn_Signal_

switch. Switch: checked
2. Continue to observe the Both signals follow • Proceed to Go to next step.

following signals: hazard switch appropriate output
command. circuit test.
Left_Turn_Signal_
Switch • Right Rear Turn
Signal Circuit Test
Right_Turn_Signal_ (See Table 56, page
Switch 117).
Operate the hazard • Left Rear Turn

switch. Signal Circuit Test
(See Table 55, page
116).
• Right Front Turn

Signal Circuit Test
(See Table 54, page
116).
• Left Front Turn

Signal Circuit Test
(See Table 53, page
115).
3. Disconnect the turn signal 12 ± 1.5V Go to next step. • Inspect circuit B56A
switch connector (1810). (left turn and hazard)
for open or short.
Key is in ON position.
Measure voltage between connector (1800) for
the turn signal switch loose, damaged, or
connector (1810), cavity corroded terminals.
1 and ground.
4. Measure continuity Continuity present Go to next step. Replace faulty turn
between the turn signal signal switch.
connector (1810), cavity
1 and cavity 7.
Operate left turn signal.
112 S08361

5. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect circuit B57A
(right turn and hazard)
Measure voltage between for open or short.
the turn signal switch
connector (1810), cavity • Inspect the IP / DCM
2 and ground. connector (1800) for
loose, damaged, or
corroded terminals.
6. Measure continuity Continuity present No switch faults Replace faulty turn
between the turn signal present. signal switch.
2 and cavity 7.
Brake Switch Circuit Test
Table 52 Brake Switch Circuit Test

1. Using Diamond Signal follows switch • No faults evident Go to next step.
Logic® Builder, command. with brake switch.
select the
CONNECTORS tab. Brake Pedal is • Proceed to
Select the BC #J5 depressed: ON appropriate output
(1602) connector. test.
Locate and observe Brake Pedal is
the following signal: released: OFF
Brake_Switch_
Signal
While depressing
and releasing brake
pedal, monitor the
value.
2. Disconnect the 12 ± 1.5V Go to next step. Stop light #1 connector
appropriate stop light (1823):
switch connector.
• Inspect circuits B9VG, B9V,
Measure voltage A9V, and A9AA for open or
at the following short.
locations:
Stop light switch #1 connector (1800) for loose,
connector (1823), pin damaged, or corroded
C and ground. terminals.
S08361 113
Table 52 Brake Switch Circuit Test (cont.)

Stop light switch #2 Stop light #2 connector

connector (1824), pin (1824):
C and ground.
• Inspect circuits B70 and
A70 for open or short.

terminals.
114 S08361

3. Measure voltage 12 ± 1.5V Replace faulty • Inspect appropriate Zero
at the following brake switch. Volt Reference (ZVR) circuits.
locations:
Stop light switch #1 connector (1800) for loose,
connector (1823), pin damaged, or corroded
C and pin D. terminals.
Stop light switch #2

connector (1824), pin
C and pin D.
Left Front Turn Signal Circuit Test
NOTE – The left front turn signal and the left fender turn light share common power and ground circuits.
NOTE – Prior to diagnosing specific circuits, ensure the turn signal switch and hazard switch are
operating properly (See Turn Signal Switch Circuit Test) (See Table 51, page 111).
Table 53 Left Front Turn Signal Circuit Test

1. Operate left turn signal while Alternating Go to next • Inspect circuit M56B for open
performing the following test: between 12 ± 1.5V step. or short.
and 0V
Measure voltage between the • Inspect the IP / forward
headlight connector (8001), chassis connector (1700) for
pin D and ground. loose, damaged, or corroded
terminals.
• Inspect the turn signal adapter

corroded terminals.
2. Operate left turn signal while Alternating Suspect • Inspect ground circuits
performing the following test: between 12 ± 1.5V faulty bulb. M11-GB and M11-G for open.
and 0V
Measure voltage between the • Inspect the turn signal adapter
headlight connector (8001), (400) for loose, damaged, or
pin D and pin B. corroded terminals.
Right Front Turn Signal Circuit Test
NOTE – The right front turn signal and the right fender turn light share common power and ground
circuits.
S08361 115
Table 54 Right Front Turn Signal Circuit Test

1. Operate right turn signal Alternating Go to next step. • Inspect circuit M57B for open or
while performing the between 12 ± short.
following test: 1.5V and 0V
Measure voltage connector (1700) for loose,
between the right damaged, or corroded terminals.
headlight connector
(8000), pin D and • Inspect the turn signal adapter
ground. (400) for loose, damaged, or
corroded terminals.
2. Operate right turn signal Alternating Suspect faulty Inspect ground circuits M11-GA
while performing the between 12 ± bulb. and M11-G for open.
following test: 1.5V and 0V
• Inspect the turn signal adapter
Measure voltage (400) for loose, damaged, or
between the right corroded terminals.
headlight connector
(8000), pin D and pin B.
Left Rear Turn Signal Circuit Test
NOTE – The rear turn and stop lights share common power and ground circuits.
Table 55 Left Rear Turn Signal Circuit Test

1. Operate the hazard Alternating Go to next step. • Inspect circuits R56 and A56 for
switch while performing between 12 ± open or short.
the following test: 1.5V and 0V
• Inspect the center / rear chassis
Measure voltage connector (9800) and IP / center
between the tail light chassis connector (1701) for
connector (9303), cavity loose, damaged, or corroded
B and ground. terminals.
• Inspect the rear turns panel

adapter (1625) for loose,
2. Operate the hazard Alternating Suspect faulty left • Inspect ground circuit R10-G and
switch while performing between 12 ± turn signal bulb. N10-G for open.
• Inspect ground adapter (8807)
between the tail light terminals.
116 S08361
SYSTEM DESCRIPTION TAIL, MARKER, PARK, AND CLEARANCE LIGHTING
Table 55 Left Rear Turn Signal Circuit Test (cont.)

B and cavity E. NOTE – All rear bulbs share
ground circuit R10-G and N10-G.
Right Rear Turn Signal Circuit Test
NOTE – The rear turn and stop lights share common power and ground circuits.
Table 56 Right Rear Turn Signal Circuit Test

1. Operate the hazard Alternating Go to next step. • Inspect circuits R57A and N57
switch while performing between 12 ± for open or short.
• Inspect the center / rear chassis
Measure voltage connector (9800) and IP / center
between the tail light chassis connector (1701) for
connector (9303), cavity loose, damaged, or corroded
C and ground. terminals.
• Inspect the rear turns panel

adapter (1625) for loose,
2. Operate the hazard Alternating Suspect faulty right • Inspect ground circuit R10-G and
switch while performing between 12 ± turn signal bulb. N10-G for open.
between the tail light terminals.
C and cavity E. NOTE – All rear bulbs share
ground circuit R10-G and N10-G.
6. TAIL, MARKER, PARK, AND CLEARANCE LIGHTING

This section contains a general overview of the tail, marker, park, and clearance lighting.
Overview
Although several features are included in this section, all of the described features operate using two output
circuits, which are controlled by the Body Controller (BC). The headlight switch is the main input for the BC and
allows for simultaneous control of the two output circuits. An additional momentary type input switch, typically
located in a center switch pack, is utilized for the marker interrupt feature. The marker interrupt feature allows
the operator to temporarily disable marker lights without affecting tail light operation.
S08361 117
TAIL, MARKER, PARK, AND CLEARANCE LIGHTING FEATURE CODES
Operation
The Electronic Gauge Cluster (EGC) monitors the headlight switch position, and will communicate the various
headlight switch positions to the BC over the J1939 data link. When the BC receives any headlight request
message other than Off, it will enable the panel lighting output circuits. One output circuit is used for controlling
both the park, side marker, clearance, and identification lights, and the second output circuit controls the tail
lights. Dual outputs allow the marker interrupt switch to deactivate only the park, side marker, clearance, and
identification lights. Tail light operation is not affected by the marker interrupt switch.
6.2. FEATURE CODES

This section contains the available Body Controller feature code definition related to the tail, marker, park,
and clearance lighting.

0595AAM BC PROG, PARK / MARKER LIGHTS
0595ALW BC PROG, STOP / TURN / PARK / MARKER DIAGNOSTICS OMIT
0595ANB BC PROG, MARKER INTERRUPT SWITCH located in switch pack
0595AZZ BC PROG, PARK / MARKER dual output 20A


This feature is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given by

CAUSE SIGNAL
2378 Tractor Marker 5 1604 G Park Lights Excessive Park_Light_
Light Under Current Resistance Cmd
In Park Light
Circuit
Proceed to the Park, Marker, Clearance, and Identification Lights Circuit Test (See Table 62, page 121).
2378 Tractor Marker 6 1604 G Park Lights Short To Park_Light_
Light Over Current Ground Or Cmd
Overload In
Park Light
Circuit
Proceed to the Park, Marker, Clearance, and Identification Lights Circuit Test (See Table 62, page 121).
118 S08361
TROUBLESHOOTING TAIL, MARKER, PARK, AND CLEARANCE LIGHTING

CAUSE SIGNAL
4024 Marker Light 2 N/A N/A Marker Light Defective Marker_Interrupt_
Interrupt Interrupt Marker Switch
Switch Switch Failure Interrupt
Switch, Or
Switch Pack
Problem
Refer to the SWITCH PACKS (J1708 DATA LINK) for further diagnostic information.
NOTE – The key switch must be in the OFF position and park brake ON.
NOTE – The headlight switch must be in the ON or PARK position.
Tail, Marker, Park, and Clearance Lighting Preliminary Check
Table 59 Tail, Marker, Park, and Clearance Lighting Preliminary Check
STEP ACTION YES NO

1. Are individual tail, marker, Inspect specific inoperative Go to next step.
park, or clearance lights bulbs and electrical circuits for
inoperative? (Example: All damage or opens. NOTE – If headlights also
lights working except left fail to operate during this
marker light is inoperative.) procedure, refer to Headlight
and Daytime Running Lights
Visually inspect all tail, marker, System in this manual.
park, and clearance lights for
proper operation.
2. Are there any Diagnostic Go to the Diagnostic Trouble Proceed to the Headlight
Using Diamond Logic® Builder

(DLB), check for diagnostic
trouble codes related to
headlight system.
Headlight Switch Test
NOTE – Refer to the Headlights and Daytime Running Lights (DTRL) section for further diagnostic
information related to the headlight switch.
S08361 119
TAIL, MARKER, PARK, AND CLEARANCE LIGHTING TROUBLESHOOTING
Table 60 Headlight Switch Test

1. Using the Diamond EGC_Headlight_ Go to next step. Refer to the
Logic® Builder (DLB), Request: ELECTRONIC
locate and observe the GAUGE CLUSTER
EGC_Headlight_Request Headlight Switch section for further
signal. Position: diagnostic information
related to the headlight
Operate headlight switch ON position value: switch.
in the ON, PARK, and OFF checked
position.
PARK position value:
unchecked
OFF position value:

unchecked
2. Using the DLB, locate Value displays low Go to next step. Refer to the
the observe the beam ON. ELECTRONIC
Headlight_Output signal. GAUGE CLUSTER
section for further
Operate the headlight diagnostic information
switch in the LOW beam related to the headlight
position. switch.
3. Using the DLB, locate Value displays high Proceed to the Tail Refer to the
the observe the beam ON. Light Circuit Test ELECTRONIC
Headlight_Output signal. (See Table 61, page GAUGE CLUSTER
121). section for further
Operate the headlight diagnostic information
switch in the HIGH beam related to the headlight
position. switch.
120 S08361
TROUBLESHOOTING TAIL, MARKER, PARK, AND CLEARANCE LIGHTING
Tail Light Circuit Test
Table 61 Tail Light Circuit Test

1. Disconnect the stop, tail, 12 ± 1.5V Go to next step. • Inspect circuits R68, N68, and
and turn lights connector A68 for open or short.
(9303).
Headlight switch is in (1604) for loose, damaged, or
ON position. corroded terminals.
Measure voltage • Inspect the IP / center chassis

between cavity D and connector (1701) for loose,
ground of the stop, tail, damaged, or corroded terminals.
and turn lights connector
(9303).
2. Headlight switch is in 12 ± 1.5V Ensure proper bulb • Inspect ground circuits R10-G
ON position. is being used and and N10-G for open.
bulb connector is
Measure voltage not damaged. • Inspect ground adapter (8807)
between cavity D and for loose, damaged, or corroded
cavity E of the stop, tail, terminals.
and turn lights connector
(9303).
Park, Marker, Clearance, and Identification Lights Circuit Test
The base 1 adapter (1623) provides voltage to the vehicle radio, driver and passenger power mirrors,
clearance lights, left and right front markers, and snow plow harness lights if equipped. If all of these features
are inoperative, inspect the base 1 adapter for loose, damaged, or corroded terminals.
Table 62 Park, Marker, Clearance, and Identification Lights Circuit Test

1. Disconnect the base 1 12 ± 1.5V Go to next step. • Inspect circuit A56 for open or
adapter (1623). short.
Headlight switch is in • Inspect the BC #J2 connector

ON position. (1604) for loose, damaged, or
corroded terminals.
Measure voltage
between the base 1
adapter (1623), cavity A
and ground.
2. Headlight switch is in 12 ± 1.5V Go to next step. Inspect circuit between base
ON position. 1 adapter and inoperative light
connector for open or short.
Measure voltage
between cavities A and
S08361 121
WORK LIGHT SYSTEM DESCRIPTION
Table 62 Park, Marker, Clearance, and Identification Lights Circuit Test (cont.)
ground of the inoperative
light connector.
3. Headlight switch is in 12 ± 1.5V Ensure proper bulb Inspect ground circuit for open.
ON position. is being used and
bulb connector is
Measure voltage not damaged.
between cavities A
and B of the inoperative
light connector.
7. WORK LIGHT
This section contains a general overview of the work light system.
Overview
The work light provides illumination of the fifth wheel area of the vehicle for easier night time trailer hook up.
The work light is operated by a switch located within the instrument panel.
Operation
The work light switch is a two-position (ON / OFF) push button or rocker-type switch located in the lower
Electronic Gauge Cluster (EGC) area or the instrument panel switch pack. When the key switch is ON and
the work light switch is ON, the EGC or switch pack will communicate with the Body Controller (BC) on the
1939 data link. When the BC receives this work light request message on the data link, the BC will supply
voltage to the work light output circuit.
The BC work light output circuit provides electrical current to all individual work lights using a single circuit. The
ground is supplied for each work light connector individually, from the left side cab ground.
7.2. FEATURE CODES

This section contains the available Body Controller feature code definitions related to the work light system.

0595ABR BC PROG, WORK LIGHT push button B
0595AMU BC PROG, WORK LIGHT rocker switch
0595BSN BC PROG, WORK LIGHT 24 Volt
0595ABS BC PROG, WORK LIGHT ON WITH BACK UP

This section contains all user programmable features directly related to the work light.
122 S08361
DIAGNOSTIC TROUBLE CODES WORK LIGHT
Name: Work_Light_Timeout_Enable
• ID: 640
• Description: This parameter defines the amount of time the work light will stay on after the key is turned OFF
• Maximum value: 24 minutes times 10
• Minimum value: 0.16 minutes times 10
• Interval: 0.16 minutes times 10
• Default value: 12

The work light is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given by

CAUSE SIGNAL
2361 Tractor Rear 2 N/A N/A Work Light Work Light Work_Light_
High Mounted Switch Error Switch Or ON_Switch
Work Lights Input Circuit
Command Malfunction
Proceed to Work Light Switch Test (See Table 66, page 124).
2362 Tractor Rear 5 1603 G Work Light Excessive Work_Light_
High Mounted Under Resistance Cmd
Work Lights Current In Work
Light Circuit
Proceed to Work Light Circuit Test (See Table 67, page 125).
2362 Tractor Rear 6 1603 G Work Light Short To Work_Light_
High Mounted Over Current Ground Or Cmd
Work Lights Overload In
Work Light
Circuit
Proceed to Work Light Circuit Test (See Table 67, page 125).
NOTE – The key switch must be in the ON position, and the park brake must be ON.
S08361 123
WORK LIGHT TROUBLESHOOTING
Work Light System Preliminary Check
Table 65 Work Light System Preliminary Check
STEP ACTION YES NO

1. Are work lights operating Problem may be intermittent. Go to next step.
correctly?
Turn work light switch ON.
Visually check all work lights.

2. Are individual work lights If bulb and circuits are OK, go Go to next step.
malfunctioning? (Example: to step 4.
One light working, other light
inoperative.) Proceed to the Work Light
Visually check if all work lights page 129).
are malfunctioning.
3. Are other features Refer to other inoperative Go to next step.
malfunctioning that may feature’s specific diagnostic
have common circuits? section.
4. Are there any Diagnostic Go to the Diagnostic Trouble Proceed to the Work Light
Work Light Switch Test
Table 66 Work Light Switch Test

1. Using Diamond Logic® Signal Go to next step. EGC mounted work light
Builder (DLB), locate follows switch:
and observe the switch
Work_Light_Req command. Refer to the ELECTRONIC
signal. GAUGE CLUSTER section
for further diagnostic
Operate the work light information.
switch.
Switch pack mounted
work light switch:
Refer to the SWITCH PACK

(J1708 DATA LINK) section
information.
124 S08361
TROUBLESHOOTING WORK LIGHT
Table 66 Work Light Switch Test (cont.)

2. Using the DLB, locate Signal Proceed to the Work Light • Verify all interlocks have
and observe the follows Circuit Test (See Table 67, been met.
Work_Light signal. switch page 125).
command. • Suspect faulty BC.
Operate the work light
switch.
Work Light Circuit Tests
Table 67 Work Light Circuit Test

1. Disconnect the work 12 ± 1.5V Go to next step. • Inspect circuits J65, N65,
light connector (9720). and A65 for open or short.
Work light switch is in • Inspect the work BOC

ON position. chassis connector (9718A)
/ work CTR / RR chassis
Measure voltage (9766) for loose, damaged, or
between the work light corroded terminals.
A and ground.
S08361 125
ROOF AUXILIARY LOAD AND AIR SHIELD LIGHT SYSTEM DESCRIPTION
Table 67 Work Light Circuit Test (cont.)

2. Work light switch is in 12 ± 1.2V Replace faulty work light. • Inspect ground circuits
ON position. J11-GK, N65-F, and N11-GB
for open.
Measure voltage
between the work light • Inspect ground adapter
connector (9720), cavity (8809) for loose, damaged, or
A and cavity B. corroded terminals.
• Inspect the work BOC

chassis connector (9718A)
/ work CTR / RR chassis
corroded terminals.
8. ROOF AUXILIARY LOAD AND AIR SHIELD LIGHT

This section contains a general overview of the roof auxiliary load and air shield light feature.
Due to vehicle wiring, these two features cannot be installed at the same time.
Overview
Roof Auxiliary Load: This feature allows the operation of auxiliary roof lights.
Air Shield Light: This feature allows the lighting of the air shield.
Roof Auxiliary Load Operation
When auxiliary roof load switch and park lights are requested, the auxiliary roof load switch will supply 12
volts to the coil of auxiliary roof load relay.
This will cause the relay to energize, supplying power to the auxiliary roof load.
Air Shield Light Operation
The air shield will be illuminated anytime the park lights are ON or with the park lights off and marker interrupt
is depressed with key ON.
This feature can be load shed.
8.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the roof auxiliary
load and air shield light.

0595ADK BC PROG, AIR SHIELD LIGHTING
126 S08361
USER PROGRAMMABLE PARAMETERS ROOF AUXILIARY LOAD AND AIR SHIELD LIGHT

There are no user programmable parameters for roof auxiliary load feature or air shield light.

Roof Auxiliary Load
There are no Diagnostic Trouble Codes (DTC) for the roof auxiliary load feature.
Lighted Air Shield
The lighted air shield is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information
Table 69 Lighted Air Shield DTC

CAUSE SIGNAL
3952 Air Shield 6 1604 F Air Shield • Short To Air_Shield_
Light Lighting Over Ground or Lights_Cmd
Current Overload in
Air Shield
Light Circuit
• Body
Controller
Proceed to the Lighted Air Shield Circuit Test (See Table 74, page 130).
Roof Auxiliary Load Preliminary Check
Table 70 Roof Auxiliary Load Preliminary Check
STEP ACTION YES NO

1. With auxiliary roof load switch • Auxiliary roof load is operating Go to next step.
and panel light ON, verify correctly.
operation of auxiliary roof load.
S08361 127
ROOF AUXILIARY LOAD AND AIR SHIELD LIGHT TROUBLESHOOTING
Table 70 Roof Auxiliary Load Preliminary Check (cont.)

STEP ACTION YES NO
Are roof load operational lights • Proceed to step 3.

functioning properly?
2. Determine if any other features Identify and repair condition Go to next step.
are malfunctioning that may causing several features to be
have common circuits. inoperative.
Are other features inoperative?

3. Are any active or stored DTCs Refer to the Diagnostic Trouble • Proceed to the appropriate
present? Codes for specific cause (See circuit test.
• Roof Auxiliary Load Switch
• Roof Auxiliary Load Circuit

• Lighted Air Shield Circuit Test

Lighted Air Shield Preliminary Check
Table 71 Lighted Air Shield Preliminary Check
STEP ACTION YES NO

1. Park lights are ON and • Lighted air shield is operating Go to next step.
marker interrupt switch is not correctly.
depressed.
• Proceed to step 3.
Is the lighted air shield
illuminated?
2. Determine if any other Identify and repair condition Go to next step.
features are malfunctioning causing several features to be
that may have common inoperative.
circuits.
Are other features

inoperative?
3. Are any active or stored DTCs Refer to the Diagnostic Trouble • Proceed to the appropriate
present? Codes for specific cause (See circuit test.
• Roof Auxiliary Load Switch
• Roof Auxiliary Load Circuit

128 S08361
TROUBLESHOOTING ROOF AUXILIARY LOAD AND AIR SHIELD LIGHT
Table 71 Lighted Air Shield Preliminary Check (cont.)

STEP ACTION YES NO
• Lighted Air Shield Circuit Test

Roof Auxiliary Load Switch Test
Table 72 Roof Auxiliary Load Switch Test

1. Disconnect the roof 12 ± 1.5V Go to next step. • Inspect 5A Fuse F9-B (1018).
auxiliary load switch
connector (1106). • Inspect circuits A12X and
A12V for open or short.
Key is in ACC position.

the IP mounted roof
auxiliary load switch
(1106), cavity 2B and
ground.
2. Key is in ACC position. 12 ± 1.5V Connect the roof • Inspect ground circuits
auxiliary roof load A12-GA, A12-GD, A11-GD, and
Measure voltage between switch (1006). A11-GKJ for open or short.
cavity 2B and cavity 9
of the roof auxiliary load Go to next step. • Inspect ground adapter (1006)
switch (1006). for loose, damaged, or corroded
terminals.
3. Remove the auxiliary roof 12 ± 1.5V Proceed to the Roof Replace faulty IP mounted roof
relay (1010) Auxiliary Load Circuit auxiliary load switch.
Test (See Table 73,
Key is in ACC position. page 130).
Roof auxiliary switch is in

ON position.

the auxiliary roof relay
ground.
S08361 129
ROOF AUXILIARY LOAD AND AIR SHIELD LIGHT TROUBLESHOOTING
Roof Auxiliary Load Circuit Test
Table 73 Roof Auxiliary Load Circuit Test

1. Remove the auxiliary roof 12 ± 1.5V Go to next • Inspect 20A Fuse F6-B (1015).
relay (1010). step.
• Inspect circuits A65AB/A12Z for open
Measure voltage between or short.
ground.
2. Key is in ACC position. 12 ± 1.5V Go to next Inspect circuit A12Y for open or short.
step.
Roof auxiliary load switch
is ON.

ground.
3. Key is in ACC position. 12 ± 1.5V Go to next • Inspect ground circuits A12-GC,
step. A12-GD, A11-GD, and A11-GKJ for
Roof auxiliary load switch open.
is ON.
• Inspect ground adapter (1006) for
Measure voltage between loose, damaged, or corroded terminals.
cavity 86.
4. Install auxiliary roof relay 12 ± 1.5V Suspect • Inspect circuits A12U and circuit D58W
(1010). faulty roof for open or short.
auxiliary
Measure voltage between load device. • Inspect the IP / auxiliary roof connector
the roof auxiliary load (2021/2020) for loose, damaged, or
connection, power and corroded terminals.
ground.
• Replace faulty auxiliary roof relay.
Lighted Air Shield Circuit Test
Table 74 Lighted Air Shield Circuit Test
STEP TEST POINT SPEC IN SPEC. NOT IN SPEC.

1. Parking lights are ON. Signal Go to next • Inspect circuit A58C for open or short.
follows step.
Using Diamond Logic® headlight • Inspect BC #J2 connector (1604) for
Builder locate and observe switch loose, damaged, or corroded terminals.
the Air_Shield_Request command.
signal. • Refer to the TAIL, MARKER, PARK, AND
CLEARANCE LIGHTING section.
130 S08361
SYSTEM DESCRIPTION TRAILER LIGHTING
Table 74 Lighted Air Shield Circuit Test (cont.)

2. Measure voltage between 12 ± 1.5V Inspect air • Inspect black wire for open or short.
the air shield light shield light
connection, power and bulbs. • Inspect circuits A58C and A68A for open
ground. or short.
• Inspect white ground wire for open.
• Inspect ground circuits A58-GC, A11-GD,

and A11-GKJ for open.
• Inspect ground adapter (1006) for loose,

9. TRAILER LIGHTING
This section contains an overview of the trailer lighting.
Overview
The trailer lighting feature includes five Body Controller (BC) controlled relays. The relays included are the
trailer left turn, right turn, trailer marker light, trailer tail light, and trailer stop light relay. When energized,
the relays provide voltage to the trailer light socket.
Operation
When the BC receives input signals from the multifunction switch, an output signal is applied to the requested
relay. Each relay shares common ground to the left side cab ground and ground adapter (1023). When a
specific relay is energized, the normally open relay closes, providing voltage to the specific pin of the trailer
socket.
9.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the trailer lighting.

0595ABC BC PROG, TRAILER LIGHTING

There are no Body Controller related programmable parameters for the trailer lights.

The trailer light system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information
S08361 131
TRAILER LIGHTING DIAGNOSTIC TROUBLE CODES

CAUSE SIGNAL
878 Clearance, 5 1601 F14 Trailer Marker Lamp • Open Circuit Trailer_Marker_
Side Marker, Relay Under Current Light
ID Lamp Circuit Or Open Circuit • Faulty Relay
(Black)
Proceed to the Trailer Marker Relay Circuit Test (See Table 81, page 137).
878 Clearance, 6 1601 F14 Trailer Marker Lamp • Short Circuit Trailer_Marker_
Side Marker, Relay Over Current Light
ID Lamp Circuit Or Open Circuit • Faulty Relay
(Black)
Proceed to the Trailer Marker Relay Circuit Test (See Table 81, page 137).
879 Left Turn Lamp 5 1601 F13 Trailer Left Turn • Open Circuit Trailer_Left
Circuit (Yellow) Lamp Relay Under _Light
Current Or Open • Faulty Relay
Circuit
Proceed to the Trailer Left Turn Relay Circuit Test (See Table 79, page 135).
879 Left Turn Lamp 6 1601 F13 Trailer Left Turn • Short Circuit Trailer_Left
Circuit (Yellow) Lamp Relay Over _Light
Current • Faulty Relay
Proceed to the Trailer Left Turn Relay Circuit Test (See Table 79, page 135).
880 Stop Lamp 5 1601 E5 Stop Lights Relay • Open Circuit Stop_relay
Circuit (Red) Under Current Or _Cmd
Open Circuit • Faulty Relay
Proceed to the Trailer Stop Light Relay Circuit Test (See Table 83, page 139).
880 Stop Lamp 6 1601 E5 Stop Lights Relay • Short Circuit Stop_relay
Circuit (Red) Over Current _Cmd
• Faulty Relay
Proceed to the Trailer Stop Light Relay Circuit Test (See Table 83, page 139).
881 Right Turn 5 1601 E15 Trailer Right Turn • Open Circuit Trailer_Right
Lamp Circuit Lamp Relay Under _Light
(Green) Current Or Open • Faulty Relay
Circuit
Proceed to the Trailer Right Turn Relay Circuit Test (See Table 80, page 136).
881 Right Turn 6 1601 E15 Trailer Right Turn • Short Circuit Trailer_Right
Lamp Circuit Lamp Relay Over _Light
(Green) Current • Faulty Relay
Proceed to the Trailer Right Turn Relay Circuit Test (See Table 80, page 136).
132 S08361
TROUBLESHOOTING TRAILER LIGHTING
Trailer Lights Preliminary Check
Table 77 Trailer Lights Preliminary Check
STEP ACTION YES NO

1. Operate the turn signals, Go to next step. • Proceed to specific inoperative circuit test.
parking lights, marker lights
and brake switch. • Trailer Left Turn Relay Circuit Test (See Table
79, page 135).
Perform the Trailer Socket
Circuit Test (See Table 78, • Trailer Right Turn Relay Circuit Test (See
page 133). Table 80, page 136).
Is voltage present at • Trailer Marker Light Relay Circuit Test (See

appropriate circuits? Table 81, page 137).
• Trailer Tail Light Relay Circuit Test (See Table

82, page 138).
• Trailer Stop Light Relay Circuit Test (See Table

83, page 139).
• Trailer ABS ECU Relay Circuit Test (See Table

83, page 139).
2. Using the Diamond Logic® Proceed to the No faults evident at this time.
Builder (DLB), locate and Diagnostic Trouble
view stored or active DTCs. Codes for specific
cause (See Table
Are any active or stored 76, page 132).
DTCs Present?
Trailer Socket Circuit Test
NOTE – Prior to diagnosing trailer socket, verify multifunction switch operation.
NOTE – Perform test with key in ON position and specific BC input operating for suspected faulty relay.
Table 78 Trailer Socket Circuit Test

1. Measure voltage 12 ± 1.5V Go to next step. Trailer Left Turn Relay Circuit
between the trailer Test (See Table 79, page
socket connector, 135)
yellow terminal, and
ground.
S08361 133
TRAILER LIGHTING TROUBLESHOOTING
Table 78 Trailer Socket Circuit Test (cont.)

Operate left turn

signal.
2. Measure voltage 12 ± 1.5V Go to next step. Trailer Right Turn Relay
between the trailer Circuit Test (See Table 80,
socket connector, page 136)
green terminal and
ground.
Operate right turn

signal.
3. Measure voltage 12 ± 1.5V Go to next step. Trailer Marker Light Relay
socket connector, page 137)
black terminal and
ground.
Operate headlight
switch.
4. Measure voltage 12 ± 1.5V Go to next step. Trailer Tail Light Relay Circuit
between the trailer Test (See Table 82, page
socket connector, 138)
brown terminal and
ground.
Operate headlight
switch.
5. Measure voltage 12 ± 1.5V Go to next step. Trailer Stop Light Relay
socket connector, red page 139)
terminal, and ground.
Operate stop light

switch.
6. Measure continuity Continuity • No faults evident at this Inspect trailer socket ground
between the trailer present time. circuit for open or source of
socket connector, high resistance.
white terminal and • Trailer wiring fault may be
ground. present.
134 S08361
Trailer Left Turn Relay Circuit Test
NOTE – Prior to diagnosing trailer turn relays, verify multifunction switch operation.
Table 79 Trailer Left Turn Relay Circuit Test

1. Using the Diamond Relay operates • No relay fault Go to next step.
Logic® Builder (DLB), with signal present.
locate and select the command.
CONNECTORS tab. • Inspect circuit to
trailer socket.
Select the BC #J4
(1601) connector.
Actuate the following

signal:
Trailer_Left_Turn_
Light
2. Remove the trailer left 12 ± 1.5V Go to next step. Inspect circuit A56C/A56K for
turn relay (1011). open or short.
Operate left turn

signal.
Measure voltage
between the trailer
left turn relay (1011),
3. Operate left turn 12 ± 1.5V Go to next step. • Inspect ground circuit A56-GC
signal. for open or short.
Measure voltage • Inspect ground adapter

between the trailer (1008) for loose, damaged, or
left turn relay (1011), corroded terminals.
cavity 85 and cavity
86.
4. Measure voltage 12 ± 1.5V • Inspect circuit A56T • Inspect 15A Fuse F2-A
between the trailer for open or short. (1011).
left turn relay (1011),
cavity 30 and ground. • Replace faulty • Inspect circuit A56J for open
relay. or short.
S08361 135
Trailer Right Turn Relay Circuit Test
NOTE – Verify multifunction switch operation prior to diagnosing trailer turn relays.
Table 80 Trailer Right Turn Relay Circuit Test

trailer socket.
Select the BC #J4
(1601) connector.

signal:
Trailer_Right_Turn_
Light
2. Remove the trailer 12 ± 1.5V Go to next step. Inspect circuit A57C for open
right turn relay (1011). or short.
Operate right turn

signal.
Measure voltage
between the trailer
right turn relay (1011),
3. Operate right turn 12 ± 1.5V Go to next step. Inspect ground circuit A54-GC
signal. for open or short.
Measure voltage • Inspect ground adapter

between the trailer (1008) for loose, damaged, or
right turn relay (1011), corroded terminals.
cavity 85 and 86.
4. Measure voltage 12 ± 1.5V • Inspect circuit A57T • Inspect 15A Fuse F2-C
right turn relay (1011),
cavity 30 and ground. • Replace faulty • Inspect circuit A57J for open
relay. or short.
136 S08361
Trailer Marker Light Relay Circuit Test
Table 81 Trailer Marker Light Relay Circuit Test

trailer socket.
Select the BC #J4
(1601) connector.

signal:
LH_Trailer_Marker
_Light_Signal
marker light relay or short.
(1012).
Headlight switch is in
ON position.
Measure voltage
between the trailer
marker light relay
ground.
3. Headlight switch is in 12 ± 1.5V Go to next step. Inspect ground circuit A58-GT
ON position. for open or short.
Measure voltage
between the trailer
marker light relay
86.
4. Measure voltage 12 ± 1.5V • Inspect circuit • Inspect 20A Fuse F3-D
between the trailer A68T/A68A/A68BB (1012).
marker light relay for open or short.
(1012), cavity 30 and • Inspect circuit A54J for open
ground. • Replace faulty or short.
relay.
S08361 137
Trailer Tail Light Relay Circuit Test
NOTE – Perform test with key in ON position and specific input operating for suspected faulty relay.
Table 82 Trailer Tail Light Relay Circuit Test

trailer socket.
Select the BC #J4
(1601) connector.

signal:
Tail_Light_Signal_
For_LH_Trailer
2. Remove the trailer tail 12 ± 1.5V Go to next step. Inspect circuit A68 for open or
light relay (1012). short.
ON position.
Measure voltage
between the trailer
tail light relay (1012),
3. Headlight switch is in 12 ± 1.5V Go to next step. Inspect ground circuit A68-GT
ON position. for open or short.
Measure voltage
between the trailer
tail light relay (1012),
cavity 85 to 86.
4. Measure voltage 12 ± 1.5V • Inspect circuit • Inspect 20A Fuse F3-B
between the trailer A68T/A68BB/A68A (1012).
tail light relay (1012), for open or short.
cavity 30 and ground. • Inspect circuit A68J for open
• Replace faulty relay. or short.
138 S08361
Trailer Stop Light Relay Circuit Test
NOTE – Perform test with key in ON position and specific input operating for suspected faulty relay.
Table 83 Trailer Stop Light Relay Circuit Test

trailer socket.
Select the BC #J4
(1601) connector.

signal:
LH_Trailer_Brake_
Signal
stop relay (1016). or short.
Operate brake switch.
Measure voltage
between the trailer
stop light relay (1016),
3. Operate brake switch. 12 ± 1.5V Go to next step. Inspect ground circuit A70-GT
for open or short.
Measure voltage
between the trailer
cavity 85 and 86.
4. Measure voltage 12 ± 1.5V • Inspect circuit A70T • Inspect 30A Fuse F7-D
cavity 30 and ground. • Replace faulty relay. • Inspect circuit A70J for open
or short.
S08361 139
AUXILIARY SNOWPLOW LIGHTING SYSTEM DESCRIPTION
Trailer ABS ECU Relay Circuit Test
Table 84 Trailer ABS ECU Relay Circuit Test

1. Remove trailer ABS 12 ± 1.5V Go to next step. • Inspect circuit A13FF for open or
ECU relay (1017). short.
Key is in ON position. • Inspect 5A Fuse F1-C (1010).
Measure voltage • Inspect circuit A94V for open

between the trailer or short between fuse and ABS
ABS ECU relay module.
(1017), cavity 85
and ground. • Refer to the 12–VOLT POWER
DISTRIBUTION AND GROUNDS
section for troubleshooting
information related to the Ignition
Relay #3 (1012/1014).
2. Measure voltage 12 ± 1.5V Go to next step. Inspect ground circuit A12-G for
between the trailer open or short.
ABS ECU relay
(1017), cavity 85
and 86.
3. Measure voltage 12 ± 1.5V • Inspect circuit • Inspect 30A Fuse F8-D (1017).
between the trailer A94T/A72 for open
ABS ECU relay or short. • Inspect circuit A94UA/A72J for
(1017), cavity 30 open or short.
and ground. • Replace faulty
relay.
10. AUXILIARY SNOWPLOW LIGHTING

This section contains a general overview of the auxiliary snowplow lighting.
Overview
The auxiliary snowplow light feature provides a wiring harness for auxiliary front headlights and turn signals for
front snow plow applications. The auxiliary snowplow lighting harness provides a 20A high beam and low
beam power circuit, a 10A right and left turn signal circuit, and a 20A park light power circuit. The auxiliary park
or identification and turn signals are directly tied to the front vehicle lighting circuits.
The auxiliary snow plow lighting switch can be located within the Electronic Gauge Cluster (EGC) or the
center panel switch pack.
Operation
When the headlight switch is in the ON position, and the auxiliary snowplow light switch is OFF, voltage provided
by the BC headlight output circuits, pass through the normally closed auxiliary snowplow light relays. The
voltage is supplied to the appropriate headlight connector (8000/8001) for standard vehicle headlight operation.
140 S08361
FEATURE CODE AUXILIARY SNOWPLOW LIGHTING
When the headlight switch is in the ON position, and the auxiliary snowplow light switch is ON, the BC
provides an output signal to the auxiliary snowplow light relays. The auxiliary snowplow relay receives the BC
signal and energizes the relays. Now energized, voltage provided the by the headlight switch is provided to
the snowplow harness connector (8102).
10.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the auxiliary
snowplow lighting feature.

0595ALL BC PROG, SNOW PLOW LIGHTS rocker switch
0595AMV BC PROG, SNOW PLOW LIGHTS push button location A

0595AMW BC PROG, SNOW PLOW LIGHTS push button location B
0595AYY BC PROG, SNOW PLOW LIGHTS GEN 2 with rocker switch

There are no user Body Controller (BC) programmable parameters associated with the auxiliary snowplow
lighting feature. Refer to the HEADLIGHTS AND DAYTIME RUNNING LIGHTS (DTRL) section for information
related to headlight programmable parameters.

The auxiliary snowplow lights are able to set Diagnostic Trouble Codes (DTC) when specific faults occur.

CAUSE SIGNAL
4038 Snow Plow 5 1601 F16 Right Plow Current Below Right_Plow_
Forward Light Relay Normal Or Lights_Relay_Req
Lighting Relay Under Current Open Circuit
2 Or Open
Circuit
Proceed to the Snowplow Lights Circuit Test (See Table 89, page 143).
4038 Snow Plow 6 1601 F16 Right Plow Current Above Right_Plow_
Lighting Relay Circuit Short Grounded
2 To Ground Circuit
S08361 141
AUXILIARY SNOWPLOW LIGHTING TROUBLESHOOTING

CAUSE SIGNAL
4039 Snow Plow 5 1601 F12 Left Plow Current Below Left_Plow_
Lighting Relay Circuit Under Open Circuit
1 Current Or
Open Circuit
4039 Snow Plow 6 1601 F12 Left Plow Current Aboce Left_Plow_
Lighting Relay Circuit Short Grounded
1 To Ground Circuit
4040 Snow Plow 2 N/A N/A Snow Plow Data Erratic Plow_Lights
Lighting Mode Switch Error Intermittent Or _Switch
Switch Incorrect
Proceed to the Snowplow Switch Test (See Table 88, page 143).
Auxiliary Snowplow Lights Preliminary Checks
Table 87 Auxiliary Snowplow Lights Preliminary Checks
STEP ACTION YES NO
1. Are the standard headlights Go to next step. Proceed to the HEADLIGHTS

working correctly? AND DAYTIME RUNNING
LIGHTS (DTRL) section for
further diagnostic information.
2. Are only left high beam and Inspect circuit M64HI for open Go to next step.
low beam snowplow headlights or short.
inoperative?
3. Are only right high beam and Inspect circuit M64LO for open Go to next step.
low beam snowplow headlights or short.
inoperative?
4 Are other features • Proceed to the POWER Proceed to the Snowplow
malfunctioning that may DISTRIBUTION AND GROUND Switch Test (See Table 88,
share common circuits? section for further diagnostic page 143).
information.

terminals.
142 S08361
TROUBLESHOOTING AUXILIARY SNOWPLOW LIGHTING
Snowplow Switch Test
Table 88 Snowplow Switch Test

1. Using the Diamond Signal Proceed to the Proceed to the SWITCH PACK
Logic® Builder follows switch Snowplow Lights (J1708 DATA LINK) section
(DLB), locate command. Circuit Test (See or ELECTRONIC GAUGE
and observe the Table 89, page 143). CLUSTER section for further
Plow_Light_Switch diagnostic information.
signal.
Operate the auxiliary

snowplow lights
switch.
Snowplow Lights Circuit Test
If both high and low beams are inoperative, suspect an open or shorted circuit to the snowplow harness
connector (8102). If only the high beam or only the low beam lights are inoperative, suspect a faulty relay or
relay circuit.
NOTE – The Snowplow Lights Circuit Test tests the functionality of the left low beam, left high beam,
right low beam, and right high beam relays.
Table 89 Snowplow Lights Circuit Test

1. Remove appropriate 12 ± 1.5V Go to next step. Inspect BC #J4 output
auxiliary headlight relay signal circuit for open or
(1018). short.
Headlight switch is in ON
position.
Auxiliary snowplow light

switch in ON position.
Measure voltage
between the relay (1018),
2. Headlight switch is in ON 12 ± 1.5V Go to next step. • Inspect headlight input
position. circuit for open or short.
Auxiliary snowplow light • Verify headlight switch

switch in ON position. operation.
Measure voltage
S08361 143
AUXILIARY SNOWPLOW LIGHTING TROUBLESHOOTING
Table 89 Snowplow Lights Circuit Test (cont.)

3. Headlight switch is in ON 12 ± 1.5V Go to next step. • Inspect relay ground
position. circuit for open.
Auxiliary snowplow light • Inspect ground adapter

switch in ON position. (1008/1003) for loose,
Measure voltage terminals.
cavity 85 and cavity 86.
4. Install appropriate relay 12 ± 1.5V Go to next step. Right High Beam or Left
(1018). High Beam Inoperative:
Auxiliary snowplow light • Inspect circuit M64HI for

switch in ON position. open or short.
Perform the appropriate • Inspect the IP / forward

test. chassis connector (1700)
for loose, damaged, or
Right High Beam or Left corroded terminals.
High Beam Inoperative:
Right Low Beam or Left
Measure voltage Low Beam Inoperative:
between the snowplow
harness connector • Inspect circuit M64LO for
(8102), cavity A and open or short.
ground.
• Inspect the IP / forward
Right Low Beam or Left chassis connector (1700)
Low Beam Inoperative: for loose, damaged, or
corroded terminals.
Measure voltage
between the snowplow
harness connector
ground.
5. Measure voltage 12 ± 1.5V • No circuit faults • Inspect ground circuit
between the snowplow present at this time. M11-GE for open.
harness connector
(8102), cavity C/A and • Ensure proper • Inspect ground adapter #1
ground. snowplow light (8800) for loose, damaged,
bulbs are used. or corroded terminals.
144 S08361
TABLE OF CONTENTS
CAB FEATURES
Table of Contents
1. CIGAR LIGHTER AND POWER FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Cigar Lighter Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Cigar Lighter Power Source and Two-Post Power Source Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Cigar Lighter and Power Feed Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Cigar Lighter Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Two-Post Power Source Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2. CB POWER RADIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
CB Radio Power Source Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
CB Radio Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3. COMPASS AND TEMPERATURE DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Temperature Display Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Compass Display Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Compass and Temperature Display Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Compass / Temperature Display Circuit Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Compass Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Ambient Temperature Sensor Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4. POWER WINDOWS AND LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Power Window Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Power Door Lock Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Power Window and Lock Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Locks and Windows Inoperative Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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Power Window Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Power Door Lock Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5. ELECTRIC HORN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Electric Horn Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Electric Horn Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6. AIR HORN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
6.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Air Horn Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Air Horn Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7. POWER MIRRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Power Mirror Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Driver Power Mirror Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Passenger Power Mirror Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8. HEATED MIRROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Heated Mirror Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Heated Mirror Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Driver Heated Mirror Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Passenger Heated Mirror Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Heated Windshield Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
9. RADIO (ENTERTAINMENT), SPEAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
9.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Radio Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Radio Circuit Test (16 Way Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Radio Circuit Test (12 Way Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Speaker Circuit Test (16 Way Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Speaker Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
10. TWO-WAY RADIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Two-Way Radio Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
11. WINDSHIELD WIPER AND WASHER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Wiper Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Park Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Washer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
11.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Wiper and Washer Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Washer Pump Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Wiper Switch Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Wiper Motor Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
12. PARK BRAKE AND BRAKE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
12.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Brake Switch Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Brake Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Park Brake Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
13. CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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TABLE OF CONTENTS
13.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Clutch Switch Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Engine Crank Clutch Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Cruise Control Clutch Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
14. LOAD SHEDDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
14.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Latching Relay Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
15. VEHICLE DATA RECORDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
15.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Vehicle Data Recorder Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Vehicle Data Recorder Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
VDR Brake Pressure Switch Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
VDR Headlight Input Relay Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
16. THEFT DETERRENT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
16.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Theft Deterrent Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Theft Deterrent System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
17. SEAT BELT AND SEAT SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
17.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Seat Belt Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Seat Belt Indicator Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
148 S08361
TABLE OF CONTENTS
18. SELF-CONTAINED AIR SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
18.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Driver and Passenger Self-Contained Air Seats Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Driver and Passenger Self-Contained Air Seat Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
19. HEATED SEATS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
19.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Driver and Passenger Heated Seats Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Driver and Passenger Heated Seat Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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TABLE OF CONTENTS
150 S08361
SYSTEM DESCRIPTION CIGAR LIGHTER AND POWER FEED
1. CIGAR LIGHTER AND POWER FEED

This section contains a general overview of the cigar lighter and power feed systems.
Overview
The cigar lighter, cigar lighter power source, and power feed have battery voltage and ground at all times with
key ON or OFF.
Cigar Lighter Operation
Battery voltage is provided on circuits A14, A14M, and A14MC to 15A Fuse F2-B (1011). The fuse provides
voltage on circuit A84 to pin A of the cigar lighter (1854). Ground is provided by the left side cab ground on
circuit A11-GE, ground adapter (1003), and circuit A84-G to pin A of the cigar lighter (1853).
Cigar Lighter Power Source and Two-Post Power Source Operation
The cigar lighter and two-post power source share 20A Fuse F3-C (1012). From the fuse, voltage is provided
to the cigar lighter on circuits A86R and A86RC. The two-post power source is provided voltage on circuits
A86R and A86S. The cigar lighter and two-post power source share common ground circuit A86-GR and
ground adapter (1006).
1.2. FEATURE CODES

There are no Body Controller feature codes related to the cigar lighter and two-post power source.

There are no Body Controller user programmable parameters related to the cigar lighter and two-post power
source.

There are no Diagnostic Trouble Codes (DTC) associated with the cigar lighter and two-post power source.
If the cigar lighter power source or two-post power source is not working, be sure the device being connected
to the socket or posts is not at fault.
Cigar Lighter and Power Feed Preliminary Check
Operate cigar lighter and power feeds, and check for proper operation.
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CIGAR LIGHTER AND POWER FEED TROUBLESHOOTING
Table 90 Cigar Lighter and Power Feed Preliminary Check
STEP ACTION YES NO

1. Verify cigar lighter operation. Go to next step. Proceed to the Cigar Lighter
Does the cigar lighter function page 152).
properly?
2. Verify two-post power source • No faults evident at this time. Proceed to the Two-Post
operation. Power Source Circuit Test
• Two-post power source (See Table 92, page 152).
Does two-post power source driven device may be at fault.
function properly?
Cigar Lighter Circuit Test
Table 91 Cigar Lighter Circuit Test
STEP TEST POINTS SPEC. IN SPEC. NOT IN SPEC.

1. Measure voltage 12 ± 1.5V Go to next • Inspect 15A Fuse F2-B or 10A Fuse
between the cigar step. F2-F (1011).
lighter connector
(1854), cavity A and • Inspect circuit A84 for open or short.
ground.
2. Measure voltage 12 ± 1.5V • Suspect • Inspect ground circuit A84-G for open.
between the cigar faulty cigar
lighter connector lighter. • Inspect ground adapter (1003) for
(1854), cavity A and loose, damaged, or corroded terminals.
connector (1853), • Verify
cavity A. customer's
cigar lighter
driven device
is not at fault.
Two-Post Power Source Circuit Test
Table 92 Two-Post Power Source Circuit Test

1. Measure voltage 12 ± 1.5V Go to next • Inspect 15A Fuse F3-C (1012).
between the two-post step.
power source (1861), • Inspect circuit A86S for open or short.
terminal A and ground.
• Inspect two-post power source
connector (2861) for loose, damaged, or
corroded terminals.
152 S08361
SYSTEM DESCRIPTION CB POWER RADIO
Table 92 Two-Post Power Source Circuit Test (cont.)

2. Measure voltage 12 ± 1.5V • Suspect • Inspect ground circuit A86-GS and
between the two-post faulty A86-GR for open.
power source (1861), two-post
terminal A and power • Inspect ground adapter (1006) for loose,
terminal B. source. damaged, or corroded terminals.
• Verify
customer's
two-post
power source
driven device
is not at fault.
2. CB POWER RADIO
This section contains a general overview of the CB power radio circuit.
Overview
The CB Radio power circuits provide power to the operator provided CB radio.
Operation
The CB Radio Power Connector receives power from Accessory Relay #1 (1011/1013) and 10A Fuse F4-F
(1013). Ground is provided by the left side cab ground.
NOTE – Refer to the 12–VOLT POWER DISTRIBUTION AND GROUNDS for specific troubleshooting
information regarding the Accessory Relay operation and diagnosis.
2.2. FEATURE CODES

There are no feature codes available for the CB Power Radio.

There are no user programmable parameters available for the CB Power Radio.

There are no Diagnostic Trouble Codes associated with the CB radio power source circuits.
Should the CB Radio power source fail to operate, the problem could be attributed to open or shorted wiring in
the power circuits, an open ground circuit, a blown fuse, or a bad relay.
If the CB Radio power connector is not working, be sure the device being connected is not at fault.
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COMPASS AND TEMPERATURE DISPLAY SYSTEM DESCRIPTION
CB Radio Power Source Preliminary Check
Table 93 CB Radio Power Source Preliminary Check
STEP ACTION YES NO

1. Is CB radio working properly? • Fault may be intermittent. Go to next step.
• Inspect connectors for

loose, damaged, or corroded
connections.
2. Determine if any other Refer to the 12–VOLT Proceed to the CB Radio
features are malfunctioning POWER DISTRIBUTION Circuit Test (See Table 94,
that may have common AND GROUNDS section for page 154).
circuits. further diagnostic information.
Are other features

inoperative?
CB Radio Circuit Test
Table 94 CB Radio Circuit Test

1. Measure voltage 12 ± 1.5V Go to next step. • Inspect the 10A Fuse F4-F (1013).
between the
CB radio power • Inspect circuits C86F, D86F, and
connector (2303), A86F for open or short.
• Inspect the console / roof connector
(2502) and roof / IP connection
corroded terminals.
2. Measure voltage 12 ± 1.5V No faults evident • Inspect ground circuits C86-GF,
between the in CB Radio C11-GF, D11-GF, and A11-GF for
CB radio power circuit. Suspect open.
connector (2303), faulty CB Radio.
cavity A and cavity • Inspect the console / roof connector
B. (2502) and roof / IP connection
corroded terminals.
3. COMPASS AND TEMPERATURE DISPLAY

This section contains a general overview of the compass and temperature display.
Overview
The compass / temperature display provides the operator with outside temperature as well as direction of
vehicle travel. The direction and temperature is displayed on the Electronic Gauge Cluster (EGC) display.
154 S08361
FEATURE CODES COMPASS AND TEMPERATURE DISPLAY
Temperature Display Operation
A temperature sensor is mounted under the front bumper to relay ambient outside temperature to the display.
The Electronic Gauge Cluster (EGC), connector 1501 pin 9, sends a 5-volt source to the temperature sensor.
As the voltage goes across the temperature sensor it decreases; the amount of voltage drop depends on
outside temperature. The reduced voltage then returns to the instrument cluster on pin 8 of connector 1500.
The EGC turns the received signal into the temperature shown on the display.
Compass Display Operation
At key ON, power is supplied to compass control module pin 1 by Ignition Relay #3. Ground is provided by
the left side cab ground. When on, the compass control module pins 2 and 3 communicate with the EGC
display via J1939 data link.
3.2. FEATURE CODES

This section contains the available feature code definition related to the compass and temperature display
feature.

0595ADH BC PROG, COMPASS DISPLAY
0595ACG BC PROG, OUTSIDE TEMP MONITOR

There are no user programmable parameters available for the compass or temperature display.

The outside temperature and compass display are able to set Diagnostic Trouble Codes (DTC) when specific
faults occur. Information given by the DTC can aid in the diagnosis of the problem.

CAUSE SIGNAL
171 Ambient Air 3 N/A N/A Fault On Voltage Above N/A
Temperature Analog Input 3 Normal, Or
Above Normal Shorted To
When Used High Source
For Outside
Temperature
Proceed to the Ambient Temperature Sensor Circuit Test (See Table 99, page 161).
S08361 155
COMPASS AND TEMPERATURE DISPLAY DIAGNOSTIC TROUBLE CODES

CAUSE SIGNAL
171 Ambient Air 4 N/A N/A Fault On Voltage Below N/A
Temperature Analog Input 3 Normal, Or
Below Normal Shorted To
When Used Low Source
For Outside
Temperature
Proceed to the Ambient Temperature Sensor Circuit Test (See Table 99, page 161).
165 Compass 12 N/A N/A Sensor Fault Faulty N/A
Bearing / Compass Compass
Bearing Module Sensor
Proceed to the Compass Display Circuit Test (See Table 98, page 158).
630 Calibration 13 N/A N/A Compass Compass N/A
Memory Is Out Of Is Out Of
Calibration Calibration
Refer to the vehicle Operator's Manual for the Compass Heading Calibration procedures.
639 Drivetrain 2 N/A N/A EEPROM Data Erratic N/A
Message Data In The Intermittent Or
Timeout Microcontroller Incorrect
Is Corrupted
Or Error In
Calibration
(The Compass
Module Is Not
Calibrated)
639 Drivetrain 19 N/A N/A HMC6352 Faulty N/A
Message Sensor Is Not Compass
Timeout Responding Module Or 12C
Or Communication
Communication Link
Link With
HMC6352 (I2C
Communication
Link) Not
Working
Reliably
Refer to MULTIPLEXING (DATA LINKS) section for further diagnostic information

regarding the J1939 data link.
156 S08361
TROUBLESHOOTING COMPASS AND TEMPERATURE DISPLAY

CAUSE SIGNAL
639 Drivetrain 9 N/A N/A J1939 Faulty N/A
Message Communication Compass Or
Timeout Link Fault Drivetrain
Datalink
Refer to MULTIPLEXING (DATA LINKS) section for further diagnostic information

regarding the J1939 data link.
Compass and Temperature Display Preliminary Check
Table 97 Compass and Temperature Display Preliminary Check
STEP ACTION YES NO

1. Do the compass and Go to next step. Proceed to the Compass
temperature display Display Circuit Test (See Table
function properly? 98, page 158).
2. Does the temperature • Go to next step. Proceed to the Ambient
display operate correctly? Temperature Sensor Circuit Test
• Refer to the ELECTRONIC (See Table 99, page 161).
GAUGE CLUSTER section for
3. Are any stored or active Refer to the Diagnostic Trouble • Proceed to the appropriate
DTCs present? Codes for specific cause (See test.
• Proceed to the Compass
Display Circuit Test (See Table
98, page 158).
• Proceed to the Ambient

Temperature Sensor Circuit Test
Compass / Temperature Display Circuit Tests
NOTE – The Electronic Gauge Cluster display will replace temperature reading with two dashes (– –) if
a fault is present with the Ambient Temperature Sensor circuit.
NOTE – The Electronic Gauge Cluster display will replace compass bearing with two dashes (– –) if a
fault is present with the Compass Module.
S08361 157
COMPASS AND TEMPERATURE DISPLAY TROUBLESHOOTING
Table 98 Compass Display Circuit Test

1. Disconnect the 12 ± 1.5V Go to next step. • Inspect 10A Fuse F5-H
compass module (1014).
connector (1912).
• Inspect circuit A28V for open
Key is in ON position. or short.
Measure voltage • Verify Ignition Relay #3

between the compass (1012/1014) operation.
module connector
ground.
2. Measure resistance ≤1 ohm Go to next step. • Inspect ground circuit
between the compass A28-GA for open or source of
module connector high resistance.
ground. • Inspect ground adapter
corroded terminals.
3. Measure voltage at the Approximately 2.5V Go to next step. • Inspect the CAN (+) circuit
Diagnostic Connector for open or short.
(1650), terminal C to
ground. • If voltage is 0 volt, the J1939
circuit is shorted to ground or
open.
• If voltage is ABOVE 5 volts,

the J1939 circuit is shorted to
voltage.
4. Measure voltage at the Approximately 2.5V Go to next step. • Inspect the CAN (-) circuit
Diagnostic Connector for open or short.
(1650), terminal D to
ground. • If voltage is 0 volt, the J1939
circuit is shorted to ground or
open.

voltage.
158 S08361
TROUBLESHOOTING COMPASS AND TEMPERATURE DISPLAY
Table 98 Compass Display Circuit Test (cont.)

5. Disconnect battery. 60 ± 6 ohms • The J1939 • If resistance is 120 ohms,
data link is the data link has an open
Measure resistance functional and circuit.
between terminals C communicating
and D of the Diagnostic on the CAN. • Inspect for damaged or
Connector (1650). missing terminating resistor.
• Go to next
step. • If resistance is 0 ohms, the
data link circuits are shorted
together.
6. Utilizing the Diamond North: 0° or 360° Compass • Perform Compass
Logic® Builder (DLB), module is active Calibration procedures.
select the SIGNALS East: 90° on the J1939
tab. Select the J1939 data link. • Replace faulty Compass
tab, locate and view South: 180° module if compass fails to
the Compass_ calibrate.
Bearing signal. West: 270°
Signal agrees with

actual current bearing.
Compass Calibration
Compass calibration procedures vary depending on the compass equipped.
AccuTech C/T Compass Calibration
1. FastCal™ Phase:
FastCal™ is the initial fast calibration procedure when the compass is first powered up and there
are no calibration settings stored in its memory or after erasing current calibration settings.
ACTIONS: While CAL is flashing on the display, complete a 90° turn.
FastCal™ phase is complete and the compass is now entering SmartCal™ phase.
2. SmartCal™ Phase:
The compass will remain in SmartCal™ phase until the following action is taken to complete
this phase:.
ACTIONS: Drive the vehicle and complete three complete circles, under normal driving conditions.
The compass has taken multiple readings to complete the calibration procedure during the
SmartCal™ phase.
S08361 159
COMPASS AND TEMPERATURE DISPLAY TROUBLESHOOTING
AccuTech C/T Compass Declination Zone Adjustment
1. Turn ignition key to ON position. Press the MODE button until the words ZONE and CAL appear
(approximately 10 seconds).
2. Press the °F / °C button to adjust the zone value.
3. Press the MODE button to store the zone value.
4. The compass will display the word CAL. Press the °F / °C button to erase the stored calibration
settings if necessary. Press the MODE button to skip clearing the calibration settings.
Honeywell Compass Module Calibration
NOTE – The Electronic Gauge Cluster (EGC) display will read NO CAL when the compass module does
not have a calibration stored in it's memory.
1. Select Quadrant 2 on the EGC display by turning the display control either clockwise (CW) or
counter-clockwise (CCW).
2. Select the CALIBRATE COMPASS message by pressing and releasing the display control until
message appears.
3. Press and hold the display control for 3-5 seconds until END CALIBRATION message is displayed.
4. Proceed to drive the vehicle to a destination (no specific routes, turns, or time consideration is
necessary).
5. At the earliest opportunity, stop the vehicle, navigate to Quadrant 2, and select the END
CALIBRATION message.
NOTE – If the NO CAL message is displayed, the above calibration procedures will need to be repeated.
Honeywell Compass Module Declination Zone Adjustment
The following steps are used to establish the vehicle's operating geographic zone.
1. With the vehicle stopped, turn the Display Control CW or CCW to navigate to Quadrant 2, then
press and release the Display Control to select the Declination Zone message. Refer to the Zone
Map in the Operator's Manual to determine correct zone.
2. Press and hold the Display Control until a zone number (0-0) is displayed (replaces DECLINATION
ZONE message).
3. Turn Display Control CW or CCW until the desired zone is displayed. NOTE – If no zone is
selected within 15 seconds, the display will return to the Declination Zone message.
4. Press and hold the Display Control for 3-5 seconds until DECLINATION ZONE message appears
(this indicates that the new Declination Zone has been programmed into the Compass).
Ambient Temperature Sensor Circuit Test
NOTE – The Electronic Gauge Cluster display will replace temperature reading with two dashes (– –) if
a fault is present with the Ambient Temperature Sensor circuit.
160 S08361
SYSTEM DESCRIPTION POWER WINDOWS AND LOCKS
Table 99 Ambient Temperature Sensor Circuit Test

1. Measure voltage 5 ± 0.5V Go to next step. Inspect M41 and A41 circuits for
between ambient open or short.
temperature sensor
connector (8601),
2. Measure voltage 5 ± 0.5V Go to next step. Inspect temperature sensors ZVR
between ambient circuit M109AA or M109A for open
temperature sensor or short.
connector (8601),
3. Utilizing the Diamond Signal agrees Refer to the Replace faulty Ambient
Logic® Builder (DLB), with actual ELECTRONIC Temperature Sensor.
locate and view the ambient air GAUGE
Ambient_Air_ temperatures. CLUSTER
Temperature signal. section for
further diagnostic
information.
4. POWER WINDOWS AND LOCKS

This section contains a general overview of the power windows and locks.
Overview
This feature allows for the vehicle operator to open or close any power window from the driver window master
switch.
• Allows operation of each window independently.
• Locks and unlocks doors from any switch.
• Allows use of Keyless Entry if equipped.
Power Window Operation
Each door has a corresponding door pod that controls power window operation individually. The driver door
pod is able to control all of the power windows by sending commands on the J1708 data link to the remaining
door pods.
The driver door pod receives battery voltage at all times from 30A Fuse F4-A/E to pin G of the door pod signal
connector. Driver door pod, pin E has constant ground from the left side cab ground. Due to the multiplexing
circuitry and software in the door pods, the windows will only operate when the ignition switch is turned to
the ON or ACC position.
When ignition switch is ON and driver window switch is operated, the driver door pod sends a power and
ground signal from pins A and B of the driver door pod load connector to the driver window motor. The driver
window motor then moves the window in the direction commanded. The driver door pod will reverse the
polarity on pins A and B of the driver door pod load connector depending on direction of command. Holding the
S08361 161
POWER WINDOWS AND LOCKS FEATURE CODES
window down button for 0.5 seconds and releasing, will command the driver door pod to supply power and
ground to the driver door window motor until the window is all the way down.
Passenger window switch for passenger window motor operation is similar to driver window operation.
When operating any of the passenger power windows from the driver window switch, a window operation
command is sent out across the J1708 data link. Once received by the appropriate door pod for the
commanded window, the door pod will then command the window motor to move the window in the desired
direction.
When the window lockout button is pushed on the driver master window switch, the driver door pod sends a
command across the J1708 data link to all other door pods to not allow any window operation from the
respective switches. All windows can still be operated from the driver door master switch when the lock-out
button is activated.
Power Door Lock Operation
The driver door pod receives battery voltage at all times from 30A Fuse F4-A/E to pin G of door pod signal
connector. Driver door pod, pin E has constant ground from the left side cab ground. Due to the multiplexing
circuitry and software in the door pods, all doors will lock and unlock when any power lock / unlock switch is
used.
Door pods also receive vehicle speed data from the Body Controller (BC) on the J1708 data link. This allows
the doors to automatically lock when a preprogrammed vehicle speed is reached.
When a power door lock switch is pressed to lock or unlock, the corresponding door pod sends a power
and ground signal from the door pod load connector to the door lock actuator. At the same time the door
pod sends a door lock / unlock command signal across the J1708 data link to the other door pods to lock /
unlock the doors. The door pods will reverse the polarity of the door pod load connector pins depending
on the direction of command.
4.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the power windows
and locks.

0595ALE BC PROG, POWER WINDOW / DOOR LOCK (1 DOOR)
0595ABY BC PROG, POWER WINDOW / DOOR LOCK (2 DOOR)
0595AEJ BC PROG, POWER WINDOW / DOOR LOCK (4 DOOR)
0595ABZ BC PROG, REMOTE KEYLESS ENTRY (RKE)

This section contains user programmable parameters directly related to the power door locks and power
windows.
NOTE – Programmable parameters for the features below are accessed directly through the Diamond
Logic® Builder software.
162 S08361
DIAGNOSTIC TROUBLE CODES POWER WINDOWS AND LOCKS
Name: AutoLock_Speed
• ID: 652
• Description: This is the speed at which the vehicle doors will lock automatically (requires power door locks).
• Access Level: Dealer
• Default Value: 15 MPH
Name: Panic_Enable (0595ABZ)
• ID: 644
• Description: This parameter enables or disables the panic mode for the keyless remote.
• Default Value: 1 (ON)
Name: Chirp_Enable (0595ABZ)
• ID: 647
• Description: This parameter enables or disables the remote lock chirp for keyless remote.
• Default Value: 1 (ON)

The power window and door lock system is able to set Diagnostic Trouble Codes (DTC), when a fault occurs.

CAUSE SIGNAL
3988 Door 1 7 N/A N/A Defective • Front Driver Side Door_Pod_
Pod Module Driver Door Door Pod Module Master_MF_Signal
Failure Pod Module Failure
• A Failure Has
Occurred In The
Door Pod Module
Circuitry
Proceed to the Locks and Windows Inoperative Circuit Test (See Table 104, page 166).
S08361 163
POWER WINDOWS AND LOCKS DIAGNOSTIC TROUBLE CODES

CAUSE SIGNAL
3989 Door 1 7 N/A N/A Driver Door • Front driver Side Door_Pod_
Window Motor Pod Module Door Pod Window Master_WMF
Failure Window Motor Motor Failure _Signal
Has Short
Or Open Or • This Could Be
Window Is A Short In The
Jammed Window Motor An
Open In The Window
Motor Or A Jammed
Window
Proceed to the Power Window Circuit Test (See Table 105, page 167).
3990 Door 2 7 N/A N/A Defective • Front Passenger Door_Pod_
Pod Module Passenger Side Door Pod Front_MF_Signal
Failure Door Pod Module Failure
Module
• Door Pod Module
Circuitry
3991 Door 2 7 N/A N/A Passenger • Front Passenger Door_Pod_
Window Motor Door Pod Side Door Pod Front_WMF
Failure Module Window Motor _Signal
Window Motor Failure
Has Short
Or Open Or • Short In The
Window Is Window Motor An
Jammed Open In The Window
Motor Or A Jammed
Window
3992 Door 3 Control 7 N/A N/A Rear Driver Defective Rear Driver Door_Pod_
Module Door Pod Door Pod Module Rear_1_MF
Module Failure _Signal
3993 Door 3 7 N/A N/A Rear Driver Rear Driver Door Door_Pod_
Window Motor Window Motor Pod Module Window Rear_1_W MF
Failure Motor Has Short Or _Signal
Open Or Window Is
Jammed
3994 Door 4 Control 7 N/A N/A Rear Defective Rear Door_Pod_
Module Passenger Passenger Door Rear_2_MF
Door Pod Pod Module _Signal
Module Failure
164 S08361
TROUBLESHOOTING POWER WINDOWS AND LOCKS

CAUSE SIGNAL
3995 Door 4 7 N/A N/A Rear Rear Passenger Door_Pod_
Window Motor Passenger Door Pod Module Rear_2_W MF
Window Motor Window Motor Has _Signal
Failure Short Or Open Or
Window Is Jammed
3994 Door 4 Control 7 N/A N/A Rear Defective Rear Door_Pod_
Module Passenger Passenger Door Rear_2_MF
Door Pod Pod Module _Signal
Module Failure
3412 Lock Status Of 7 N/A N/A Driver Door • Front driver Side N/A
Door 1 Pod Module Door Pod Door Lock
Has Shorted Motor Failure
Opened Or
Jammed • This Could Be
Solenoid A Short In The
Solenoid Open In
The Solenoid Or A
Jammed Solenoid
Proceed to the Power Door Lock Circuit Test (See Table 106, page 168).
3415 Lock Status Of 7 N/A N/A Passenger • Front Passenger N/A
Door 2 Door Pod Side Door Pod Door
Module Has Lock Motor Failure
Shorted
Opened Or • Short In The
Jammed Solenoid Open In
Solenoid The Solenoid Or A
Jammed Solenoid
3418 Lock Status Of 7 N/A N/A Rear Driver Rear Driver Door Pod N/A
Door 3 Door Lock Module Has Short /
Motor Failure Open / Or Jammed
Solenoid
3421 Lock Status Of 7 N/A N/A Rear Rear Passenger N/A
Door 4 Passenger Door Pod Module
Door Lock Has Short / Open /
Motor Failure Or Jammed Solenoid
S08361 165
POWER WINDOWS AND LOCKS TROUBLESHOOTING
Power Window and Lock Preliminary Check
1. Check for any related inoperative features that may have common circuits.
2. Operate all power windows and locks, and check for proper operation.
NOTE – The following tests should be performed only after verifying that no communication DTCs are
present.
Table 102 Power Locks Preliminary Check
STEP ACTION NO, ONE DOOR LOCK INOP. NO, ALL DOOR LOCKS INOP.
1. Operate power Proceed to the Power Door Lock Proceed to the Locks and Windows
door locks from all Circuit Test (See Table 106, page Inoperative Circuit Test (See Table
switches. 168). 104, page 166).
Are all power locks

operating correctly?
Table 103 Power Windows Preliminary Check
STEP ACTION NO, ONE WINDOW INOP. NO, ALL WINDOWS INOP.
1. Operate power Proceed to the Power Window Proceed to the Locks and Windows
windows from all Circuit Test (See Table 105, page Inoperative Circuit Test (See Table
switches. 167). 104, page 166).
Are all power windows

operating correctly?
Locks and Windows Inoperative Circuit Test
Perform the Locks and Windows Inoperative Circuit Test only when both the power locks and the power
windows are inoperative.
Table 104 Locks and Windows Inoperative Circuit Test

1. Perform test at door 12 ± 1.5V, Go to next step. • Inspect circuit E81B to
pod of affected door, the Door / IP connector
with door pod connector (3204/3200) for open or
disconnected. short.
Measure voltage • Inspect appropriate Door

between door pod Pod fuse:
G and ground. Driver Door Pod 30A Fuse
F4-A (1013).
Passenger Door Pod 30A

Fuse F4-E (1013).
2. Perform test at door 12 ± 1.5V, Go to next step. • Inspect ground circuit
pod of affected door, E81-GA to Door / IP
166 S08361
TROUBLESHOOTING POWER WINDOWS AND LOCKS
Table 104 Locks and Windows Inoperative Circuit Test (cont.)

with door pod connector connector (3204/3200)
disconnected. for open or short.
Measure voltage • Inspect ground circuit

between door pod A81-G/GA/GH for open.
G and cavity E. • Inspect left side cab ground
or corroded connections.
3. Measure voltage Approximately 0.5V Go to next step. • If voltage is 0 volt, the
between affected door J1708 circuit is shorted to
pod connector (3202), ground or open.
cavities C and ground.
the J1708 circuit is shorted
to voltage.
4. Measure voltage Approximately 4.5V The J1708 data link • If voltage is 0 volt, the
between affected door is functional and J1708 circuit is shorted to
pod connector (3202), communicating. ground or open.
cavities D and ground.
Replace faulty door • If voltage is ABOVE 5 volts,
pod. the J1708 circuit is shorted
to voltage.
Power Window Circuit Test
NOTE – Prior to diagnosing specific window motor and circuit faults to ensure door pod operation,
always perform the Locks and Windows Test .
Table 105 Power Window Circuit Test

1. Disconnect inoperative Test light illuminated. Replace faulty window • Inspect circuits E83E
window motor connector motor. and E83A for open or
(3100). Using a test short.
light, check for voltage
between cavities A and • Replaced faulty door
B. pod.
Make sure to test circuit

voltage in both switch
positions.
Operate window switch

up and down.
S08361 167
ELECTRIC HORN SYSTEM DESCRIPTION
Power Door Lock Circuit Test
NOTE – Prior to diagnosing specific window motor and circuit faults to ensure door pod operation,
always perform the Locks and Windows Test .
Table 106 Power Door Lock Circuit Test

1. Disconnect appropriate Test light Replace faulty door lock • Inspect circuits E81A
door lock connector illuminated. actuator. and E81E for open or
(3203). Using a test light, short.
check for voltage between
cavities A and B. • Replace faulty door
pod.
Make sure to test circuit
voltage in both switch
positions.
Operate door lock switch.
5. ELECTRIC HORN
This section contains a general overview of the electric horn system.
Overview
The electric horn is an external audible warning device. Electric horns provide a means of signaling or
warning other vehicle drivers.
Operation
The electric horn switch is a direct input to the Body Controller (BC). When the horn button is pressed, the
steering wheel switch closes. Horn command signal passes through the clockspring and to the BC. Once the
BC receives the signal from the horn switch, it provides voltage to the horns. The circuits from the steering
wheel travel through a clockspring assembly that is used instead of a slip ring assembly. It winds and unwinds
as the wheel is turned.
5.2. FEATURE CODES

This section contains the available feature code definition related to the electric horn system.

0595AAV ELECTRIC HORN

This section contains user programmable parameters directly related to the electric horn.
168 S08361
USER PROGRAMMABLE PARAMETERS ELECTRIC HORN
NOTE – Under normal circumstances (OEM equipment installed), these parameter values should not be
changed from the default settings. If the equipment has been changed (post OEM assembly plant), then
these parameter values may need adjustment to prevent faults from being set incorrectly by the Body
Controller.
Name: Elec_City_Horn_High_Current
• ID: 1902
• Description: This parameter sets the Electric City Horn High Current Detection Level (Amps).
• Minimum: 0A
• Maximum: 12A
• Interval: 0.1A
• Default Value: 12A
Name: Elec_City_Horn_Low_Current
• ID: 1901
• Description: This parameter sets the Electric City Horn Low Current Detection Level (Amps).
• Minimum: 0A
• Maximum: 10A
• Interval: 0.1A
• Default Value: 0.5A
Name:Elec_City_Horn_OC_Current
• ID: 1903
• Description: This parameter sets the Electric City Horn Open Circuit Detection Level (Amps).
• Minimum: 0A
• Maximum: 10A
• Interval: 0.1A
• Default Value: 0.5A
S08361 169
ELECTRIC HORN DIAGNOSTIC TROUBLE CODES

The city horn is able to set Diagnostic Trouble Codes (DTC) when a fault occurs. Information given by the DTC
can aid in the diagnosis of the problem.

CAUSE SIGNAL
2641 Horn 5 1603 E Electric • Faulty Body Elec_City_
Horn Under Controller Horn_Cmd
Current
• Faulty Horn
• Open In
Electric Horn
Circuit
Proceed to the Electric Horn Circuit Test (See Table 110, page 171).
2641 Horn 6 1603 E Electric Horn • Faulty Body Elec_City_
Over Current Controller Horn_Cmd
• Faulty Horn
• Short To
Ground Or
Overload In
City Horn
Circuit
Proceed to the Electric Horn Circuit Test (See Table 110, page 171).
Electric Horn Preliminary Check
Table 109 Electric Horn Preliminary Check
STEP ACTION YES NO

1. Verify electric horns are • Problem may be Go to next step.
inoperative. intermittent.
Does the electric horn • Go to step 4.

function properly?
2. Determine if any other Refer to the Go to next step.
features are malfunctioning 12–VOLT POWER
that may have common DISTRIBUTION AND
circuits. GROUNDS section
170 S08361
TROUBLESHOOTING ELECTRIC HORN
Table 109 Electric Horn Preliminary Check (cont.)

STEP ACTION YES NO
Are other features information.
inoperative?
3. If more than one electric horn Go to next step. Proceed to the Electric Horn Circuit
is connected to this circuit, Test (See Table 110, page 171).
are all horns inoperative?
Are both electric horns

inoperative?
4. Are there any active or stored Refer to Diagnostic Proceed to the Electric Horn Circuit
DTCs present? Trouble Codes for Test (See Table 110, page 171).
specific cause(See
Electric Horn Circuit Test
Table 110 Electric Horn Circuit Test

1. Using Diamond Logic® Signal Go to next • Suspect faulty Switch.
Builder, select the follows step.
CONNECTORS tab. switch • Inspect circuit B85B for open or short
Select the J3 (1600) command. between clockspring (1809) and BC.
connector. Locate and
view the Elec_City_Horn • Inspect Zero Volt Reference (ZVR)
_SW_Signal signal. circuits B9R, B9V, and A9V for open or
short.
Operate the horn switch
and monitor the value. • Suspect faulty Clockspring (1809)
if other steering wheel switches are
inoperative.
2. Using Diamond Logic® Signal Go to next Suspect faulty Body Controller (BC).
Builder, select the follows step.
Select the J1 (1603) command.
connector. Locate and
view the City_Horn signal.
Operate the horn switch

and monitor the value
S08361 171
AIR HORN SYSTEM DESCRIPTION
Table 110 Electric Horn Circuit Test (cont.)

3. Measure voltage between 12 ± 1.5V Go to next • Inspect the appropriate voltage input
the electric horn connector, step. circuit for open or short.
pin A and ground.
• Inspect the IP / Chassis connector
Operate horn switch. (1700-21) for loose, damaged, or
corroded terminals.
4. Measure voltage between 12 ± 1.5V Replace • Inspect appropriate ground circuit for
the horn connector, pin A appropriate open.
and pin B. inoperative
horn. • Inspect ground adapter #1 (8800/8803)
Operate horn switch. for loose, damaged, or corroded
terminals.
6. AIR HORN
This section provides a general overview of the air horn feature.
Overview
This feature gives the driver the option to sound an air horn using a switch mounted on the steering wheel.
Operation
The air horn switch is a direct input to the Body Controller (BC). When the horn button is pushed, the BC
provides voltage to the air solenoid to operate the air horn. The circuits from the steering wheel travel through
a clockspring assembly, which is used instead of a slip ring assembly. It winds and unwinds as the wheel is
turned. Ground for the air horn is provided by the left side cab ground.
6.2. FEATURE CODES

This section contains the available feature code definition related to the air horn system.

0595ACN BC PROG, AIR HORN

There are no user programmable parameters for the air horn.

The air horn is able to set Diagnostic Trouble Codes (DTC) when a fault occurs. Information given by the DTC
can aid in the diagnosis of the problem.
172 S08361
TROUBLESHOOTING AIR HORN

CAUSE SIGNAL
3950 Air Horn 5 1602 E12 Air Horn Under • Air Horn Air_Horn
Current _Cmd
• Open In Air
Horn Circuit
Proceed to the Air Horn Circuit Test (See Table 114, page 174).
3950 Air Horn 6 1602 E12 Air Horn Over • Air Horn Air_Horn
Current _Cmd
• Short To
Ground In Air
Horn Circuit
Proceed to the Air Horn Circuit Test (See Table 114, page 174).
Air Horn Preliminary Check
NOTE – Before performing the Air Horn Preliminary Check, make sure there is air pressure to the Air
Solenoid 4-Pack, there are no air line restrictions to the air horn, and the horn is mechanically sound .
Table 113 Air Horn Preliminary Checks
STEP ACTION YES NO

1. Ensure there is air pressure to Air horn is operating. Go to next step.
the air solenoid pack. Problem may be
intermittent.
Does the air horn function
properly?
2. Determine if any other features Identify and repair Go to next step.
are malfunctioning that may condition causing several
have common circuits. features to be inoperative.
Are other features inoperative?

3. Are there any active or stored Refer to Diagnostic Trouble Proceed to the Air Horn Circuit
DTCs? Codes for specific cause Test (See Table 114, page 174).
S08361 173
POWER MIRRORS SYSTEM DESCRIPTION
Air Horn Circuit Test
Table 114 Air Horn Circuit Test

1. Using Diamond Logic® Signal Go to next step. • Inspect circuits B85C and A85K from
Builder, select the follows clockspring to BC for open or short.
Select the BC #J5 command. • Inspect Zero Volt Reference (ZVR)
(1602) connector. circuits B9R, B9V, and A9V for open
Locate and observe the or short.
Air_Horn_SW_Signal
signal. • Suspect faulty switch.
Operate the air horn • Suspect faulty clockspring (1802)

switch. if other steering wheel switches are
inoperative.
NOTE – The electric horn and air

horn share common ZVR signal to
the BC#J5 connector (1602), pin E5.
2. Measure voltage at the 12 ± 1.5V Go to next step. • Inspect circuit N59B and A59B for
Solenoid 4-Pack (9737), open or short.
terminal B to ground
while operating horn • Inspect BC connector #J5 (1602)
switch. for loose, damaged, or corroded
terminals.
• Suspect faulty Body Controller (BC).

3. Measure voltage at the 12 ± 1.5V Replace faulty • Inspect ground circuit N59A-G
Solenoid 4-Pack (9737), air horn. to Air Solenoid Ground Adapter
terminal A to terminal (8805/8809).
B while operating horn
switch. • Inspect ground adapter circuit
N11-GB to dash ground.
7. POWER MIRRORS
This section contains a general overview of the power mirror feature.
Overview
Power mirrors allow the operator to adjust the exterior driver and passenger mirrors from inside the vehicle.
Operation
When the ignition key is turned to ACC or ON position, battery voltage is provided by the Accessory Relay
#1 (1013/1011) to a 10A Fuse F4-B (1013), to pin A2 of the mirror switch (254M). Pin A4 provides the mirror
switch with a ground path to ground adapter (1008).
DRIVER POWER MIRROR:
174 S08361
FEATURE CODES POWER MIRRORS
Voltage for the mirror switch lighting feature is supplied by the panel light adapter (1002).
When the mirror switch is in the LEFT position, pin A3 (yellow wire) and pin B3 (brown wire) supply voltage
while pin B1 (orange wire) provides ground.
When the mirror switch is in the RIGHT position, pin B1 (orange wire) and pin A3 (yellow wire) supply voltage
while pin B3 (brown wire) provides ground.
When the mirror switch is in the UP position, pin A3 (yellow wire) and pin B1 (orange wire) supply voltage
while pin B3 (brown wire) provides ground.
When the mirror switch is in the DOWN position, pin B3 (brown wire) and pin A3 (yellow wire) supply voltage
while pin B1 (orange wire) provides ground.
PASSENGER POWER MIRROR:
When the mirror switch is in the LEFT position, pin B4 (blue wire) and pin A3 (yellow wire) supply voltage,
while pin B2 (white wire) provides ground.
When the mirror switch is in the RIGHT position, pin B2 (white wire) supplies voltage while pin B4 (blue wire)
and pin A3 (yellow wire) provide ground.
When the mirror switch is in the UP position, pin A3 (yellow wire) and pin B2 (white wire) supply voltage
while pin B4 (blue wire) provides ground.
When the mirror switch is in the DOWN position, pin B4 (blue wire) supplies voltage while pin A3 (yellow
wire) and B2 (white wire) provide ground.
7.2. FEATURE CODES

There are no feature codes available for the power mirrors.

There are no user programmable parameters associated with the power mirrors.

There are no Diagnostic Trouble Codes (DTC) associated with the power mirrors.
If the power mirrors fail to operate, the problem could be a blown 10A Fuse F4-B (1013), a faulty power mirror
switch, a faulty motor in the mirror, open or shorted wiring between the switch and the mirror, or missing
power or ground to the switch.
S08361 175
POWER MIRRORS TROUBLESHOOTING
Power Mirror Preliminary Check
Table 115 Power Mirror Preliminary Check
STEP ACTION YES NO

1. Are both mirrors operational? No faults evident at this Go to next step.
time.
2. Is the driver power mirror Go to next step. Proceed to the Driver Power Mirror
functioning properly in all Circuit Test (See Table 116, page 176).
directions?
3 Is the passenger mirror Problem may be Proceed to the Passenger Power Mirror
functioning properly in all intermittent. Circuit Test (See Table 117, page 177).
directions?
Driver Power Mirror Circuit Test
Table 116 Driver Power Mirror Circuit Test

1. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect 10A Fuse F4-B
(1013).
the driver door connector • Inspect circuits A78V for
(3000), cavity G and ground. open or short.
2. Key is in ON position. 12 ± 1.5V Go to next step. Inspect ground circuit A78-GA
for open or short.
cavities G and H of the driver
door connector (3000).
3. Key is in ON position. 12 ± 1.5V Go to next step. Replace faulty power mirror
switch.
the power mirror switch, pin
A3 (yellow wire) and ground.
Operate the window motor

UP and LEFT.
switch.
the power mirror switch,
pin B1 (orange wire) and
ground.

UP and RIGHT.
176 S08361
TROUBLESHOOTING POWER MIRRORS
Table 116 Driver Power Mirror Circuit Test (cont.)

5. Key is in ON position. 12 ± 1.5V Replace Replace faulty power mirror
driver power switch.
Measure voltage between mirror motor /
the power mirror switch, pin assembly.
B3 (brown wire) and ground.

DOWN and LEFT.
Passenger Power Mirror Circuit Test
Table 117 Passenger Power Mirror Circuit Test

1. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect 10A Fuse F4-B (1013).
Measure voltage • Inspect circuits A78V for open

between the driver or short.
door connector (3000),
cavity G and ground.
2. Key is in ON position. <1 ohm Go to next step. Inspect ground circuit A78-GB
for open.
Measure resistance
between the passenger
door connector (3003),
cavity H and ground.
switch.
Measure voltage
between the power
mirror switch, pin
A3 (yellow wire) and
ground.
Operate the window

motor UP and LEFT.
switch.
Measure voltage
between the power
mirror switch, pin
B2 (white wire) and
ground.
Operate the window

motor UP and RIGHT.
S08361 177
HEATED MIRROR SYSTEM DESCRIPTION
Table 117 Passenger Power Mirror Circuit Test (cont.)

5. Key is in ON position. 12 ± 1.5V Replace Replace faulty power mirror
passenger power switch.
Measure voltage mirror motor /
between the power assembly.
mirror switch, pin B4
(blue wire) and ground.
Operate the window

motor DOWN and
LEFT.
8. HEATED MIRROR
This section contains a general overview of the heated mirror feature.
Overview
Heated mirrors are used to melt ice, snow, or evaporate frost, condensation, or rain from the exterior mirrors.
Operation
The Body Controller (BC) receives the command from the mirror heat switch via the switch pack (J1708) data
link. The BC supplies power to the heated mirrors using two 10A output circuits.
8.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the heated mirrors.

0595AAU BC PROG, HEATED MIRROR, rocker switch
0595AMP BC PROG, HEATED MIRROR, push button A
02595AMR BC PROG, HEATED MIRROR, push button B

There are no user programmable parameters for the heated mirrors.

The heated mirror is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given
178 S08361
TROUBLESHOOTING HEATED MIRROR
Table 119 Diagnostic Trouble codes

CAUSE SIGNAL
2642 Mirror Heat 1 5 1603 H Left Mirror Open In Left Left_Mirror_
Heat Under Mirror Heat Heat_Cmd
Current Circuit
Proceed to the Driver Heated Mirror Circuit Test (See Table 122, page 180).
2642 Mirror Heat 1 6 1603 H Left Mirror Short To Left_Mirror_
Heat Over Ground Or Heat_Cmd
Current Overload In
Left Mirror
Heat Circuit
Proceed to the Driver Heated Mirror Circuit Test (See Table 122, page 180).
4026 Mirror Heat 2 5 1603 L Right Mirror Open In Right_Mirror_
Heat Under Right Mirror Heat_Cmd
Current Heat Circuit
Proceed to the Passenger Heated Mirror Circuit Test (See Table 124, page 182).
4026 Mirror Heat 2 6 1603 L Right Mirror Short To Right_Mirror_
Heat Over Ground Or Heat_Cmd
Current Overload In
Right Mirror
Heat Circuit
Proceed to the Passenger Heated Mirror Circuit Test (See Table 124, page 182).
Heated Mirror Preliminary Check
Table 120 Heated Mirror Preliminary Check
STEP ACTION YES NO

1. Are both heated mirrors • Problem may be intermittent. Go to next step.
functioning properly?
2. Is the driver side heated Go to next step. Proceed to the Driver Heated Mirror
mirror operational? Circuit Test (See Table 122, page
180).
3. Is the passenger Go to next step. Proceed to the Passenger Heated
side heated mirror Mirror Circuit Test (See Table 124,
operational? page 182).
4. Are any active or stored Refer to the Diagnostic Trouble Proceed to the Heated Mirror Switch
DTCs present? Codes for specific cause (See Test (See Table 121, page 180).
S08361 179
HEATED MIRROR TROUBLESHOOTING
Heated Mirror Switch Test
Table 121 Heated Mirror Switch Test

1. Using Diamond Logic® Signal follows Go to next Verify heated mirror switch
Builder, locate and view switch command. step. location and refer to the
the Mirror_Heat signal. appropriate section.
Operate the switch ON • Refer to the SWITCH PACK

and OFF while monitoring (J1708) section for further
the value. diagnostic information.
• Refer to the ELECTRONIC

GAUGE CLUSTER section for
2. Using the DLB, locate Command operates Go to next • Proceed to appropriate heated
and observe the following heated mirror. step. mirror circuit test.
signals:
• Proceed to the Driver Heated
Right_Mirror_ Mirror Circuit Test (See Table 122,
Heat_Cmd page 180).
Left_Mirror_ • Proceed to the Passenger

Heat_Cmd Heated Mirror Circuit Test (See
Actuate each signal
command.
Driver Heated Mirror Circuit Test
Table 122 Driver Heated Mirror Circuit Test

1. Key and mirror heater switch 12 ± 1.5V Go to next step. • Inspect circuit A78A for
is ON. open or short.
Measure voltage at the • Inspect the BC #J1

driver door connector connector (1601), pin H
(3000), cavity D to ground. for loose, damaged, or
corroded terminals.
180 S08361
TROUBLESHOOTING HEATED MIRROR
Table 122 Driver Heated Mirror Circuit Test (cont.)

2. Key and mirror heater switch 12 ± 1.5V Replace faulty • Inspect ground circuit
is ON. driver heated A78-GA for open or short.
mirror assembly.
Measure voltage between • Inspect ground adapter
cavity D and cavity H of (1008) for loose, damaged,
the driver door connector or corroded terminals.
(3000).
NOTE – If equipped with

lighted mirrors, ground
circuit can be verified by
operating the mirror lights
as they share ground
circuit A78-GB.
Passenger Heated Mirror Circuit Test
Table 123 Passenger Heated Mirror Circuit Test

1. Key and mirror heater switch 12 ± 1.5V Go to next step. • Inspect circuit A78B for
is ON. open or short.
Measure voltage between • Inspect the BC #J1

the passenger door connector (1601), pin L
connector (3003), cavity for loose, damaged, or
D and ground. corroded terminals.
2. Key and mirror heater switch 12 ± 1.5V Replace faulty • Inspect ground circuit
is ON. passenger A78-GB for open or short.
heated mirror
Measure voltage between assembly. • Inspect ground adapter
cavity D and cavity H of the (1008) for loose, damaged,
passenger door connector or corroded terminals.
(3003).
NOTE – If equipped with

lighted mirrors, ground
circuit can be verified by
operating the mirror lights
as they share ground
circuit A78-GB.
Heated Windshield Circuit Test
The heated windshield is controlled by the windshield relay right (1020) and windshield relay left (1019)
relays. Terminal 30 of the windshield relays are provided constant fused battery voltage. The windshield
relays are energized when the heated mirror switch is turned ON. Voltage from the BC heated mirror output
circuits provide voltage to the windshield relays, energizing the coils, and closing the switch. Once closed,
the relays provide voltage to the windshield heater elements. The relays and windshield heater element are
provided ground by the left side cab ground (4081).
S08361 181
HEATED MIRROR TROUBLESHOOTING
NOTE – The heated windshield feature will not operate if there is a heated mirror feature fault.
NOTE – Prior to performing the Heated Windshield Circuit Test, perform the Heated Mirror Switch Test
Table 124 Heated Windshield Circuit Test

1. Remove the right / 12 ± 1.5V Go to next step. Windshield relay right
left windshield relay (1020):
(1019/1020).
• Inspect 15A Fuse F2-H
Key is in ON position. (1011).
Measure voltage between • Inspect circuit A78 for

the right / left windshield open or short.
relay (1019/1020), cavity 30
and ground. Windshield relay left
(1019):
• Inspect 20A Fuse F6-B

(1015) or 25A Fuse F7-F
(1015).
• Inspect circuit A78A for

open or short.
2. Key is in ON position. 12 ± 1.5V Go to next step. Windshield relay right
(1020):
Heated mirror switch is ON.
• Inspect circuit A78BC for
Measure voltage between open or short.
the right / left windshield
relay (1020/1019), cavity 86 Windshield relay left
and ground. (1019):
• Inspect circuit A78AC for

open or short.
182 S08361
SYSTEM DESCRIPTION RADIO (ENTERTAINMENT), SPEAKERS
Table 124 Heated Windshield Circuit Test (cont.)

3. Heated mirror switch is ON. 12 ± 1.5V Go to next step. Windshield relay right
(1020):
the right / left windshield • Inspect ground circuit
relay (1020/1019), cavity 86 A78-GBH for open.
and cavity 85.
Windshield relay left
(1019):
• Inspect appropriate
ground circuit for open.
NOTE – The left

windshield relay
provides ground for the
right windshield relay.
4. Install both windshield 12 ± 1.5V Replace faulty Windshield left:
relays. relay(s).
• Inspect circuit A78C for
Key is in ON position. Go to next step. open or short.
Heated mirror switch is ON. Windshield right:
Measure voltage between • Inspect circuit A78B for

the windshield heater open or short.
element terminals
(3001/3004) and ground.
5. Key is in OFF position. <1 ohm Replace faulty • Inspect ground circuits
windshield heater A78-G and A11-GKJ for
Measure resistance element. open.
between windshield heater
element terminal 3005 and • Inspect the left side cab
the left side cab ground ground (4081) for loose,
(4081). damaged, or corroded
terminals.
9. RADIO (ENTERTAINMENT), SPEAKERS

This section contains a general overview of the radio and speaker system.
Overview
The function of the radio is to provide entertainment, news, and weather information to the driver and
passenger.
S08361 183
RADIO (ENTERTAINMENT), SPEAKERS FEATURE CODES
Operation
The entertainment radio receives constant fused battery voltage at radio connector (1300), pin 4 from 10A
Fuse F4-F (1013).
Radio memory voltage is provided at radio connector (1300), pin 7 from 10A Fuse F2-E (1011).
Ground for the radio is supplied at radio connector (1300), pin 8 to the left side cab ground (1004).
Panel light dimmer voltage is supplied at radio connector (1300), pin 6 from Electronic Gauge Cluster (EGC)
Connector (1500), pin 4.
9.2. FEATURE CODES

There are no feature codes available for the radio and speakers.

There are no user programmable parameters associated with the radio and speakers.

If the radio fails to operate, the problem could be attributed to a blown 10A Fuse F4-F or a fault between
radio and left side cab ground.
If no sound is emitted from one or more of the speakers, the cause could be open, shorted, or damaged wiring
between radio and speakers, or a blown speaker.
Radio Preliminary Check
Table 125 Radio Preliminary Check
STEP ACTION YES NO

1. Verify radio operation. • Problem may be Proceed to the Radio Circuit Test (See
intermittent. Table 126, page 185).
Does the radio function when
turned ON? • Proceed to step 3.
2. Are all speakers operating Go to next step. • If one or more, but not all speakers
correctly? are inoperative, proceed to the
Speaker Circuit Test (See Table 128,
page 186).
• If all speakers are inoperative,

proceed to the Radio Circuit Test (See
184 S08361
TROUBLESHOOTING RADIO (ENTERTAINMENT), SPEAKERS
Radio Circuit Test (16 Way Connector)
Table 126 Radio Circuit Test (16 Way Connector)

1. Measure voltage 12 ± 1.5V Go to next step. • Inspect 10A Fuse F4-F (1013).
between the radio
connector (1300), cavity • Inspect circuit A86 for open or
4 and ground. short.
• Verify accessory relay #1

(1013/1011) operation.
2. Measure voltage 12 ± 1.5V Replace faulty • Inspect ground circuit A86-G for
between cavity 4 and radio. open.
cavity 8 of the radio
connector (1300). • Inspect left side cab ground (1004)
terminals.
Radio Circuit Test (12 Way Connector)
Table 127 Radio Circuit Test (12 Way Connector)

1. Measure voltage 12 ± 1.5V Go to next step. • Inspect 10A Fuse F4-F (1013).
between the radio
connector (1301), cavity • Inspect circuit A86 for open or
6 and ground. short.
• Verify accessory relay #1

2. Measure voltage 12 ± 1.5V Replace faulty • Inspect ground circuit A86-G for
between cavity 4 and radio. open.
cavity 5 of the radio
connector (1301). • Inspect left side cab ground (1004)
terminals.
Speaker Circuit Test (16 Way Connector)
If the vehicle is equipped with an amplifier, perform speaker circuit tests at amplifier connector B (5312).
NOTE – Verify radio operation and speaker output prior to diagnosing specific speaker circuits.
NOTE – Refer to specific circuit diagram information when diagnosing speakers, amplifier and sleeper
radio features.
S08361 185
RADIO (ENTERTAINMENT), SPEAKERS TROUBLESHOOTING
Table 128 Speaker Circuit Test (16 Way Connector)

1. LEFT FRONT 4 ohms Go to next step. • If resistance is >4 ohms, inspect
SPEAKER: speaker circuits for source of high
resistance.
Measure resistance
between the radio • If infinite impedance (open circuit)
connector (1300), cavity is detected, a blown left front
13 and cavity 14. speaker (3300) is suspected.
2. RIGHT FRONT 4 ohms Go to next step. • If resistance is >4 ohms, inspect
resistance.
Measure resistance
between the radio • If infinite impedance (open
connector (1300), cavity circuit) is detected, a blown right
11 and cavity 12. front speaker (3300/3300M) is
suspected.
3. RIGHT REAR 4 ohms Go to next step. • If resistance is >4 ohms, inspect
resistance.
Measure resistance
connector (1300), cavity is detected, a blown right rear
4. LEFT REAR SPEAKER: 4 ohms No faults present. • If resistance is >4 ohms, inspect
speaker circuits for source of high
Measure resistance resistance.
between the radio
connector (1300), cavity • If infinite impedance (open circuit)
15 and cavity 16. is detected, a blown left rear
speaker (2301) is suspected.
Speaker Circuit Test
If the vehicle is equipped with an amplifier, perform speaker circuit tests at amplifier connector B (5312).
NOTE – Verify radio operation and speaker output prior to diagnosing specific speaker circuits.
NOTE – Refer to specific circuit diagram information when diagnosing speakers, amplifier and sleeper
radio features.
186 S08361
SYSTEM DESCRIPTION TWO-WAY RADIO
Table 129 Speaker Circuit Test (12 Way Connector)

1. LEFT FRONT 4 ohms Go to next step. • If resistance is >4 ohms, inspect
resistance.
Measure resistance
connector (1301), cavity is detected, a blown left front
2. RIGHT FRONT 4 ohms Go to next step. • If resistance is >4 ohms, inspect
resistance.
Measure resistance
between the radio • If infinite impedance (open
connector (1301), cavity circuit) is detected, a blown right
7 and cavity 8. front speaker (3300/3300M) is
suspected.
3. RIGHT REAR 4 ohms Go to next step. • If resistance is >4 ohms, inspect
resistance.
Measure resistance
connector (1301), cavity is detected, a blown right rear
4. LEFT REAR SPEAKER: 4 ohms No faults present. • If resistance is >4 ohms, inspect
speaker circuits for source of high
Measure resistance resistance.
between the radio
connector (1301), cavity • If infinite impedance (open circuit)
3 and cavity 4. is detected, a blown left rear
speaker (2301) is suspected.
10. TWO-WAY RADIO

This section contains a general overview of the two-way radio accommodation package.
Overview
The two-way radio accommodation package provides wiring for customer supplied radios. The radio can be
mounted either on the floor (6334) or on the overhead compartment (6900).
Operation
The two-way radio is supplied battery voltage through 20A 2-Way Radio Feed Fuse and ignition voltage from
ignition relay #1 (1011/1013) and a 5A Fuse F9-A (1018).
Ground is supplied by the vehicle batteries on circuit N14-GD.
S08361 187
WINDSHIELD WIPER AND WASHER PUMP FEATURE CODES
10.2. FEATURE CODES

There are no feature codes available for the two-way radio.

There are no user programmable parameters for the two-way radio.

There are no diagnostic trouble codes associated with the radio.
If the radio fails to operate, the problem could be attributed to a blown 5A Fuse F9-A, 20A 2-Way Radio Feed
Fuse, or a fault in either the power or ground circuits.
Two-Way Radio Circuit Test
Table 130 Two-Way Radio Circuit Test

1. Measure voltage 12 ± 1.5V Go to next step. • Inspect 20A 2-Way Radio Feed
between the two-way Fuse.
radio connection (6900),
cavity A and ground. • Inspect circuit A14HF to the
two-way radio IP / Engine
Connection (6334) for open or
short.
• Inspect circuits N14HC and

N14HB for open or short.
2. Measure voltage 12 ± 1.5V Go to next step. • Inspect 5A Fuse F9-A (1018).
between the two-way
radio connection (6900), • Inspect circuits A86P and A13FM
cavity C and ground. for open or short.
3. Measure resistance ≤1 ohm Replace faulty Inspect ground circuits A11-GAP
between the two-way two-way radio. and N14-GD for open or source of
radio connection (6900), high resistance.
cavity B and ground.
11. WINDSHIELD WIPER AND WASHER PUMP

This section contains a general overview of the windshield wiper and washer pump feature.
Overview
The wiper system provides a means to clear the outer windshield surface from rain, snow, contaminants, or
other debris.
188 S08361
FEATURE CODES WINDSHIELD WIPER AND WASHER PUMP
Wiper Operation
Both wiper relays are located in the interior Power Distribution Center (PDC). The wiper switches located in
the turn signal assembly are hardwired directly to the Body Controller. A Zero Volt Reference (ZVR) signal
will pass through the appropriate wiper switch to the Body Controller (BC) when any of these switches is
closed. The windshield wipers have eight speeds: off, high, low, and five intermittent speeds. These speeds
are determined by the condition of the three wiper switches. Each of the eight possible wiper switch settings
causes a different combination of open and closed switches. The combination of open or closed switches is
used by the BC to determine which switch position the operator has selected.
Park Operation
The BC de-energizes both wiper relays when the wipers are switched to OFF while the key switch is in the
ignition position. The BC provides battery voltage to the wiper park switch (internal to wiper motor) while the
wipers are not parked and the key switch is in the ignition position. Battery voltage is therefore provided
through the park switch to the normally closed contact of the wiper power relay. Current flows through the
normally closed contact of the wiper power relay and through the normally closed contact of the high / low relay
to the low speed terminal of the wiper motor. This causes the wiper motor to operate at low speed, until the
wipers are parked. The voltage being supplied to the wiper motor will be replaced by a ground when the wipers
reach the park position, causing the wiper motor to stop in the parked position.
Washer Operation
The washer pump is wired directly to the washer switch in the turn signal switch assembly. Ignition voltage is
also provided to the washer pump. Ground is supplied to the washer pump when the washer switch closes,
causing the washer pump to activate.
The ground from the washer switch is also applied to the BC, which signals the BC that the washer has been
activated. The BC activates the low speed wipers for three wiper cycles when it receives this signal. This
occurs only if the wipers are not currently in the high speed wiper mode.
11.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the windshield
wipers and washer feature.

0595AAE BC PROG, WINDSHIELD WIPER
0595AYC BC PROG, WINDSHIELD WIPER without low washer fluid indicator
0595AYD BC PROG, LOW WASHER FLUID IND.
0595AJD BC PROG, WIPER SPEED OVERRIDE

This section contains user programmable parameters directly related to the windshield wiper and washer.
Name: Wipers_Hi_Current
• ID: 1887
• Description: Windshield Wipers High Current Detection Level (Amps).
S08361 189
WINDSHIELD WIPER AND WASHER PUMP USER PROGRAMMABLE PARAMETERS
• Access level: Fleet
• Minimum: 0A
• Maximum: 20A
• Interval: 0.1A
Name: Wiper_OC_Current
• ID: 1888
• Description: Windshield Wipers Open Circuit Detection Level (Amps).
• Minimum: 0A
• Maximum: 20A
• Interval: 0.1A
Name: Wipers_Low_Current
• ID: 1886
• Description: Windshield Wipers Low Current Detection Level (Amps).
• Minimum: 0A
• Maximum: 20A
• Interval: 0.1A
Name: Wipers_To_Low_Int_Enabled
• ID: 2171
• Description: This parameter is used to enable or disable the wiper speed override.
• Value: ON / OFF
• Default Value: ON
190 S08361
DIAGNOSTIC TROUBLE CODES WINDSHIELD WIPER AND WASHER PUMP

The wiper and washer system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.

CAUSE SIGNAL
2636 Windshield 5 1601 E7 Wiper ON / • Body Controller Wiper_Low_
Wiper Motor ON OFF Relay Speed_Relay_Cmd
/ OFF Under • Faulty Relay
Current
Or Open • Wiper Switch
Circuit
• Open Circuit In
Wiper ON / OFF
Circuit
Proceed to the Wiper Switch Circuit Test (See Table 135, page 194).
2636 Windshield 6 1601 E7 Wiper ON / • Body Controller Wiper_Low_
Wiper Motor ON OFF Relay Speed_Relay_Cmd
/ OFF Over • Faulty Relay
Current
• Wiper Switch
• Short To Ground
In Wiper ON / OFF
Circuit
2637 Windshield 5 1601 E6 Wiper • Body Controller Wiper_High_
Wiper Motor High / Speed_Relay_ Cmd
Speed Low Relay • Faulty Relay
Under
Current • Wiper Motor
Or Open
Circuit • Open Circuit In
Wiper High / Low
Circuit
2637 Windshield 6 1601 E6 Wiper • Body Controller Wiper_High_
Wiper Motor High / Speed_Relay_ Cmd
Speed Low Relay • Faulty Relay
Over
Current • Wiper Motor
• Short To Ground
In Wiper High /
Low Circuit
S08361 191
WINDSHIELD WIPER AND WASHER PUMP TROUBLESHOOTING

CAUSE SIGNAL
4057 Wiper Motor 6 1604 A Wiper • Body Controller Wipers_Cmd
Motor
Over • Faulty Relay
Current
• Wiper Motor
• Short To Ground
or Overload in
Wiper Motor
Circuit
4057 Wiper Motor 5 1604 A Wiper • Body Controller Wipers_Cmd
Motor
Under • Faulty Relay
Current
• Wiper Motor
• Open in Wiper
Motor Circuit
Wiper and Washer Preliminary Check
Table 133 Wiper and Washer Preliminary Check
STEP ACTION YES NO

1. Do the wipers operate on all Go to next step. • Proceed to the Wiper Switch Circuit
settings? Test (See Table 135, page 194).
• If no faults are found with wiper

switch, proceed to the Wiper Motor
Circuit Test (See Table 136, page 195).
2. Does the washer pump Go to next step. Proceed to the Washer Pump Circuit
operate properly? Test (See Table 134, page 193).
3. Are any active or stored Refer to the Diagnostic • Proceed to the appropriate circuit
DTCs Present? Trouble Codes for specific test.
cause (See Table 132,
page 191). • Wiper Switch Circuit Test (See Table
135, page 194).
• Wiper Motor Circuit Test (See Table

136, page 195).
192 S08361
TROUBLESHOOTING WINDSHIELD WIPER AND WASHER PUMP
Table 133 Wiper and Washer Preliminary Check (cont.)

STEP ACTION YES NO
• Washer Pump Circuit Test (See Table

134, page 193).
Washer Pump Circuit Test
Table 134 Washer Pump Circuit Test

1. Key is in OFF position. Washer switch Connect turn Replace faulty turn signal switch
operated: ≤1 signal switch (1810).
Disconnect turn signal ohm connector
switch connector (1810). (1810).
No continuity
Measure continuity when switch Go to next
between cavity 12 and pin is not being step.
6 of the turn signal switch operated.
(1810).
Operate washer switch.

2. Key is in ON position. 12 ± 1.5V Go to next • Inspect 10A Fuse F4-H (1013).
step.
Measure voltage between • Inspect appropriate power circuit
the washer pump for open or short.
(4021/9747/9745), cavity
1 and ground. • Inspect the Forward Chassis / IP
connector (1700/1701) for loose,
3. Measure voltage between 12 ± 1.5V Go to next • Inspect appropriate ground circuit
cavity 1 and 2 of the step. for open.
washer pump connector
(4021/9747/9745). • Inspect the Forward Chassis / IP
connector (1700/1701) for loose,
Operate the washer damaged, or corroded terminals.
switch.
4. Using the Diamond ON Replace faulty • Inspect the BC #J3 connector
Logic® Builder washer pump. (1600), for loose, damaged, or
(DLB), select the corroded terminals.
CONNECTORS tab.
• Suspect faulty BC.
Select the BC #J3 (1600)
connector.
Locate and observe the

following signal:
Washer_Pump_Signal
signal.
S08361 193
WINDSHIELD WIPER AND WASHER PUMP TROUBLESHOOTING
Table 134 Washer Pump Circuit Test (cont.)

Operate washer switch.
Wiper Switch Circuit Test
Table 135 Wiper Switch Circuit Test

1. Using the Diamond Logic® Signal follows • The BC has Go to next step.
Builder (DLB), select the switch command. received switch
CONNECTORS tab. input signal.
Select the BC #J4 (1601) • Proceed to

connector. the Wiper Motor
Circuit Test (See
Locate and observe the Table 136, page
following signals: 195).
Wiper_Low_Speed_Cmd
signal.
Wiper_High_Speed_Cmd
signal.
Operate the wiper switch in

the low and high positions.
2. Disconnect the turn signal 12 ± 1.5V Go to next step. • Inspect the appropriate
switch connector (1810). circuits for open or short
between the Body Controller
Measure voltage between (BC) and turn signal switch.
the turn signal switch
(1810), pins 8, 11, 5 and • Inspect the DCM / IP
ground. connector (1800) for loose,
terminals.
3. Measure continuity ≤1 ohm Replace faulty turn • Inspect Zero Volt Reference
between the turn signal signal switch. (ZVR) circuit B9S, B9V, A9V
switch (1810), pin 7 and and A9AA for open.
ground.
• Inspect the DCM / IP
terminals.
194 S08361
SYSTEM DESCRIPTION PARK BRAKE AND BRAKE SWITCH
Wiper Motor Circuit Test
Table 136 Wiper Motor Circuit Test

1. Disconnect the wiper Continuity present. Go to next step. Inspect both the Wiper Power
motor connector Relay (1012) and the Wiper
(4500). High / Low Relay (1012).
Set the wiper switch to

the PARK position.
Measure continuity
between cavity E
and cavity B of the
wiper motor connector
(4500).
2. Key is in ON position. 12 ± 1.5V Go to next step. Inspect circuit A82D for open or
short.
Measure voltage
between the wiper
motor connector
(4500), cavity A and
ground.
3. Measure voltage 12 ± 1.5V Go to next step. Inspect ground circuit A82-G for
between cavity A open to ground.
and cavity C of the
(4500).
4. Measure voltage 12 ± 1.5V Go to next step. Inspect circuit A82L for open or
between the wiper short.
motor connector
(4500), cavity E and
cavity C.

the LOW position.
5. Measure voltage 12 ± 1.5V Replace faulty Inspect circuit A82K for open or
between cavity D wiper motor. short.
and cavity C of the
(4500).

the HIGH position.
12. PARK BRAKE AND BRAKE SWITCH

This section contains a general overview of the park brake and brake switch.
S08361 195
PARK BRAKE AND BRAKE SWITCH FEATURE CODES
Overview
Brake Switch
The brake switch senses when the driver is pressing the brake pedal to apply the brakes and thus signal
the Body Controller (BC) to turn on the stop lights.
Park Brake Switch
The park brake switch allows the operator to engage and disengage the vehicle parking brakes.
Operation
Brake Switch
The stop light signal to the BC comes from two switches operated by air pressure. The BC uses a Zero Volt
Reference (ZVR) to determine when the brake pedal is being applied. Voltage is always supplied to the
brake switches. When the brake pedal is depressed, the switches close and send above 0 volts to the Body
Controller. The BC then turns on the brake lights.
Park Brake Switch
The BC uses a Zero Volt Reference (ZVR) to determine when the park brake is being requested. Voltage
is always supplied to the park brake. When the park brake switch is applied (switch pulled out), the park
brake switch (1808) is open. When the parking brake is released (switch pushed in), the park brake switch
(1808) is closed providing a voltage signal to the BC.
12.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the brake switch.

0595AAD BRAKE SWITCH
0595AAZ PARK BRAKE INDICATOR

This section contains user programmable parameters associated with the park brake switch. There are no
user programmable parameters for the brake switch.
Name: Park_Brake_Reminder
• ID: 2349
• Description: Park brake reminder.
• Value: ON / OFF
196 S08361
DIAGNOSTIC TROUBLE CODES PARK BRAKE AND BRAKE SWITCH

The brake switch is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given

CAUSE SIGNAL
597 Brake Switch 0 1602 E14 Brake • Brake Switch Brake_Analog
And Switch Shorted High _Switch_
E15 Reading Raw_ Signal
Above • Open Circuit
Normal Or Faulty Sensor
Range System
597 Brake Switch 1 1602 E14 Brake • Brake Switch Short Brake_Analog
And Switch To Ground _Switch_
E15 Reading Raw_Signal
Below • Faulty Sensor
Normal System
Range
597 Brake Switch 2 1602 E14 Brake • High Resistance In Brake_Switch
And Switch The Wire Harness _Signal
E15 Inputs Do
Not Match • Defective Brake
Switch
• Defective Body
Controller
• Defective ABS
Controller Or
Datalink
597 Brake Switch 7 1602 E14 Brake • Brake Switch Stuck Brake_Switch
And Switch Open _Signal
E15 Stuck
Open Or • Brake Switch Stuck
Closed Closed
• Defective Brake
Switch
S08361 197
PARK BRAKE AND BRAKE SWITCH TROUBLESHOOTING

CAUSE SIGNAL
597 Brake Switch 14 N/A N/A Brake Defective Brake Brake_Switch
Switch Is Switch _Signal
Stuck In
The Open
Or Closed
Position
597 Brake Switch 14 N/A N/A Brake • Defective Brake Brake_Switch
Switch Switch _Signal
Inputs Do
Not Match • Defective Body
Controller
70 Air Powered 14 N/A N/A Air Park Brake Switch Park_Brake_Switch
Park Brake Powered Does Not Match The _Signal
Park Brake Spring Apply-Air
Is Stuck Release (SAAR)
Chamber Travel
Sensor.
Proceed to the Park Brake Switch Test (See Table 141, page 200).
Brake Switch Preliminary Check
Table 139 Brake Switch Preliminary Check
STEP ACTION YES NO

1. Do park brakes operate when No faults present. Proceed to the Park Brake Switch
the park brake switch is Circuit Test (See Table 141, page
applied? Go to next step to verify 200).
brake switch operation.
2. Verify brake light operation. • Brake lights are working Go to next step.
properly at this time. Problem
Are brake lights illuminated may be intermittent.
when pedal is depressed?
198 S08361
TROUBLESHOOTING PARK BRAKE AND BRAKE SWITCH
Table 139 Brake Switch Preliminary Check (cont.)

STEP ACTION YES NO
3. Determine if any other Identify and repair condition Go to next step.
features are malfunctioning causing several features to
that may have common be inoperative.
circuits.
Are other features

inoperative?
4. Are any active or stored DTCs Refer to the Diagnostic Proceed to the Brake Switch Circuit
present? Trouble Codes for specific Test (See Table 140, page 199).
cause (See Table 138, page
197).
Brake Switch Test
Table 140 Brake Switch Circuit Test

1. Using Diamond Logic® Signal follows switch Refer to the LIGHTING Go to next step.
Builder, select the command. SYSTEMS section
CONNECTORS tab. for further diagnostic
Select the BC #J5 Brake Pedal is information related to
(1602) connector. depressed: ON stop light circuits.
Locate and observe
the following signal: Brake Pedal is
released: OFF
Brake_Switch_Signal
While depressing and

releasing brake pedal,
monitor the value.
2. Disconnect the 12 ± 1.5V Go to next step. Stop light #1
appropriate stop light connector (1823):
connector.
• Inspect circuits
Measure voltage at the B9VG, B9V, A9V,
following locations: and A9AA for open or
short.
Stop light #1 connector
(1823), pin C and • Inspect the IP / DCM
ground. connector (1800) for
loose, damaged, or
Stop light #2 connector corroded terminals.
(1824), pin C and
ground. Stop light #2
connector (1824):
• Inspect circuits B70

and A70 for open or
short.
S08361 199
PARK BRAKE AND BRAKE SWITCH TROUBLESHOOTING


connector (1800) for
loose, damaged, or
corroded terminals.
3. Measure voltage at the 12 ± 1.5V Replace faulty brake • Inspect appropriate
following locations: switch. Zero Volt Reference
(ZVR) circuits.
Stop light #1 connector
(1823), pin C and pin • Inspect the IP / DCM
D. connector (1800) for
loose, damaged, or
Stop light #2 connector corroded terminals.
(1824), pin C and pin
D.
Park Brake Switch Test
NOTE – Always inspect Body Controller (BC) connectors for loose, damaged, or corroded connections
each time it is disconnected.
NOTE – Always use the Breakout Box (ZTSE4477) to take measurements at BC connectors.
Table 141 Park Brake Switch Circuit Test

1. Using Diamond Logic® Signal follows No faults present at Go to next step.
Builder, select the switch command. this time.
CONNECTORS tab.
Select the BC #J3 (1600) Inspect brake
connector. Locate and system for
observe the following mechanical
signal: failures.
Park_Brake_Switch_
Signal signal.
Apply and release the

park brake.
2. Key is in ON position. 12 ± 1.5V Connect Body Suspect faulty BC.
Controller #J3
Measure voltage between connector.
the BC #J3 connector
(1600), pin A12 and Go to next step.
ground.
200 S08361
TROUBLESHOOTING PARK BRAKE AND BRAKE SWITCH

3. Disconnect park brake 12 ± 1.5V Connect the park Hydraulic Brakes:
switch connector. brake switch.
• Inspect circuit B44BB,
Key is in ON position. Go to next step. A44A, and white wire to
park brake switch (1815)
the hydraulic park brake
switch (1815), terminal A • Inspect the DCM / IP
or air park brake (1813), connector (1800) for loose,
terminal C and ground. damaged, or corroded
terminals.
Air Brakes:
• Inspect circuit B44BB and

A44A to park brake switch
(1813) for open or short.

terminals.
S08361 201
CLUTCH SWITCH SYSTEM DESCRIPTION

4. Key is in ON position. ≤1 ohm Park brake switch • Replace faulty park brake
(1813/1815) is switch (1813/1815).
Measure resistance operating properly.
between the hydraulic • Inspect Zero Volt
park brake switch (1815), Reference (ZVR) circuits
terminal A and B or B9V, A9V, and A9AA for
air park brake (1813), open.
terminal C and D.
terminals.
13. CLUTCH SWITCH

This section contains a general overview of the clutch switch.
Overview
The clutch switch module contains two clutch switches. One switch is an input to the Body Controller (BC) and
senses clutch pedal position to disengage the cruise control. The other clutch switch is an input to the engine
controller and senses clutch pedal position to enable engine cranking.
Operation
The clutch switch provides engine cranking capabilities by controlling the start relay (1010) or provided the
Engine Control Module (ECM) with a switched input.
MaxxForce® 11 and 13
When the key is in the ON position, voltage is supplied to pin A of the clutch switch (1807). When the clutch
pedal is depressed, the clutch switch closes, providing voltage to cavity 86 of the start relay (1010).
MaxxForce® DT, 9, 10, and MaxxForce® 7
When the key is in the ON position, voltage is supplied to pin B of the clutch switch (1807). When the clutch
pedal is depressed, the clutch switch closes, providing the Engine Control Module (ECM) with an engine
crank enable input signal.
Cruise control operation:
The BC uses a Zero Volt Reference (ZVR) on pin D of the clutch switch. When the clutch pedal is depressed,
voltage from pin C sends an input signal to the BC.
13.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the clutch switch.
202 S08361
USER PROGRAMMABLE PARAMETERS CLUTCH SWITCH

0595ADP BC PROG, CLUTCH SWITCH

There are no user programmable parameters associated with the clutch switch.

The clutch switch is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given

CAUSE SIGNAL
598 Clutch Switch 0 1600 B4 Clutch • Clutch Switch Clutch_Switch_
Switch Reading Above Raw_Signal
Reading Normal Range
Above
Normal • Upper Clutch Switch
Range Shorted High
• Open Circuit
• Faulty Sensor
System
Proceed to the Clutch Switch Preliminary Checks (See Table 144, page 204).
598 Clutch Switch 1 1600 B4 Clutch • Clutch Switch Clutch_Switch_
Switch Reading Below Raw_Signal
Reading Normal Range
Below
Normal • Upper Clutch Switch
Range Short To Ground
• Faulty Sensor
System
598 Clutch Switch 7 1600 B4 Clutch • Clutch Switch Stuck Clutch_Switch_
Switch Stuck Raw_Signal
• Defective Upper
Clutch Switch
S08361 203
CLUTCH SWITCH TROUBLESHOOTING

CAUSE SIGNAL
598 Clutch Switch 14 N/A N/A Upper Clutch • Defective upper Clutch_Switch_
Switch Stuck clutch switch Raw_Signal
In The Open
Or Closed • Occurs if the vehicle
Position speed increases from
0 MPH to 45 MPH
(72 KM/H) without a
change in state of the
clutch switch
Clutch Switch Preliminary Checks
Table 144 Clutch Switch Preliminary Checks
STEP ACTION YES NO

1. Attempt to crank engine with Go to next step. Proceed to the Engine Crank Clutch
clutch pedal depressed. Switch Test (See Table 145, page
205).
Does the engine crank?
2. Start engine and operate cruise Go to next step. Proceed to the Cruise Control
control. Disengage cruise Clutch Switch Test (See Table 146,
control by depressing clutch page 207).
pedal.
Does the clutch switch

disengage the cruise control?
3. Are any active or stored DTCs Refer to the Diagnostic No faults evident at this time.
present? Trouble Codes for specific
cause (See Table 143,
page 203).
204 S08361
TROUBLESHOOTING CLUTCH SWITCH
Engine Crank Clutch Switch Test
NOTE – Always use the ECM Breakout Box (1180-N4-0X0) to take measurements at ECM connectors.
Table 145 Engine Crank Clutch Switch Test

1. Using the Diamond Logic® Signal follows switch Refer to the Go to next step.
Builder (DLB), select the command. BATTERY,
CONNECTORS tab. CHARGING
AND CRANKING
Select the BC #J3 (1600) SYSTEMS
connector. section for
further diagnostic
Locate and observe the information.
Clutch_Switch
_Signal Signal.
Operate clutch pedal.

2. Disconnect the clutch 12 ± 1.5V Connect clutch MaxxForce® 11 and
switch connector (1807). switch (1807). 13:
Key is in ON position. Go to next step. • Inspect circuits A17A

and B17J for open or
MaxxForce® 11 and 13: short.
Measure voltage between MaxxForce® DT, 9,

the clutch switch (1807), 10, and MaxxForce®
cavity A and ground. 7:
Crank engine. • Inspect 10A Fuse

F5-E (1014).
MaxxForce® DT, 9, 10,
and MaxxForce® 7: • Inspect circuits
A17HB and B17H
the clutch switch (1807),
cavity B and ground.
S08361 205
CLUTCH SWITCH TROUBLESHOOTING
Table 145 Engine Crank Clutch Switch Test (cont.)

3. MaxxForce® 11 and 13: Clutch pedal depressed: Refer to the MaxxForce® 11 and
BATTERY, 13:
Remove start relay (1010). 12 ± 1.5V CHARGING,
AND CRANKING • Inspect circuits B17H
Key is in ON position. Clutch pedal released: SYSTEM section and A17D for open or
for further short.
Measure voltage between 0V diagnostic
the start relay (1010), information. • Inspect the DCM /
cavity 86 and ground. IP connector (1800)
Depress clutch pedal. corroded terminals.
MaxxForce® DT, 9, and • Replace faulty clutch

10: switch.
Measure voltage between MaxxForce® DT, 9,

the ECM connector (6020), 10, and MaxxForce®
pin 65 and ground. 7:
Depress clutch pedal. • Inspect circuits B17J,

A17B, and K17E for
MaxxForce® 7: open or short.
Measure voltage between • Inspect the DCM /

the ECM connector IP connector (1800)
(6020M), pin 60 and for loose, damaged, or
ground. corroded terminals.
Depress clutch pedal. • Replace faulty clutch

switch.
206 S08361
SYSTEM DESCRIPTION LOAD SHEDDING
Cruise Control Clutch Switch Test
Table 146 Cruise Control Clutch Switch Test

1. Using the Diamond Signal follows switch Refer to the Go to next step.
Logic® Builder (DLB), command. FANS AND
select the CONNECTORS ENGINE
tab. ACCESSORIES
section
Select the BC #J3 (1600) for further
connector. diagnostic
information
Locate and observe the related to the
Clutch_Switch cruise control.
_Signal signal.
Operate clutch pedal.

2. Disconnect the clutch 12 ± 1.5V Go to next step. Inspect circuits A97A and
switch connector (1807). B96A for open or short.

the clutch switch
C and ground.
3. Key is in ON position. 12 ± 1.5V Go to next step. Inspect Zero Volt
Reference (ZVR) circuits
Measure voltage between B9VB, B9V, A9V, and
the clutch switch A9AA for open.
C and cavity D.
4. Key is in OFF position. Clutch pedal Refer to the Replace faulty clutch
depressed: FANS AND switch.
Measure resistance ENGINE
between the clutch switch 1200 ohms ACCESSORIES
connector (1807), cavity section
C and cavity . Clutch pedal for further
released: diagnostic
information
2400 ohms related to the
cruise control.
14. LOAD SHEDDING

This section contains a general overview of the load shedding feature.
S08361 207
LOAD SHEDDING FEATURE CODES
Overview
Electrical Load Control and Shedding (ELCS) is an optional feature (standard with sleepers) used to protect
the vehicle's batteries from excessive discharge by automatically shutting down electrical loads to conserve
battery power.
If the Body Controller (BC) determines the battery voltage is low for a period of time, the feature begins a
sequence of events that result in the disabling of certain electrical loads. The feature also provides audible and
visual indications to alert the operator that the feature is about to disable loads.
Operation
The ELCS feature consists of a latching relay (1007) used to disconnect battery voltage from certain electrical
loads. The BC is used to monitor battery voltage, control the latching relay, and disable certain electrical loads
by turning off the appropriate outputs.
The latching relay is located under the engine cover on the module plate. The BC momentarily supplies near
battery voltage to the appropriate input circuit of the latching relay, causing the switch contacts of the relay to
open or close. The input circuits of the latching relay normally rest at ground. The latching relay either supplies
or removes voltage from certain electrical loads depending on the position of the relay switch. The latching
relay switch contacts are closed when ELCS is deactivated.
The BC monitors system voltage while the engine is OFF, regardless of key state. The following will occur if
the BC detects that battery voltage is at or below 12.1 volts for 30 seconds:
1. The operator will receive an audible and visual indication that load shedding is about to disable electrical
loads.
2. The appropriate electrical loads will be disabled by the feature.
14.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the ELCS.

0595ACL BC PROG, ELECTRICAL LOAD CONTROL

There are no user programmable parameters for the load shedding system.

The load shedding system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Using the
information given by the DTC can aid in the diagnosis of the problem.
208 S08361
TROUBLESHOOTING LOAD SHEDDING

CAUSE SIGNAL
3998 Electrical Load 5 1601 F7 Load Shed OFF Open Circuit In Load Load_Shed_
Shed OFF Relay Under Shed OFF Circuit Power_Off_
Current Or Open RD _Cmd
Circuit
Proceed to the Latching Relay Circuit Test (See Table 149, page 210).
3998 Electrical Load 6 1601 F7 Load Shed OFF Short To Ground Load_Shed_
Shed OFF Relay Over In Load Shed OFF Power_Off_
Current Circuit RD _Cmd
3999 Electrical Load 5 1601 F6 Load Shed ON Load Shed ON Relay Load_Shed_
Shed ON Relay Under Open Circuit Power_ON_
Current Or Open RD _Cmd
Circuit
3999 Electrical Load 6 1601 F6 Load Shed ON Short To Ground Load_Shed_
Shed ON Relay Over In Load Shed ON Power_ON_
Current Circuit RD _Cmd
The BC monitors the voltage of the load shedding circuits between the Body Controller and the latching relay.
The BC will set the appropriate DTC if it determines that an open or short to ground is present on either of
the circuits.
If a load shedding related DTC is present, test for the following conditions:
• Open or shorted input circuits to the latching relay.

• Open or high resistance in the ground circuit of the latching relay.
Latching Relay Circuit Test
NOTE – Verify vehicle battery state of charge prior to diagnosing conditions related to load shedding.
S08361 209
VEHICLE DATA RECORDER SYSTEM DESCRIPTION
Table 149 Latching Relay Circuit Test

1. Measure voltage 12 ± 1.5V Go to next step. • Inspect circuit A14X for
between the latching open or short.
relay (1007), B1
terminal and ground. • Inspect the load
shedding connector
(1008F/1005M) for loose,
terminals.
• Inspect the 100A Mega

Fuse (1000/1001).
2. Measure resistance ≤1 ohm Go to next step. Inspect circuit A14LA for
between the BC #J4 open or source of high
connector (1601), resistance.
cavity F6 and
the latching relay
connector (1007),
cavity 2.
3. Measure resistance ≤1 ohm Go to next step. Inspect circuit A14LB for
between the BC #J4 open or source of high
connector (1601), resistance.
cavity F7 and
the latching relay
connector (1007),
cavity 3.
4. Measure resistance ≤1 ohm Replace faulty latching • Inspect ground circuit
between the latching relay. A14-GL for open
relay connector or source of high
(1007), cavity 1 resistance.
and ground adapter
connector (1003), • Inspect ground adapter
cavity 3. (1003) for loose,
terminals.
15. VEHICLE DATA RECORDER

This section contains a general overview of the Vehicle Data Recorder (VDR) feature.
Overview
This feature provides a pre-wired accommodation package for VDR applications.
The VDR collects essential data including vehicle speed, acceleration, deceleration, engine speed, throttle
position, ABS event, service brake, time, date, and engine hours. The feature also provides an Occupant
Restraint Indicator (ORI) display, which indicates which seats are occupied and if the seat belt is fastened.
210 S08361
FEATURE CODE VEHICLE DATA RECORDER
Operation
The VDR is provided constant battery voltage from 10A Fuse F2-F (1011). Ground path is provided by ground
adapter (1006) and the left side cab ground (4081). When the key is in the ON position, ignition voltage from
ignition relay #2 (1012/1014) is provided to 10A Fuse F5-J (1014).
The VDR receives input voltage from the headlight input relay (1019) when the headlights are illuminated. The
VDR also monitors brake switch input using brake pressure switch (1825). Other information is transmitted
on the J1708 data link.
15.2. FEATURE CODE

There are no available Body Controller (BC) feature codes related to the VDR.

There are no user programmable parameters associated with the VDR feature.

There are no Diagnostic Trouble Codes (DTC) associated with this feature.
Vehicle Data Recorder Preliminary Check
Table 150 Vehicle Data Recorder Preliminary Check
STEP ACTION YES NO

1. Key is in ON position. Go to next step. Proceed to the Vehicle Data
Recorder Circuit Test (See
Is the VDR operational? Table 151, page 212).
2. Determine if any other features • Identify and repair condition Proceed to the Vehicle Data
are malfunctioning that may causing several features to be Recorder Circuit Test (See
have common circuits. inoperative. Table 151, page 212).
Are other features • Refer to the 12–VOLT

inoperative? POWER DISTRIBUTION AND
GROUNDS section for further
diagnostic information.
S08361 211
VEHICLE DATA RECORDER TROUBLESHOOTING
Vehicle Data Recorder Circuit Test
Table 151 Vehicle Data Recorder Circuit Test

1. Disconnect the 12 ± 1.5V Go to next step. • Inspect 10A Fuse
TripMaster data max F2-F (1011).
connector (827).
• Inspect circuit A14SD
Measure voltage for open or short.
between the
TripMaster data max
A and ground.
2. Measure resistance ≤1 ohm Go to next step. • Inspect ground
between the circuits A11-GSD
TripMaster data max and A11-GSH for
connector (827), cavity open or source of high
A and C. resistance.
• Inspect ground
adapter (1006) for
loose, damaged, or
corroded terminals.
3. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect 10A Fuse
F5-J (1014).
Measure volage
between the • Inspect circuit A13SD
TripMaster data max for open or short.
B and ground.
4. Measure voltage Approximately 2.5V Go to next step. • If voltage is 0 volts,
between the the J1708 circuit is
TripMaster data max shorted to ground or
connector (827), cavity open.
E and ground.
• If voltage is ABOVE 5
volts, the J1708 circuit
is shorted to voltage.
5. Measure voltage Approximately 2.5V • The J1708 data • If voltage is 0 volts,
between the link is functional and the J1708 circuit is
TripMaster data max communicating. shorted to ground or
connector (827), cavity open.
D and ground. • Go to next step.
212 S08361
TROUBLESHOOTING VEHICLE DATA RECORDER
Table 151 Vehicle Data Recorder Circuit Test (cont.)

6. Measure voltage 12 ± 1.5V Go to next step. • Inspect circuit H70E
between the and A70E for open or
TripMaster connector short.
(5927), cavity G and
ground. • Proceed to the Brake
Switch Test (See Table
Operate the brake 140, page 199).
pedal.
7. Measure voltage 12 ± 1.5V Replace faulty • Bench test the
between the TripMaster. TripMaster headlight
TripMaster connector input relay (1019).
(5927), cavity F and
ground. • Inspect circuit A50S
and H50S for open or
short.
VDR Brake Pressure Switch Circuit Test
NOTE – Prior to performing the VDR Brake Pressure Switch Circuit Test, ensure no brake system faults
are present .
Table 152 VDR Brake Pressure Switch Circuit Test

1. Disconnect the brake 12 ± 1.5V Connect the brake • Inspect 10A F5-J
pressure switch (1825). pressure switch (1825). (1014).
Key is in ON position. Go to next step. • Inspect circuit A70DA

for open or short.
Measure voltage
between the brake • Inspect the DCM /
pressure switch IP connector (1800)
connector (1825), for loose, damaged, or
cavity D and ground. corroded terminals.
2. Disconnect the 12 ± 1.5V No brake pressure • Inspect circuit A70EA
TripMaster data max switch faults present. for open or short.
connector (827).
• Inspect the DCM /
Measure voltage IP connector (1800)
between the for loose, damaged, or
TripMaster data max corroded terminals.
G and ground. • Replace faulty brake
pressure switch.
Depress brake pedal.
S08361 213
VEHICLE DATA RECORDER TROUBLESHOOTING
VDR Headlight Input Relay Circuit Test
NOTE – Prior to performing the VDR Headlight Input Relay Circuit Test, ensure no lighting system faults
are present.
Table 153 VDR Headlight Input Relay Circuit Test

1. Remove headlight 12 ± 1.5V Go to next step. Inspect circuit A53AB
input relay (1019). for open or short.
Headlight switch is in NOTE – If left low

ON position. beam headlight is
inoperative, inspect
Measure voltage circuit A53AA for
between the headlight open or short.
input relay (1019),
2. Headlight switch is in 12 ± 1.5V Go to next step. • Inspect ground circuit
ON position. A53-G for open or
short.
Measure voltage
between the headlight • Inspect ground
input relay (1019), adapter (1006) for
cavity 85 and cavity 86. loose, damaged, or
corroded terminals.
3. Headlight switch is in 12 ± 1.5V Install headlight input Inspect circuit A52AB
ON position. relay (1019). for open or short.
Measure voltage Go to next step. NOTE – If left high

between the headlight beam headlight is
input relay (1019), inoperative, inspect
cavity 30 and ground. circuit A52AA for
open or short.
4. Disconnect the 12 ± 1.5V No faults present. • Inspect circuit A50S
TripMaster data max for open or short.
connector (827).
• Replace faulty
Measure voltage headlight input relay
between the (1019).
TripMaster data max
F and ground.
ON position.
214 S08361
SYSTEM DESCRIPTION THEFT DETERRENT SYSTEM
16. THEFT DETERRENT SYSTEM

This section contains a general overview of the theft deterrent system.
Overview
The International Theft Deterrent System limits vehicle mobility once the vehicle is started, or when driving is
resumed after the vehicle was at idle with the park brake set. The theft deterrent code is a combination of
one to eight digits.
Operation
When the theft deterrent system is active, the Body Controller (BC) provides ground to the auxiliary power
relay (1873), cavity 85. With the key in the ON position, the auxiliary power relay (1873) is energized. Now
energized, the relay switch opens, creating an open power circuit to the ignition relay #1 (1011/1013), crank
inhibit relay (1019), and Engine Control Module (ECM). While the auxiliary power relay (1873) is energized, the
vehicle cannot be started or operated.
When the operator enters the correct theft deterrent code, the BC receives the J1708 data link message, and
removes the ground path to the auxiliary power relay (1873). When de-energized, the relay switch remains
closed. When the key is in the ON position, voltage is provided to the ignition relay #1 and the ECM, and
the vehicle can be started and operated.
16.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the theft deterrent
feature.

0595BBG BC PROG, THEFT DETERRENT SYSTEM

There are no user programmable parameters associated with the theft deterrent system.

The theft deterrent system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Using the
information given by the DTC can aid in the diagnosis of the problem.
S08361 215
THEFT DETERRENT SYSTEM TROUBLESHOOTING

CAUSE SIGNAL
520775 Anti-Theft 5 1601 E4 Anti-Theft Open Circuit In Anti_Theft
Ignition Relay Ignition Anti-Theft Ignition _Ignition_Relay
Relay Under Circuit
Current Or
Open Circuit
• Proceed to the Theft Deterrent System Test (See Table 157, page 217).
520775 Anti-Theft 6 1601 E4 Anti-Theft Short To Ground In Anti_Theft
Ignition Relay Ignition Anti-Theft Ignition _Ignition_Relay
Relay Over Circuit
Current
520776 Anti-Theft 2 N/A N/A Anti-Theft Faulty Switch Actuator Anti_Theft_
Engine Stop Engine Stop Or Microswitch For Engine_Stop
Switch Switch Error Anti-Theft Engine Stop _Switch
Switch
Switch 0 Switch 0 Or Microswitch For Switch_0
Error Anti-Theft Switch 0
This section contains diagnostic tips and troubleshooting information related to the theft deterrent system.
216 S08361
TROUBLESHOOTING THEFT DETERRENT SYSTEM
Theft Deterrent Preliminary Check
Table 156 Theft Deterrent Preliminary Check
STEP ACTION YES NO

1. Determine if any other features Identify and repair condition Proceed to Theft Deterrent
are malfunctioning that may causing several features to be System Test (See Table 157,
have common circuits. inoperative. page 217).
Are other features

malfunctioning?
Theft Deterrent System Test
NOTE – Prior to performing the Theft Deterrent System Test, Ensure the key switch and park brake
operate.
Table 157 Theft Deterrent System Test

1. Using Diamond Logic® Signal follows switch Do not enter theft Refer to the SWITCH
Builder, locate and command. deterrent code. PACK (J1708) section
observe the following for further diagnostic
signals: Go to next step. information related
to switch packs
Anti_Theft_Switch_0 and J1708 data link
operation.
Anti_Theft_Switch_1
Anti_Theft_Switch_2
Anti_Theft_Switch_3
Anti_Theft_Switch_4
Anti_Theft_Switch_5
Anti_Theft_Switch_6
Anti_Theft_Switch_7
Anti_Theft_Switch_8
Anti_Theft_Switch_9
Operate each switch.

2. Remove the auxiliary 12 ± 1.5V Go to next step. Inspect circuit 13DB
power relay (1873). for open or short.

the auxiliary power relay
S08361 217
SEAT BELT AND SEAT SENSOR SYSTEM DESCRIPTION
Table 157 Theft Deterrent System Test (cont.)

(1873), terminal 86 and
ground.
3. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect circuit
A104A for open or
Measure voltage between short.
terminal 86 and 85 of
the auxiliary power relay • Inspect the BC
(1873). #J4 (1601) for
loose, damaged,
NOTE – Entering
the theft deterrent
code will remove
BC ground path to
the auxiliary power
relay (1873).
4. Key is in ON position. 12 ± 1.5V Install auxiliary power Inspect circuit 13XA
relay (1873). for open or short.
the auxiliary power relay Go to next step.
(1873), terminal 87A and
ground.
5. Key is in ON position. Theft deterrent code No problems evident • Inspect circuit A13F
not entered: at this time. for open or short.
5A Fuse F1-A (1010), 0V • Replace faulty
cavity E1 and ground. auxiliary power relay
Theft deterrent code (1873).
entered:
12 ± 1.5V
17. SEAT BELT AND SEAT SENSOR

This section contains a general overview of the seat belt and seat sensor features.
Overview
The seat belt indicator reminds the operator to fasten the seat belt. The indicator illuminates immediately after
the ignition key is turned ON. The optional seat belt reminder with seat belt monitoring causes the initial
visual reminder followed by a flashing reminder and audible alarm. This optional seat belt reminder monitors
driver seat. The optional seat belt reminder will only operate when the ignition is turned ON, parking brake is
released, and the seat belt is not fastened.
218 S08361
FEATURE CODE SEAT BELT AND SEAT SENSOR
Operation
Seat Belt Indicator
The Electronic Gauge Cluster (EGC) illuminates the indicator when it receives the indicator command on the
J1939 data link from the Body Controller (BC). The BC generates the indicator command 17 seconds after the
BC receives an ignition signal.
Seat Belt Light Indicator and Alarm
The seat belt light indicator and alarm feature monitors the driver seat belt only.
When the ignition is ON, the BC will request the seat belt indicator ON. The EGC will display the warning
indicator for 17 seconds.
The BC will request the light to flash and request the EGC to emit an audible alarm.
If park brake is released and seat belt is not latched, the light will continue to flash until seat belt is latched
or key is shut off.
If park brake is released and seat belt is not latched, the alarm will sound for 10 to 12 seconds, discontinue to
sound for 10 seconds, then sound again for 10 to 12 seconds. This cycle will continue to repeat until seat
belt is latched or key is shut off.
17.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the seat belt and
seat sensor feature.

0595ABA BC PROG, SEAT BELT INDICATOR
0595BAG BC PROG, SEAT BELT LIGHT INDICATOR AND ALARM

This section contains all user programmable parameters directly related to the seat belt and seat sensor
feature.
Name: Seatbelt_Alarm_Interval
• Description: The number of beeps in a 10 second interval while flashing the seat belt indicator.
• Access Level: Fleets
• Maximum value: 10 seconds
• Minimum value: 0 seconds
• Interval: 1 second
• Default value: 6 seconds
S08361 219
SEAT BELT AND SEAT SENSOR DIAGNOSTIC TROUBLE CODES
Name: Seatbelt_Alarm_Timeout
• Description: The number of beeps in a 10 second interval while flashing the seat belt indicator.
• Maximum value: 10 minutes
• Minimum value: 0 minutes
• Interval: 1 minute
• Default value: 1 minute

There are no Diagnostic Trouble Codes (DTC) associated with the seat belt or seat sensor.
This section contains diagnostic tips and troubleshooting information related to the seat belt or seat sensor.
Seat Belt Preliminary Check
NOTE – Visually inspect seat belt buckles and latches for dirt, debris, and other physical damage.
Table 159 Seat Belt Preliminary Check
STEP ACTION YES NO

1. Latch driver seat belt into seat Go to next step. Visually inspect seat belt.
belt buckle and pull on seat If seat belt shows damage,
belt. replace seat belt.
Does the seat belt remain

securely latched?
220 S08361
TROUBLESHOOTING SEAT BELT AND SEAT SENSOR
Table 159 Seat Belt Preliminary Check (cont.)

STEP ACTION YES NO
2. Determine if any other features Identify and repair condition Proceed to the Seat Belt
are malfunctioning that may causing several features to be Indicator Circuit Test (See Table
have common circuits. inoperative. 160, page 221).
Visually check for other

malfunctioning features.
Are other features

malfunctioning?
Seat Belt Indicator Circuit Test
The Seat Belt Indicator Circuit Test can be performed to diagnose seat sensor switches.
Table 160 Seat Belt Indicator Circuit Test

1. Using the Diamond Signals follow ignition • Refer to the • Refer to the
Logic® Builder (DLB), sense command. ELECTRONIC ELECTRONIC
locate and observe the GAUGE CLUSTER GAUGE CLUSTER
following signals: section for warning section for information
lamp diagnostic related to the EGC
Fasten_Belts_ information. J1939 data link
Ind_Cmd communication.
• Go to next step.
EGC_Warning_ • Suspect faulty BC.
Light_17
Turn key to ON position

and observe signals.
2. Disconnect driver seat Driver seat belt • Inspect input circuits Replace faulty seat
belt switch connector latched: to the seat belt seat belt assembly.
(2997). indicator module
Continuity. (8999/8882) for open
Measure continuity or short.
between pin A and pin Driver seat belt
B of the driver seat unlatched: • Inspect circuits to
belt switch connector ground adapter (8995)
(2997). No continuity for open or short.
Latch and unlatch seat • Inspect ground

belt while observing adapter (8995/8882)
continuity reading. for loose, damaged, or
corroded terminals.
S08361 221
SELF-CONTAINED AIR SEAT SYSTEM DESCRIPTION
18. SELF-CONTAINED AIR SEAT

Overview
Allows the driver to adjust the firmness of the seat.
Operation
The self-contained air seat is controlled by a switch located on the seat. Battery voltage is supplied to the
switch at all times. Ground is supplied to the switch at all times.
18.2. FEATURE CODE

There are no feature codes available for this feature.

There are no user programmable parameters for this feature.

There are no Diagnostic Trouble Codes (DTC) associated with the self-contained air seats.
Driver and Passenger Self-Contained Air Seats Preliminary Check
Table 161 Driver and Passenger Self-Contained Air Seats Preliminary Check
STEP ACTION YES NO

1. Are other features • Identify and repair condition Proceed to the Driver and
malfunctioning that may causing several features to Passenger Self-Contained
have common circuits? be inoperative. Air Seat Test (See Table 162,
page 223).
• Refer to the 12–VOLT
POWER DISTRIBUTION
AND GROUNDS section in
the applicable Circuit Diagram
manual.
222 S08361
TROUBLESHOOTING SELF-CONTAINED AIR SEAT
Driver and Passenger Self-Contained Air Seat Test
NOTE – Verify switch operation by performing continuity test while operating switch prior to further
circuit testing.
Table 162 Driver and Passenger Self-Contained Air Seat Test

1. Measure voltage 12 ± 1.5V Go to next step. • Inspect 10A Fuse F7-E (1016).
between the driver
seat power connector With Self-Contained Passenger
(1918), cavity A and Seat:
ground.
• Inspect circuits A14A and A14B
for open or short.
Without-Self Contained
Passenger Seat:
• Inspect circuits A14A and AD for

open or short.
2. Measure voltage 12 ± 1.5V • Replace Driver With Self-Contained Passenger
between the driver Seat Power Seat:
seat power connector Motor.
(1918), cavity A to • Inspect circuits A11-GP,
cavity B. • Go to next step A11-GN, A11–G, and A11-GKJ
for Passenger for open or short.
Seat Circuit Test.
Without Self-Contained
Passenger Seat:
• Inspect circuits AH, A11-GN,

A11-G, and A11-GKJ for open or
short.
3. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect 10A Fuse F7-E (1016)
Measure voltage • Inspect circuits A14A and A14C

between the for open or short.
passenger seat power
connector (1935),
4. Measure voltage 12 ± 1.5V Replace Inspect circuits A11-GR, A11-GN,
between the Passenger Seat A11-G, and A11-GKJ for open or
passenger seat power Power Motor. short.
connector (1935),
S08361 223
HEATED SEATS SYSTEM DESCRIPTION
19. HEATED SEATS

Heated seats are optional equipment.
Heated seats can be ordered individually.
Overview
Allows the driver or passenger to heat each seat individually.
Each seat has two levels of heat adjustment.
Operation
The heated seats are controlled by a three-position switch located on the seats. Battery voltage is supplied to
the switch any time the key is on. Ground is supplied to the switch at all times.
When the switch is in the OFF position, the circuit is open and the seat will not be heated.
Turning the switch to level 1 or 2 closes the circuit and allows current to flow to the heating element inside
the seat.
19.2. FEATURE CODES

There are no feature codes available for the heated seats.

There are no user programmable parameters for the heated seat.

There are no Diagnostic Trouble Codes (DTC) associated with the heated seats.
Driver and Passenger Heated Seats Preliminary Check
Table 163 Driver and Passenger Heated Seats Preliminary Check
STEP ACTION YES NO

1. Are other features Identify and repair Proceed to the Driver and
malfunctioning that may condition causing several Passenger Heated Seat Test
have common circuits? features to be inoperative. (See Table 164, page 225).
Driver and Passenger Heated Seat Test
NOTE – Very Switch operation by performing continuity test while operating switch prior to further circuit
testing.
224 S08361
TROUBLESHOOTING HEATED SEATS
Table 164 Driver and Passenger Heated Seat Test

1. Key is in ON position. 12 ± 1.5V Go to next • Inspect 10A or 20A Fuse F7-G (1016)
step.
Measure voltage between Heated seat with passenger heated seat:
the Driver Heated Seat
connector (1918), cavity • Inspect circuits A105B and A105 for open
B and ground. or short.
Heated seat without passenger heated

seat:
• Inspect circuits A105 for open or short.

2. Key is in ON position. 12 ± 1.5V • Replace Heated seat with passenger heated seat:
driver
Measure voltage between heated • Inspect ground circuits A105-GB, A105-G,
the Driver Heated Seat seat A11-G, and A11-GKJ to left side cab ground
connector (1918), cavity element. (4081) for open or short.
B and cavity A.
• Proceed Heated seat without passenger heated
to next seat:
step for
passenger • Inspect ground circuits A105-G, A11-G,
heated and A11-GKJ to left side cab ground (4081)
seat test. for open or short.
3. Key is in ON position. 12 ± 1.5V Go to next • Inspect 10A or 20A Fuse F7-G (1016)
step.
Measure voltage between • Inspect circuits A105A and A105 for open
the Passenger Heated or short.
Seat connector (1935),
cavity B and ground. NOTE – The Driver and Passenger
Heated Seats share common power and
ground.
4. Key is in ON position. 12 ± 1.5V Replace Inspect ground circuit A105-GA, A105-G,
passenger A11-G, and A11-GKJ to left side cab ground
Measure voltage between heated (4081) for open or short.
the Passenger Heated seat
Seat connector (1935), element. NOTE – The Driver and Passenger
cavity B and cavity A. Heated Seats share common power and
ground.
S08361 225
HEATED SEATS TROUBLESHOOTING
226 S08361
TABLE OF CONTENTS
CHASSIS FEATURES
Table of Contents
1. HEATED AIR DRYER AND DRAIN VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Air Dryer and Heated Drain Valve Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Heated Drain Valve Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Air Dryer Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2. AIR SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Air Solenoid Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Air Solenoid Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3. SUSPENSION DUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Suspension Dump Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Suspension Dump Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4. DIFFERENTIAL LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Differential Lock Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Differential Lock Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
5. POWER DIVIDER LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
S08361 227
TABLE OF CONTENTS
5.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Power Divider Lock Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Power Divider Lock Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
6. POWER TAKE OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Power Take Off Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Power Take Off Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
7. ANTI-LOCK BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Anti-Lock Braking System Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Bendix® ABS Circuit Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Wabco® ABS Module Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
8. FIFTH WHEEL SLIDE AND JAW LOCK RELEASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
8.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Fifth Wheel Slide Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Fifth Wheel Slide Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Fifth Wheel Jaw Lock Release Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
9. FUEL HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
9.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Fuel Heater Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Fuel Heater Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
228 S08361
TABLE OF CONTENTS
10. REMOTE POWER MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
10.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
RPM Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
RPM Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
11. REMOTE START / STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
11.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Remote Start / Stop Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Remote Start / Stop Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
12. TWO-SPEED AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
12.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Two-Speed Switch Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Two-Speed Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
13. CUSTOMER INSTALLED LIFT GATE POWER SOURCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
13.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Lift Gate Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Lift Gate Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
14. AUTO NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
14.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Auto Neutral Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
S08361 229
TABLE OF CONTENTS
Auto Neutral Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Auto Neutral Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
15. AXLE LOAD MONITOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
15.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Axle Load Monitor Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Axle Pressure Transducer Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
16. WATER-IN-FUEL MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
16.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Water-In-Fuel Monitor Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Water Probe Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
230 S08361
SYSTEM DESCRIPTION HEATED AIR DRYER AND DRAIN VALVE
1. HEATED AIR DRYER AND DRAIN VALVE

This section contains a general overview of the air dryer and heated drain valve.
Overview
When air is compressed by the air compressor, condensation is formed in the compressor discharge tube.
Moisture can accumulate and contaminate brake reservoirs, lines, and valves. The function of air dryer is
to collect moisture and contaminants before air reaches the first reservoir. The heated air dryer prevents
freeze-up of moisture in the purge drain valve during cold weather operation.
Operation
When the key is in the ON position, battery voltage is provided to 20A Fuse F5-K (1014). Voltage from the fuse
is provided to both the air dryer (9900/9900E) and heated drain valve (9001). The air dryer and heated drain
valve are provided ground by ground adapter (8807) and the left side dash ground (9717B).
1.2. FEATURE CODES

There are no Body Controller (BC) feature codes related to the air dryer or heated drain valve.

There are no user programmable parameters associated with the air dryer or heated drain valve.

There are no Diagnostic Trouble Codes (DTC) related to the air dryer or heated drain valve.
This section contains diagnostic tips and troubleshooting information related to the air dryer and heated
drain valve.
Air Dryer and Heated Drain Valve Preliminary Check
Table 165 Air Dryer and Heated Drain Valve Preliminary Check
STEP ACTION YES NO

1. Is the air dryer and heated drain • Inspect ground adapter Go to next step.
valve inoperative? (8807) for loose, damaged, or
corroded terminals.
• Inspect 20A Fuse F5-K

(1014).
S08361 231
HEATED AIR DRYER AND DRAIN VALVE TROUBLESHOOTING
Table 165 Air Dryer and Heated Drain Valve Preliminary Check (cont.)
STEP ACTION YES NO
2. Are other features powered by Refer to the 12–VOLT Proceed to the appropriate
ignition voltage inoperative? POWER DISTRIBUTION inoperative feature circuit test.
AND GROUNDS section for
further diagnostic information. • Heated Drain Valve Test (See
• Air Dryer Test (See Table 167,

page 233).
Heated Drain Valve Circuit Test
Table 166 Heated Drain Valve Circuit Test

1. Disconnect the 12 ± 1.5V Go to next step. • Inspect 20A Fuse F5-K (1014).
heated drain valve
connector (9001). • Inspect circuit N39A for open
or short.
Key is in ON
position. • Inspect the IP / Center Chassis
Measure voltage damaged, or corroded terminals.
between the
heated drain valve NOTE – The heated drain valve
connector (9001), and air dryer share 20A Fuse
cavity A and ground. F5-K (1014).
2. Key is in ON 12 ± 1.5V Replace faulty heated • Inspect circuit N39-GF for open
position. drain valve. or short.
Measure voltage • Inspect the ground adapter

between the (8807) for loose, damaged, or
heated drain valve corroded terminals.
connector (9001),
cavity A and cavity NOTE – The heated drain valve
B. and air dryer share common
232 S08361
SYSTEM DESCRIPTION AIR SOLENOID
Air Dryer Circuit Test
Table 167 Air Dryer Circuit Test

1. Key is in ON 12 ± 1.5V Go to next step. • Inspect 20A Fuse F5-K (1014).
position.
• Inspect circuits N39B and A39
Measure voltage for open or short.
between the air
dryer connector, • Inspect the IP / Center Chassis
cavity A and ground. connector (1701) for loose,
NOTE – The heated drain valve

and air dryer share 20A Fuse
F5-K (1014).
2. Key is in ON 12 ± 1.5V Replace faulty air dryer. Inspect ground circuit N39-GB to
position. ground adapter (8807) for open
or short.
Measure voltage
between the air NOTE – The heated drain valve
dryer connector, and air dryer share common
cavity A and cavity ground adapter (8807).
B.
2. AIR SOLENOID
This section contains a general overview of the air solenoid.
Overview
The air solenoids provide the operator with control of air operated components.
Operation
Air solenoids are controlled by input switches. The input switches provide a multiplexed signal to the Body
Controller (BC). The switch pack mounted input switches provide information to the BC over the J1708 data
link. When an air solenoid input switch is operated, the BC will send voltage to energize corresponding air
solenoids.
The air solenoid switch indicator has four modes of illumination that can aid in diagnosis:
• Indicator ON - Air solenoid is activated.
• Indicator OFF - Air solenoid is deactivated.
• Indicator Flashes Fast (Twice per second) - There is a problem in the air solenoid switch or
corresponding air solenoid circuit.
S08361 233
AIR SOLENOID FEATURE CODES
• Indicator Flashes Slow (Once per second) - This indicates that all interlocks have not been met to
operate the air solenoid feature.
2.2. FEATURE CODES

This section contains the available Body Controller (BC) feature code definition related to the air solenoid.

0595AHX BC PROG, AIR SOLENOID MODULE #1 normally closed
0595AHY BC PROG, AIR SOLENOID MODULE #2 normally closed
0595AHZ BC PROG, AIR SOLENOID MODULE #3 normally closed
0595AJA BC PROG, AIR SOLENOID MODULE #4 normally closed
0595AKZ BC PROG, AIR SOLENOID MODULE #5 normally open
0595AJC BC PROG, AIR SOLENOID MODULE #6 normally open
0595BBD BC PROG, AIR SOLENOID MODULE #6 normally closed
0595BPP BC PROG, AIR SOLENOID MODULE #1 normally open

There are no user programmable parameters associated with the air solenoids.

The air solenoid system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information

CAUSE SIGNAL
520819 Universal Air 5 Refer To Refer To Universal • Open Univ_Air_Relay_
Solenoid Relay DLB To DLB To Air Solenoid Circuit Driver_1
Driver 1 Verify Verify Relay Driver
Connector. Connector 1 Under • Defective
Pin. Current Or Solenoid
Open Circuit
Proceed to the Air Solenoid Circuit Test (See Table 171, page 241).
520819 Universal Air 6 Refer To Refer To Universal • Short To Univ_Air_Relay_
Solenoid Relay DLB To DLB To Air Solenoid Ground Driver_1
Connector. Connector 1 Over • Defective
Pin. Current Solenoid
234 S08361
DIAGNOSTIC TROUBLE CODES AIR SOLENOID

CAUSE SIGNAL
Open Circuit
Open Circuit
Open Circuit
S08361 235
AIR SOLENOID DIAGNOSTIC TROUBLE CODES

CAUSE SIGNAL
Open Circuit
Open Circuit
Open Circuit
236 S08361
DIAGNOSTIC TROUBLE CODES AIR SOLENOID

CAUSE SIGNAL
Open Circuit
Open Circuit
Open Circuit
S08361 237
AIR SOLENOID DIAGNOSTIC TROUBLE CODES

CAUSE SIGNAL
Open Circuit
Open Circuit
Open Circuit
238 S08361
TROUBLESHOOTING AIR SOLENOID

CAUSE SIGNAL
Open Circuit
Open Circuit
Open Circuit
This section contains diagnostic tips and troubleshooting information related to the air solenoids.
S08361 239
AIR SOLENOID TROUBLESHOOTING
Air Solenoid Preliminary Check
Table 170 Air Solenoid Preliminary Check
STEP ACTION YES NO

1. Are other features Refer to the 12–VOLT Go to next step.
malfunctioning that may POWER DISTRIBUTION
have common circuits? AND GROUNDS section of
manual.
2. Are all air solenoid operated • Verify switch pack operation. Go to next step.
features inoperative?
• Verify BC operation.
• Inspect ground adapter

(8805/8809) for loose,
terminals.
3. Are there any Diagnostic Refer to the Diagnostic Trouble Proceed to the Air Solenoid
Trouble Codes present? Codes for specific cause (See Circuit Test (See Table 171,
Air Solenoid Circuit Test
Use the Diamond Logic® Builder (DLB) to assist in diagnosis.
NOTE – Before performing diagnostic checks on electrical system, ensure there is air pressure to the
Air Solenoid 4-Pack, there are no air line restrictions to air powered feature, and the air powered feature
is mechanically sound and adjusted properly.
A. To ensure air solenoids have proper ground, measure continuity between cavity A and ground of
the appropriate air solenoid connector.
B. The Body Controller (BC) supplies 12 ± 1.5V to each air solenoid from the BC #J4 connector
(1601). BC #J5 connector (1602) provides voltage to air solenoid (9736), pin B for air horn
operation.
C. Depending on vehicle configuration, all air solenoids will be normally open or normally closed.
The BC controls each air solenoid individually. Due to various features and combination of features that can be
installed on vehicle, the connector and pin for a specific air solenoid can be different with each vehicle.
240 S08361
SYSTEM DESCRIPTION SUSPENSION DUMP
Table 171 Air Solenoid Circuit Test

1. Using the Diamond Signal • An input signal fault is Go to next step.
Logic® Builder follows switch present.
(DLB), select the command.
CONNECTORS tab. • Refer to the SWITCH
PACKS (J1708 DATA
Select the appropriate LINK) section for further
BC connector and diagnostic information.
locate the faulty air
solenoid signal.
Operate switch and

observe signal.
2. Measure voltage 12 ± 1.5V Go to next step. • Inspect specific BC output
at the appropriate signal circuit for open or short.
air solenoid cavity
while actuating the air • Inspect the BC #J4
solenoid signal. connector (1601) for loose,
terminals.
NOTE – Inspect BC #J5

connector (1602) for air horn
operation.
3. Measure continuity <1 ohm Replace faulty air • Inspect appropriate ground
between cavity solenoid. circuit for open.
A and ground of
the appropriate air • Inspect ground adapter
solenoid connector. (8805/8809) for loose,
terminals.
3. SUSPENSION DUMP
This section contains a general overview of the suspension dump feature.
Overview
This feature allows operator to lower rear of vehicle by dumping air from suspension bags, or raise the rear
of vehicle to set point controlled by suspension height control valve.
Operation
The switch pack sends a request message on the J1708 data link to Body Controller (BC) to dump or raise the
suspension depending on switch position. The BC provides near battery voltage to energize appropriate air
solenoid. Air solenoids, within the Air Solenoid 4-Pack, share a common ground.
Dumping (Lowering) Suspension: During this time solenoid A will be de-energized (open) and solenoid
B will be energized (closed).
S08361 241
SUSPENSION DUMP FEATURE CODE
• Key switch is in the ON position.
• Dump switch is ON.
• Vehicle speed is less than or equal to 5 MPH (8 KM/H).
• Solenoids A and B have a good status (no faults present).
Raising Suspension: During this time solenoid A will be energized (closed) and solenoid B will be
de-energized (open).
• Key switch is in the ON position.
• Dump switch is OFF.
• If vehicle speed increases to more than 5 MPH (8 KM/H), suspension will automatically raise.
3.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the suspension dump.

0595ACA BC PROG, AIR SUSPENSION DUMP
0595BBC BC PROG, AIR SUSPENSION DUMP Programmable Max Speed

This section contains all user programmable parameters directly related to suspension dump feature.
Name: Raise_Suspension_OK
• ID: 2529
• Description: This parameter allows the suspension to raise when Diamond Logic
Suspension_Dump_Request signal becomes inactive.
• Maximum value: 1 (Automatic inflation of suspension using Suspension_Dump_Request is active.)
• Minimum value: 0 (Automatic inflation of suspension using Suspension_Dump_Request is inactive.)
Name: Susp_Dump_KeyState_Param
• ID: 2472
• Description: Parameter only applies to Suspension_Dump_Request Signal.
242 S08361
DIAGNOSTIC TROUBLE CODES SUSPENSION DUMP
• Maximum value: 2 (Key in ACC, ON, or OFF)
• Minimum value: 0 (Key in ACC or ON)
• Default value: 1 (Key in Run only)
Name: Max_Dump_Spd
• ID: 328
• Description: Maximum vehicle speed at which suspension dump is allowed to occur.
• Maximum value: 18 MPH (30 KM/H)
• Minimum value: 0 MPH (0 KM/H)
• Default value: 5 MPH (8 KM/H)

The suspension dump system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.
Information given by DTC can aid in diagnosis of the problem.
Always check for any DTC before doing any intrusive wire tests or parts replacement.

CAUSE SIGNAL
1747 Kneeling 2 Refer To DLB Refer To Suspension Faulty Switch Susp_Dump_
Control Mode To Verify DLB To Dump Switch Actuator Or Dump_Switch
Request Connector Verify Error Microswitch
For This Connector For
Feature. Pin For This Suspension
Feature. Dump Switch
Proceed to the Suspension Dump Test (See Table 175, page 245).
1755 Lowering 5 Refer To DLB Refer To Suspension Open Circuit Susp_Dump_
Control Mode To Verify DLB To Dump In Suspension Solenoid_
Rear Axle Connector Verify Solenoid B Dump B_Cmd
For This Connector Relay Under Solenoid B
Feature. Pin For This Current Or Circuit
Feature. Open Circuit
S08361 243
SUSPENSION DUMP TROUBLESHOOTING

CAUSE SIGNAL
1755 Lowering 6 Refer To DLB Refer To Suspension Short To Susp_Dump_
Control Mode To Verify DLB To Dump Ground In Solenoid_
Rear Axle Connector Verify Solenoid B Suspension B_Cmd
For This Connector Relay Over Dump
Feature. Pin For This Current Solenoid B
Feature. Circuit
1756 Lifting Control 5 Refer To DLB Refer To Suspension Open Circuit Susp_Dump_
Mode Rear To Verify DLB To Dump In Suspension Solenoid_
Axle Connector Verify Solenoid A Dump A_Cmd
For This Connector Relay Under Solenoid A
Feature. Pin For This Current Or Circuit
Feature. Open Circuit
1756 Lifting Control 6 Refer To DLB Refer To Suspension Short To Susp_Dump_
Mode Rear To Verify DLB To Dump Ground In Solenoid_
Axle Connector Verify Solenoid A Suspension A_Cmd
For This Connector Relay Over Dump
Feature. Pin For This Current Solenoid A
Feature. Circuit
This section contains diagnostic tips and troubleshooting information related to the suspension dump.
Suspension Dump Preliminary Check
The Body Controller will compare the last known state of the suspension (raised or dumped) with the dump
switch position when the key switch is turned to the ON position. The Body Controller will command the
solenoids to the last known state if the last known state of the suspension and the position of the switch are the
same. If they are not the same or the last known state of the suspension is not known, the Body Controller will
leave both solenoids de-energized, and the switch indicator will flash slowly until the switch is moved.
244 S08361
TROUBLESHOOTING SUSPENSION DUMP
Table 174 Suspension Dump Preliminary Check
STEP ACTION YES NO

1. Are other features Refer to the 12–VOLT Go to next step.
malfunctioning that may POWER DISTRIBUTION
have common circuits? AND GROUNDS section of
manual.
2. Are other air solenoid operated • Verify Body Controller Go to next step.
features malfunctioning? operation.
• Refer to the Air Solenoid

page 241).
3. Are there any Diagnostic Refer to the Diagnostic Trouble Proceed to the Suspension
Trouble Codes stored in Body Codes for specific cause (See Dump Test (See Table 175,
Suspension Dump Test
Table 175 Suspension Dump Test

1. Using the Diamond The air solenoid Go to next step. • Inspect circuit A59C
Logic® Builder follows actuated and N59C for open or
(DLB), select the command. short.
CONNECTORS tab.
• Inspect the IP
Select the BC #J4 / Center Chassis
connector (1601). connector (1701) for
loose, damaged, or
Locate and view the corroded terminals.
Susp_Dump_Solenoid
_A_Cmd signal • Refer to the Air
Solenoid Circuit Test
Actuate the suspension (See Table 171, page
dump signal. 241).
S08361 245
DIFFERENTIAL LOCK SYSTEM DESCRIPTION
Table 175 Suspension Dump Test (cont.)

2. Locate and view the The air solenoid Go to next step. • Inspect circuit A59D
Susp_Dump_Solenoid follows actuated and N59D for open or
_B_Cmd signal command. short.
Actuate the suspension • Inspect the IP

dump signal. / Center Chassis
connector (1701) for
loose, damaged, or
corroded terminals.
• Refer to the Air

Solenoid Circuit Test
(See Table 171, page
241).
3. Observe both command Signals follow switch Suspect mechanical • No input signal to BC.
signals. position. fault.
• Suspect faulty switch
Operate the suspension pack.
dump rocker switch.
• Refer to the
MULTIPLEXING
(DATA LINKS) section
of this manual for
diagnostic information
specific to the J1708
data link.
4. DIFFERENTIAL LOCK
This section contains a general overview of the differential lock system.
Overview
This feature locks the drive axle differential, which transmits power equally to each of the drive wheels on
the axle equipped with a differential lock.
Operation
The switch pack switch sends a request message on the J1708 data link to the Body Controller (BC) to lock or
unlock the differential depending on the position of the differential lock switch. The BC provides battery voltage
to energize the differential lock air solenoid when certain conditions are met. The air solenoids, within the Air
Solenoid 4-Pack, share a common ground. The differential lock switch also provides the operator with an
indication of the differential lock feature electrical status.
Locking Differential: All of the following parameters must first be met for differential lock to function.
• Key switch is in Ignition position.

• Vehicle speed is less than programmed Diff_Lock_Engmt_Speed value.
246 S08361
FEATURE CODE DIFFERENTIAL LOCK
• Vehicle speed is less than programmed Max_Diff_Lock_Speed value.

• Differential lock switch is ON.
• Vehicle speed status is good.
• Differential lock switch has a good status.
• Air solenoid has a good status.
Unlocking Differential: The differential will unlock if any of the following occurs.
• Differential lock switch is OFF.

• Vehicle speed is greater than or equal to programmed Max_Diff_Lock_Speed value.
• Vehicle speed has a bad status.
• Key switch is not in the Ignition position.
• Differential lock switch has a bad status.
• Air solenoid has a bad status.
4.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the differential
lock feature.

0595ACU BC PROG, LOCKING DIFFERENTIAL for Single and Dual With Single Switch
0595ACT BC PROG, LOCKING DIFFERENTIAL two switches, one for each differential
0595BST BC PROG, LOCKING DIFFERENTIAL Elocker System

This section contains all user programmable parameters directly related to differential lock feature.
Name: Max_Diff_Lock_Speed
• ID: 2388
• Description: The differential will be unlocked automatically when the vehicle speed reaches a programmed
value.
• Maximum value: 25 MPH ( 40 KM/H)
• Interval: 1 MPH (1 KM/H)
• Default value: 25 MPH ( 40 KM/H)
S08361 247
DIFFERENTIAL LOCK DIAGNOSTIC TROUBLE CODES
Name: Diff_Lock_Engmt_Speed
• ID: 2386
• Description: The maximum vehicle speed at which the differential may be locked.
• Maximum value: 25 MPH ( 40 KM/H)

The differential lock system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.

CAUSE SIGNAL
569 Differential 5 Refer To Refer To Forward Open Circuit (0595ACT) Diff_Lock_
Lock State - DLB To DLB To Rear In Forward 1_Solenoid_Cmd,
Rear Axle 1 Verify Verify Diff Lock Rear Diff
Connector Connector Relay Lock Circuit (0595ACU) Diff_Lock_
For This Pin For Under Solenoid_Cmd
Feature. This Current
Feature. Or Open
Circuit
Proceed to the Differential Lock Test (See Table 179, page 250).
569 Differential 6 Refer To Refer To Forward Short To (0595ACT) Diff_Lock_
Lock State - DLB To DLB To Rear Ground In 1_Solenoid_Cmd,
Rear Axle 1 Verify Verify Diff Lock Forward
Connector Connector Relay Rear Diff (0595ACU) Diff_Lock_
For This Pin For Over Lock Circuit Solenoid_Cmd
Feature. This Current
Feature.
570 Differential 5 Refer To Refer To Rear Rear Open Circuit Diff_Lock_
Lock State - DLB To DLB To Diff Lock In Rear 2_Solenoid_Cmd
Rear Axle 2 Verify Verify Relay Rear Diff
Connector Connector Under Lock Circuit
For This Pin For Current
Feature. This Or Open
Feature. Circuit
248 S08361
TROUBLESHOOTING DIFFERENTIAL LOCK

CAUSE SIGNAL
570 Differential 6 Refer To Refer To Rear Rear Short To Diff_Lock_
Lock State - DLB To DLB To Diff Lock Ground In 2_Solenoid_Cmd
Rear Axle 2 Verify Verify Relay Rear Rear
Connector Connector Over Diff Lock
For This Pin For Current Circuit
Feature. This
Feature.
685 Disengage 2 Refer To Refer To Forward Data Erratic Diff_Lock_
Differential DLB To DLB To Axle 1 Intermittent 1_Switch
Lock Request Verify Verify Diff Lock Or Incorrect
- Front Axle 1 Connector Connector Switch
For This Pin For Error
Feature. This
Feature.
687 Disengage 2 Refer To Refer To Forward Faulty (0595ACU) Diff_Lock_
Differential DLB To DLB To Rear Switch Switch
Lock Request Verify Verify Diff Lock Actuator Or
- Rear Axle 1 Connector Connector Switch Microswitch (0595ACT) Diff_Lock_
For This Pin For Error For Forward 1_Switch
Feature. This Rear Diff
Feature. Lock Switch
688 Disengage 2 Refer To Refer To Rear Rear Faulty Diff_Lock_
Differential DLB To DLB To Diff Lock Switch 2_Switch
Lock Request Verify Verify Switch Actuator Or
- Rear Axle 2 Connector Connector Error Microswitch
For This Pin For For Rear
Feature. This Rear Diff
Feature. Lock Switch
This section contains diagnostic tips and troubleshooting information related to the differential lock.
S08361 249
DIFFERENTIAL LOCK TROUBLESHOOTING
Differential Lock Preliminary Check
Table 178 Differential Lock Preliminary Check
STEP ACTION YES NO

1. Are other features Refer to the other inoperative Go to next step.
2. Are all air solenoid operated • Verify Body Controller Go to next step.
features inoperative? operation.

page 241).
3. Are there any Diagnostic Refer to the Diagnostic Trouble Proceed to the Differential Lock
Trouble Codes stored in Body Codes for specific cause (See Test (See Table 179, page 250).
Controller? Table 177, page 248).
Differential Lock Test
Table 179 Differential Lock Test

1. Using the Diamond Signal follows switch Go to next step. Refer to SWITCH
Logic® Builder, locate command. PACK (J1708) section
and observe the for further diagnostic
Diff_Lock_1_Switch information.
signal.
Operate differential
lock switch while
monitoring signal.
2. Using the DLB, locate Signal follows switch Go to next step. • Review operational
and observe the command. information and
Diff_Lock_2_Switch preliminary tests before
signal. replacing switch.
Operate the differential • Refer to SWITCH

lock switch while PACK (J1708) section
monitoring the signal. for further diagnostic
information.
250 S08361
SYSTEM DESCRIPTION POWER DIVIDER LOCK
Table 179 Differential Lock Test (cont.)

3. Using the DLB, locate Signal follows switch • Suspect faulty • Review operational
and observe the command. differential lock signal information and
Diff_Lock_1_ circuit. preliminary tests before
Solenoid_Cmd signal. replacing switch.
Operate the differential Solenoid Circuit Test • Suspect faulty BC.
lock switch while (See Table 171, page
monitoring the signal. 241).
4. Using the DLB, locate Signal follows switch • Suspect faulty • Review operational
and observe the command. differential lock signal information and
Differential_Lock_ circuit. preliminary tests before
Solenoid_2 signal. replacing switch.
Operate the differential Solenoid Circuit Test • Suspect faulty BC.
lock switch while (See Table 171, page
monitoring the signal. 241).
5. POWER DIVIDER LOCK

This section contains a general overview of the power divider lock system.
Overview
This feature allows the operator to lock the front axle and the rear axle of a tandem axle set, which transmits
power equally to each of the drive axles.
Operation
The switch pack switch sends a request message on the J1708 data link to the Body Controller to lock or
unlock the Power Divider Lock (PDL), depending on the position of the switch. The Body Controller (BC)
provides near battery voltage to energize the Power Divider Lock (PDL) air solenoid when certain conditions
are met. The air solenoids, within the Air Solenoid 4-Pack, share a common ground. The PDL switch also
provides the operator with an indication of the PDL feature's electrical status.
Lock PDL: All of the following parameters must first be met for differential lock to function.
• Key switch is in the Ignition position.

• PDL switch is ON.
• PDL switch has a good status.
• PDL air solenoid has a good status.
When the BC commands the lock PDL operation, the air solenoid will be energized. If the solenoid is
energized, the solenoid is open (supplying air).
Unlock PDL: The power divider lock will unlock if any of the following occurs.
• PDL switch is OFF.
S08361 251
POWER DIVIDER LOCK FEATURE CODE
• Key switch is not in the Ignition position.

• PDL switch has a bad status.
• PDL air solenoid has a bad status.
When the BC commands the unlock PDL operation, the air solenoid will be de-energized. If the solenoid is
de-energized, the solenoid is closed (exhausting air). Therefore, the system is depressurized.
5.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the power divider lock.

0595ACZ BC PROG, POWER DIVIDER LOCK

This section contains all user programmable parameters directly related to the power divider feature.
Name: PDL_Warning_Spd
• ID: 2383
• Description: The vehicle speed at which the PDL switch indicator will begin to flash slowly while the PDL is
locked.
Name: PDL_Buzzer_Parameter
• ID: 1938
• Description: The Electronic Gauge Cluster (EGC) will sound a continuous beep while the PDL is locked.
• Available values are enabled (1) or disabled (0).

The power divider system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.
252 S08361
TROUBLESHOOTING POWER DIVIDER LOCK

CAUSE SIGNAL
566 Differential 5 Refer To DLB Refer To Power Open PDL_Lock_
Lock State - To Verify DLB To Divider Circuit In Solenoid_Cmd
Central Rear Connector Verify Lock Relay Power
For This Connector Under Divider
Feature. Pin For Current Lock
This Or Open Circuit
Feature. Circuit
Proceed to the Power Divider Lock Test (See Table 183, page 254).
566 Differential 6 Refer To DLB Refer To Power Short To PDL_Lock_
Lock State - To Verify DLB To Divider Ground Solenoid_Cmd
Central Rear Connector Verify Lock Relay In Power
For This Connector Over Divider
Feature. Pin For Current Lock
This Circuit
Feature.
691 Disengage 2 Refer To DLB Refer To Power Faulty PDL_Lock_
Differential To Verify DLB To Divider Switch Switch
Lock Request Connector Verify Lock Switch Actuator Or
- Central Rear For This Connector Error Microswitch
Feature. Pin For For Power
This Divider
Feature. Lock
Switch
This section contains diagnostic tips and troubleshooting information related to the power divider lock.
S08361 253
POWER DIVIDER LOCK TROUBLESHOOTING
Power Divider Lock Preliminary Check
Table 182 Power Divider Lock Preliminary Check
STEP ACTION YES NO

2. Are all air solenoid operated • Verify Body Controller Go to next step.
features inoperative? operation.

page 241).
3. Are there any Diagnostic Refer to the Diagnostic Trouble Proceed to the Power Divider
Trouble Codes stored in Body Codes for specific cause (See Lock Test (See Table 183, page
Controller? Table 181, page 253). 254).
Power Divider Lock Test
Table 183 Power Divider Lock Test

1. Using the Diamond Signal follows switch Go to next • Suspect faulty switch.
Logic® Builder command. step.
(DLB), select the • Refer to the SWITCH PACKS
CONNECTORS tab. (J1708 DATA LINK) section for
Select the BC #J4
connector.
Locate and
observe the
PDL_Lock_Switch
signal.
Operate the PDL

switch.
2. Using the DLB, locate The signals • Inspect the Suspect faulty Body Controller.
and observe the follow PDL switch appropriate
following signals: command. BC output
circuit for open
PDL_Lock_ or short.
Solenoid_Cmd
• Refer to the
PDL_Lock_Switch Air Solenoid
_Ind_Cmd Circuit Test
(See Table
PDL switch ON. 171, page
241).
254 S08361
SYSTEM DESCRIPTION POWER TAKE OFF
6. POWER TAKE OFF

This section contains a general overview of the Power Take Off (PTO).
Overview
This feature provides the operator with one or more switches to control the vehicle PTO.
Operation
The PTO A and PTO B relays are provided battery voltage through 10A Fuse F5-B (1014). When the
appropriate PTO switch is operated, ground is provided to the coil of the relay. When energized, the normally
open relay closes, allowing a Body Controller (BC) voltage sense to pass through the relay to Zero Volt
Reference circuit A9Z to the BC #J5 (1602) connector. The BC will communicate the signal to the Transmission
Control Module (TCM) over the J1939 data link, operating the PTO.
Once the BC has communicated to the Electronic Gauge Cluster (EGC) that the PTO has been engaged, the
EGC will illuminate the PTO indicator.
6.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the PTO feature.

0595BKJ BC PROG, TRANSMISSION PTO
0595BKK BC PROG, TRANSMISSION PTO Dual PTO
0595AHH BC PROG, TRANSFER CASE PTO
0595AJU BC PROG, PTO HOURMETER ENABLER
0595AJV BC PROG, PTO SHIFT Lectra Shift Control
0595AJW BC PROG, PTO SHIFT Hydraulic clutch or Pneumatic non-clutch engagement
0595AJY BC PROG, PTO SHIFT Pneumatic clutch electric over air
0595AJX BC PROG, PTO SHIFT Pneumatic non-clutch engagement
0595AJZ BC PROG, PTO CONTROL LOGIC dash switch
0595AMZ BC PROG, PTO SHIFT customer supplied PTO
0595BKY BC PROG, PTO SHIFT customer supplied PTO dash switch
0595BJT BC PROG, PTO MONITOR Body Controller indicator
0595BJS BC PROG, PTO MONITOR Remote Power Module indicator

Many PTO related parameters are customer programmable. To change a feature code programmable
parameter, use the Diamond Logic® Builder (DLB).
S08361 255
POWER TAKE OFF DIAGNOSTIC TROUBLE CODES

The PTO system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given

CAUSE SIGNAL
3453 Enable Switch 2 Refer To Refer To Transmission Faulty PTOb_ON_Switch
- Transmission DLB To DLB To PTO B Switch
Input Shaft Verify Verify Switch Error Actuator Or
PTO 2 Connector Connector Microswitch
For This Pin For For
Feature. This Transmission
Feature. PTO B
Switch
Proceed to Power Take Off Circuit Test (See Table 187, page 258).
3452 Enable Switch- 2 Refer To Refer To Transmission Faulty PTOa_ON_Switch
Transmission DLB To DLB To PTO A Switch
Input Shaft Verify Verify Switch Error Actuator Or
Feature. PTO A
Switch
3452 Enable Switch- 2 Refer To Refer To PTO Faulty TEM_PTO_
Transmission DLB To DLB To Engagement Switch Engagement_
Input Shaft Verify Verify Switch Error Actuator Or Switch_ON
Feature. PTO A
Switch
3456 Engagement 5 Refer To Refer To Transmission Open PTO1_Air_Solenoid
Consent - DLB To DLB To PTO A Circuit In _Cmd
Transmission Verify Verify Solenoid Transmission
Input Shaft Connector Connector Relay Under PTO A PTOa_Air_Solenoid
PTO 1 For This Pin For Current Or Solenoid _Cmd
Feature. This Open Circuit Circuit
Feature.
256 S08361
TROUBLESHOOTING POWER TAKE OFF

CAUSE SIGNAL
3456 Engagement 6 Refer To Refer To Transmission Short To PTO1_Air_Solenoid
Consent - DLB To DLB To PTO A Ground In _Cmd
Input Shaft Connector Connector Relay Over PTO A PTOa_Air_Solenoid
PTO 1 For This Pin For Current Solenoid _Cmd
Feature. This Circuit
Feature.
3457 Engagement 5 Refer To Refer To Transmission Open PTOb_Air_
Consent - DLB To DLB To PTO B Circuit In Solenoid_Cmd
Input Shaft Connector Connector Relay Under PTO B
PTO 2 For This Pin For Current Or Solenoid
Feature. This Open Circuit Circuit
Feature.
3457 Engagement 6 Refer To Refer To Transmission Short To PTOb_Air_
Consent - DLB To DLB To PTO B Ground In Solenoid_Cmd
Input Shaft Connector Connector Relay Over PTO B
PTO 2 For This Pin For Current Solenoid
Feature. This Circuit
Feature.
3461 Engagement 5 Refer To Refer To PTO Air Current TEM_PTO_Air_
Status - DLB To DLB To Solenoid Below Solenoid_Cmd
Transmission Verify Verify Under Normal Or
Input Shaft Connector Connector Current Or Open Circuit
PTO 2 For This Pin For Open Circuit
Feature. This
Feature.
3461 Engagement 6 Refer To Refer To PTO Air Current TEM_PTO_Air_
Status - DLB To DLB To Solenoid Above Solenoid_Cmd
Transmission Verify Verify Over Current Normal Or
Input Shaft Connector Connector Grounded
PTO 2 For This Pin For Circuit
Feature. This
Feature.
This section contains diagnostic tips and troubleshooting information related to the PTO.
S08361 257
POWER TAKE OFF TROUBLESHOOTING
Power Take Off Preliminary Check
NOTE – Proceed to the ELECTRONIC GAUGE CLUSTER section for warning and indicator light operation
when a mechanically engaged PTO is equipped.
Table 186 Power Take Off Preliminary Check
STEP ACTION YES NO

1. Does the PTO switch operate • Fault may be intermittent. Go to next step.
the PTO unit?
• Go to step 4.
2. Are other air solenoid operated Refer to the Air Solenoid Circuit Go to next step.
features inoperative? Test (See Table 171, page 241).
3. Are other switch pack mounted Proceed to the SWITCH PACK Go to next step.
switches inoperative? (J1708) section for further
4. Are any active or stored DTCs Proceed to the Diagnostic Proceed to the Power Take Off
present? Trouble Codes for specific Circuit Test (See Table 187,
cause (See Table 185, page page 258).
256).
Power Take Off Circuit Test
Table 187 Power Take Off Circuit Test

1. Using the Diamond Logic® Signal • BC is receiving Go to next step.
Builder (DLB), locate and follows switch PTO switch request.
observe the following command.
signal: • Refer to
appropriate
PTOa_Switch_ON transmission
manual for
Operate the PTO switch. further diagnostic
information related
to the PTO feature.
2. Measure voltage at the PTO 12 ± 1.5V Go to next step. • Inspect 10A Fuse F5-B
A relay (1020), cavity C3 to (1014).
ground.
• Inspect circuit A88V for
open or short.
3. Measure voltage between 12 ± 1.5V Go to next step. • Inspect ground circuit
cavity C3 and D4 of the A88 for open.
PTO A relay (1020).
• Suspect faulty switch.
Operate the PTO switch
ON.
258 S08361
SYSTEM DESCRIPTION ANTI-LOCK BRAKING SYSTEM
Table 187 Power Take Off Circuit Test (cont.)

4. PTO switch ON. ≤1 ohm Go to next step. • Inspect the ZVR circuit
A9ZB and A9Z for open or
Disconnect the BC #J5 short.
connector (1602).
• Inspect the ZVR adapter
Measure resistance (1620) for loose, damaged,
between cavity F14 and E3. or corroded terminals.
• Replace faulty relay.

5. Using the Diamond Logic® Signal Go to next step. Suspect faulty BC.
Builder (DLB), locate and follows switch
observe the following command.
signal:
PTOa_Air_Solenoid_Cmd
OR
PTO1_Air_Solenoid_Cmd
OR
PTOb_Air_Solenoid_Cmd
Operate the PTO switch.

6. PTO switch ON. 12 ± 1.5V • Refer to the Air • Inspect the appropriate
Solenoid Circuit BC output circuit to the air
Measure voltage at the Test (See Table solenoid for open or short.
appropriate cavity of the 171, page 241).
air solenoid connector • Inspect the IP / Center
(9736/9737). • Suspect faulty air Chassis connector (1701)
solenoid. for loose, damaged, or
corroded terminals.
7. ANTI-LOCK BRAKING SYSTEM

This section contains a general overview of the Anti-lock Braking System (ABS).
Overview
The ABS system is designed to provide the operator with steering controls during hard braking and slippery
road conditions. This feature provides vehicle traction control by monitoring vehicle speed, accelerator pedal
input, wheel speed, steering wheel position, and vehicle yaw (angular velocity). ABS systems include models
made by Bendix® and Wabco®.
Operation
The Anti-lock Brake System (ABS) module monitors inputs from the following sensors:
S08361 259
ANTI-LOCK BRAKING SYSTEM FEATURE CODE
• Wheel Speed Sensor

• Steering Wheel Position or Angle Sensor
• Yaw Sensor
• Vehicle Speed
• Accelerator pedal position
If input signals suggest the vehicle is braking rapidly or losing traction, the ABS module will perform the
appropriate actions to maintain vehicle control and keep input signals within an acceptable range.
If one or more input signals do not agree or are not rational, an ABS fault code will be set and the ABS
system will be inoperative.
Communication
The ABS module, Body Controller (BC), and Electronic Gauge Cluster (EGC) communicate on the J1939
data link. The following signals are communicated so that the EGC can illuminate the appropriate warning
and indicator lights:
• ABS is fully operational.

• ABS warning light is ON / OFF when fault is present.
• Trailer ABS warning light is ON / OFF when fault is present.
• ABS active signal is set when brake pressure starts to be modulated by the ABS and resets to passive
when the wheels are in a stable condition.
• Off-road or mud / snow switch is in the ON position (J1708 data link).
7.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the anti-lock brake
system.

0595ABV BC PROG, ABS INDICATOR
• Full power hydraulic brakes
• Air braking system
• Does not include trailer

0595BMS BC PROG, TRACTION CONTROL IND
• Bendix® Automatic Traction Control
• Enabled / disabled with traction warning light
• Air brakes
260 S08361
USER PROGRAMMABLE PARAMETERS ANTI-LOCK BRAKING SYSTEM
Table 188 Feature Code (cont.)

0595BJY BC PROG, TRACTION CONTROL IND
• Wabco® Automatic Traction Control
• Enabled / disabled with traction control light

0595BJL BC PROG, TRACTION CONTROL IND
• Bendix® ATC Off Road
• Traction Warning Light
• Air brakes
0595BJP BC PROG, TRACTION CONTROL IND
• Wabco® ATC Mud / Snow
• Traction Warning Light

There are no Body Controller (BC) programmable parameters available for the ABS.

The Anti-lock Braking System is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.
The ABS warning light will perform a bulb check and then extinguish after a successful self-test of the electrical
system. If an error is detected at any time, the warning light will remain illuminated.
NOTE – The vehicle must be driven above 4 MPH (6 KM/H) after any faults are cleared to ensure the ABS
dash warning light remains off.
NOTE – The trailer ABS warning light will remain on until any of the following conditions are true:
• The fault is cleared.

• The trailer with the fault is disconnected AND the Electronic Gauge Cluster goes to sleep. Ignition
must be OFF and driver's door is closed.
• The trailer with the fault is disconnected AND the ignition key is cycled.
The EGC display and the Vehicle Information Display (VID) if equipped are capable of displaying ABS
Diagnostic Trouble Codes (DTCs).
Refer to the appropriate supplier documentation for more information regarding DTCs.
S08361 261
ANTI-LOCK BRAKING SYSTEM TROUBLESHOOTING

CAUSE SIGNAL
2011 Source 9 N/A N/A Loss Of Data • Open Or N/A
Address 11 Link From ABS Short In J1939
Controller Data Link
• Faulty ABS
Module
Proceed to the appropriate ABS Module Circuit Test
• Bendix® ABS Module Circuit Test (See Table 191, page 263).
• Wabco® ABS Module Circuit Test (See Table 194, page 266).
2011 Source 9 N/A N/A ABS Data Link • Open Or J1939DT_Rcv_
Address 11 Commu- Short In J1939 61441_xxx_011
nication Failure Data Link _Timer
• Faulty ABS
Module
Proceed to the appropriate ABS Module Circuit Test.
• Bendix® ABS Module Circuit Test (See Table 191, page 263).
• Wabco® ABS Module Circuit Test (See Table 194, page 266).
This section contains diagnostic tips and troubleshooting information related to the ABS.
NOTE – Always refer to Bendix® or Wabco® Service Manuals and diagnostic software for further air and
hydraulic brake troubleshooting procedures.
Anti-Lock Braking System Preliminary Check
Table 190 Anti-Lock Braking System Preliminary Check
STEP ACTION YES NO

1. Are other features Refer to the latest circuit Go to next step.
malfunctioning that may diagrams and the 12–VOLT
have common circuits? POWER DISTRIBUTION AND
GROUNDS sections for shared
circuits.
262 S08361
TROUBLESHOOTING ANTI-LOCK BRAKING SYSTEM
Table 190 Anti-Lock Braking System Preliminary Check (cont.)

STEP ACTION YES NO
2. Are there any Diagnostic Refer to the Diagnostic Trouble • Proceed to the appropriate
Trouble Codes stored in Body Codes for specific cause (See ABS Module Circuit Test.
Controller? Table 189, page 262).
• Bendix® ABS Module Circuit
• Wabco® ABS Module Circuit

Bendix® ABS Circuit Tests
Table 191 Bendix® ABS Module Circuit Test

1. Measure voltage 12 ± 1.5V Go to next step. • Inspect 30A Fuse
between the ABS F8-B (1017).
module #1 connector
(1400), cavity 16 and • Inspect circuit A94AY
ground. for open or short.
2. Measure voltage 12 ± 1.5V Go to next step. Inspect ground circuit
between the ABS A94-GA for open or
module #1 connector short.
cavity 1.
3. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect 5A Fuse F1-C
(1010).
Measure voltage
between the ABS • Inspect circuit A94V
module #1 connector for open or short.
ground. • Verify Ignition
Relay #3 (1012/1014)
operation.
4. Measure voltage Approximately 2.5V Go to next step. • Inspect the CAN
between the ABS (+) circuit for open or
ground. • If voltage is 0 volts,
the J1939 circuit is
shorted to ground or
open.
S08361 263
Table 191 Bendix® ABS Module Circuit Test (cont.)

between the ABS (-) circuit for open or
open.
6. Disconnect battery. 60 ± 6 ohms Go to next step. • If resistance is 120
ohms, the data link has
Measure resistance an open circuit.
between cavities 7 and
8 of the ABS module • Inspect for damaged
#1 connector (1400). or missing terminating
resistor.
• If resistance is 0
ohms, the data link
circuits are shorted
together.
7. Measure voltage Approximately 2.5V Go to next step. • If voltage is 0 volts,
between the ABS the J1708 circuit is
module #1 connector shorted to ground or
(1400), cavity 14 and open.
ground.
8. Measure voltage at Approximately 2.5V • ABS module has • If voltage is 0 volts,
the ABS module #1 power and ground. the J1708 circuit is
connector (1400), shorted to ground or
cavity 13 to ground. • J1939 and J1708 open.
data links are
operational. • If voltage is ABOVE 5
• Replace faulty ABS is shorted to voltage.
module.
264 S08361
TROUBLESHOOTING ANTI-LOCK BRAKING SYSTEM
Table 192 Bendix® Steering Wheel Sensor Circuit Test

1. Disconnect the 12 ± 1.5V Go to next step. • Inspect circuit B94SA
steering wheel position for open or short.
sensor connector
(1821). • Inspect the ATC
/ RSP splice pack
Measure voltage (1410) for loose,
between the steering damaged, or corroded
wheel position terminals.
connector (1821),
2. Measure voltage 12 ± 1.5V Replace faulty steering • Inspect ground circuit
between the steering wheel position sensor. B94SC for open.
wheel position
connector (1821), • Inspect the ATC
cavity 2 and cavity 1. / RSP splice pack
(1410) for loose,
terminals.
Table 193 Bendix® Yaw Sensor Circuit Test

1. Disconnect the yaw 12 ± 1.5V Go to next step. • Inspect circuit
sensor (9511/9511A). N94SAB for open
or short.
Measure voltage
between cavity 1 • Inspect the IP / Center
and ground of the yaw Chassis connector
sensor (9511/9511A). (1701) for loose,
terminals.
2. Measure voltage 12 ± 1.5V Replace faulty yaw • Inspect ground circuit
between cavity 2 and sensor. N94SCB for open.
cavity 1 of the yaw
sensor (9511/9511A). • Inspect the IP / Center
Chassis connector
(1701) for loose,
terminals.
S08361 265
Wabco® ABS Module Circuit Test
Table 194 Wabco® ABS Module Circuit Test

1. Measure voltage 12 ± 1.5V Go to next step. • Inspect 15A Fuse
between the ABS F8-B (1017).
module connector
(1420), cavity 8 and • Inspect circuit A94AY
ground. for open or short.
2. Measure voltage 12 ± 1.5V Go to next step. • Inspect ground circuit
between the ABS A94A-G2 for open or
module connector short.
cavities 4/9. • Inspect ground circuit
A94A-G1 for open or
short.
(1010).
Measure voltage
between the ABS • Inspect circuit A94V
module connector for open or short.
ground. • Verify Ignition
Relay #3 (1012/1014)
operation.
between the ABS (+) circuit for open or
open.
between the ABS (-) circuit for open or
open.
266 S08361
SYSTEM DESCRIPTION FIFTH WHEEL SLIDE AND JAW LOCK RELEASE
Table 194 Wabco® ABS Module Circuit Test (cont.)

6. Disconnect battery. 60 ± 6 ohms Go to next step. • If resistance is 120
ohms, the data link has
Measure resistance an open circuit.
between cavities 3 and
1 of the ABS module • Inspect for damaged
connector (1420). or missing terminating
resistor.
• If resistance is 0
ohms, the data link
circuits are shorted
together.
7. Measure voltage at the Approximately 2.5V Go to next step. • If voltage is 0 volts,
ABS module connector the J1708 circuit is
(1420), cavity 11 to shorted to ground or
ground. open.
volts the J1708 circuit
8. Measure voltage at the Approximately 2.5V • ABS module has • If voltage is 0 volts,
ABS module connector power and ground. the J1708 circuit is
(1420), cavity 10 to shorted to ground or
ground. • J1939 and J1708 open.
data links are
operational. • If voltage is ABOVE 5
• Replace faulty ABS is shorted to voltage.
module.
8. FIFTH WHEEL SLIDE AND JAW LOCK RELEASE

This section contains a general overview of the fifth wheel slide and fifth wheel jaw lock release.
Overview
Fifth Wheel Slide
The fifth wheel slide allows the operator to unlock the fifth wheel and adjust its position forward or backward.
The fifth wheel slide is controlled by a switch pack mounted rocker switch and operated by a designated
air solenoid.
Fifth Wheel Jaw Lock Release
The jaw lock release feature allows the operator to disengage the vehicle's fifth wheel from inside the cab.
S08361 267
FIFTH WHEEL SLIDE AND JAW LOCK RELEASE FEATURE CODE
The parking brake must be set and the jaw lock release switch must be held for three to five seconds to allow
the fifth wheel to disengage.
Operation
Fifth Wheel Slide
The switch pack switch sends a request message on the J1708 data link to the Body Controller (BC) to lock
or unlock the fifth wheel slide, depending on the position of the switch. The BC provides battery voltage to
energize the fifth wheel slide air solenoid when certain conditions are met. The air solenoids, within the Air
Solenoid 4-Pack, share a common ground. The fifth wheel slide switch also provides the operator with an
indication of the fifth wheel slide feature’s electrical status.
Fifth Wheel Jaw Lock Release
When the jaw lock release switch is held for three to five seconds, the switch pack switch sends a request
message on the J1708 data link to the Body Controller (BC). The BC will command the air solenoid to release
the fifth wheel jaw lock. The BC provides battery voltage to energize the jaw lock release air solenoid when
certain conditions are met. The air solenoids, within the Air Solenoid 4-Pack, share a common ground.
The fifth wheel jaw lock release switch also provides the operator with an indication of the fifth wheel jaw
lock release feature’s electrical status.
8.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the fifth wheel
slide and fifth wheel jaw lock release.

0595ACY BC PROG, FIFTH WHEEL SLIDE
0595BAW BC PROG, FIFTH WHEEL UNLOCK (Includes two air solenoids)

This section contains all user programmable features directly related to the fifth wheel slide and fifth wheel
jaw lock release.
Name: Fifth_Wheel_Slide_Max_Speed
• ID: 1336
• Description: Maximum allowable speed for sliding fifth wheel to be unlocked.
• Minimum value: 0 MPH ( 0 KM/H)
• Interval: 1
• Default value: 2 MPH ( 3 KM/H)
268 S08361
DIAGNOSTIC TROUBLE CODES FIFTH WHEEL SLIDE AND JAW LOCK RELEASE

The fifth wheel slide and fifth wheel jaw lock release feature is able to set Diagnostic Trouble Codes (DTC)
when specific faults occur. Information given by the DTC can aid in the diagnosis of the problem.

CAUSE SIGNAL
3316 Fifth Wheel 5 1601 E13 Open Circuit Open Fifth_Wheel_
Slider Lock In Fifth Circuit Slide_Cmd
Indicator Wheel Slide
Circuit
Proceed to Fifth Wheel Slide Test (See Table 198, page 270).
3316 Fifth Wheel 6 1601 E13 Short To Short Fifth_Wheel_
Slider Lock Ground In Circuit Slide_Cmd
Indicator Fifth Wheel
Slide Circuit
4007 Fifth Wheel 2 N/A N/A Fifth Wheel Faulty Fifth_Wheel_
Slide Lock Slide Switch Switch Slide_Switch
Switch Error
3313 Fifth Wheel 5 N/A N/A Fifth Wheel Open Fifth_Wheel
Lock Couple Jaw Unlock Circuit Or _Jaw_Unlock_
Status Solenoid Defective Solenoid_Cmd
Indicator 1 Output Solenoid
Is Under
Current Or
Open Circuit
Proceed to the Fifth Wheel Jaw Lock Release Circuit Test (See Table 199, page 271).
3313 Fifth Wheel 6 N/A N/A Fifth Wheel Short To Fifth_Wheel_
Lock Couple Jaw Unlock Ground Or Jaw_Unlock_
Status Solenoid 1 Defective Solenoid_Cmd
Indicator Output is Solenoid
Over Current
3314 Fifth Wheel 2 N/A N/A Fifth Wheel Data Erratic Fifth_Wheel
Release Jaw Unlock Intermittent _Jaw_Unlock
Control Switch State Or Incorrect _Switch
Is Invalid
S08361 269
FIFTH WHEEL SLIDE AND JAW LOCK RELEASE TROUBLESHOOTING
This section contains diagnostic tips and troubleshooting information related to the fifth wheel slide and
jaw lock release feature.
Fifth Wheel Slide Preliminary Check
Table 197 Fifth Wheel Slide Preliminary Check
STEP ACTION YES NO

1. Are other switch pack operated Refer to the SWITCH PACK Go to next step.
features inoperative? (J1708) section for further
2. Are other air solenoid operated Refer to the Air Solenoid Circuit Go to next step.
features inoperative? Test (See Table 171, page 241).
3. Check for any active or stored Refer to the Diagnostic Trouble Proceed to the Fifth Wheel
DTCs related to the fifth wheel Codes for specific cause (See Slide Circuit Test (See Table
slide. Table 196, page 269). 198, page 270).
Are any DTCs present?
Fifth Wheel Slide Circuit Test
Table 198 Fifth Wheel Slide Circuit Test

1. Using the Diamond Logic® Signal follows • Go to next step. • Suspect faulty switch.
Builder (DLB), locate and switch command.
observe the following • The BC is receiving • Refer to the SWITCH
signals: input command over PACK (J1708) section
the J1708 data link. for further diagnostic
Fifth_Wheel_ information.
Slide_Switch signal.
Fifth_Wheel_
Slide_Cmd signal.
Operate the fifth wheel slide

switch and observe signal
states.
2. Using the DLB, select the The air solenoid • No faults evident at Go to next step.
CONNECTORS tab. receives the BC this time.
output signal and
Select the BC #J4 (1601) operates the fifth • Verify mechanical
connector. wheel slide. operation of the fifth
wheel slide.
Locate the Fifth_Wheel_
Slide_Cmd signal.
Actuate the signal.
270 S08361
SYSTEM DESCRIPTION FUEL HEATER
Table 198 Fifth Wheel Slide Circuit Test (cont.)

3. Perform the following 12 ± 1.5V Go to next step. • Inspect circuits A59E
voltage check while and N59E for open or
actuating the Fifth_Wheel_ short.
Slide_Cmd signal:
• Inspect the IP / Center
Measure voltage between Chassis connector
the air solenoid connector (9737) for loose,
(9737), cavity B and ground. damaged, or corroded
terminals.
4. Perform the following 12 ± 1.5V • Suspect faulty air • Inspect ground circuit
voltage check while solenoid. N59-GA for open or
actuating the Fifth_Wheel_ short.
Slide_Cmd signal: • Refer to the Air
Solenoid Circuit Test • Inspect ground adapter
Measure voltage between (See Table 171, (8804) for loose,
cavity B and cavity A of page 241). damaged, or corroded
the air solenoid connector terminals.
(9737).
Fifth Wheel Jaw Lock Release Circuit Test
Table 199 Fifth Wheel Jaw Lock Release Circuit Test

1. Using the Diamond Logic® Signal follows Go to next step. • Suspect faulty switch.
Builder (DLB), locate and switch command.
observe the Fifth_Wheel_ • Refer to the SWITCH
Jaw_Unlock_Switch PACK (J1708) section
signal. for further diagnostic
information.
Operate the fifth wheel jaw
unlock switch.
2. Using the DLB, locate and Signal follows No electrical faults • Inspect fifth wheel lock
observe the Wedge_State switch command. present. for mechanical failures.
signal.
• Inspect lock cylinder for
Operate the fifth wheel jaw damage.
unlock switch.
Solenoid section for
further diagnostic
information.
9. FUEL HEATER
This section contains a general overview of the fuel heater.
S08361 271
FUEL HEATER FEATURE CODE
Overview
The fuel heater is mounted in the fuel filter. It prevents fuel from gelling in the unfiltered side of the filter
during cold weather conditions.
Operation
The fuel heater consists of a fuel heater relay (1018) and fuel heating element. The fuel heater relay (1018)
is energized when the ignition key is in the ON position. The fuel heater relay (1018) is provided constant
battery voltage from 20A Fuse F6-D (1015). The fuel heater relay (1018) is provided ground by ground adapter
(1008). When energized, fused battery voltage is provided to the fuel heater.
9.2. FEATURE CODE

There are no Body Controller (BC) feature codes related to the fuel heater.

There are no user programmable parameters associated with the fuel heater.

There are no Diagnostic Trouble Codes (DTC) related to the fuel heater feature.
This section contains diagnostic tips and troubleshooting information related to the fuel heater.
Fuel Heater Preliminary Check
Table 200 Fuel Heater Preliminary Check
STEP ACTION YES NO

1. Determine if any other features • Inspect ground adapter Proceed to the Fuel Heater
are malfunctioning that may (1008) for loose, damaged, or Circuit Test (See Table 201,
have common circuits. corroded terminals. page 273).
Are other features • Verify ignition relay #3

malfunctioning? (1012/1014) operation.
Faults may include compass
module failure, backup lights
inoperative, or heated seat
failures.

POWER DISTRIBUTION AND
GROUNDS section for further
circuit information.
272 S08361
SYSTEM DESCRIPTION REMOTE POWER MODULE
Fuel Heater Circuit Test
Table 201 Fuel Heater Circuit Test

1. Remove the fuel heater 12 ± 1.5V Go to next step. • Inspect 20A Fuse F6-D (1015).
relay (1018).
• Inspect circuit A19V for open or
the fuel heater relay (1018),
2. Measure voltage between 12 ± 1.5V Go to next step. • Inspect ground circuit A19-GB
the fuel heater relay (1018), for open.
cavity 30 and cavity 86.
terminals.
3. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect circuits A13FK for open
or short.
the fuel heater relay (1018), • Verify ignition relay #3
cavity 85 and ground. (1012/1014) operation.
4. Install the fuel heater relay 12 ± 1.5V Go to next step. • Inspect circuit N19 and circuit
(1018). A19 for open or short.
Disconnect the fuel heater • Inspect the IP / Center chassis

connector (9108). connector (1701), pin 67 for
Key is in ON position. terminals.
Measure voltage between • Replace faulty fuel heater relay

the fuel heater connector (1018).
ground.
5. Measure voltage between 12 ± 1.5V Replace faulty • Inspect ground circuit N19-G
the fuel heater relay (1018), fuel heater. for open.
terminals.
10. REMOTE POWER MODULE

This section contains a general overview of the Remote Power Module (RPM)
S08361 273
REMOTE POWER MODULE FEATURE CODE
Overview
The RPM serves as a gateway into International's® electrical system. The RPM is used to control different
types of optional equipment that are added to the vehicle. The standard RPM provides six additional inputs
and six 20A outputs.
The BC is capable of controlling up to seven RPMs on a single vehicle.
The RPMs can be cab mounted, battery box mounted, or end of frame (EOF) mounted.
Operation
The RPM communicates with the Body Controller (BC) via the J1939 data link. The RPM is provided fused
battery voltage, ground path, and J1939 data link circuitry. RPMs are also provided a 4 gauge fused battery
circuit to drive RPM components.
Each RPM has six independently controllable 20A outputs with virtual fusing similar to the BC. If higher current
capacity is needed, two outputs can be paralleled or the RPM can control a high current relay while still
maintaining logic and diagnostic capability without having to wire inside of the cab.
Because the RPM is connected to the BC via the data link, it also serves as an integration gateway to the BC
and the vehicle electrical system. Six inputs on each RPM allow information from body accessories to be
communicated to the BC and processed for interlocks, operator information, and warning indicators. These
inputs also allow the body builder to add body-mounted switches to turn ON or OFF the same electrical
devices controlled by in-cab switches.
Switch Packs and Remote Power Modules
Each RPM comes with a six-pack of switches that is inserted into the center section of the instrument panel.
The switch pack is connected to the J1708 data link that communicates switch operation to the BC, which
communicates that operation to the RPM on the J1939 data link. The lamp indicator on the instrument panel
switch will always display the current status of the output channel as long as the ignition key is in the ON or
ACCESSORY position. Each RPM in-cab switch operates with the key in the ON or ACCESSORY position.
A maximum of four RPMs may be connected to the vehicle from the factory, which allows a total of 24 devices
to be controlled as long as the 80A per module is not exceeded. The modules can be relocated from their
mounting position as long as the data link cable will reach the new mounting location without modifying
the data link.
If multiple RPMs are installed, the power, ground, and data link circuits are daisy chained from one RPM to
the next by means of a jumper harness. If only one RPM is installed, a terminating resistor will be located in
the same connector as the jumper wire.
RPM circuits and connectors will vary depending on the number and location of RPMs installed on the vehicle.
Refer to the latest applicable Circuit Diagram manual and the Body Builder Book for more detailed information.
The CONNECTORS tab in Diamond Logic® Builder (DLB) can be used to determine pin assignments and
connectors for the various RPM inputs and outputs. The locations for RPM # 1, 2, 4, and 7 shown in DLB are
the factory locations, but they can be moved as desired.
10.2. FEATURE CODE

There are many Body Controller features that may require RPM, depending on the customer's needs.
274 S08361
USER PROGRAMMABLE PARAMETERS REMOTE POWER MODULE
Refer to the FEATURES tab in Diamond Logic® Builder (DLB) for a list of 0595 feature codes equipped
on a particular vehicle.

Due to the variety of RPM configurations and packages, programmable parameters will vary per vehicle.
Many RPM related parameters are customer programmable in the Body Controller using Diamond Logic®
Builder (DLB). Refer to the Body Builder Manual for more information. To find applicable feature specific
parameters using DLB, highlight the feature in question. The parameters specific to that feature will be
displayed in the lower portion of the DLB screen.

The Remote Power Module (RPM) is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.

CAUSE SIGNAL
2225 Remote Power 9 N/A N/A RPM #1 Data Abnormal J1939BB_Rcv_65313_
Module #1 Link Commu- Update Rate xxx_225_Timer
Fuse nication
Failure
This Diagnostic code is the result of a defective remote power module (RPM).
NOTE – Cycle the key switch. If this does not clear the DTC, then replace the RPM.
2225 Remote Power 14 N/A N/A Remote Drivetrain J1939BB_Rcv_65313_
Module #1 Power Module J1939 Data xxx_225_Timer
Fuse #1 (Address Link An
225) Has Improperly
An Address Addressed
Problem RPM Module
Or A Missing
RPM Module
That The BC
Is Expecting
Proceed to the RPM Circuit Test (See Table 204, page 279).
2226 Remote Power 9 N/A N/A RPM#2 Data Abnormal J1939BB_Rcv_65313_
Fuse nication
Failure
S08361 275
REMOTE POWER MODULE DIAGNOSTIC TROUBLE CODES

CAUSE SIGNAL
226) Has Improperly
Problem RPM Module
Or A Missing
RPM Module
That The BC
Is Expecting
2227 Source 9 N/A N/A RPM #3 Data Abnormal J1939BB_Rcv_65313_
Address 227 Link Commu- Update Rate xxx_227_Timer
nication
Failure
2227 Source 14 N/A N/A Remote Drivetrain J1939BB_Rcv_65313_
Address 227 Power Module J1939 Data xxx_227_Timer
#3 (Address Link An
227) Has Improperly
Problem RPM Module
Or A Missing
RPM Module
That The BC
Is Expecting
Fuse nication
Failure
276 S08361
DIAGNOSTIC TROUBLE CODES REMOTE POWER MODULE

CAUSE SIGNAL
228) Has Improperly
Problem RPM Module
Or A Missing
RPM Module
That The BC
Is Expecting
nication
Failure
#5 (Address Link An
229) Has Improperly
Problem RPM Module
Or A Missing
RPM Module
That The BC
Is Expecting
nication
Failure
S08361 277
REMOTE POWER MODULE TROUBLESHOOTING

CAUSE SIGNAL
#6 (Address Link An
230) Has Improperly
Problem RPM Module
Or A Missing
RPM Module
That The BC
Is Expecting
Fuse nication
Failure
231) Has Improperly
Problem Rpm Module
Or A Missing
RPM Module
That The BC
Is Expecting
This section contains diagnostic tips and troubleshooting information related to the RPM.
To view RPM configuration, use the Diamond Logic® Builder (DLB). Select the CONNECTORS tab. Select the
appropriate RPM being diagnosed, then select a RPM connector to view pin usage.
278 S08361
TROUBLESHOOTING REMOTE POWER MODULE
RPM Preliminary Check
Table 203 RPM Preliminary Check
STEP ACTION YES NO

1. Does the feature operate • Check for intermittent and Go to next step.
properly? poor connections.
• Inspect connectors for

terminals.
2. Are there any other features • Check common ground Go to next step.
malfunctioning that may have adapters for loose, damaged,
common circuits? or corroded terminals.

POWER DISTRIBUTION AND
GROUNDS section of the
applicable Circuit Diagram
manual.
3. Are any DTCs present in the Refer to the Diagnostic Trouble Go to next step.
BC? Codes for specific cause (See
4. Go to the MESSAGES tab Resolve any errors found. Proceed to the RPM Circuit
in DLB. Are there any errors Refer to the Body Builder Test(See Table 204, page 279).
shown on the screen? Manual for information about
adding the software for the
feature to the Body Controller.
RPM Circuit Test
Make sure the body builder data link is operational. Refer to the MULTIPLEXING (DATA LINKS) section for
NOTE – Prior to performing the RPM Circuit Test, inspect the RPM's 4 gauge red battery circuit for
damage. The 4 gauge battery circuit is connected to connector J5 of the appropriate RPM.
Table 204 RPM Circuit Test

1. Disconnect the 12 ± 1.5V Go to next step. • Inspect 10A Fuse
appropriate RPM F8-C (1017).
connector.
• Inspect circuits N20
Key is in ON position. and A20 for open or
short.
Measure voltage
between the • Inspect the IP /
appropriate inoperative Center chassis (1701)
RPM connector
S08361 279
REMOTE POWER MODULE TROUBLESHOOTING
Table 204 RPM Circuit Test (cont.)

(4410A/B/C/D/E/F/G), for loose, damaged, or
cavity 6 and ground. corroded terminals.
2. Key is in ON position. 12 ± 1.5V Go to next step. Cab mounted RPM:
Battery box, cab, • Inspect ground circuit

or end of frame N10-GR for open.
mounted RPM:
• Inspect ground
Measure voltage adapter (8809) for
between the loose, damaged, or
appropriate inoperative corroded terminals.
RPM connector
(4410A/B/C/D/E/F/G), Battery box mounted
cavity 6 and cavity 2. RPM:
• Inspect ground circuit

N11-GPM for open.
• Inspect ground
adapter (8809) for
loose, damaged, or
corroded terminals.
End of frame
mounted RPM:

N10-GP for open.
• Inspect ground
adapter (8809) for
loose, damaged, or
corroded terminals.
3. Key is in OFF position. 120 ohms Go to next step. • If resistance is 0
ohms, the data link
Measure resistance circuits are shorted
between the together.
appropriate inoperative
RPM connector • Inspect for damaged
(4410A/B/C/D/E/F/G), or missing terminating
cavity 3 and cavity 4. resistor.
• Inspect data link for

open.
280 S08361
SYSTEM DESCRIPTION REMOTE START / STOP
Table 204 RPM Circuit Test (cont.)

4. Key is in ON position. Approximately 2.5V Go to next step. • Inspect the CAN
(+) circuit for open or
Measure voltage short.
between the
appropriate inoperative • If voltage is 0 volt, the
RPM connector J1939 circuit is shorted
(4410A/B/C/D/E/F/G), to ground or open.
5. Key is in ON position. Approximately 2.5V • The RPM has power • Inspect the CAN
and ground and is (+) circuit for open or
Measure voltage communicating on the short.
between the J1939 data link.
appropriate inoperative • If voltage is 0 volt, the
RPM connector • Replace faulty RPM. J1939 circuit is shorted
(4410A/B/C/D/E/F/G), to ground or open.
11. REMOTE START / STOP

This section contains a general overview of the Remote Start / Stop system.
Overview
This feature is used to start or stop the vehicle engine from the sleeper area. The remote start / stop feature
emits an audible alarm prior to engine operation.
This feature consists of the following electrical components:
• Sleeper Control Enable Switch: Located on the instrument panel.

• Remote Start / Stop Switch: Located in the sleeper control panel.
• Hood Switch: Located under the hood on the splash guard near the driver side headlight.
• Neutral Switch (manual transmission): Located on the transmission.
• Audible Engine Start Alarm: Located in the driver side engine compartment on the air cleaner mounting
bracket.
• Remote Start Relay: Located in the sleeper fuse box.
• Remote Stop Relay: Located in the sleeper fuse box.
• Remote Start / Stop Relays #1 and #2: Located in the Power Distribution Center (PDC).
• Ignition Relay #1, #2, and #3: Located in the PDC.
S08361 281
REMOTE START / STOP FEATURE CODE
Operation
When the sleeper control enable switch is closed, a Zero Volt Reference (ZVR) signal is provided to the Body
Controller (BC). The BC supplies voltage through the sleeper control enable switch to the sleeper control
enable switch indicator, the remote stop relay coil, and the remote start / stop switch illumination.
When the remote start / stop switch is closed, the ZVR passes through the remote start / stop switch sending
a digital request to the Body Controller.
Ground is provided through the remote start / stop switch to remote start relay coil, and ground is applied to
the engine start alarm.
NOTE – The remote start relay will not energize until the BC determines that conditions are appropriate.
When the hood switch and the neutral switch are closed, ignition voltage is supplied to the coil of the remote
start / stop relay #1 and remote start / stop relay #2.
When the remote start / stop relay #1, and relay #2 are energized, the ZVR signal passes through the switch
contacts of the remote start / stop relay #1 sending an input signal to the BC. Ignition voltage passes through
the switch contacts of the remote start / stop relay #2 to the switch contact of the remote start relay.
The BC activates the remote start relay, remote stop relay, and the engine start alarm when conditions are met.
The engine will crank when all of the following conditions are met:
• The remote start / stop switch is pressed for more than 15 seconds.
• The sleeper control enable switch is in the ENABLED position.
• The key is in the IGNITION position.
• The park brake is set.
• The hood is closed.
• The transmission is in neutral or park.
• The vehicle speed is equal to zero.
• The engine is NOT running.
• Engine protection is NOT active.
11.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definitions related to the Remote Start /
Stop feature.

0595AKW BC PROG, REMOTE START / STOP without emergency pump motor
functionality
0595AKV BC PROG, REMOTE START / STOP with emergency pump motor functionality
282 S08361
USER PROGRAMMABLE PARAMETERS REMOTE START / STOP

There are no user programmable parameters associated with the remote start / stop feature.

The remote start / stop system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.

CAUSE SIGNAL
520687 Engine 5 N/A N/A Remote Start Open Circuit Remote_Start_Relay

Remote Start Relay Under In Remote
Command Current Or Bunk Start
Open Circuit Circuit
Proceed to the Remote Start / Stop Test (See Table 208, page 284).
520687 Engine 6 N/A N/A Remote Start Short To Remote_Start_Relay
Remote Start Relay Over Ground In
Command Current Remote
Bunk Start
Circuit
520688 Engine 5 N/A N/A Remote Stop Open Circuit Remote_Stop_Relay
Remote Stop Relay Under In Remote
Command Current Or Bunk Stop
Open Circuit Circuit
520688 Engine 6 N/A N/A Remote Stop Short To Remote_Stop_Relay
Remote Stop Relay Over Ground In
Command Current Remote
Bunk Stop
Circuit
This section contains diagnostic tips and troubleshooting information related to the remote start / stop system.
S08361 283
REMOTE START / STOP TROUBLESHOOTING
Remote Start / Stop Preliminary Check
Table 207 Remote Start / Stop Preliminary Check
STEP ACTION YES NO

1. Does the engine crank using Go to next step. Refer to the CRANKING AND
the ignition key or push button CHARGING section for further
start? diagnostic information.
2. Using the Diamond Logic® Refer to Diagnostic Trouble Proceed to the Remote Start /
Builder (DLB), check for DTCs. Codes for specific cause of Stop Test (See Table 208, page
fault code (See Table 206, page 284).
283).
Remote Start / Stop Test
NOTE – It is necessary to bench test any suspected relays prior to circuit testing the remote start / stop
system.
Table 208 Remote Start / Stop Test

1. Using the Diamond Signal is true. • The switch is supplying the • Inspect the ZVR circuit
Logic® Builder (DLB), ZVR signal to the BC. A9RA for open or short.
locate and observe the
following signal: • Go to next step. • Inspect the ZVR
splice (1620) for loose,
Sleeper_Enable_ damaged, or corroded
Request terminals.
Ensure the sleeper

control enable switch
is in the ENABLED
position.
2. Using the Diamond Signal is true. • The BC is supplying voltage Inspect circuit H104AD
Logic® Builder (DLB), to the remote stop relay for open or short.
locate and observe the coil (opening the switch),
following signal: sleeper control enable switch
indicator, and the remote start
Sleeper_Control_ / stop switch illumination.
Enable_RD
• Go to next step.
3. Using the Diamond Signal is true. • The BC is receiving an input • Inspect circuit H104AC
Logic® Builder (DLB), signal from the remote start / for open or short.
locate and observe the stop switch.
following signal: • Inspect the IP / Sleeper
• Go to next step. connector (5000) for
Remote_Engine_Start_ loose, damaged, or
Stop_Request corroded terminals.
Ensure the remote

start / stop switch is
pressed.
284 S08361
TROUBLESHOOTING REMOTE START / STOP
Table 208 Remote Start / Stop Test (cont.)

4. Using the Diamond Signal is true. • Voltage is being supplied • Inspect circuit H104AB
Logic® Builder (DLB), to the remote start relay coil for open or short.
locate and observe the from the BC.
Remote_Start_RD loose, damaged, or
corroded terminals.
5. Using the Diamond Signal is true. • Ground is being provided • Inspect circuit H104AA
Logic® Builder (DLB), to the remote stop relay coil for open or short.
locate and observe the from the BC.
Remote_Stop_RD loose, damaged, or
corroded terminals.
6. Using the Diamond Signal is true. • Voltage is being supplied to • Inspect circuit A104AF
Logic® Builder (DLB), the engine start alarm from for open or short.
locate and observe the the BC.
following signal: • Suspect faulty engine
• Go to next step. start alarm (4101).
Remote_Start_Alarm_
Buzzer_RD
7. Using the Diamond Signal is true. • The BC is communicating • Verify J1939 data link
Logic® Builder (DLB), with the Electronic Gauge communication.
locate and observe the Cluster (EGC) when in remote
following signal: stop or emergency shutdown • Refer to the
mode. MULTIPLEXING section
Remote_Stop_ for further diagnostic
Message_to_Driver • Go to next step. information.
8. Using the Diamond Signal is true • The ECM is communicating • Verify J1939 data link
Logic® Builder (DLB), (1). with the BC when the engine communication.
locate and observe the protection system is active.
following signal: • Refer to the
• Go to next step. MULTIPLEXING section
Engine_Protection_ for further diagnostic
Shutdown information.
9. Using the Diamond Signal is true. • The hood is closed and / or Inspect circuit A104AR
Logic® Builder (DLB), transmission is in neutral. for open or short.
locate and observe the
following signal: • The BC is being supplied a
ZVR signal.
Hood_Closed_and_
Neutral_Signal • All remote start / stop
components are operational.
S08361 285
TWO-SPEED AXLE SYSTEM DESCRIPTION
12. TWO-SPEED AXLE

This section contains a general overview of the two-speed axle.
Overview
The two-speed axle provides the operator with HI and LOW range rear axle operation for increased torque.
The two-speed axle is controlled by the dash mounted two-speed axle switch.
Operation
The Body Controller (BC) provides a input signal to the two-speed axle switch (7130M). The BC's Zero
Volt Reference (ZVR) signal monitors switch operation. When the switch is operated, the BC energizes the
appropriate air solenoid, operating the two-speed axle.
12.2. FEATURE CODES

This section contains the available Body Controller feature code definition related to the two-speed axle.

0595ANL BC PROG, RR AXLE SWITCH CON'T with dash mounted HI / LOW switch
0595ALN BC PROG, REAR AXLE SHIFT CONTROL without dash mounted HI / LOW
switch

There are no Body Controller (BC) programmable parameters available for the two-speed axle.

The two-speed axle switch is able to set DTCs when specific faults occur. Using the information given by

CAUSE SIGNAL
69 Two Speed 2 N/A N/A Two Speed Axle Data Erratic Two_Spd_Axle
Axle Switch Switch Error Intermittent Or _Switch
Incorrect
• Proceed to the Two Speed Switch Test (See Table 212, page 287).
4056 Two Speed 5 N/A N/A Two Speed Axle Current Below Two_Spd_Axle
Axle Actuator Solenoid Relay Normal Or Open _Solenoid_Cmd
Under Current Or Circuit
Open Circuit
286 S08361
TROUBLESHOOTING TWO-SPEED AXLE

CAUSE SIGNAL
4056 Two Speed 6 N/A N/A Two Speed Axle Current Above Two_Spd_Axle
Axle Actuator Solenoid Relay Normal Or _Solenoid_Cmd
Short To Ground Grounded Circuit
Two-Speed Switch Preliminary Check
Table 211 Two-Speed Switch Preliminary Check
STEP ACTION YES NO

1. Are other air solenoid operated Refer to the Air Solenoid Go to next step.
features inoperative? section for further diagnostic
information.
2. Are DTCs present in the Body Refer to the Diagnostic Trouble • Proceed to the Two Speed
Controller? Codes for specific cause (See Switch Test (See Table 212,
Two-Speed Switch Test
Table 212 Two-Speed Switch Test

1. Using Diamond Signal follows Refer to the Air Go to next step.
Logic Builder, switch command. Solenoid section for
locate and observe further diagnostic
the following signal: information.
Two_Spd_Axle
_Switch signal.
Operate the
two-speed axle
switch.
2. Disconnect the 12 ± 1.5V Go to next step. • Inspect circuits K93 and A93 for
two-speed axle open or short.
switch connector
(7103M). • Inspect the engine / IP connector
(1702), pin 39 for loose, damaged,
Measure voltage or corroded terminals.
between the
S08361 287
CUSTOMER INSTALLED LIFT GATE POWER SOURCE SYSTEM DESCRIPTION
Table 212 Two-Speed Switch Test (cont.)

two-speed axle
switch connector • Inspect the BC #J5 (1602)
(7103M), cavity A connector for loose, damaged, or
and ground. corroded terminals.
3. Measure voltage 12 ± 1.5V Replace faulty • Inspect circuit K9TS for open.
between the switch.
two-speed axle • Inspect ZVR adapter (6747)
switch connector for loose, damaged, or corroded
(7103M), cavity A terminals.
and cavity B.
• Inspect circuits K9E, A9E, and
A9AA for open.
• Inspect the BC #J5 (1602) for

terminals.
13. CUSTOMER INSTALLED LIFT GATE POWER SOURCE

This section contains a general overview of the customer installed lift gate.
Overview
This feature provides a trailer mounted lift gate power source. The lift gate power source is operated by a
instrument panel mounted switch, battery cables, battery protection module, and magnetic switch.
Operation
The lift gate can be enabled or disabled using a center panel mounted switch.
The lift gate will also be disabled when the system voltage falls below 11.5V or rises above 13.8V for more
than 60 seconds.
13.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the customer
installed lift gate.

0595AYM BC PROG, LIFT GATE WIRING PAK rocker position
0595AGN BC PROG, LIFT GATE WIRING PAK push button B
288 S08361
USER PROGRAMMABLE PARAMETERS CUSTOMER INSTALLED LIFT GATE POWER SOURCE

This section contains all user programmable features directly related to the lift gate.
Name: Lift_Gate_Alarm_Time
• ID: 2249
• Description: This parameter defines the Lift Gate Alarm time value.
• Maximum value: 120 seconds
• Minimum value: 1 second
• Interval: 1 second
• Default value: 60 seconds
Name: Lift_Gate_Enable_Timeout
• Description: This parameter defines the amount of time the lift gate is enabled.
• ID: 2235
• Maximum value: 240 minutes
• Minimum value: 10 minutes
• Interval: 10 minutes
• Default value: 60 minutes

The lift gate system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information

CAUSE SIGNAL
4022 Lift Gate 5 1603 J Lift Gate Current Lift_Gate_
Power Control Enable Below Enable_Cmd
Enable Under Normal Or
Current Open Circuit
Proceed to the Lift Gate Test (See Table 216, page 291).
S08361 289
CUSTOMER INSTALLED LIFT GATE POWER SOURCE TROUBLESHOOTING

CAUSE SIGNAL
4022 Lift Gate 6 1603 J Lift Gate Current Lift_Gate_
Power Control Enable Over Above Enable_Cmd
Enable Current Normal Or
Grounded
Circuit
4023 Lift Gate 2 N/A N/A Lift Gate Data Erratic Lift_Gate_
Power Control Switch Error Intermittent Enable_Switch
Switch Or Incorrect
This section contains diagnostic tips and troubleshooting information related to the lift gate feature.
Lift Gate Preliminary Check
Table 215 Lift Gate Preliminary Check
STEP ACTION YES NO

1. Does the lift gate function when Go to next step. Proceed to the Lift Gate Test
operated? (See Table 216, page 291).
2. Are there any DTCs stored in Refer to the Diagnostic Trouble Proceed to the Lift Gate Test
the Body Controller? Codes for specific cause (See (See Table 216, page 291).
290 S08361
SYSTEM DESCRIPTION AUTO NEUTRAL
Lift Gate Circuit Test
NOTE – Prior to testing the lift gate solenoid, inspect two 10-gauge circuits to solenoid for damage.
Table 216 Lift Gate Test

1. Using the Diamond Signal follows switch Go to next step. • Inspect lift gate
Logic® Builder (DLB), command. switch circuits for open
locate and observe the or short.
Lift_Gate_
Enable_Req signal. • Replace faulty lift
gate switch.
Operate the lift gate
switch.
2. Key is in ON position. 12 ± 1.5V Go to next step. • Inspect the light
green wire for open or
Lift gate switch ON. short.
Measure voltage • Ensure the battery

between the 200A production module is
solenoid, light green receiving BC input on
wire and ground. the orange wire.
3. Measure voltage 12 ± 1.5V • Inspect 2 gauge cable • Inspect tan wire
between the 200A to power lift gate. ground circuit for open.
solenoid, light green
wire and tan wire. • Inspect lift gate for
mechanical failure.
14. AUTO NEUTRAL

This section contains a general overview of the auto neutral feature.
Overview
The auto neutral feature is designed to automatically place the transmission into neutral if the parking brake is
set. Auto neutral feature can be used with vehicles that require frequent stops and starts, and when exiting the
vehicle is required. When using the auto neutral feature, the operator must leave the shift selector in gear,
bring the vehicle to a stop, and apply the parking brake.
Operation
The auto neutral switch is located within the vehicle switch pack. When enabled, the auto neutral switch
communicates switch status to Body Controller (BC) on the J1708 data link. If all interlocks have been met,
the BC provides ground signal to the Transmission Control Module (TCM). Once the TCM receives the BC
input, the TCM places the transmission in neutral and provides ground to the auto neutral relay (1017). Once
energized, voltage is provided by the auto neutral relay (1017) to the normally closed auto neutral light relay
(1019). Voltage passes through the normally closed relay and illuminates the EGC's auto neutral warning light.
S08361 291
AUTO NEUTRAL FEATURE CODE
14.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the auto neutral
feature.

0595BSG BC PROG, AUTO NEUTRAL with high side driver
0595BUP BC PROG, AUTO NEUTRAL without ON / OFF switch
0595AYP BC PROG, AUTO NEUTRAL

There are no Body Controller (BC) programmable parameters associated with the auto neutral feature.

The auto neutral feature is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information

CAUSE SIGNAL
604 Transmission 2 N/A N/A Transmission Data Erratic Auto_Neutl
Neutral Switch Auto Neutral Intermittent Or _Switch
Enable Switch Incorrect
Error
Proceed to the Auto Neutral Switch Test (See Table 220, page 293).
This section contains diagnostic tips and troubleshooting information related to the auto neutral feature.
292 S08361
TROUBLESHOOTING AUTO NEUTRAL
Auto Neutral Preliminary Check
Table 219 Auto Neutral Preliminary Check
STEP ACTION YES NO

1. Are other switch pack operated Refer to the SWITCH PACK Go to next step.
features inoperative? (J1708 DATA LINK) section for
2. Are any DTCs present in the Refer to the appropriate Go to next step.
TCM? transmission service manual.
3. Are any DTCs present in the Refer to the Diagnostic Trouble Proceed to the Auto Neutral
BC? Codes for specific cause (See Circuit Test (See Table 221,
Auto Neutral Switch Test
NOTE – Prior to testing the lift gate solenoid, inspect two 10 gauge circuits to solenoid for damage.
Table 220 Auto Neutral Switch Test

1. Using the Diamond Signal follows switch Proceed to the Auto Refer to the SWITCH
Logic® Builder (DLB), command. Neutral Circuit Test PACK (J1708 DATA
locate and observe the (See Table 221, page LINK) section for
following signal: 293). further diagnostic
information.
Auto_Neutl_Switch
Operate the auto

neutral switch.
Auto Neutral Circuit Test
Perform the Auto Neutral Switch Test (See Table 220, page 293) prior to performing the Auto Neutral Circuit
Test.
Table 221 Auto Neutral Circuit Test

1. Disconnect the TCM Continuity present. Connect the TCM • Inspect circuits K92,
connector (7150). connector. K92A, and A92 for
open.
Auto neutral switch is Go to next step.
ON. • Inspect the engine / IP
connector (1702), pin
Measure continuity 25 for loose, damaged,
between the TCM or corroded terminals.
connector (7250),
cavity 17 and ground. • Suspect faulty Body
Controller.
2. Remove the auto Continuity present. Go to next step. • Inspect circuits A92
neutral relay (1017). and K92 for open.
S08361 293
AUTO NEUTRAL TROUBLESHOOTING
Table 221 Auto Neutral Circuit Test (cont.)

Auto neutral switch is • Inspect the engine /

ON. IP connector (1702),
cavity 6 for loose,
Measure continuity damaged, or corroded
between the auto terminals.
neutral relay (1017),
cavity 85 and ground. • Suspect faulty TCM.
3. Key is in ON position. 12 ± 1.5V Install the auto neutral • Inspect 10A Fuse
relay (1017). F5-E (1014).
Measure voltage
between the auto Go to next step. • Inspect circuit A92J
neutral relay (1017), for open or short.
• Verify ignition relay #2
4. Remove the auto 12 ± 1.5V Install the auto neutral • Inspect circuit A92BC
neutral light relay light relay (1019). for open or short.
(1019).
Go to next step. • Inspect circuit A92JA
Measure voltage for open or short
between the auto between cavity 87 and
neutral light relay cavity 86 of the auto
(1019), cavity 87A and neutral relay (1017).
ground.
• Replace faulty auto
neutral relay (1017).
5. Disconnect the right 12 ± 1.5V Go to next step. • Inspect circuit
bank optional warning A92APA for open
lights connector or short.
(1510).
• Replace faulty auto
Measure voltage neutral light relay
between the right bank (1019).
optional warning lights
connector (1510),
cavity E and ground.
6. Measure voltage 12 ± 1.5V No electrical faults • Inspect ground circuit
between the right bank evident at this time. A92-GR for open.
optional warning lights
connector (1510), • Inspect ground
cavity E and cavity D. adapter (1003) for
loose, damaged, or
corroded terminals.
294 S08361
SYSTEM DESCRIPTION AXLE LOAD MONITOR
15. AXLE LOAD MONITOR

This section contains a general overview of the axle load monitor system.
Overview
The optional axle load monitoring feature displays to the operator the axle load on the front and / or rear axle.
The Electronic Gauge Cluster (EGC) digital display is used to provide this information.
Operation
NOTE – Refer to the Operator's Manual for proper operation of the feature.
This feature consists of the following:
• Front and / or rear axle load sensor

• EGC digital display
This feature reports the axle load in pounds or kilograms on the EGC digital display (depending on customer
preference) with an accuracy of +/- 1000 pounds (454 kilograms). Refer to Electronic Gauge Cluster (EGC) in
the Electrical Troubleshooting Guide for more information.
The feature works if no errors have been detected on the circuits and the key switch is in the ACCESSORY
or IGNITION position.
A vehicle may be equipped with a front axle monitor, rear axle monitor, or both. If equipped with a rear axle
monitor, a pressure transducer in the rear suspension will output a voltage to represent the average pressure
in the suspension. If equipped with a front axle monitor, a pressure transducer in the front suspension will
output a voltage to represent the average pressure in the suspension. These voltages are input to the EGC.
The EGC will send an J1939 drive train data link message to the Body Controller with a calculated pressure
based on the input voltages from the pressure transducer described above. The Body Controller then does its
own axle load calculation and broadcasts the information on the J1939 drive train data link. The rear axle load
consists of both forward rear and rear rear axles when the vehicle has a tandem axle.
If a pressure value cannot be determined for any reason other than the vehicle is not configured for rear
axle load monitoring, then the rear axle pressure value will be displayed as SENSOR FAULT. If the vehicle
is not configured for rear axle load monitoring, then the rear axle pressure value will be displayed as DATA
NOT AVAILABLE.
15.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the axle load
monitor feature.

0595AZK BC PROG, FRONT AXLE LOAD MONITOR Forward Axle
0595AZL BC PROG, REAR AXLE LOAD MONITOR Rear Axle
S08361 295
AXLE LOAD MONITOR USER PROGRAMMABLE PARAMETERS

This section contains all user programmable features directly related to the axle load monitor.
Name: Axle_Load_Filter_Value
• ID: 2509
• Description: This value is used to change the rate at which the displayed axle load will update.
• Access Level: Dealers
• Maximum value: 99
• Minimum value: 1
• Interval: 1
Name: Axle_Load_Front_Error_Offset
• ID: 2508
• Description: This value is used to help calibrate the front axle load monitor. Increase this parameter's value to
add poundage to the displayed weight to match the actual weight on the front axle. Decrease this parameter's
value to remove poundage from the displayed weight to match the actual weight on the front axle.
• Maximum value: 4000 Lbs (1814 Kg)
• Minimum value: 0 Lbs ( 0 Kg)
• Interval: 100 Lbs (45 Kg)
• Default value: 2000 Lbs (907 Kg)
Name: Axle_Load_Rear_Error_Offset
• ID: 2507
• Description: This value is used to help calibrate the rear axle load monitor. Increase this parameter's value to
add poundage to the displayed weight to match the actual weight on the rear axle. Decrease this parameter's
value to remove poundage from the displayed weight to match the actual weight on the rear axle.
NOTE – This value may be different from vehicle to vehicle.
• Maximum value: 20000 Lbs (9071 Kg)
• Minimum value: 0 Lbs ( 0 Kg)
296 S08361
DIAGNOSTIC TROUBLE CODES AXLE LOAD MONITOR
• Interval: 100 Lbs (45 Kg)
• Default value: 1000 Lbs (454 Kg)

The axle load monitor system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.
SPN DESCRIPTION FMI CONN. PIN MESSAGE POSSIBLE LOGICAL

CAUSE SIGNAL
1725 Front Axle 3 1501 8 Fault ON Voltage N/A
Above Analog Input Above
Pressure 2 Above Normal Or
Normal Shorted To
For Axle
Load
Proceed to the Axle Pressure Transducer Circuit Test (See Table 225, page 298).
1725 Front Axle 4 1501 8 Fault ON Voltage N/A
Below Analog Input Below
Pressure 2 Below Normal Or
Normal Shorted To
For Axle
Load
1727 Rear Axle 3 1501 7 Fault ON Voltage N/A
Above Analog Input Above
Pressure 1 Above Normal Or
Normal Shorted To
For Axle
Load
1727 Rear Axle 4 1501 7 Fault ON Voltage N/A
Below Analog Input Below
Pressure 1 Below Normal Or
Normal Shorted To
For Axle
Load
Proceed to the Axle Pressure Transducer Circuit Test (See Table 225, page 298)3.
S08361 297
AXLE LOAD MONITOR TROUBLESHOOTING
This section contains diagnostic tips and troubleshooting information related to the axle load monitor feature.
Axle Load Monitor Preliminary Check
Table 224 Axle Load Monitor Preliminary Check
STEP ACTION YES NO

1. Park the vehicle on a level Check for intermittent and poor Go to next step.
surface. connections.
Key switch is in the ACC or ON

position. The cluster should
display an approximate value
of axle load. Does the feature
operate properly?
2. Are there multiple features Identify and repair condition Go to next step.
malfunctioning that may have causing several features to be
common circuits? inoperative.
3. Are there any active or stored Refer to the MULTIPLEXING Go to next step.
Loss of Communication related (DATA LINKS) section for
DTCs? further diagnostic information.
4. Are there any active or stored Refer to the Diagnostic Trouble Go to next step.
BC DTCs? Codes for specific cause (See
5. Are there any active or stored Refer to the appropriate engine Go to next step.
engine DTCs? diagnostic manual.
6. Does the digital display No problems evident at this Proceed to the Axle Pressure
work properly? (odometer, time. Transducer Circuit Test (See
temperature, and compass Table 225, page 298).
display)
Axle Pressure Transducer Circuit Test
Table 225 Axle Pressure Transducer Circuit Test

1. Axle pressure 5 ± 0.5V Go to next step. Inspect for open or shorts on
transducer harness the axle pressure transducer
connector, cavity B to 5-volt reference circuit between
ground. the appropriate axle pressure
transducer and the Electronic
Gauge Cluster (EGC).
2. Axle pressure 5 ± 0.5V Go to next step. Inspect for open zero volt
transducer harness reference circuit between the
298 S08361
SYSTEM DESCRIPTION WATER-IN-FUEL MONITOR
Table 225 Axle Pressure Transducer Circuit Test (cont.)

connector, cavity B to appropriate axle pressure
A. transducer and the EGC.
3. Axle pressure 5 ± 0.5V Replace Inspect for open or short to
transducer harness appropriate faulty voltage on the axle pressure
connector, cavity B to axle pressure transducer input circuit between
C. transducer. the appropriate axle pressure
transducer and the EGC.
16. WATER-IN-FUEL MONITOR

This section contains a general overview of the Water-In-Fuel (WIF) monitor.
Overview
The WIF sensor detects the presence of water in the fuel filter.
Operation
When water accumulates to an unacceptable level in the fuel filter, the WIF sensor will become grounded. The
water completes the ground path between the probe contacts and the fuel filter housing. The fuel filter housing
is grounded through the fuel filter mounting bracket. When grounded, the Engine Control Module (ECM)
provides the Electronic Gauge Cluster (EGC) a message over the J1939 data link. The EGC will illuminate the
Water-In-Fuel message alerting the operator to drain the fuel-water separator.
16.2. FEATURE CODE

There are no Body Controller feature codes related to the Water-In-Fuel monitor.


The Water-In-Fuel monitor is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.
S08361 299
WATER-IN-FUEL MONITOR TROUBLESHOOTING

CAUSE SIGNAL
97 Water-In-Fuel 4 N/A N/A Water • Short to N/A
Indicator In Fuel ground
Indicator
• Water
Probe
• Body
Controller
Proceed to Water Probe Circuit Test (See Table 228, page 301).
97 Water-In-Fuel 6 N/A N/A Water • Output N/A
Indicator In Fuel overheat
Indicator
• Water
Probe
Proceed to Water Probe Circuit Test (See Table 228, page 301).
This section contains diagnostic tips and troubleshooting information related to the Water-In-Fuel monitor.
NOTE – When diagnosing the Water-In-Fuel (WIF) Sensor, refer to the appropriate engine service manual
and applicable Circuit Diagram manual.
Water-In-Fuel Monitor Preliminary Check
Table 227 Water-In-Fuel Monitor Preliminary Check
STEP ACTION YES NO

2. Are any active or stored DTCs Refer to the Diagnostic Trouble Proceed to Water Probe Circuit
present? Codes for specific cause (See Test (See Table 228, page 301).
300 S08361
TROUBLESHOOTING WATER-IN-FUEL MONITOR
Water Probe Circuit Test
NOTE – Make sure there is no water in the fuel filter prior to performing the Water Probe Circuit Test.
Table 228 Water Probe Circuit Test

1. Disconnect the ECM No continuity. Verify ECM J1939 data Inspect circuits
connector 2 (6019), link communication. K95-GF and K95W
and measure continuity for short to ground.
between cavities 34
and 37. Replace faulty WIF
sensor.
S08361 301
WATER-IN-FUEL MONITOR TROUBLESHOOTING
302 S08361
TABLE OF CONTENTS
TRANSMISSIONS
Table of Contents
1. TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
1.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Transmission Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Eaton UltraShift®® TCM Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Eaton UltraShift® Selector Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Eaton T-Handle Shifter Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Eaton Hybrid TCM Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Allison TCU Circuit Test with IBB Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Allison Shift Selector with IBB Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Allison TCU Circuit Test with I6/V8 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Allison Shifter with I6/V8 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Shifter Ignition Relay Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Park Position Unlock Solenoid Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1.6. BODY CONTROLLER SIGNALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Body Controller Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
S08361 303
TABLE OF CONTENTS
304 S08361
SYSTEM DESCRIPTION TRANSMISSION
1. TRANSMISSION
This section contains a general overview of the transmission as it relates to the Body Controller (BC).
Overview
The transmission electrical system allows the drive axle to be driven at a speed that matches the desired
vehicle speed. This is accomplished while the engine remains at the most efficient speed. The operator may
shift the transmission between its speed ranges. With automatic transmissions, shifting may be through
electronic means. The operator has the ability to place and hold the transmission in any desired gear range.
Automatic or automated transmissions also inform the operator of the current or selected gear range. This
display is commonly referred to as the PRNDL (Park-Reverse-Neutral-Drive-Low), although not all of these
ranges may be available on every transmission. The transmission control module (TCM) works with other
electronic control modules such as the engine control module (ECM) to optimize the shifting process. The
Body Controller and the Electronic Gauge Cluster (EGC) are also used for transmission related functionality
discussed further in this section.
NOTE – Transmission electrical diagnostics in this section are limited to power and data link circuits,
some optional transmission related features, and respective Body Controller signals. Refer to the
appropriate transmission diagnostic manual for additional transmission diagnostic information and
diagnostic codes set by the TCM.
Operation
The TCM and the shift selector receive fused 12-volt ignition supply from the ignition relay and fused 12-volt
battery supply directly from the battery.
The BC, ECM, TCM, and Electronic Gauge Cluster (EGC) communicate on the SAE J1939 drive train data link
for transmission related functionality. The shifter communicates on a proprietary data link with the TCM for
shifting and directional signals.
Automatic Transmission
The BC monitors the current gear position from the TCM as an interlock. The EGC monitors TCM messages
to display warning lights such as range inhibited and indications in the digital display (such as shift indicator
and gear display). The RANGE INHIBITED warning lamp located in the EGC will activate if another feature
is preventing the vehicle from being shifted. The EGC will also indicate improper transmission operation or
operating conditions to the operator by means of the amber warning light (AWL) and the digital display. Refer
to the ELECTRONIC GAUGE CLUSTER section for warning light operation or to the appropriate transmission
diagnostic manual for more diagnostic information.
Manual Transmission
The BC broadcasts the clutch switch status on the 1939 data link.
Refer to the appropriate transmission diagnostic troubleshooting manual for detailed transmission functionality
and related diagnostics.
Refer to the Operator’s Manual for information about operating the transmission.
Refer to the applicable Circuit Diagram manual for a visual representation of the transmission circuits.
S08361 305
TRANSMISSION FEATURE CODE
1.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the transmission.

0595AEL BC PROG, PRNDL with 1000/2000 5 SPD Transmission with park pawl and
shifter interlock
0595AET BC PROG, PRNDL with 1000/2000 5 SPD Transmission no power park or park
pawl
0595AEU BC PROG, PRNDL with 3000/4000 5 and 6 SPD Transmission
0595AEV BC PROG, PRNDL with 1000/2000 5 SPD Transmission with power park and
shifter interlock
0595BBH BC PROG, PRNDL No PRNDL with 1000/2000 6 SPD Transmission no power
park or park pawl
0595BBJ BC PROG, PRNDL No PRNDL with 1000/2000 6 SPD Transmission with power
park and shifter interlock
0595BPD BC PROG, PRNDL With 1000/2000 6 SPD Transmission no power park or park
pawl
0595BPE BC PROG, PRNDL With 1000/2000 6 SPD Transmission with park pawl and
shifter interlock
0595BPG BC PROG, PRNDL With 1000/2000 6 SPD Transmission with power park and
shifter interlock
0595BPK BC PROG, PRNDL With 1000/2000 6 SPD Transmission with sixth-gear disable,
park pawl, and shifter interlock
0595BPM BC PROG, PRNDL With 1000/2000 6 SPD Transmission with sixth-gear disable,
power park, and shifter interlock
0595BPL BC PROG, PRNDL With 1000/2000 6 SPD Transmission with sixth-gear disable,
no power park, no park pawl
0595ADR BC PROG, PRNDL No PRNDL, Manual Transmission
0595AHJ BC PROG, TRANSMISSION RETARDER
0595AND BC PROG, ECONOMY MODE LIGHT 95 for Allison Transmissions
0595BJK BC PROG, RANGE INHIBITED WARN light 2010 for 1000/2000/3000/4000
Allison Gen 4 Transmission
0595BMH BC PROG, TRANS HILL START AID for UltraShift®® Plus Transmission

There are no Body Controller programmable parameters related to the transmission. Refer to the appropriate
transmission documentation for applicable programmable parameters in the TCM.

Diagnostic Trouble Codes (DTC) in this section are set by the Body Controller (BC).
306 S08361
DIAGNOSTIC TROUBLE CODES TRANSMISSION
Refer to the appropriate supplier documentation for fault codes set by any of the following:
• Engine Control Module (ECM)

• Transmission Control Module (TCM)
• Shift Selector Module

CAUSE SIGNAL
2003 Source Address 3 9 N/A N/A Loss Of Abnormal N/A
Data Link Update Rate
From The
Transmission
Controller
Proceed to the appropriate transmission module circuit test.
1709 Transmission 5 1601 E3 PRNDL Current PRNDL_Trans
Controller Power Psuedo Below _Pseudo
Relay Ignition Normal Or _Ignition_Cmd
Relay Driver Open Circuit
Output Under
Current Or
Open Circuit
Proceed to the Shifter Ignition Relay Circuit Test (See Table 244, page 324).
1709 Transmission 6 1601 E3 PRNDL Current PRNDL_Trans
Controller Power Pseudo Above _Pseudo
Relay Ignition Relay Normal Or _Ignition_Cmd
Driver Output Grounded
Over Current Circuit
Proceed to the Shifter Ignition Relay Circuit Test (See Table 244, page 324).
2819 Park Interlock 5 1601 E8 Park Position Current Park_Pos_
Error Interlock Below Unlock_
Solenoid Normal Or Solenoid_Cmd
Output Open Circuit
Is Under
Current Or
Open Circuit
Proceed to the Park Position Unlock Solenoid Test (See Table 245, page 325).
2819 Park Interlock 6 1601 E8 Park Position Current Park_Pos_

Error Interlock Above Unlock_
Solenoid Normal Or Solenoid_Cmd
Output Is Grounded
Over Current Circuit
Proceed to the Park Position Unlock Solenoid Test (See Table 245, page 325).
S08361 307
TRANSMISSION TROUBLESHOOTING
This section contains diagnostic tips and troubleshooting information related to the transmission.
NOTE – Refer to the ELECTRONIC GAUGE CLUSTER section for diagnostic information associated with
the speedometer and transmission oil temperature / pressure gauge.
Transmission Preliminary Check
Table 231 Transmission Preliminary Check
STEP ACTION YES NO

1. Does the transmission operate • Fault may be intermittent. Go to next step.
properly?
• Inspect electrical connectors
A road test may be necessary. for loose, damaged, or corroded
terminals.
• Refer to the Diagnostic

Trouble Codes for specific
cause (See Table 230, page
307).
2. Are there multiple features Identify and repair condition Go to next step.
malfunctioning that may have causing several features to be
common circuits? inoperative.
3. Are there any active or stored Proceed to the appropriate Go to next step.
loss of communication DTCs transmission module circuit
related to the transmission? test.
4. Are there any other active • Refer to the Diagnostic Go to next step.
or previously active DTCs Trouble Codes for specific
associated specifically with the cause (See Table 230, page
transmission or shift selector? 307).
• Refer to the applicable

transmission diagnostic manual
for more information.
5. Is there an amber warning lamp • Refer to the Diagnostic Go to next step.
illuminated in conjunction with a Trouble Codes for specific
transmission diagnostic related cause (See Table 230, page
text message in the gauge 307).
cluster?
• Refer to the applicable
transmission diagnostic manual
308 S08361
TROUBLESHOOTING TRANSMISSION
Table 231 Transmission Preliminary Check (cont.)

STEP ACTION YES NO
6. Does the engine crank when Go to next step. • Refer to the STARTING AND
the transmission is in neutral? CHARGING section for further
• Fault related to the neutral

signal circuit.
• Problem with the starter or

related circuits.
8. Are there general problems Refer to the applicable Go to next step.
related to shifting? transmission diagnostic manual
9. Is there an issue with the shifter Proceed to the appropriate Go to next step.
powering up? shifter / selector circuit test.
10. Do the backup lights come Go to next step. • There is a problem related to
on when the transmission is the backup light switch.
shifted into reverse?
• There is a problem related to
the backup light circuits or the
light itself.
• Refer to the Lighting

section for further diagnostic
information.
11. Is the RANGE INHIBITED • There is a problem in the Proceed to the appropriate
indicator in the Electronic transmission, or the auto transmission control module
Gauge Cluster (EGC) neutral feature is preventing circuit test.
illuminated? the transmission from being
shifted.
• (If equipped) The wheelchair

lift interlock feature is
preventing the transmission
from being shifted.
Eaton UltraShift®® TCM Circuit Test
NOTE – Refer to the appropriate transmission diagnostic troubleshooting manual for detailed
transmission functionality and related diagnostics.
S08361 309
Table 232 Eaton UltraShift® TCM Circuit Test

1. Disconnect the Eaton Gen 3 12 ± 1.5V Go to next step. • Inspect 10A Fuse
TCM connector (7909). F4-C (1013).
Key is in ON position. • Inspect circuits A13D

and K13D for open or
the Eaton Gen 3 TCM
connector (7909), cavity 35 • Inspect the engine /
and ground. IP connector (1702),
pin 8 for loose,
terminals.
cavity 35 and cavity 36 K11-GAM for open.
of the Eaton Gen 3 TCM
connector (7909). • Inspect the engine
block left side ground
(9260).
3. Measure voltage at the Approximately Go to next step. • Inspect the CAN
Eaton Gen 3 TCM connector 2.5V (+) circuit for open or
(7909), cavity 28 to ground short.
• If voltage is 0 volts,
open.
4. Measure voltage at the Approximately Go to next step. • Inspect the CAN
Eaton Gen 3 TCM connector 2.5V (-) circuit for open or
(7909), cavity 27 to ground. short.
• If voltage is 0 volts,
open.
310 S08361
Table 232 Eaton UltraShift® TCM Circuit Test (cont.)

5. Measure Resistance 60 ± 6 ohms The J1939 data link • If resistance is 120
between cavities 27 and 28 circuit is functional, ohms, the data link
of the Eaton Gen 3 TCM and the TCM is has an open circuit.
connector (7909). communicating on
the Controller Area • Inspect for damaged
Network (CAN). or missing terminating
resistor.
Go to next step
for J1708 data • If resistance is 0
link communication ohms, the data link
testing. circuits are shorted
together.
6. Measure voltage between Approximately Go to next step. • If voltage is 0 volt,
the Eaton Gen 3 TCM 2.5V the J1708 circuit is
connector (7909), cavity 10 shorted to ground or
and ground. open.
7. Measure voltage between Approximately The J1708 data link • If voltage is 0 volt,
the Eaton Gen 3 TCM 2.5V is functional and the J1708 circuit is
connector (7909), cavity 11 communicating. shorted to ground or
and ground. open.
S08361 311
Eaton UltraShift® Selector Circuit Test
NOTE – The Eaton UltraShift® Selector Circuit Test also applies to the Eaton Hybrid Transmission.
Table 233 Eaton UltraShift® Selector Circuit Test

1. Disconnect the Eaton 12 ± 1.5V Go to next step. MaxxForce® 11 and 13:
UltraShift® selector
connector (7905). • Inspect circuit K92ER for
open or short.
• Inspect circuit A92YB for
Measure voltage between open or short.
the Eaton UltraShift®
selector (7905), cavity C1 • Inspect the IP / engine
and ground. connector (1702), pin 31 for
terminals.
MaxxForce® DT, 9, and 10:
• Inspect circuit K92YB for

open or short.
• Inspect circuit A92YB for

open or short.
• Inspect the IP / engine

connector (1702), pin 31 for
terminals.
312 S08361
Table 233 Eaton UltraShift® Selector Circuit Test (cont.)

2. Measure voltage between 12 ± 1.5V Go to next step. MaxxForce® 11 and 13:
the Eaton UltraShift®
selector (7905), cavity C1 • Inspect ground circuit
and cavity J3. A92AE for open.

K92J/K92A for open.

terminals.
MaxxForce® DT, 9, and 10:

A92AE for open.

terminals.
3. Measure voltage between Approximately Go to next step. • Inspect the CAN (+) circuit
the Eaton UltraShift® 2.5V for open or short.
selector (7905), cavity F1
and ground • If voltage is 0 volts, the
J1939 circuit is shorted to
ground or open.

to voltage.
4. Measure voltage between Approximately Go to next step. • Inspect the CAN (-) circuit
the Eaton UltraShift® 2.5V for open or short.
selector (7905), cavity F2
and ground. • If voltage is 0 volts, the
ground or open.

to voltage.
S08361 313
Table 233 Eaton UltraShift® Selector Circuit Test (cont.)

5. Measure resistance 60 ± 6 ohms The J1939 data link • If resistance is 120 ohms,
between cavities F1 and circuit is functional the data link has an open
F2 of the Eaton UltraShift® and the selector is circuit.
selector (7905). communicating on
the Controller Area • Inspect for damaged or
Network (CAN). missing terminating resistor.
• If resistance is 0 ohms, the

together.
Table 234 Eaton UltraShift® Selector Lighting Circuit Test

1. Disconnect the Eaton 12 ± 1.5V Suspect faulty • Inspect circuit A62P for
UltraShift® selector selector. open or short.
connector (7905).
• Inspect the panel light
Measure voltage between feed adapter (1002) for
the Eaton UltraShift® loose, damaged, or corroded
selector connector (7905), terminals.
cavity B3 and ground.
NOTE – If other panel lights
Headlight switch is in ON are inoperative, suspect
position. faulty Electronic Gauge
Cluster (EGC) or headlight
switch input.
314 S08361
Eaton T-Handle Shifter Circuit Test
Table 235 Eaton T-Handle Shifter Circuit Test

1. Disconnect the Eaton 12 ± 1.5V Go to next step. • Inspect circuit A92YD for
T-Handle shifter connector open or short.
(7900).
• Ensure proper Eaton Gen3
Key is in ON position. TCM operation.

the Eaton T-Handle shifter
connector (7900), cavity A
and ground.
2. Measure resistance <1 ohm Suspect faulty park • Inspect circuit A92YE for
between the Eaton T-Handle solenoid / shifter. open or short.
shifter (7900), cavity B and
ground. • Inspect the BC #J4
connector (1601), pin E8 for
Brake pedal is depressed. loose, damaged, or corroded
terminals.
Table 236 Eaton T-Handle Shifter Lighting Circuit Test

1. Disconnect the Eaton 12 ± 1.5V Go to next step. • Inspect circuit A62P for
T-Handle shifter open or short.
connector (7900).
Measure voltage feed adapter (1002) for
between the Eaton loose, damaged, or corroded
T-Handle shifter terminals.
connector (7900),
cavity C and ground. NOTE – If other panel lights
are inoperative, suspect
faulty Electronic Gauge
switch input.
2. Measure voltage 12 ± 1.5V Suspect faulty • Inspect ground circuit
between the Eaton shifter. A62-GP for open.
T-Handle shifter
connector (7900), • Inspect ground adapter
cavity C and cavity D. (1003) for loose, damaged,
Eaton Hybrid TCM Circuit Test
NOTE – Refer to the appropriate transmission diagnostic troubleshooting manual for detailed
transmission functionality and related diagnostics.
S08361 315
Table 237 Eaton Hybrid TCM Circuit Test

1. Disconnect the Eaton Gen 3 12 ± 1.5V Go to next step. • Inspect the 30A
TCM connector (7909). Transmission ECU Fuse
(9255).
the Eaton Gen 3 TCM • Inspect circuits N14BB,
connector (7909), cavity 38 N92A, and K14AW for open
and ground. or short.
• Inspect the hybrid power and

ground connector (7104A),
pin A for loose, damaged, or
corroded terminals.
(1013).
the Eaton Gen 3 TCM • Inspect circuits A13D and
connector (7909), cavity 35 K13D for open or short.
and ground.
• Inspect the engine / IP
terminals.
3. Measure voltage between 12 ± 1.5V Go to next step. • Inspect ground circuits
cavity 35 and cavity 36 K11-GAM and N92-G for
of the Eaton Gen 3 TCM open.
connector (7909).
• Inspect the hybrid power and
ground connector (7104A),
pin B for loose, damaged, or
corroded terminals.
• Inspect the ECM negative

connector (9260), pin B for
terminals.
the Eaton Gen 3 TCM 2.5V for open or short.
connector (7909), cavity 3
ground or open.

voltage.
316 S08361
Table 237 Eaton Hybrid TCM Circuit Test (cont.)

5. Measure voltage between Approximately Go to next step. • Inspect the CAN (-) circuit for
the Eaton Gen 3 TCM 2.5V open or short.
ground or open.

voltage.
6. Measure resistance 60 ± 6 ohms The J1939 data • If resistance is 120 ohms, the
between cavities 2 and link circuit is data link has an open circuit.
3 of the Eaton Gen 3 TCM functional, and
connector (7909). the TCM is • Inspect for damaged or
communicating missing terminating resistor.
on the Controller
Area Network • If resistance is 0 ohms, the
(CAN). data link circuits are shorted
together.
Go to next step for
J1708 data link
communication
testing.
7. Measure voltage between Approximately Go to next step. • If voltage is 0 volt, the J1708
the Eaton Gen 3 TCM 2.5V circuit is shorted to ground or
connector (7909), cavity 10 open.
and ground.
voltage.
8. Measure voltage between Approximately The J1708 • If voltage is 0 volt, the J1708
the Eaton Gen 3 TCM 2.5V data link is circuit is shorted to ground or
connector (7909), cavity 11 functional and open.
and ground. communicating.
voltage.
Allison TCU Circuit Test with IBB Engine
NOTE – The Allison TCU Circuit Test With IBB Engine should be performed when a MaxxForce® 11 or
MaxxForce® 13 is so equipped.
S08361 317
Table 238 Allison TCU Circuit Test with IBB Engine

1. Disconnect the TCU 12 ± 1.5V Go to next step. • Inspect 10A XMSN ECU
connector (7150). Feed Fuse (9255).
Measure voltage between • Inspect circuits N14BB, N92,

the TCU connector (7150), and K92A170 for open or
cavity 10/70 and ground. short.
• Inspect the clean battery

feed connector (7104), pin
A for loose, damaged, or
corroded terminals.
• Inspect the ECM positive

connector (9260), pin A for
terminals.
2. Measure voltage between 12 ± 1.5V Go to next step. • Inspect ground circuits
cavity 10/70 and cavity N14-G, N92-G, and K92-G for
9/69 of the TCU connector open.
(7150).
• Inspect the ECM negative
terminals.
• Inspect the clean battery

feed connector (7104), pin
B for loose, damaged, or
corroded terminals.
the TCU connector (7150), 2.5V for open or short.
cavity 28 and ground
• If voltage is 0 volts, the
ground or open.

voltage.
318 S08361
Table 238 Allison TCU Circuit Test with IBB Engine (cont.)
the TCU connector (7150), 2.5V for open or short.
• If voltage is 0 volts, the
ground or open.

voltage.
5. Measure resistance 60 ± 6 ohms The J1939 data • If resistance is 120 ohms, the
between cavities 28 and link circuit is data link has an open circuit.
8 of the TCU connector functional, and
(7150). the TCU is • Inspect for damaged or
communicating missing terminating resistor.
on the Controller
Area Network • If resistance is 0 ohms, the
(CAN). data link circuits are shorted
together.
Allison Shift Selector with IBB Engine
NOTE – The Allison Shift Selector Circuit Test should be performed when a MaxxForce® 11 or
MaxxForce® 13 is so equipped.
Table 239 Allison Shift Selector Circuit Test

1. Disconnect the shift 12 ± 1.5V Go to next step. • Inspect 10 Fuse F8-F
selector connector (1017).
(1852A).
• Inspect circuit A92BT for
Measure voltage open or short.
between the shift
selector connector
(1852A), cavity 13 and
ground.
2. Measure voltage 12 ± 1.5V Go to next step. • Inspect ground circuit
between the shift A92-GG for open.
selector connector
(1852A), cavity 13 and • Inspect ground adapter
cavity 5. (1003) for loose, damaged,
S08361 319
Table 239 Allison Shift Selector Circuit Test (cont.)

(1013).
Measure voltage
between the shift • Inspect circuit A92A163 for
selector connector open or short.
ground.
4. Measure voltage Approximately 2.5V Go to next step. • Inspect the CAN (+) circuit
between the shift for open or short.
selector connector
(1852A), cavity 8 and • If voltage is 0 volts, the
ground. J1939 circuit is shorted to
ground or open.

to voltage.
5. Measure voltage Approximately 2.5V Go to next step. • Inspect the CAN (-) circuit
between the shift for open or short.
selector connector
(1852A), cavity 15 and • If voltage is 0 volts, the
ground. J1939 circuit is shorted to
ground or open.

to voltage.
between cavities 8 and circuit is functional, the data link has an open
15 of the shift selector and the selector is circuit.
connector (1852A). communicating on

together.
320 S08361
Table 240 Allison Shift Selector Lighting Circuit Test

1. Disconnect the shift 12 ± 1.5V Suspect faulty • Inspect circuit A62BE for
selector connector shifter. open or short.
(1852A).
Measure voltage feed adapter (1002) for
between the shift loose, damaged, or corroded
selector connector terminals.
ground. NOTE – If other panel lights
are inoperative, suspect
Headlight switch ON. faulty Electronic Gauge
Panel dimmer on switch input.
brightest setting.
Allison TCU Circuit Test with I6/V8 Engine
NOTE – The Allison TCU Circuit Test with I6/V8 Engine should be performed when a MaxxForce® 7 or
MaxxForce® DT, 9, and 10 is so equipped.
Table 241 Allison TCU Circuit Test with I6/V8 Engine

1. Disconnect the XMSN 12 ± 1.5V Go to next step. • Inspect 10A ECU Feed
control module connector Fuse (9255).
(7151).
• Inspect circuits N14BB and
Measure voltage between K92B110 for open or short.
the XMSN control module
connector (7151), cavity • Inspect the ECM positive
10/70 and ground. connector (9261), pin B for
terminals.
cavity 10/70 and cavity K92-G for open.
9/69 of the XMSN control
module connector (7151). • Inspect the ECM negative
terminals.
3. Key is in ON position. 12 ± 1.5V Go to next step. Proceed to the Shifter Ignition
Relay Circuit Test (See Table
Measure voltage between 244, page 324).
the XMSN control module
63 and ground.
S08361 321
Table 241 Allison TCU Circuit Test with I6/V8 Engine (cont.)
the XMSN control module 2.5V for open or short.
28 and ground. • If voltage is 0 volts, the
ground or open.

voltage.
the XMSN control module 2.5V for open or short.
ground or open.

voltage.
between cavities 28 and circuit is functional, the data link has an open
8 of the XMSN control and the TCU is circuit.
module connector (7151). communicating on

together.
Allison Shifter with I6/V8 Engine
NOTE – The appropriate Allison Shifter Circuit Test should be performed when a MaxxForce® 7 or
MaxxForce® DT, 9, and 10 is so equipped.
Table 242 Allison Column Mounted Shifter

1. Disconnect the column 12 ± 1.5V Go to next step. • Inspect 10A Fuse F4-C
mounted shifter connector (1013).
(1828).
• Inspect circuit A92A163 for
Key is in ON position. open or short.
Measure voltage between • Verify ignition relay #1

the column mounted (1011/1013) operation.
322 S08361
Table 242 Allison Column Mounted Shifter (cont.)

shifter connector (1828),
cavity C and ground.
the column mounted A92-GG for open.
shifter connector (1828),
cavity C and cavity B. • Inspect ground adapter
3. Measure continuity <1 ohm Suspect faulty • Inspect circuit A92D for
between the column shifter. open or short.
mounted shifter connector
(1828), cavity D and • Inspect the BC #J4
ground. connector (1601), pin E8
corroded terminals.
Table 243 Allison T-Handle Shifter

1. Disconnect the T-handle 12 ± 1.5V Go to next step. • Inspect 10A Fuse F4-C
shifter connector (422F). (1013).
Key is in ON position. • Inspect circuit A82A163 for

open or short.
the T-handle shifter
connector (422F), cavity A
and ground.
2. Key is in ON position. 12 ± 1.5V Suspect faulty • Inspect circuit A92D for
shifter. open.
the T-handle shifter • Inspect the BC #J4
connector (422F), cavity A connector (1601), pin E8
and cavity B. for loose, damaged, or
corroded terminals.
Shifter Ignition Relay Circuit Test
The Body Controller monitors the current and requested gear of the transmission and controls the column
shifter relay (1017). The column shifter relay provides the TCM with ignition sense voltage. The TCM is
normally powered by the ignition relay #1 (1011/1013) when the key is in the ON position. When the key is
in the OFF position and the transmission is not in PARK, the BC will maintain ground path to the column
shifter relay (1017), energizing the relay. When the relay is energized, battery voltage is provided to the
TCM and displays the PRNDL in the Electronic Gauge Cluster (EGC). The EGC will sound an alarm until
the transmission is placed into PARK.
S08361 323
Table 244 Shifter Ignition Relay Circuit Test

1. Remove the column 12 ± 1.5V Go to next step. • Inspect 10A Fuse F4-C
shifter relay (1017). (1013).
Key is in ON position. • Inspect circuit A92FN for

open or short.
the column shifter relay
(1017), cavity 87A and
ground.
2. Measure voltage between 12 ± 1.5V Go to next step. • Inspect 10A Fuse F8-A
the column shifter relay (1017).
ground. • Inspect circuits A92FB and
A92FBA for open or short.
3. Place transmission in any 12 ± 1.5V Install column • Inspect ground circuit
forward or reverse gear. shifter relay (1017). A82RD for open or short.
Key is in OFF position. Go to next step. • Inspect the BC #J4

connector (1601), pin E3
Measure voltage between for loose, damaged, or
cavity 85 and cavity 86 of corroded terminals.
the column shifter relay
(1017).
4. Keep transmission in any 12 ± 1.5V Go to next step. • Inspect circuits A92#163
forward or reverse gear. and K92#163 for open or
short.
Key is in OFF position.
Disconnect the XMSN connector (1702), pin 8 for
control module connector loose, damaged, or corroded
(7151). terminals.
Measure voltage between • Suspect faulty column

the XMSN control module shifter relay (1017).
63 and ground.
5. Place transmission in 12 ± 1.5V No circuit faults • Inspect circuits A92#163
PARK. present. and K92#163 for open or
short.
Measure voltage between connector (1702), pin 8 for
the XMSN control module loose, damaged, or corroded
connector (7151), cavity terminals.
63 and ground.
• Suspect faulty column
shifter relay (1017).
324 S08361
BODY CONTROLLER SIGNALS TRANSMISSION
Park Position Unlock Solenoid Test
Table 245 Park Position Unlock Solenoid Test
STEP ACTION YES NO

1. NOTE – Perform this test if the shift • Test for an open or short Check for feature configuration
selector will not move out of the on circuit A92 between errors by viewing the
park position. the Body Controller #J4 MESSAGES tab in DLB.
connector (1601), pin If no errors are found, consider
• Move the shift selector into the E8 and the shift selector replacing the Body Controller.
PARK position and apply the service module.
brake pedal.
• If the circuit tests okay,
• Monitor the following signals using refer to the appropriate
Diamond Logic® Builder (DLB): transmission diagnostic
manual.
Current_Gear
Brake_Switch
Park_Pos_Unlock_Solenoid_Cmd
• The Current_Gear signal should

indicate that the transmission is
in park. Refer to the appropriate
transmission diagnostic manual if
there is a problem with this signal.
• The Brake_Switch signal should

indicate that the brake pedal is being
applied. Refer to the Lighting section
for further diagnostic information.
• Is the Park_Pos_Unlock_
Solenoid_Cmd signal active?
1.6. BODY CONTROLLER SIGNALS

Certain Body Controller signals are useful when troubleshooting the transmission electrical system. These
signals are available to be viewed and monitored using Diamond Logic® Builder (DLB).
NOTE – The signals shown in the WATCHED tab may vary from what is shown in the table.
S08361 325
TRANSMISSION BODY CONTROLLER SIGNALS
Body Controller Signals
Table 246 Body Controller Signals
BODY CONTROLLER SIGNAL DESCRIPTION

Key_State Digital input from the vehicle wiring to the BC. This signal indicates the
state of the vehicle ignition key. DLB displays the following values (0
= OFF, 1 = Crank, 2 = Acc, 3 = Run) OR (0 = OFF, 1 = Ignition only,
2 = Acc only, 3 = Ignition & Acc).
Park_Brake Digital input from the parking brake switch to the BC. This is used
to determine if the parking brake is engaged. DLB displays the (box
checked) symbol indicating the parking brake is engaged.
Brake_Switch Digital input from the brake switch to the BC. DLB displays the (box
checked) symbol indicating the brake pedal is being applied.
Current_Gear Drivetrain data link input from the Transmission Control Module (TCM)
to the BC that represents the current gear of an automatic transmission.
DLB should display a value of (0), for example, while the transmission
is in neutral.
Trans_Req_Range_ Drivetrain data link input from the TCM to the BC that represents the
Input_Signal requested gear of an automatic transmission. DLB should display a
value of (0), for example, while the transmission is in neutral.
Park_Position_Unlock Digital output from the BC that represents a low side relay driver
_Solenoid solenoid output that will lock / unlock the shifter on an automatic
transmission. DLB displays (box checked) while the BC is actively
supplying ground on the shifter input circuit.
PRNDL_Trans_Pseudo Digital output from the BC to the column shifter relay, which represents
_Ignition_Cmd a low side relay driver output that will keep the PRNDL active in the
EGC for an automatic transmission. DLB displays (box checked) while
the BC is actively supplying ground to the column shifter relay coil
(energizing the relay). The TCM receives 12-volt ignition voltage while
the relay is energized.
Alarm(Cluster)_OnSteady Drive train data link output from the BC to the gauge cluster (EGC).
This signal is used to request the audible alarm in the EGC, warning
the operator that the transmission is not currently in the park position
while the ignition power is off.
326 S08361
TABLE OF CONTENTS
MULTIPLEXING (DATA LINKS)

Table of Contents
1. MULTIPLEXING (DATA LINKS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
1.1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
J1939 Data Link Terminating Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Body Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
J1939 Data Link Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
J1708 Data Link Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
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TABLE OF CONTENTS
328 S08361
DESCRIPTION MULTIPLEXING (DATA LINKS)
1. MULTIPLEXING (DATA LINKS)

1.1. DESCRIPTION
This section contains a general overview of the multiplexing system.
Overview
Multiplexing allows multiple electronic controllers to communicate on a data link.
The data link is a pair of twisted insulated wires that interconnect all of the associated control modules on
the network.
The information transmitted on the network is done in a digital encoded format. Digital means only two states
are used to transmit information, high and low or ON and OFF.
The goal of multiplexing is to reduce cab harness wiring and to simplify circuits. This is accomplished by
using low current data link circuits for communication between cab switches, electrical system controllers,
and the Electronic Gauge Cluster (EGC).
International’s multiplexing uses two types of data links, J1708 and J1939. The J1708 data link is often
referred to as ATA, and J1939 is often referred to as the Controller Area Network (CAN).
Power Train Data Link – J1939
This data link provides a path for communication between the Engine Controller Module (ECM), Transmission
Controller Module (TCM), Anti-Lock Brake System (ABS), Pyrometer Ammeter Module (PAM), Body Controller
(BC), Auxiliary Gauge Switch Pack (AGSP), and the Electronic Gauge Cluster (EGC). It also provides
programming and diagnostic functions.
Body Builder Data Link – J1939
This data link provides a path for communication between the Remote Power Module(s), remote PTO, air
solenoid pack(s), and the BC.
Switch Data Link – J1708
This J1708 data link provides a path for communication between the center panel switch packs, door pods,
and BC.
ATA Data Link – J1708
This is the same J1708 data link (sometimes referred to as ATA) that has been used in the past. This data
link is used almost exclusively for communicating with the engine diagnostic and programming tool to identify
engine electrical system problems or program desired settings controlled by the engine ECM.
Operation
J1939 Data Link (CAN)
• Fastest of the two data links, the J1939 data link transmits at 250 kbit/s.
• This is equipped with two 120 ohm terminating resistors. One resistor will be located inside the cab
and one resistor will be located outside the cab.
S08361 329
MULTIPLEXING (DATA LINKS) TROUBLESHOOTING
• Shielded twisted pair wire. One wire will be CAN_H the other wire will be CAN_L, also referred to as CAN+
and CAN-. Refer to wiring schematic for individual wire information.
• The control modules look at the voltage difference between CAN_H and CAN_L to make an output
determination. This is referred to as differential voltage.
• There is no single controller in charge.
J1708 Data Link
• Transmits at 9600 bps.

• Shielded twisted pair wire. One full twist (360 degrees) every inch.
• The control modules look at the voltage difference between the two wires to make an output / control
determination. This is referred to as differential voltage.
• The J1708 data link has a public data link in which communication between the ECM and ABS module
occurs.
• The data link provides a private switch communication between the BC, Instrument Panel Switches, and
the Door Pods.
• Aftermarket devices cannot be added to the private data link.
Body Controller
The Body Controller (BC) is a body systems computer used to control many of the vehicle's electrical functions.
• After receiving a communication message on the data link or an input voltage from a hard wired
component, the BC will use an internal algorithm to control the desired electrical feature.
• The BC will provide either a high side (+12-volt) or low side (ground) to hard wired outputs. Refer to
electrical schematic for specific system information.
• For some components, the BC provides a 5 volt reference. Numerous components will be tied to a
single 5-volt reference.
• The BC has an internal Zero Volt Reference (ZVR). This is to provide a clean ground to ensure accurate
differential voltage calculations by the BC.
J1939 Data Link Terminating Resistors
NOTE – The following test for the terminating resistors should only be done with the battery
disconnected.
• When data link is active (control modules communicating), CAN_H and CAN_L voltage will be
approximately 5 volt when added together. If both CAN_H and CAN_L have consistent 2.5 volt, there
is no communication on the data link occurring.
• With both 120 ohm terminating resistors connected to the data link, resistance between the two conductors
should read 60 ohms.
• If resistance on the data link is 120 ohms, there is an open circuit or a terminating resistor is missing.
• If resistance is 0 ohms, the two conductors are shorted together.
330 S08361
TROUBLESHOOTING MULTIPLEXING (DATA LINKS)
Open Data Link Circuit
• The vehicle can respond differently depending on where the open circuit is located in the data link.
• The CAN system is designed to have no single controller in charge. Therefore controllers on either side of
the open data link will respond as though there are two separate data links.
• Use diagnostics function located on Diamond Logic Builder (DLB) to view communicating controllers
on the data link.
Shorted Data Link Circuit
• While the data link is active, there should be approximately 2.5 volt on the CAN_H and CAN_L wires.
The voltages will not be the same on both wires.
• If CAN_H is shorted to ground or CAN_L is shorted to battery voltage, network communication will stop.
• If you read battery voltage on data link, there is a short to power in the circuit.
• If you read 0 volts while the network is active, there is a short to ground or an open in the circuit.
• Internal control module failures can stop the entire network from communicating. If there are no harness
problems, disconnect control modules one at a time until network communication returns.
Body Controller
• It is extremely important to verify the BC has ignition voltage, accessory voltage, and proper ground for
operation.
Quick Check for Ground to BC
• Dome light will work with key ON or OFF. With key OFF, check for proper dome light operation by
opening door. If dome light does not turn on, BC may have lost its ground. If dome light turns on, BC
has proper ground.
Quick Check for Ignition and Accessory Voltage to BC
• Windshield wipers should only work with the key ON position. With the key ON position, turn on wipers. If
wipers do not turn on, BC may have lost ignition or accessory power feed. If wipers do turn on, BC
has proper voltage supplied.
Problems on the J1939 data link could be the result of open or short circuits in the backbone, missing or
damaged terminating resistors, interference on the data link, internal shorts, or incorrect output from an
electronic controller connected to the data link.
Utilizing the Diamond Logic Builder (DLB) to view active communication Diagnostic Trouble Codes (DTC)
stored within specific modules can lead to more specific CAN circuit fault locations.
Inspect Terminating Resistor connectors for loose, damaged, or corroded terminals.
Cleaning and applying Dielectric Grease to suspected faulty connections will provide a protective moisture
tight seal that ensures the data link connectors will continue to perform effectively, each time that a data link
connector is separated, applying Dielectric Grease as necessary.
S08361 331
MULTIPLEXING (DATA LINKS) TROUBLESHOOTING

1. Measure voltage Approximately Go to next step. • Inspect the CAN (+) circuit for open
at the Diagnostic 2.5V or short.
Connector (1650),
terminal C to • If voltage is 0 volt, the J1939 circuit
ground. is shorted to ground or open.
• If voltage is ABOVE 5 volts, the

J1939 circuit is shorted to voltage.
2. Measure voltage Approximately Go to next step. • Inspect the CAN (-) circuit for open
at the Diagnostic 2.5V or short.
Connector (1650),
terminal D to • If voltage is 0 volt, the J1939 circuit
ground. is shorted to ground or open.
• If voltage is ABOVE 5 volts, the

J1939 circuit is shorted to voltage.
3. Disconnect battery. 60 ± 6 ohms The J1939 data • If resistance is 120 ohms, the data
link circuit is link has an open circuit.
Measure functional and
Resistance communicating • Inspect for damaged or missing
between terminals on the CAN. terminating resistor.
C and D of
the Diagnostic • If resistance is 0 ohms, the data link
Connector (1650). circuits are shorted together.

1. Measure voltage Approximately Go to next step. • If voltage is 0 volt, the J1708 circuit
at the Diagnostic 2.5V is shorted to ground or open.
Connector (1650),
terminal F to • If voltage is ABOVE 5 volts, the
ground. J1708 circuit is shorted to voltage.
2. Measure voltage Approximately The J1708 • If voltage is 0 volt, the J1708 circuit
at the Diagnostic 2.5V data link is is shorted to ground or open.
Connector (1650), functional and
terminal G to communicating. • If voltage is ABOVE 5 volts, the
ground. J1708 circuit is shorted to voltage.
332 S08361
TABLE OF CONTENTS
12-VOLT POWER DISTRIBUTION AND GROUND

Table of Contents
1. 12-VOLT POWER DISTRIBUTION AND GROUNDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
1.1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Battery Power Distribution Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Accessory Power Distribution Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Accessory Power Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Body Controller Accessory Feed Input Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Ignition Power Distribution Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Ignition Power Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Ground Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
S08361 333
TABLE OF CONTENTS
334 S08361
DESCRIPTION 12-VOLT POWER DISTRIBUTION AND GROUNDS
1. 12-VOLT POWER DISTRIBUTION AND GROUNDS

1.1. DESCRIPTION
This section contains a general overview of battery power and ground circuits.
Overview
Vehicle batteries are used to provide electrical energy to various vehicle systems.
Power distribution can be broken into three sections for diagnosis:
• Battery Power Distribution

• Accessory Power Distribution
• Ignition Power Distribution
Operation
Battery Power Distribution: Supplies electrical energy to certain features at all times regardless of ignition
key position. For example, cigar lighter will operate with ignition switch in OFF or ON position. Refer to Battery
Power Distribution Preliminary Check (See Table 249, page 336).
NOTE – If there is a problem with battery power distribution, it will affect all electrical circuits on vehicle.
Accessory Power Distribution: Supplies electrical energy to certain features when ignition key is in
Accessory (ACC) or ON position. For example, the CB radio power connector will turn on only if ignition key is
in ACC or ON position. Refer to Accessory Power Distribution Check (See Table 250, page 336).
Ignition Power Distribution: Supplies electrical energy to certain features when ignition key is ON position
only. For example, the heated seats will turn on only when ignition key is in ON position. Refer to Ignition
Power Distribution Check (See Table 253, page 339).
Ground Distribution: The frame rail is utilized as ground path for negative battery cable. Refer to Ground
Circuit Test (See Table 255, page 341).
The dash ground studs are connected to frame rail ground. The dash ground studs provide electrical ground
for various electrical features installed on vehicle.
NOTE – Always check battery condition and state of charge before performing electrical troubleshooting.
A faulty or low charged battery will cause electrical features to not operate as designed, and give
incorrect readings while performing electrical tests.
If battery power distribution has failed, there will be problems with all electrical features on vehicle.
If ground distribution has failed, there can be problems with all electrical features on vehicle.
S08361 335
12-VOLT POWER DISTRIBUTION AND GROUNDS TROUBLESHOOTING
Battery Power Distribution Check
Table 249 Battery Power Distribution Preliminary Check
STEP ACTION YES NO

1. Inspect the 200A • Repair or replace battery cables. Go to next step.
Block Type Fuse.
• Replace 200A Block Type Fuse.
Inspect all battery
terminals and
cables for loose,
damaged, or
corroded terminals.
Are any faults

present with 200A
Fuse or cable to
battery?
2. Will starter crank the • No circuit faults present between • Failed battery or batteries.
engine? battery, 200A Block Type Fuse, and
100A Mega Fuse (1001). • Damaged, corroded, or loose
battery cables at starter terminal.
• Refer to the applicable Circuit
Diagram manual to isolate faulty • Faulty battery ground.
power circuit.
• Refer to the applicable Circuit
Diagram manual's 12-VOLT POWER
DISTRIBUTION, GROUNDS, DATA
BUS AND ELECTRICAL SYSTEM
CONTROLLER section.
Accessory Power Distribution Preliminary Check
Table 250 Accessory Power Distribution Check
STEP ACTION YES NO

1. Key is in ACC Proceed to the Accessory Power Refer to individual feature
position. Circuit Test (See Table 251, page troubleshooting in this manual
337). for failed feature.
Are all features
related to accessory NOTE – If more than one but
power inoperative? not all features have failed, use
circuit diagrams to find common
wires and connections for failed
features.
336 S08361
TROUBLESHOOTING 12-VOLT POWER DISTRIBUTION AND GROUNDS
Accessory Power Circuit Test
Table 251 Accessory Power Circuit Test

1. Key is in OFF position. 12 ± 1.5V Go to next step. Inspect circuits A14PB, A14P, and
A14 for open or short.
10A Fuse F3-A (1012),
cavity D1 and ground.
2. Key is in OFF position. 12 ± 1.5V Go to next step. • Inspect 10A Fuse F3-A (1012).
Disconnect key switch • Inspect circuit A15 for open or

connector (1100). short.

the key switch connector
ground.
3. Connect key switch 12 ± 1.5V Go to next step. Replace faulty key switch.
connector (1100).

the Key Switch connector
(1100), pin C to ground.
NOTE – It may be
necessary to probe the
key switch connector
(1100). Caution must
be used not to damage
connector terminals.
4. Remove accessory relay 12 ± 1.5V Go to next step. Inspect circuit A12A and A12 for
#1 (1013/1011). open or short.
Key is in ACC position. NOTE – Circuit A12 provides

the BC with a accessory power
Measure voltage between input signal.
the accessory relay #1
(1011/1013), cavity 86 and
ground.
S08361 337
Table 251 Accessory Power Circuit Test (cont.)

5. Key is in any position. 12 ± 1.5V Go to next step. Inspect circuits A14MD and A14M
for open or short.
the accessory relay #1
(1011/1013), cavity 30 and
ground.
6. Key is in any position. 12 ± 1.5V • Inspect fuse • Inspect ground circuit A12-G for
for specific open or short.
Measure voltage between failed accessory
cavity 30 and cavity 85 powered • Inspect ground adapter (1006)
of the accessory relay #1 feature. for loose, damaged, or corroded
(1013/1011). terminals.
• Replace faulty
accessory relay
(1013/1011).
Body Controller Accessory Feed Input Circuit Test
Perform the Accessory Power Circuit Test (See Table 251, page 337) prior to checking accessory voltage input
at the Body Controller.
Table 252 Body Controller Accessory Feed Input Circuit Test

1. Key is in ACC position. 12 ± 1.5V Go to next step. Inspect circuit A12B for open or
short.
5A Fuse F4-J (1013),
cavity A1 and ground.
2. Disconnect the Body 12 ± 1.5V Suspect faulty • Inspect 5A Fuse F4-J (1013).
Controller (BC) #J3 BC.
connector (1600). • Inspect circuit A12C for open or
short.
Measure voltage between (1600) for loose, damaged, or
the BC #J3 connector corroded terminals.
(1600), cavity A1 and
ground.
338 S08361
Ignition Power Distribution Preliminary Check
Table 253 Ignition Power Distribution Check
STEP ACTION YES NO

1. Key is in ON position. Proceed to the Ignition • Not all ignition features are
Power Circuit Test (See inoperative.
Are all features related to Table 254, page 339).
ignition power inoperative? • Refer to individual feature
troubleshooting in this manual for
failed feature.
NOTE – If more than one but not

all features have failed, use circuit
diagrams to find common wires
and connections for failed features.
Ignition Power Circuit Test
NOTE – Refer to specific circuit diagram for Theft Deterrent and Remote Start / Stop components related
to the Ignition system.
Table 254 Ignition Power Circuit Test

1. Key is in OFF position. 12 ± 1.5V Go to next step. Inspect circuit A14PB for open or
short.
10A Fuse F3-A (1012),
cavity D1 and ground.
2. Key is in OFF position. 12 ± 1.5V Go to next step. • Inspect 10A Fuse F3-A (1012).
Disconnect key switch • Inspect circuit A15 for open or

connector (1100). short.

the key switch connector
(1100M), cavity A and
ground.
S08361 339
Table 254 Ignition Power Circuit Test (cont.)

3. Connect key switch 12 ± 1.5V Go to next step. Replace faulty key switch.
connector (1100).

the key switch (1100), pin D
and ground.
NOTE – It may be
necessary to probe the
key switch connector
(1100). Caution must
be used not to damage
connector terminals.
4. Remove ignition relay #1 12 ± 1.5V Go to next step. Inspect circuit A13FN for open or
(1011/1013). short.
Key is in ON position. NOTE – Circuits A13FN and

A13FD provide switched voltage
Measure voltage to all ignition relays.
between ignition relay
#1 (1011/1013), cavity 85
and ground.
5. Key is in ON position. 12 ± 1.5V Go to next step. Inspect circuits A14JB , A14J, and
A14 for open or short from battery
Measure voltage 100A Mega Fuse.
between ignition relay
#1 (1011/1013), cavity 30
and ground.
6. Key is in ON position. 12 ± 1.5V Replace faulty • Inspect ground circuit A13-GF
relay. for open or short.
Measure voltage at ignition
relay #1 (1011/1013), NOTE – If • Inspect Ground Adapter (1006)
between cavities 30 and more than for loose, damaged, or corroded
86. one feature terminals.
has failed,
use circuit NOTE – Ground circuit A13-GF
diagrams to provides a ground path for all
find common Ignition Relays.
wires and
connections
for failed
features.
340 S08361
Ground Circuit Test
Table 255 Ground Circuit Test

1. Key is in ON position. 0.1V or less Go to next step. Inspect for loose, damaged, or
corroded connections between
Measure voltage drop the negative battery cable and
between negative battery chassis ground.
terminal and left side of
frame rail.
2. Key is in ON position. 0.1V or less Refer to the Inspect for loose, damaged, or
troubleshooting corroded connections between
Measure voltage drop section of the chassis ground cable and cab
between chassis ground specific ground stud.
and cab ground stud. inoperative
feature. NOTE – If more than one feature
has failed, use circuit diagrams
to find common grounds and
connections for failed features.
S08361 341
342 S08361
TABLE OF CONTENTS
FANS AND ENGINE ACCESSORIES

Table of Contents
1. FAN SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
1.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Fan System Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Fan Override Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
2. COMPRESSION / EXHAUST BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
2.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Compression / Exhaust Brake Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Compression / Exhaust Brake Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3. AFTERTREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Aftertreatment Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Inhibit Regeneration Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Parked Regeneration Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Warning Lamp Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
4. CRUISE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
4.2. FEATURE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Cruise Control Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Cruise Control Switch Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
5. SNOW VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
S08361 343
TABLE OF CONTENTS
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
5.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Snow Valve Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Snow Valve Module Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
344 S08361
SYSTEM DESCRIPTION FAN SYSTEM
1. FAN SYSTEM
This section contains a general overview of the fan system.
Overview
Engine Fan
The engine fan system provides controlled air circulation to the engine area, maintaining operating temperature
specifications at all times.
The Engine Control Module (ECM) monitors engine coolant, intake manifold temperature, and air conditioning
pressure. When any of these systems operate beyond their set parameters, the ECM will control turning the
fan ON by energizing a solenoid to control air pressure to the fan. In the event of a solenoid circuit fault, the
fan will remain on continuously.
Variable Electronic Fan
The variable speed viscous fan is electronically controlled by the ECM. If an increase in fan speed is required,
a lower duty cycle signal is sent from the ECM to the fan connector. The lower duty cycle reduces current to
the fan's control coil. If less fan speed is required, a higher duty cycle signal is sent.
Operation
MaxxForce® 7 and MaxxForce® DT, 9, and 10
The fan relay (1015), cavity 30, and cavity 86 receive constant battery voltage from the engine / melrose
connector (6011). The ECM provides ground signal to the fan relay (1015), cavity 85. Once energized, the fan
relay closes, providing the fan air solenoid and fan clutch voltage. The fan air solenoid and fan clutch are
provided ground by Zero Volt Reference (ZVR) adapter (6747) and the engine block ground (6304A).
The engine fan can be controlled by an instrument panel mounted override switch. The fan override switch is
located in a switch pack and communicates switch position over the J1708 data link to the Body Controller
(BC). The BC requests fan override to the ECM over the J1939 data link.
Refer to the 2010 MaxxForce® DT, 9, and 10 Diagnostic / Troubleshooting Manual or the 2010 MaxxForce®
7 Diagnostic / Troubleshooting Manual.
MaxxForce® 11 and 13
The variable speed fan drive is provided a 12-volt signal from the ECM. Ground is provided by the ECM zero
volt adapter (6707). The ECM provides a Pulse Width Modulated (PWM) signal for fan speed operation. The
engine fan is controlled by an instrument panel mounted override switch. The fan override switch is located in
a switch pack and communicates switch position over the J1708 data link to the Body Controller (BC). The BC
requests fan override to the ECM over the J1939 data link.
Refer to the 2010 MaxxForce® 11 and 13 Diagnostic / Troubleshooting Manual for engine fan diagnostics.
1.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definitions related to the fan system.
S08361 345
FAN SYSTEM USER PROGRAMMABLE PARAMETERS

0595BBB BC PROG, ENGINE FAN OVERRIDE for low air pressure, no switch
0595AYH BC PROG, ENGINE FAN DRIVE variable speed
0595BNY BC PROG, ENGINE FAN WARNING BUZZER
0595BPB BC PROG, ENGINE FAN DRIVE VARIABLE SPEED with On / Off state at low
engine speeds
0595ACW BC PROG, ENGINE FAN OVERRIDE manual switch for automatic fan control

There are no Body Controller related programmable parameters associated with engine fan system.
NOTE – Refer to ServiceMaxx™ Software for cruise control programmable parameters.

The fan system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information given by

CAUSE SIGNAL
986 Requested 2 NA NA Engine Fan Faulty Fan_Ovrd_Switch
Percent Fan Switch Error Switch
Speed Actuator Or
Microswitch
For Engine
Fan Switch
Proceed to Fan Override Switch Test (See Table 259, page 347)
This section contains diagnostic tips and troubleshooting information related to the fan system.
NOTE – Always refer to the applicable Circuit Diagram manual for the latest circuit information.
NOTE – Utilizing the Diamond Logic® Builder (DLB) will be necessary to diagnose faults related to the
fan system.
346 S08361
TROUBLESHOOTING FAN SYSTEM
Fan System Preliminary Check
Table 258 Fan System Preliminary Check
STEP ACTION YES NO

1. Check switch pack operation. • Refer to the SWITCH PACK • Go to next step.
(J1708 DATA LINK) section for
Are other switches further diagnostic information.
malfunctioning?
2. Start engine. • Override switch is operating • Go to next step.
properly.
Operate the fan override switch.
• The switch pack is
Does engine fan operate with communicating with the
override switch? BC over the J1708 data link.
• The BC is communicating with

the ECM over the J1939 data
link.
2. Using the Diamond Logic® • Proceed to Diagnostic Trouble • Condition may not be due to a
Builder (DLB), check for DTCs. Codes for specific cause (See faulty switch or Body Controller
Table 257, page 346). (BC) operation.
Are any stored or active DTCs
present? • Refer to the appropriate
engine diagnostic /
troubleshooting manual for
Fan Override Switch Test
fan system.
Table 259 Fan Override Switch Test

1. Using the Diamond Signal • Body Controller is • Verify J1708 data link
Logic® Builder (DLB), follows switch receiving signal over the communication.
locate and observe the command. J1708 data link.
following signal: • Suspect faulty switch.
• Verify J1939 data link
Fan_Ovrd_ communication between • Refer to the SWITCH
Switch the BC and Engine Control PACKS (J1708 DATA
Module (ECM). LINK) section for further
Operate the fan diagnostic information.
override switch. • Refer to specific engine
manual for fan system
troubleshooting.
S08361 347
COMPRESSION / EXHAUST BRAKE SYSTEM DESCRIPTION
2. COMPRESSION / EXHAUST BRAKE

This section contains a general overview of the compression / exhaust brake system.
Overview
Compression Brake
The compression brake, also called an engine brake, uses combustion chamber pressures to allow the engine
to rotate freely or to restrict engine rotation. The operator can adjust the compression brake operation with a
three-stage rocker switch located in the switch pack.
Exhaust Brake
The exhaust brake uses exhaust to provide back pressure in cylinders, slowing the engine down. The exhaust
brake provides improved braking performance and fuel efficiency. The exhaust brake feature is enabled with
an instrument panel mounted switch located in the switch pack. The switch packs communicate switch position
to the Body Controller (BC) over the J1708 data link.
Operation
Compression Brake
When the compression brake switch in the cab is activated, the switch pack will communicate with the Body
Controller (BC) on the J1708 data link. The BC will send a J1939 message to the Engine Control Module
(ECM) requesting that the engine retarder be enabled. The ECM determines when the compression brake
relay is energized. When the relay energizes, air pressure will be applied to the compression brake closing a
valve and restricting combustion chamber pressure flow.
Exhaust Brake
The in-cab exhaust brake switch provides an input to the BC over the J1708 data link. When the switch
command is ON, the BC checks engine brake interlocks. If interlocks have been met, the BC sends a J1939
data link request to the ECM to activate the exhaust brake. The exhaust brake switch indicator is used to
indicate the status of the exhaust brake electrical system.
2.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the compression /
exhaust brake feature.

0595AZD BC PROG, ENGINE COMPRESSION BRAKE with variable and programmable
levels; located in switch pack
0595AGC BC PROG, ENGINE EXHAUST BRAKE
348 S08361
USER PROGRAMMABLE PARAMETERS COMPRESSION / EXHAUST BRAKE

There are no Body Controller user programmable parameters associated with the compression / exhaust
brake feature.
NOTE – Refer to ServiceMaxx™ Software for compression or exhaust brake programmable parameters.

The compression / exhaust brake system is able to set Diagnostic Trouble Codes (DTC) when specific faults
occur. Information given by the DTC can aid in the diagnosis of the problem.

CAUSE SIGNAL
3987 Compression 5 1601 E4 Compression Circuit Below Comp_Brake_
Brake Enable Brake Normal Or LED_Ind_Cmd
Switch Indicator Open Circuit
Indicator Lamp Output
Is Under
Current Or
Open Circuit
Proceed to the Compression Brake Switch Test (See Table 263, page 350).
3987 Compression 6 1601 E4 Compression Current Below Comp_Brake_
Brake Enable Brake Normal Or LED_Ind_Cmd
Switch Indicator Grounded
Indicator Lamp Is Over Circuit
Current Or
Grounded
Circuit
Proceed to the Compression Brake Switch Test (See Table 263, page 350).
4000 Engine 2 N/A N/A Retarder Data Erratic Exhaust_Brake
Exhaust Brake Enable-Brake Intermittent Or _Switch
Enable Switch Assist On / Incorrect
Off Switch
Failure
Refer to the SWITCH PACKS (J1708 DATA LINK) section for further diagnostic information.
This section contains diagnostic tips and troubleshooting information related to the compression / exhaust
brake system.
S08361 349
AFTERTREATMENT SYSTEM DESCRIPTION
Compression / Exhaust Brake Preliminary Check
Table 262 Compression / Exhaust Brake Preliminary Check
STEP ACTION YES NO

1. Road test vehicle and verify the • No faults evident at this time. Go to next step.
compression / exhaust brake is
operational. • Check for DTCs.
Does the compression / exhaust

brake operate properly?
2. Using the Diamond Logic® Refer to the Diagnostic Trouble Refer to the appropriate engine
Builder (DLB), check for DTCs. Codes for specific cause (See diagnostic / troubleshooting
Table 261, page 349). manual for further diagnostic
Are any stored or active DTCs information.
present?
Compression / Exhaust Brake Switch Test
compression brake system.
Table 263 Compression Brake Switch Test

1. Using the Diamond Signal follows rocker • Compression / • Faulty switch.
Logic® Builder (DLB), switch position. Exhaust brake switch
select the CENTER functioning properly. • Faulty switch pack or
PANEL tab. J1708 data link circuit.
• Switch pack is
Locate and observe communicating to • Refer to the SWITCH
the compression brake the BC on the J1708 PACK (J1708 DATA
switch. data link. LINK) section for
further diagnostic
Move the compression • Verify BC J1939 information.
brake rocker switch communication to the
to each position and ECM.
observe the center panel
display.
3. AFTERTREATMENT
This section contains a general overview of the aftertreatment system.
Overview
The aftertreatment system monitors the amount of particulate matter contained in the vehicle's exhaust gas.
The Diesel Particulate Filter (DPF) traps the particulate matter. A regeneration process is used to burn off the
particulate matter in the DPF. This system is utilized to maintain emission regulations.
350 S08361
SYSTEM DESCRIPTION AFTERTREATMENT
The Engine Control Module (ECM) controls the aftertreatment system. Therefore, discussion in this section is
limited to the Body Controller’s (BC) interface to the aftertreatment system.
Operation
The parked regeneration and inhibit regeneration switches can be located either in the lower right portion of
the Electronic Gauge Cluster (EGC) or in a switch pack, depending on the vehicle configuration. The High
Exhaust System Temperature (HEST) and Diesel Particulate Filter (DPF) warning lights are located in a
hardwired warning light four pack within the EGC.
The Parked Regeneration switch is used to request regeneration of the DPF. The Inhibit Regeneration switch
is used to prevent DPF regeneration. These switches provide inputs to the Body Controller (BC).
The BC sends the appropriate requests to the Engine Control Module (ECM) for parked regeneration or
inhibit regeneration.
NOTE – The actual control of the aftertreatment system is performed by the ECM. Refer to the appropriate
engine diagnostic / troubleshooting manual for further diagnostic information.
The following conditions must be true for parked regeneration:
Parked Regeneration
• The Parked Regeneration switch is pressed.

• The Parked Regeneration switch is in a good status.
• The vehicle speed is less than 4 MPH (6 KM/H).
• The key switch is in the ON position.
• Regeneration is permitted by ECM.
• The J1939 data link is operational and communicating.
• The Inhibit Regeneration function is NOT requested and the switch is in a good status.
The following conditions must be true for regeneration to be inhibited.
Inhibit Regeneration
The BC will request inhibit regeneration only if all of the following conditions are true:
• The key is in the ON position.

• The Inhibit Regeneration switch is in the upper ON position.
• The Inhibit Regeneration switch is in a good status.
• The Parked Regeneration switch is NOT requested and the switch is in a good status.
Soot Accumulation Level Indications
This feature will indicate different levels of soot accumulation using a combination of the DPF status warning
lamp, amber warning lamp (if applicable), red stop lamp, audible alarm, and related text messages in the EGC.
S08361 351
AFTERTREATMENT SYSTEM DESCRIPTION
Table 264 Soot Accumulation Level Indications
SOOT ACCUMULATION OPERATOR INDICATOR

Level 0 (Optional) PARKED REGEN AVAILABLE: Appears in the EGC display (2010 emission
engines).
Level 1 (Low) DPF status warning lamp illuminates continuously.
• PARKED REGEN REQUIRED: Appears in the EGC display (2010 emission

engines).
• SEE VISOR FOR INFO (cluster software version 2.2 and above): Appears in
the EGCl display.
NOTE – (2010 emission engines) The digital display screen scrolls

between SEE VISOR FOR INFO and PARKED REGEN REQUIRED.
Level 2 (Moderate) DPF status warning lamp flashes.
• PARKED REGEN REQUIRED: Appears in the EGC display (2010 emission

engines).
• SEE VISOR FOR INFO (cluster software version 2.2 and above): Appears in
the EGC display.

Level 3 (Full) DPF status warning lamp flashes.
• AND (pre-2010 emission engines) the amber warning lamp illuminates

continuously.
• AND PARKED REGEN REQUIRED appears in the EGC display (2010

emission engines).
• AND SEE VISOR INFO (cluster software version 2.2 and above) appears in
the EGC display.
• AND the audible alarm sounds five-short-beeps every minute.

Level 4 (Over-Full) Red Stop Lamp Illuminates.
NOTE – Regeneration • The audible alarm sounds a repetitive one-short-beep while the red stop
cannot be performed at lamp is illuminated.
this level.
NOTE – The red stop lamp, amber warning lamp, and the audible alarm,
are not specific to the aftertreatment system, but activate as a result of a
high level soot accumulation.
352 S08361
FEATURE CODE AFTERTREATMENT
3.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the aftertreatment
system.

0595BJC BC PROG, EXHAUST CLOGGED IND 2010 indicator for clogged diesel
particulate filter in aftertreatment
0595BJD BC PROG, EXHAUST HIGH TEMP 2010 indicator for high exhaust temperatures
0595BJJ BC PROG, ENGINE EXHAUST REGENERATION control and monitoring
0595BMZ BC PROG, PARKED REGEN SWITCH 2010 aftertreatment to allow parked
regen below light level for service use only
0595BJE BC PROG, INHIBIT REGEN SWITCH 2010 latched
0595BJG BC PROG, INHIBIT REGEN SWITCH 2010 momentary

There are no Body Controller related programmable parameters related to the aftertreatment system.
NOTE – Refer to ServiceMaxx® Software for aftertreatment programmable parameters.

The aftertreatment system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur.

CAUSE SIGNAL
2000 Source 19 N/A N/A PTC1 (PGN • ECM Not N/A
Address 0 64892) Not Programmed
Received For
From Engine Aftertreatment
• Faulty ECM
• J1939 Data
Link Failure
Refer to the SWITCH PACK (J1708 DATA LINK) section for further diagnostic information.
3695 Diesel 2 N/A N/A Regen Inhibit Faulty Switch N/A
Particulate Switch Error Actuator Or
Filter Microswitch
Regeneration
Inhibit Switch
S08361 353
AFTERTREATMENT TROUBLESHOOTING

CAUSE SIGNAL
Proceed to the Inhibit Regeneration Switch Test (See Table 268, page 355).
3696 Diesel 5 N/A N/A Open Circuit Open Circuit Regen_Switch_
Particulate In Regen In The Ind_Cmd
Filter Switch Regen Switch
Regeneration Indicator Indicator
Switch Circuit Circuit
Proceed to the Parked Regeneration Switch Test (See Table 269, page 356).
3696 Diesel 6 N/A N/A Over Current Short Circuit Regen_Switch_
Particulate For Parked In Parked Ind_Cmd
Filter Regen Regen Switch
Regeneration Switch Indicator
Switch Indicator
Proceed to the Parked Regeneration Switch Test(See Table 269, page 356).
3696 Diesel 2 N/A N/A Parked Faulty Switch Regen_Switch
Particulate Regen Actuator Or _ON
Filter Switch Error Microswitch
Regeneration For Parked
Switch Regen Switch
Proceed to the Parked Regeneration Switch Test (See Table 269, page 356).
3697 Diesel 5 N/A N/A Particulate Open Circuit Particulate_Trap
Particulate Trap Lamp In Particulate _Ind_Cmd
Filter Lamp Relay Under Trap Lamp
Current Or Circuit
Open Circuit
3697 Diesel 6 N/A N/A Particulate Short To Particulate_Trap
Particulate Trap Lamp Ground In _Ind_Cmd
Filter Lamp Relay Over Particulate
Current Trap Lamp
Circuit
This section contains diagnostic tips and troubleshooting information related to the aftertreatment system.
354 S08361
TROUBLESHOOTING AFTERTREATMENT
Aftertreatment Preliminary Check
Table 267 Aftertreatment Preliminary Check
STEP ACTION YES NO

1. Operate switches located on Refer to the SWITCH PACK Go to next step.
the switch pack. (J1708 DATA LINK) section for
Are multiple switches
inoperative?
2. Are there any active or stored Refer to the Diagnostic Trouble Refer to the appropriate engine
DTCs? Codes for specific cause (See diagnostic / troubleshooting
Table 266, page 353). manual for further diagnostic
information.
Inhibit Regeneration Switch Test
NOTE – The following test can be performed using the Diamond Logic® Builder (DLB) to assist in
diagnosing the inhibit regeneration switch.
NOTE – Verify switch pack operation and J1708 data link communication prior to specific switch tests.
Table 268 Inhibit Regeneration Switch Test

1. Locate and observe Signal follows switch Go to next step. • Suspect faulty switch.
the Regen_Inhibit_ command.
Switch_ON signal. • Refer to the SWITCH
PACKS (J1708 DATA
Press and hold the LINK) section for
inhibit regeneration further diagnostic
switch in the upper ON information.
position.
2. Locate and view the Signal follows switch Go to next step. • Suspect faulty switch.
Regen_Inhibit_ command.
Switch_Cancel signal. • Refer to the SWITCH
PACKS (J1708 DATA
inhibit regeneration further diagnostic
switch in the lower information.
CANCEL position.
3. Place the inhibit Signal follows switch • Inhibit regeneration • Suspect faulty switch.
regeneration switch in command. switch input to the BC
the CENTER position. is functioning properly. • Refer to the SWITCH
PACKS (J1708 DATA
Observe both signals. • Refer to the LINK) section for
appropriate engine further diagnostic
diagnostic / information.
troubleshooting
manual for further
S08361 355
AFTERTREATMENT TROUBLESHOOTING
Parked Regeneration Switch Test
diagnosing the parked regeneration switch.
NOTE – Prior to specific switch tests, verify switch pack operation and J1708 data link communication.
Table 269 Parked Regeneration Switch Test

the Parked_Regen_ command.
Switch_ON signal. • Refer to the SWITCH
PACKS (J1708 DATA
parked regeneration further diagnostic
switch in the upper ON information.
position.
the Parked_Regen_ command.
Switch_Cancel signal. • Refer to the SWITCH
PACKS (J1708 DATA
parked regeneration further diagnostic
switch in the lower information.
CANCEL position.
3. Place the parked Signal follows switch • Parked regeneration • Suspect faulty switch.
regeneration switch in command. switch input to the BC
the CENTER position. is functioning properly. • Refer to the SWITCH
PACKS (J1708 DATA
Observe both signals. • Refer to the LINK) section for
appropriate engine further diagnostic
diagnostic / information.
troubleshooting
manual for further
Warning Lamp Test
diagnosing the aftertreatment system.
Table 270 Warning Lamp Test

1. Locate the The DPF status Go to next step. Refer to Warning
DPF_Status_Warning_ warning lamp is Lamp Test (See
Lamp_Cmd signal. illuminated. Table 12, page 60)
in the ELECTRONIC
Actuate the signal. GAUGE CLUSTER
section to perform the
Warning Lamp Test.
356 S08361
SYSTEM DESCRIPTION CRUISE CONTROL
Table 270 Warning Lamp Test (cont.)

2. Locate the The HEST warning No problems evident Refer to Warning
High_Temp_Exhaust_ lamp is illuminated. with the warning lamp Lamp Test (See
Light signal. operation. Table 12, page 60)
in the ELECTRONIC
Actuate the signal. GAUGE CLUSTER
section to perform the
Warning Lamp Test.
4. CRUISE CONTROL
This section contains a general overview of the cruise control feature.
Overview
Cruise Control
The cruise control system feature works to maintain a selected vehicle speed.
Adaptive Cruise Control
The Adaptive Cruise Control (ACC) feature operates with the vehicle cruise control to maintain a set speed.
The system also intervenes as needed, to help maintain a set following distance behind the forward vehicle,
using a radar sensor mounted to the front of the vehicle. ACC also provides means of safe lane changing,
collision mitigation, and collision alerts.
The ACC system utilizes the vehicle foundation brakes, compression / engine brake, and throttle position to
perform ACC functions.
Operation
Cruise Control
When the cruise control switch is turned ON and the minimum vehicle speed has been reached (this speed
can vary among vehicles):
1. Operation of the cruise control set switch sends a command from the cruise control switch to
the Body Controller (BC).
2. The BC sends a signal across the data link to the Engine Control Module (ECM).
3. The ECM activates the cruise control.
The engine controller governs the operation of the cruise control.
• Vehicle must be moving above the minimum speed for the cruise control to operate.
• Both the brake and clutch switch must be off for cruise control operation.
• Cruise control will deactivate when an Anti-lock Brake System (ABS) event, a traction control event, or
the engine brake is activated.
S08361 357
CRUISE CONTROL FEATURE CODES
• Cruise will also deactivate if there is a loss of communications with the ABS Module.
Adaptive Cruise Control
Bendix® VORAD®, Bendix® Wingman®, and Wabco® OnGuard™ are optional ACC systems that provide
similar functions.
Bendix® VORAD® provides ACC operation through the use of SmartCruise®. SmartCruise® adjusts the
vehicle cruise speed in order to match the speed of detected traffic ahead, allowing the driver to maintain
a safe following distance. VORAD® also provides a Collision Warning System (CWS). The CWS provides
audible and visual alerts to warn the driver when following distances become unsafe. Bendix® BlindSpotter®
also provides side object detection to warn of unsafe lane changes. Cruise control does not need to be on
for Bendix® VORAD® CWS to function.
Bendix® Wingman® Advanced™ provides ACC operation through throttle position, engine brake, and
foundation brakes. Wingman® Advanced™ provides audible and visual alerts when road obstructions are
detected. Wingman® Advanced™ also provides collision mitigation to alert and intervene when a possible
collision is detected. Cruise control does not need to be on for Wingman® Advanced™ collision mitigation
to intervene.
Wabco® OnGuard™ provides ACC operation through throttle position, engine brake, and foundation brakes.
OnGuard™ provides audible and visual alerts when an unsafe following distance or possible collision is
detected. OnGuard™ also provides a CWS to alert the driver when a possible collision is detected. Cruise
control does not need to be on for OnGuard™ CWS to intervene
4.2. FEATURE CODES

This section contains the available feature codes related to the cruise control system.

0595AAP BC PROG, CRUISE CONTROL ON STEERING WHEEL
0595BPC BC PROG, CRUISE SWITCH DISABLE with park brake set

There are no user programmable parameters associated with the cruise control and ACC feature.
NOTE – Refer to ServiceMaxx® Software for cruise control programmable parameters.

The cruise control is able to set Diagnostic Trouble Codes (DTC) when a fault occurs. Information given by
358 S08361
TROUBLESHOOTING CRUISE CONTROL

CAUSE SIGNAL
596 Cruise Control 0 1600 B16 Cruise Control • Shorted High Or Cruise_Switch_
Enable Switch Switch Open In Cruise Raw_Signal
Reading Control Switches
Above Normal Circuit
Range
• Defective Cruise
Control Switch
Proceed to the Cruise Control Preliminary Check (See Table 273, page 360).
596 Cruise Control 1 1600 B16 Cruise Control • Short To Ground Cruise_Switch_
Enable Switch Switch In Cruise Control Raw_Signal
Reading Switches Circuit
Below Normal
Range • Defective Cruise
Control Switch
BUS_Cruise_
Cruise Control Data Erratic On_Switch
Cruise Control
596 2 N/A N/A Enable Switch Intermittent Or
Enable Switch
Error Incorrect Cruise_Switch_
Raw_Signal
Cruise SET /
Data Erratic
Cruise Control Resume Panel BUS_Cruise_
599 2 N/A N/A Intermittent Or
Set Switch Mounted Set_Switch
Incorrect
Switch Error
NOTE – Performing a vehicle road test will be necessary to verify specific cruise control functions.
NOTE – For further information, refer to the appropriate Vorad®, OnGuard™, or Wingman® user guide.
S08361 359
CRUISE CONTROL TROUBLESHOOTING
Cruise Control Preliminary Check
Table 273 Cruise Control Preliminary Check

1. Make sure the brake and No DTCs present. Go to next Refer to the Diagnostic
clutch are released, there step. Trouble Codes for specific
are no active brake or clutch cause (See Table 272,
DTCs, and no ABS / Automatic page 359).
Traction Control (ATC) events.
Are cruise control related

DTCs present in the Body
Controller?
2. Determine if any other features No other features are Go to next Identify and repair
are malfunctioning that may malfunctioning. step. condition causing several
have common circuits. features to be inoperative.
3. Using Diamond Logic® The Cruise_Switch_ Cruise Proceed to the Cruise
Builder, locate the Signal value will switches are Control Switch Test(See
Cruise_Switch_Signal change among 1, 3, functioning Table 274, page 361).
signal. or 5, depending on properly.
switch position.
Using Diamond Logic®
Builder, locate the The following switch
Cruise_Control_Coast values will change
signal. from ON to OFF with
switch operation:
Using Diamond Logic®
Builder, locate the Cruise_Control_
Cruise_Resume_Req signal. Coast
Using Diamond Logic® Cruise_Resume_

Builder, locate the Req
Cruise_Disable_Req signal.
Cruise_Disable_
Operate the switches on Req
and off while monitoring the
values.
360 S08361
TROUBLESHOOTING CRUISE CONTROL
Table 273 Cruise Control Preliminary Check (cont.)

4. Using Diamond Logic® Cruise commands are Body • Proceed to the Cruise
Builder, locate the being generated by Controller is Control Clutch Switch Test
Cruise_Enable_Cmd signal. the Body Controller. processing (See Table 274, page 361).
switch
Verify cruise commands from Signal will be inputs and • Message from Body
the Body Controller to the displayed as a generating Controller is not being
engine controller. numeric value, cruise transmitted.
switching between commands to
0 and 1. the Engine • Suspect faulty Body
Control Controller.
Module
(ECM). Refer
to the engine
trou-
bleshooting
manual for
the engine
installed in
the vehicle.
Cruise Control Switch Test
Table 274 Cruise Control Switch Test

1. Key is in OFF position >100K ohms Go to next • Short in one of the switches.
and clockspring connector step.
(1809) disconnected. • Continue test to locate faulty
switch.
Measure resistance
between the clockspring
and cavity B.
No switches pressed.
2. Measure resistance 2.4K ± 470 ohms Go to next Replace the SET / RESUME
between the clockspring step. switch.
and cavity B.
RESUME switch pressed.

3. Measure resistance 6.2K ± 1200 Go to next Replace the SET / RESUME
between the clockspring ohms step. switch.
and cavity B.
SET switch pressed.
S08361 361
SNOW VALVE SYSTEM DESCRIPTION
Table 274 Cruise Control Switch Test (cont.)

4. Measure resistance 1.2K ± 250 ohms Go to next Replace the ON / OFF switch.
between the clockspring step.
and cavity B.
CRUISE ON switch
pressed.
5. Measure resistance ≤1 ohm No problems Replace the ON / OFF switch.
between the clockspring evident at this
connector (1809), cavity A time.
and cavity B.
CRUISE OFF switch

pressed.
5. SNOW VALVE
This section contains a general overview of the snow valve.
Overview
The snow valve feature turns a drum inside the air cleaner to divert air or snow intake from outside the vehicle
to inside the engine compartment. The snow valve prevents heavy snow or dirt from clogging the air intake.
NOTE – Refer to the Operator's Manual for operating information.
Operation
The feature is controlled by a switch on the instrument panel connected directly to the snow valve module.
The snow valve module is part of the air cleaner housing assembly.
A snow valve warning light in the instrument cluster, directly controlled by the snow valve module, illuminates
when the snow valve is turning or movement is blocked. The switch indicator will light when the valve is
completely closed.
The snow valve switch receives voltage from the ignition relay #3 (1012/1014). Ground is provided by
When the snow valve switch is OFF, 12 volts is applied to terminal C of the snow valve module and the
snow valve motor. The switch also applies ground to pin D. This will spin the drum inside the air cleaner to
open the valve (allows outside air only and blocks off engine compartment air) until it opens a reed switch to
open the circuit which stops the snow valve motor.
When the snow valve switch is ON, voltage is applied through the warning light to pin A of the snow valve
module and the snow valve motor. The switch also applies ground to pin E and the other side of the motor.
This will spin the drum inside the air cleaner to close the valve (allows engine compartment air only and blocks
off outside air) until it opens a reed switch to open the circuit, which stops the snow valve motor.
362 S08361
FEATURE CODE SNOW VALVE
NOTE – The snow valve motor is protected by a thermal switch.
5.2. FEATURE CODE

This section contains the available Body Controller (BC) feature code definition related to the snow valve.

0595BLT BC PROG, SNOW VALVE engine air intake

There are no Body Controller user programmable parameters associated with the snow valve.

There are no Diagnostic Trouble Codes (DTC) associated with the snow valve.
This section contains diagnostic tips and troubleshooting information related to the snow valve.
Snow Valve Preliminary Check
Table 276 Snow Valve Preliminary Check
STEP ACTION YES NO

1. Does the snow valve warning • Inspect for mechanical Go to next step.
lamp stay ON? failures, obstructions, or
damage to the snow valve and
air intake drum.
• If the snow valve motor runs

constantly, inspect snow valve
magnets for damaged.
2. Are other features Refer to the 12-VOLT Proceed to the Snow Valve
malfunctioning that may POWER DISTRIBUTION Module Circuit Test (See Table
have common circuits? AND GROUNDS section of 277, page 364).
manual for circuit information.
S08361 363
SNOW VALVE TROUBLESHOOTING
Snow Valve Module Circuit Test
Table 277 Snow Valve Module Circuit Test

1. Disconnect the snow Switch ON: 12 ± 1.5V Go to next step. • Inspect 10A Fuse
valve module connector F5-A (1014).
(4120). Switch OFF: 0V NOTE – If snow
valve warning lamp • Inspect circuit A23J
Key is in ON position. does not illuminate, for open or short.
replace faulty bulb.
Measure voltage • Suspect faulty snow
between the snow valve switch (1107).
valve module connector
ground.
2. Measure voltage Switch ON: 0V Go to next step. • Inspect 10A Fuse
between the snow F5-A (1014).
valve module connector Switch OFF: 12 ± NOTE – If snow
(4120), cavity D and 1.5V valve warning lamp • Inspect circuit A23K
ground. does not illuminate, for open or short.
replace faulty bulb.
• Suspect faulty snow
valve switch (1107).
3. Measure resistance Switch ON: <1 ohm Suspect faulty snow • Inspect ground
between the snow valve motor. adapter (1003) for
valve module connector Switch OFF: No loose, damaged, or
(4140), cavity D and continuity corroded terminals.
ground.
364 S08361
TABLE OF CONTENTS
BATTERY, CHARGING, AND CRANKING SYSTEM

Table of Contents
1. BATTERY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
1.1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Battery Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Battery Test Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Cable Drop Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Battery Pack Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Battery Pack Test Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
2. CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

2.1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Charging System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
Charging System Test Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
3. CRANKING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

3.1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Starting System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Starting System Test Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4. POWERPACK 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4.1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
S08361 365
TABLE OF CONTENTS
366 S08361
DESCRIPTION BATTERY SYSTEM
1. BATTERY SYSTEM
1.1. DESCRIPTION
This section contains a general overview of the battery system.
Overview
Vehicle batteries are used to provide electrical energy to various vehicle systems.
Battery systems for these vehicles consist of two or more 12-volt, maintenance-free batteries.
Batteries are equipped with state-of-charge view eyes for quick checks.
Operation
There are three main functions of storage battery:
• To supply power to starter and ignition system so engine can be cranked and started.
• To supply extra power required when vehicle’s electrical load requirements exceed supply from charging
system.
• To act as a voltage stabilizer by smoothing out or reducing temporary high voltage within electrical system.
Vehicle batteries are connected in parallel with positive battery cable connected to cranking motor solenoid
(B) terminal. Depending upon battery quantity and box location, some vehicles have two positive cables to
cranking motor solenoid. The additional cable reduces voltage drop during cranking.
The negative battery terminals are connected to left side frame ground.
S08361 367
BATTERY SYSTEM DIAGNOSTIC TROUBLE CODES

The battery system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information

CAUSE SIGNAL
168 Electrical 3 N/A N/A Battery See below N/A
Potential Voltage High for details.
(Voltage)
• Battery voltage above 16V
Refer to the Midtronics EXP-1000HD Expandable Electrical Diagnostic Platform Instruction

Manual for specific instructions and diagnostic steps.
168 Electrical 4 N/A N/A Battery See below N/A
Potential Voltage Low for details.
(Voltage)
• Battery voltage below 12.1V
Refer to the Midtronics EXP-1000HD Expandable Electrical Diagnostic Platform Instruction

Manual for specific instructions and diagnostic steps.
WARNING
To prevent personal injury or death, always wear face or eye protection, have water
supply available, assure good ventilation, and be sure no open flames are present when
handling batteries.
The Battery Test will require the use of the Midtronics inTELLECT EXP-1000HD diagnostic equipment.
Battery Test
CAUTION
The Midtronics analyzer may display FROZEN BATTERY. Warm the batteries and retest.
To prevent damage to the batteries, never charge a frozen battery. Gases may form,
cracking the case, and leak battery acid.
The Battery Test function tests one battery in or out of the vehicle. To test the battery pack, the analyzer will
guide the user through steps of selecting specific battery test parameters and interpreting the results.
368 S08361
TROUBLESHOOTING BATTERY SYSTEM
Battery Test Results
The result of the Battery Test is either GOOD BATTERY, GOOD-RECHARGE, CHARGE AND RETEST,
REPLACE BATTERY, or BAD CELL-REPLACE.
The analyzer may also display other results during the Battery Test:
• SYSTEM NOISE DETECTED
The analyzer has detected vehicle computer, ignition noise, or parasitic drain, and will attempt to retest.
Ensure all load devices are OFF, doors are closed, and ignition is in the off position.
• UNSTABLE BATTERY DETECTED
A weak battery or a recently charged battery may retain electrical activity detected by the analyzer that will
affect the test results.
• SURFACE CHARGE DETECTED
The battery will hold a surface charge if the engine has been running or after the battery has been charged.
Be sure to remove the battery surface charge prior to performing the Battery Test.
Cable Drop Test
NOTE – The batteries should be fully charged prior to performing the Cable Drop Test.
The Cable Drop Test determines if a fault is due to worn cables or bad connections between the battery and
the alternator or starter. Worn cables or bad connections create excess resistance that causes a voltage drop
across a circuit. The voltage drop reduces the current carrying capability that can give false indications of a
faulty alternator or starter motor.
The analyzer will determine the voltage drop on the positive and negative side of any circuit as well as the
total voltage drop.
Battery Pack Test
The test is designed to provide a quick approximation of the pack's state of health and its capability to deliver
current. If the analyzer determines that the pack has a low state of charge, it will provide the option to test the
batteries individually or other system test options.
Prior to beginning test, inspect the alternator drive belt. The alternator will fail to achieve optimum output if a
belt is glazed, worn, or lacks the proper tension.
This system test evaluates the battery pack with up to six batteries.
Battery Pack Test Results
The result of the Pack Test is either GOOD PACK, CHECK BATTERY PACK, or FROZEN BATTERY. The
Midtronics EXP-1000HD will generate a Pack Code for each result.
When the Pack Test results in a CHECK BATTERY PACK message, perform individual battery testing to
determine if one or more batteries are at fault.
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CHARGING SYSTEM DESCRIPTION
2. CHARGING SYSTEM
2.1. DESCRIPTION
This section contains a general overview of charging system.
NOTE – To ensure optimal diagnostic testing, it is recommended to use the Midtronics EXP-1000HD and
related documentation for charging system tests.
Overview
The charging system is used to supply power to vehicle electrical system and to charge batteries.
Operation
When vehicle is running, the alternator supplies power through alternator or battery (BAT) terminal. Current
flows to crank motor solenoid battery stud. From this stud, current flows to batteries through positive battery
cable. Power is also applied to fuse block.
The alternator is grounded through the ground (GND) terminal to starter motor ground stud.

The charging system is able to set Diagnostic Trouble Codes (DTC) when specific faults occur. Information

CAUSE SIGNAL
115 Alternator 2 N/A N/A Phase Missing See below N/A
Current Fault/Alternator for details.
Fault.
• One or more of the three phase wires from the Dynamic Alternator to the Power
Pack Module may be disconnected.
• One or more of the three phase wires from alternator is disconnected. The Power Pack
system is shut down and requires an ignition cycle.
• Test Battery and Charging system with Midtronics EXP-1000HD and Midtronics EXP-1000HD
Expandable Electrical Diagnostic Platform Instruction Manual.
370 S08361
TROUBLESHOOTING CHARGING SYSTEM

CAUSE SIGNAL
168 Electrical 8 N/A N/A Phase Missing See below N/A
Potential Fault / for details.
(Voltage) Alternator
Fault.
• One or more of the three phase wires from the Dynamic Alternator to the Power
Pack Module may be disconnected.
• One or more of the three phase wires from alternator is disconnected. The Power Pack
system is shut down and requires an ignition cycle.
• Test Battery and Charging system with Midtronics EXP-1000HD and Midtronics EXP-1000HD
Expandable Electrical Diagnostic Platform Instruction Manual.
The Charging System Test will require the use of the Midtronics EXP-1000HD diagnostic equipment.
Charging System Test
The Charging System Test will test the alternator capabilities to charge the vehicle batteries under most
operating conditions. The test will determine the alternator output during low-engine-speed conditions with and
without electrical loads as well as high-engine-speed conditions with and without electrical loads.
The test will require the operation of the vehicle headlight system and HVAC blower motor operation.
Charging System Test Results
The Charging System Test will result in one of eight faults:
• NO PROBLEMS
The alternator is showing normal output form the alternator. No problem is evident at this time.
• NO OUTPUT
The alternator is not providing charging current to the battery.
Inspect alternator drive belts, and inspect all alternator connections. If no belt or connection fault is
evident, replace faulty alternator.
• LOW OUTPUT
The alternator is not providing enough current to power the system's electrical loads and charge the battery.
Inspect alternator drive belts, and inspect all electrical connections for loose, damaged, or corroded
connections.
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CRANKING SYSTEM DESCRIPTION
• HIGH OUTPUT
The voltage output from the alternator to the battery exceeds the normal limits of a functioning regulator.
• EXCESSIVE RIPPLE
One or more diodes in the alternator are not functioning, or there is stator damage, which is shown by
an excessive amount of AC ripple current supplied to the battery.
Inspect the alternator mounting and alternator drive belt conditions. If no faults are evident, replace
alternator.
• OPEN PHASE
The analyzer has detected an open phase within the alternator. Replace the alternator.
• OPEN DIODE
The analyzer has detected a open diode within the alternator. Replace the alternator.
• SHORTED DIODE
The analyzer has detected an shorted diode within the alternator. Replace the alternator.
3. CRANKING SYSTEM
3.1. DESCRIPTION
This section contains a general overview of the engine cranking system.
NOTE – To ensure optimal diagnostic testing, it is recommended to use the Midtronics EXP-1000HD and
related documentation for charging system tests.
Overview
The starting motor provides rotation of the engine crankshaft, through the flywheel, which is needed to start
engine.
The standard starting motor is a Soft-Touch starter delaying rotation until starter gear is fully engaged with
the flywheel.
An optional Thermal Over-Crank starting motor is available.
NOTE – Verify the specific starting motor equipped prior to troubleshooting.
Operation
When clutch pedal is pushed or automatic transmission is in park or neutral, the engine controller will provide a
ground to starter-ISO-power relay. When key is in start position, 12 volts will be applied to relay, causing it
to energize. The energized relay will supply 12 volts to cranking motor solenoid, causing it to energize and
apply battery voltage to cranking motor.
Before engine controller can apply a ground to starter-ISO-power relay, engine controller must first receive a
12-volt signal from clutch switch or neutral safety switch.
372 S08361
TROUBLESHOOTING POWERPACK 3
On vehicles using starters with Thermal Overcrank Protection, excessive cranking will cause cranking motor
temperature to reach a preset thermal overcrank limit. The thermal switch will then open, causing motor
to disengage. When thermal switch opens, it interrupts a ground signal from engine controller to coil of
starter relay, preventing it from energizing. When crank motor cools, switch closes, permitting crank motor
to operate again.
The Starting System Test will require the use of the Midtronics EXP-1000HD diagnostic equipment.
Starting System Test
The performance of the starting and charging systems depends on the battery's condition. It is important that
the battery or pack is good and fully charged before any further system testing.
Starting System Test Results
The starting system test will result in one of six faults:
• CRANKING NORMAL
The starter voltage is normal, and the battery is fully charged.

• LOW VOLTAGE
The starter voltage is low, and the battery is fully charged.

• CHARGE BATTERY
The starter voltage is low, and the battery is discharged. Fully charge the battery and repeat the starter
system test.
• REPLACE BATTERY
If the battery test result was REPLACE or BAD CELL, the battery must be replaced before testing the
starter.
• NO START
The engine did not start and the test was aborted.
• CRANKING SKIPPED
The Midtronics EXP-1000HD did not detect the vehicle starting profile and skipped the starter test.
4. POWERPACK 3
4.1. DESCRIPTION
This section contains a general overview of Diamond Logic® PowerPack 3.
S08361 373
POWERPACK 3 TROUBLESHOOTING
Overview
Diamond Logic® PowerPack 3 is an integrated 120-volt, alternating current and 14-volt, direct current (Vdc),
vehicle, power generation system. It provides both 120-volt, alternating current power for body mounted
accessories plus 14V to power vehicle electrical system.
Operation
The Diamond Logic® PowerPack 3 inverter module, which is the primary power conversion device of system,
provides:
• Three-phase alternator outputs

• Ignition input
• Controller Area Network (CAN) SAE J1939 communication data link
The alternator is designed to supply full power at an alternator speed of 2400 revolutions per minute (RPM).
NOTE – Always check battery condition and state of charge before performing electrical troubleshooting.
A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect
readings while performing electrical tests.
NOTE – Always check for any Diagnostic Trouble Codes before doing any intrusive wire tests or parts
replacement.
The performance of PowerPack 3 depends on battery’s condition. It is important that battery or pack is good
and fully charged before any further system testing.
Before doing any electrical testing on PowerPack 3 and related circuits:
• Check alternator drive belt tension.

• Inspect for defective batteries.
• Visually check wiring, clamps, and connections for clean, tight connections, free of damage and corrosion.
If none of the above conditions are found, use Diamond Logic® PowerPack 3 Operator's Manual 3676032R1
and PowerPack circuit diagrams in applicable Circuit Diagram manual for testing information.
374 S08361
TABLE OF CONTENTS
VEHICLE AND DRIVER INFORMATION DISPLAY

Table of Contents
1. VEHICLE INFORMATION DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
1.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Vehicle Information Display Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Vehicle Information Display Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
2. DRIVER INFORMATION DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
2.2. FEATURE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Driver Information Display Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Driver Information Display Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
S08361 375
TABLE OF CONTENTS
376 S08361
SYSTEM DESCRIPTION VEHICLE INFORMATION DISPLAY
1. VEHICLE INFORMATION DISPLAY

This section contains a general overview of the Vehicle Information Display (VID).
Overview
The Vehicle Information Display provides detailed vehicle and diagnostic information.
The VID has the ability to display Diagnostic Trouble Codes (DTC). Codes will not be displayed on the
Electronic Gauge Cluster (EGC) if the vehicle is equipped with the VID.
Suspect Parameter Number (SPN), failure mode indicator (FMI), and occurrence count numbers are listed.
Source addresses and DTC descriptions are presented in plain text.
NOTE – The VID will display NOT AVAILABLE if a description is not available for a particular fault.
Displaying codes will only be allowed if all of the following conditions are true:
• The key switch is in the IGNITION position.

• Displaying codes is allowed due to vehicle orderable options.
• The programmable parameter DIAGNOSTICS is enabled using Diamond Logic® Builder (DLB).
• The vehicle speed is equal to zero.
• The feature is not password protected to prevent unauthorized access.
Refer to the Vehicle Information Display Owner’s Manual for more information.
The VID is capable of the following functions:
• Tripometer
• Fuel economy
• Vehicle and engine usage
• Prognostics including tire pressure monitoring, brake monitor, and air systems
• Video inputs for aftermarket cameras or other video sources
Operation
The VID, which is located in the wing panel, is connected to the J1939 and J1708 data link. Data is received
through the links and displayed on the VID. The VID is connected to battery and accessory voltage.
When the key switch is turned to the ON position, voltage is applied to 10A Fuse F4-J and circuit A12C. The
Vehicle Information Display receives constant battery voltage from 5A Fuse F11-B and circuit A14SE.
The VID must receive both battery and accessory voltage inputs to operate properly.
Ground is provided by ground adapter (1003) and ground circuit A11-GKH.
1.2. FEATURE CODE

This section contains the available feature code definition related to the VID.
S08361 377
VEHICLE INFORMATION DISPLAY USER PROGRAMMABLE PARAMETERS

0016HKG ELECTRONIC VEHICLE MONITORING
0595ANX DIAGNOSTIC LOCATION


There are no Diagnostic Trouble Codes (DTC) associated with the VID.
This section contains diagnostic tips and troubleshooting information related to the VID.
Vehicle Information Display Preliminary Check
Table 281 Vehicle Information Display Preliminary Check
STEP ACTION YES NO

1. Are other accessory Proceed to the Vehicle Refer to the 12-VOLT
power driven components Information Display Circuit POWER DISTRIBUTION
operational? Test (See Table 282, page AND GROUNDS section for
378). further diagnostic information.
Vehicle Information Display Circuit Test
Table 282 Vehicle Information Display Circuit Test

1. Measure voltage at the 12 ± 1.5V Go to next step. • Inspect 5A Fuse
VID connector (1550), F11-B (1020).
cavity M to ground.
• Inspect circuit A14SE
for open or short.
378 S08361
SYSTEM DESCRIPTION DRIVER INFORMATION DISPLAY
Table 282 Vehicle Information Display Circuit Test (cont.)

F4-J (1013).
Measure voltage at the
VID connector (1550), • Inspect circuit A12C
cavity B to ground. for open or short.
• Verify accessory
relay #2, 4 (1011/1013)
operation.
3. Measure voltage 12 ± 1.5V Go to next step. Inspect ground circuit
between cavity J and A11-GKH for open or
cavity M of the VID short.
connector (1550).
4. Measure voltage at Approximately 2.5V J1939 communication Refer to the
cavities L and C to is present. MULTIPLEXING
ground of the VID (DATA LINKS) section
connector (1550). Go to next step. for further diagnostic
information.
5. Measure voltage at Approximately 2.5V J1708 communication Refer to the
cavities D and K to is present. MULTIPLEXING
ground of the VID (DATA LINKS) section
connector (1550). Replace faulty VID for further diagnostic
assembly. information.
2. DRIVER INFORMATION DISPLAY

This section contains a general overview of the Driver Information Display (DID) system.
Overview
The Driver Information Display (DID) is an in-dash controller unit, monitoring vehicle information. The DID
system offers information processing and display capabilities. The DID communicates over the J1939 data
link, providing the operator with vehicle data. It can support up to four cameras and will use the factory installed
radio system to emit audible alarms and other functions.
The base system provides these functions:
• J1939 truck information and alarms

• Trip computer to record time, fuel, and mileage
• Camera support for up to 4 cameras
• Driver checklist(s) for routine inspections and procedures
• Telematics display eliminating separate displays for Qualcomm’s OmniVision™
• Tire pressure display for tire data received over the J1939 data link; can be used with the optional Lectronix
tire pressure monitoring system or other industry standard solutions.
S08361 379
DRIVER INFORMATION DISPLAY FEATURE CODE
• Customized OEM / Fleet graphics
Optional functions include:
• GPS navigation with truck logistics

• Hands-free Bluetooth® phone with voice recognition and microphone
• Cameras
• iPod interface cable
• Tire pressure sensors and receiver box
Operation
The DID is supplied battery voltage on circuit A14A and a 10A Fuse F6-C (1013). The ground path is provided
by ground adapter (1003).
The DID will automatically turn on when the ignition key is turned to the ON or ACC positions.
The DID is connected to the vehicle radio for use of speakers for navigation commands and other audio
features.
2.2. FEATURE CODE

This section contains the available feature code definition related to the DID.

0016HKX DRIVER INFORMATION DISPLAY
0016HKY DRIVER INFORMATION DISPLAY


There are no Diagnostic Trouble Codes (DTC) associated with this feature.
This section contains diagnostic tips and troubleshooting information related to the Driver Information Display
system.
NOTE – Refer to the Lectronix Operating Instructions for further information.
380 S08361
TROUBLESHOOTING DRIVER INFORMATION DISPLAY
Driver Information Display Preliminary Check
Table 284 Driver Information Display Preliminary Check
STEP ACTION YES NO

1. Does the DID screen illuminate Go to next step. Proceed to the Driver
with key is in ON or ACC Information Display Circuit
position? Test (See Table 285, page
381).
2. Are all DID features Go to next step. • Suspect faulty DID unit.
functioning?
• Proceed to the Driver
Information Display Circuit Test
3. Does the DID function with the • No faults present at this time. • Verify vehicle radio and
vehicle's radio? speaker operation.
• Refer to the Lectronix
Operating Instructions for • Refer to the RADIO
further information. (ENTERTAINMENT),
SPEAKERS section for further
Driver Information Display Circuit Test
Table 285 Driver Information Display Circuit Test

F6-C (1013).
Measure voltage at the
DID connector (2224), • Inspect circuit A14A
cavity 1 to ground. for open or short.
2. Key is in ON position. 12 ± 1.5V Go to next step. Inspect ground circuit
A10AB and A10AE for
Measure voltage open.
between cavity 1
and cavity 5 of the DID
connector (2224).
S08361 381
DRIVER INFORMATION DISPLAY TROUBLESHOOTING
Table 285 Driver Information Display Circuit Test (cont.)

3. Key is in ACC position. 12 ± 1.5V Go to next step. • Inspect 10A Fuse
F4-J (1013).
Measure voltage
between cavity 3 and • Inspect circuit A14B
5 of the DID connector for open or short.
(2224).
• Verify accessory relay
operation.
4. Measure voltage at Approximately 2.5V • J1939 Refer to the
cavities 6 and 7 to communication is MULTIPLEXING
ground of the DID present. (DATA LINKS) section
connector (2224). for further diagnostic
• Replace faulty DID information.
unit.
382 S08361
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SERVICE MANUAL

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — DuraStar®,

2 ELECTRONIC GAUGE CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3 SWITCH PACKS (J1708 DATA LINK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5 CAB FEATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

6 CHASSIS FEATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

8 MULTIPLEXING (DATA LINKS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

9 12-VOLT POWER DISTRIBUTION AND GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

10 FANS AND ENGINE ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

11 BATTERY, CHARGING, AND CRANKING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

12 VEHICLE AND DRIVER INFORMATION DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

A warning indicates procedures that must be followed exactly. Personal injury or

2. VEHICLE ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. ELECTRICAL CIRCUIT DIAGRAM BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5. ELECTRICAL TEST EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6. BENCH TESTING RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2. VEHICLE ELECTRICAL SYSTEM OVERVIEW

3. ELECTRICAL CIRCUIT DIAGRAM BOOK

3.1. CIRCUIT DIAGRAMS

Figure 1 Sample Circuit Diagram

Figure 2 Sample Circuit Diagram Instructions

Figure 3 Sample Circuit Diagram Instructions and Abbreviations

Figure 4 Sample Schematic Symbol Chart

3.2. CONNECTOR BODY COMPOSITE

Figure 5 Sample Pin Configuration

4.1. VERIFY THE PROBLEM

1. Check the accuracy and completeness of the concern.

4.2. IMPORTANT STEPS BEFORE PERFORMING CIRCUIT TESTS

A. What happened and when?

2. VERIFY THE CUSTOMER'S CONCERN

3. CHECK FOR ACTIVE OR STORED DIAGNOSTIC TROUBLE CODES

5. Do the DTCs relate to other symptoms?

7. PERFORM THE FOLLOWING PRELIMINARY STEPS:

4.3. REVIEW FEATURE OPERATION

4.4. CHECK THE CIRCUIT DIAGRAM

4.5. PERFORMING CIRCUIT AND SYSTEM TESTS

4.6. PERFORM THE REPAIR

4.7. VERIFY THE REPAIR

5. ELECTRICAL TEST EQUIPMENT

5.2. BODY CONTROLLER BREAKOUT BOX (ZTSE4477)

Figure 6 BC Breakout Box

5.3. FLUKE 88 DIGITAL MULTIMETER (DMM)

1. DIGITAL MULTIMETER 2. ANALOG VOLTMETER

5.4. MIDTRONICS EXP-1000HD

Figure 8 Midtronics EXP-1000HD Diagnostic Equipment

5.5. JUMPER WIRES, TEST LEADS, AND TEST LIGHTS

Figure 9 Jumpers in Circuits

5.6. OHM'S LAW REVIEW

Table 1 Ohm's Law

The mathematical equation that describes this relationship is:

E = Electromotive Force (Volts)

Table 1 Ohm's Law (cont.)

Figure 10 Typical Circuit

I = 12V / 2 ohms or I = 12 divided by 2 = 6 amperes of current flow.

In electrical diagnosis, the voltmeter is used to perform the following:

2. Measurement or force of voltage

3. Voltage drop or voltage used across a given point

Figure 11 Voltmeter Lead Connections Diagram

Figure 12 Connecting the Meter in Series Diagram

Figure 13 Checking Voltage Drop Across a Load Device Diagram

1. DMM SET TO MEASURE DC 4. METER LEAD CONNECTED TO

Resistance measurements determine:

4. Operation of variable resistors

Figure 15 Measuring Resistance Diagram