Вы находитесь на странице: 1из 610

SERVICE MANUAL

TRUCK SERVICE MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 5000i and 9000i Model: 5000i Start Date: 05/01/1999 Model: 9100i Start Date: 05/01/1999 Model: 9200i Start Date: 05/01/1999 Model: 9400i Start Date: 05/01/1999 Model: 9900i Start Date: 05/01/1999 s08210 06/26/2002

s08210 Copyright 06/26/2002 International Truck and Engine Corporation

TRUCK SERVICE MANUAL

Table of Contents

INTRODUCTION. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .1 SAFETY INFORMATION.. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .2 GROUP 08 ELECTRICAL.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . ..3 1 POWER DISTRIBUTION AND GROUND SYSTEM. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .3 2 CAB ACCESSORIES. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .19 3 BATTERY, CHARGING AND CRANKING SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 4 ELECTRICAL TROUBLESHOOTING ETHER START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139 5 ELECTRICAL TROUBLESHOOTING FANS. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .151 6 CATERPILLAR C-10, C-12 AND 3406E ENGINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 7 DETROIT DIESEL SERIES 60 ENGINES. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .227 8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265 9 CUMMINS ISM AND AHD ENGINE SYSTEM. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .319 10 INTERNATIONAL 530E I6 HEUI ENGINES.. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .371 11 CHASSIS ACCESSORIES. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .407 12 LIGHT SYSTEMS. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .433 13 SLEEPER LIGHTING AND ACCESSORIES . . . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .509 14 HEATER AND AIR CONDITIONER. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .559

s08210

ii

TRUCK SERVICE MANUAL

s08210

TRUCK SERVICE MANUAL

INTRODUCTION
Use with Circuit Diagram Book CTS-5298 or S08225.

s08210

TRUCK SERVICE MANUAL

SAFETY INFORMATION
IMPORTANT Read the following before starting the service procedure. The information contained in this International Service Manual Section was current at the time of printing and is subject to change without notice or liability. You must follow your company safety procedures when you service or repair equipment. Be sure to understand all of the procedures and instructions before you begin work on the unit. International uses the following types of notations to give warning of possible safety problems and to give information that will prevent damage to the equipment being serviced or repaired.

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

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

NOTE A note indicates an operation, procedure or instruction that is important for correct service. Some procedures require the use of special tools for safe and correct service. Failure to use these special tools when required can cause injury to service personnel or damage to vehicle components. This service manual section is intended for use by professional technicians, NOT a do-it-yourselfer. It is written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the service section applies to your vehicle. See your International Truck Dealer for information on whether this service section applies to your vehicle.

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

Group ELECTRICAL Table of Contents

1. DESCRIPTION. .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..5 1.1. POWER DISTRIBUTION SYSTEM. .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . ..5 1.2. GROUND SYSTEM. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . ..5 2. OPERATION.. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .5 2.1. COMMON SYSTEM COMPONENTS. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .5 Fuses And Circuit Breakers. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .5 Junction Adapters And Studs. .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . ..5 Relays And Solenoids. . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. .6 2.2. BATTERY POWER DISTRIBUTION (WITHOUT 3+1 BATTERY SYSTEM). . . . . . . . . . . . . . . . . . . . . . . . .6 2.3. IGNITION POWER.. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .6 2.4. ACCESSORY POWER. .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . ..6 2.5. START POWER.. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . ..6 2.6. VEHICLE GROUND SYSTEM.. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .6 2.7. 3+1 BATTERY SYSTEM. . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . ..6 Engine Running Mode. . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . ..7 Engine OFF Mode.. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .7 3. TROUBLESHOOTING. .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . ..7 3.1. GENERAL TROUBLESHOOTING. .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .7 3.2. TESTING 3 +1 BATTERY SYSTEM. .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . .8 3.3. TESTING IGNITION POWER DISTRIBUTION SYSTEM. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .9 4. COMPONENT LOCATIONS. .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .9

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

1. DESCRIPTION
1.1. POWER DISTRIBUTION SYSTEM
The power distribution system provides power to the key switch, the starter solenoid, and the (B1) and (B2) battery studs. The 150 amp. megafuse, which must be replaced when blown, supplies power to the (B1) and (B2) battery studs. Power from the (B1) and (B2) battery studs is then distributed to the fuse block and individual fused circuits. Fuse F7-A is located in the feed circuit for the key switch and provides protection for the key switch and any unfused circuits attached to the key switch.

1.2. GROUND SYSTEM


The ground system provides a power return path to the vehicle batteries. Included in this system are ground straps that connect the cab, engine and frame to the negative battery terminals.

2. OPERATION
Refer to the 12V POWER DISTRIBUTION circuit diagrams in CTS-5298 or S08225.

2.1. COMMON SYSTEM COMPONENTS


Fuses And Circuit Breakers CAUTION Never replace a fuse or circuit breaker with a higher load rated fuse or circuit breaker.

Fuses are standard (Type III circuit breakers are optional), except for headlights and windshield wipers, which have Type I circuit breakers. Most of the fuses and/or circuit breakers are located in the Power Distribution panel in the cab. The Power Distribution panel cover contains a listing of installed circuit protection devices, size and location. 1. Type III Circuit Breakers Type III circuit breakers open if current ow exceeds the rated capacity and can be reset by depressing the reset button on the breaker after the overload condition has been removed. 2. Type I Circuit Breakers Type I circuit breakers (headlights and windshield wipers) reset automatically. However, if the excessive current ow condition causing the breaker to open is not corrected, the circuit breaker will reopen and remain open until the winding cools, then automatically reset. With an overload condition present, the circuit breaker will cycle (open and close) until the condition is corrected. The circuit breaker will become hot to the touch. NOTE Type I circuit beakers must only be replaced with approved Navistar Type I circuit breakers. Junction Adapters And Studs In the circuit diagrams, bussed adapters and studs are most often, but not always, given a name such as (B2) Battery Adapter (498), etc. These junction connections can be either feeds or grounds and are identied as

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

such. The bus adapters have a common feed or ground and the other terminals are connected internally by a bus bar. Relays And Solenoids Relays and solenoids are switching devices. International uses only suppressed relays and solenoids to prevent voltage spikes from damaging electronic components in the vehicle electrical system. Once a transistor has been "spiked," it may not fail immediately, but its life will be shortened. Note that relays used inside the cab are not sealed, but relays in less protected areas, such as the engine compartment, are sealed for longer life. NOTE Only replace relays and solenoids with correct International parts.

2.2. BATTERY POWER DISTRIBUTION (WITHOUT 3+1 BATTERY SYSTEM)


With the ignition key switch in the off position, the batteries provide power to the (B1) and (B2) battery studs, through the 150 amp. megafuse. From the (B1) and (B2) battery studs power is distributed to selected electrical systems. With 3+1 System, refer to 3+1 Battery System below.

2.3. IGNITION POWER


Battery power from the (B1) battery stud is applied to the common terminal (30) of the ignition relay (462)/R1 and to the key switch "B" terminal. With the key switch in the on position, power from the key switch "I" terminal energizes the ignition relay, applying power to the ignition adapters and fuses. With the key switch in the start or ignition position, power is present at the "I" terminal.

2.4. ACCESSORY POWER


Battery power from the (B1) battery stud is applied to the common terminal (30) of the accessory relay (145) and to the key switch "B" terminal. With the key switch in the ACC position (or IGN position), power from the key switch "A" terminal: A. Energizes the accessory adapter relay (145), applying power to A3 accessory adapter (501). B. Flows to A1 Accessory Adapter (499) and to the Electric Wiper Intermittent Relay.

2.5. START POWER


With the key switch in the start position, battery power from (B1) battery stud is applied through the key switch "S" and "I" terminals to the start circuits.

2.6. VEHICLE GROUND SYSTEM


The engine, frame, cab and negative battery terminals are electrically connected by ground cables, which provide common ground points (studs or ground adapters).

2.7. 3+1 BATTERY SYSTEM


The 3+1 battery system includes three cranking batteries and one deep cycle battery. The purpose of this system is to prevent discharging the three cranking batteries while operating certain electrical accessories connected to (B2), off the fourth battery, when the engine is not running.
s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

Engine Running Mode With the engine running, power (7 volts) from the alternator R terminal energizes the isolated battery magnetic switch, closing the contacts. This links the positive terminal of the deep cycle and cranking motor batteries, recharging all four batteries and supplying power from all four batteries to both the (B1) and (B2) battery studs. Engine OFF Mode The deep cycle battery supplies power to components receiving power from the (B2) battery stud. The three cranking batteries supply power to the components receiving power from the (B1) stud.

3. TROUBLESHOOTING
Refer to the 12V POWER DISTRIBUTION circuit diagrams in CTS-5298 or S08225. 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 laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual. D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid.

3.1. GENERAL TROUBLESHOOTING


If more than one electrical circuit is not working, a good place to begin troubleshooting is with the power and ground distribution diagrams. Refer to 12V POWER DISTRIBUTION, GROUND ADAPTER COMPOSITE and GROUND STUD COMPOSITE circuit diagrams in CTS-5298 or S08225 for ground composites. Look for common power sources, common grounds, common fuses, etc. In the event that several circuits malfunction, check common feeds and ground rst as they are likely the problem. If this does not assist in correcting the problem, proceed to the section(s) that provide detailed troubleshooting guide for the specic circuits.

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

3.2. TESTING 3 +1 BATTERY SYSTEM


Table 1 STEP 1. Testing 3+1 Battery System KEY Off ACTION At 7V isolated battery magnetic switch, measure resistance from circuit 11H to ground. At mag. switch and 1/0 red cable, measure voltage to gnd. At mag. switch and 1/0 black wire, measure voltage to gnd. Measure voltage across large terminals of the mag. switch. Start engine and at 7V isolated battery magnetic switch, measure voltage from circuit 7 to gnd. Remove battery cables and at 7V mag. switch, measure resistance across large terminals. Reconnect any disconnected circuits and start vehicle. Measure voltage across large terminals of 7V mag. switch. Check voltage to ground at (B2) battery stud. TEST POINTS 7V mag switch, 11H to gnd. SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 11H, then repair. Locate cause of low or no voltage in 1/0 red cable, then repair. Locate cause of no or low voltage in 1/0 black wire, then repair.

2.

Off

Mag. sw., 1/0 red cable to gnd. Mag. sw., black wire to gnd. Across mag. sw. Mag. sw., 7 to gnd.

12 1.5 volts.

Go to next step.

3.

Off

Approx. 12 volts (same as deep cycle battery.) Less than or greater than 0 volts. Approx. 7 volts (pulsating DC). >100K ohms.

Go to next step.

4.

Off

Go to Step Go to next step. 7. Go to next step. Locate cause of low or no voltage in circuit 7, then repair. Replace mag. switch; it is not opening the circuit. Turn off key switch, disconnect battery cables, and replace defective magnetic switch. Locate cause of low or no voltage in fusible link 14-FL, circuit 14A or 14AB, then repair.

5.

On

6.

Off

Mag. sw., across large term. Mag. sw., across large term.

Go to next step.

7.

Off/ On

0 volts.

Go to next step.

8.

Off

(B2) to gnd.

12 1.5 volts.

3+1 battery circuits check good.

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

3.3. TESTING IGNITION POWER DISTRIBUTION SYSTEM


Table 2 STEP 1. Testing Ignition Power Distribution System KEY Off ACTION Check fuses F2-C and F7-A for open condition. TEST POINTS F2-C and F7-A. SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace the fuse(s). Locate cause of low or no voltage, then repair.

2.

Off/ On Remove ignition relay (462-R1). Turn key on. At conn. (462-R1) measure voltage to ground at circuits 14S and 13A. On At conn. (462-R1) measure voltage between circuits 14S and 13-GA. Measure resistance between circuit 13H/13P between conn. (462-R1) and ignition adapter (495).

(462-R1), 14S and 13A to gnd.

12 1.5 volts.

Go to next step.

3.

(462-R1) between 14S and 13-GA.

12 1.5 volts.

Go to next step.

Locate open or poor connection in circuit 13-GA to ground, then repair. Locate open or poor connection in circuit 13H/13, then repair.

4.

Off

Between conn. (462-R1) & ignition adapter (495). (495), 13P to gnd.

<5 ohms.

Go to next step.

5.

Off/ On Re-install relay at conn. (462-R1). Turn key on. At adapter (495) circuit 13P, measure voltage to gnd. On Measure voltage from circuit 13H to ground (at connection to fuse F4-C). Measure voltage from circuit 13F to ground [at connection to adapter (494)].

12 1.5 volts.

Go to next step.

Replace the relay.

6.

13H to gnd.

12 1.5 volts.

Go to next step.

Locate cause of low or no voltage in circuit 13H, then repair. Locate cause of low or no voltage in circuit 13F, then repair.

7.

On

13F to gnd.

12 1.5 volts.

Ignition power system checks good.

4. COMPONENT LOCATIONS
(B1) Battery Stud. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . . Power Distribution Panel (B2) Battery Stud. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . . Power Distribution Panel (1) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Left Side of Engine Cowl (2) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Right Side of Engine Cowl, Above Conn. 3 (3) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Right Side of Engine Cowl, Below Conn. 2
s08210

10

1 POWER DISTRIBUTION AND GROUND SYSTEM

(40) Key Switch. .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . ... . . . . . Behind Left Side of Instrument Panel (41) Push Button Start Switch. . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Center of Instrument Panel (149) Accessory Adapter Relay.. .. . .. .. . .. .. . .. . .. ... . . . . . Power Distribution Panel (425) Panel Light Switch.. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . . . . . At Switch Cluster (453) Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Center of Dash Behind Wing Panel (454) G2 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel (455) G3 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel (456) G4 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Center Instrument Panel (462) R1 Ignition Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (494) I1 Ignition Adapter. .. . . . .. . . . .. . . . .. . . . .. . . . .. . .. . . . . . Behind Fuse Panel (495) I2 Ignition Adapter. .. . . . .. . . . .. . . . .. . . . .. . . . .. . .. . . . . . Behind Fuse Panel (497) B1 Battery Adapter. .. . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . Behind Fuse Panel (498) B2 Battery Adapter. .. . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . Behind Fuse Panel (499) A1 Accessory Adapter. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Fuse Panel Right Side (501) A3 Accessory Adapter. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Fuse Panel Right Side (503) L1 Panel Light Feed Adapter. .. . .. . .. . .. . .. . ... . . . . . Behind Lt Instrument Panel (504) L2 Panel Light Feed Adapter. .. . .. . .. . .. . .. . ... . . . . . Behind Instrument Panel/Switch Breakout (506) L4 Panel Light Gnd Adapter.. . .. . . .. . .. . .. . . ... . . . . . At Right of Instrument Panel (509) Start Feed Adapter. .. . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . 6 Inches Left of Fuse Panel Near Heater Controls

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

11

Figure 1 Cab Wiring (Dash)

s08210

12

1 POWER DISTRIBUTION AND GROUND SYSTEM

1. 150A MEGAFUSE 2. TO (B1) BATTERY STUD 3. START MAG SWITCH 4. NO BUS BAR WITH 3+1 BATTERY SYSTEM 5. TO HEATER 6. (3) ENGINE HARNESS CONNECTOR 7. (2) CHASSIS HARNESS CONNECTOR 8. RIGHT HAND DASH GROUND STUD 9. FUSE BLOCK GROUND STUD 10. (B2) BATTERY STUD 11. (B1) BATTERY STUD 12. KEY SWITCH 13. LEFT HAND DASH GROUND STUD 14. (1) FRONT END HARNESS CONNECTOR 15. GROUND CIRCUITS 16. DASH PANEL

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

13

Figure 2 Cab Wiring (Power Distribution Center/Fuse Panel) (B1) and (B2) Battery Stud 1. CIRCUIT 14A FROM START MAG SWITCH 2. 3+1 CAB HARNESS CONNECTS TO 3+1 ENGINE HARNESS 3. CIRCUIT 14A FROM 3+1 MAG SWITCH

s08210

14

1 POWER DISTRIBUTION AND GROUND SYSTEM

Figure 3

Isolated Battery Wiring (Typical)

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

15

1. 2. 3. 4. 5. 6. 7. 8. 9.

3+1 BATTERY SYSTEM HARNESS SEE FIGURE 4 SEE VIEW BELOW CIR 14A TO B2 BATTERY STUD CIRCUIT 7 CIRCUIT 7 SEE VIEW ABOVE 3+1 BATTERY SYSTEM HARNESS

s08210

16

1 POWER DISTRIBUTION AND GROUND SYSTEM

Figure 4

Isolated Battery Wiring (Typical)

s08210

1 POWER DISTRIBUTION AND GROUND SYSTEM

17

1. DEEP CYCLE BATTERY 2. RED CABLE TO 7V MAGNETIC SWITCH 3. CRANKING BATTERY 4. GROUND 5. CIRCUITS 4A & 7 6. SEE FIGURE 3 7. 3+1 BATTERY SYSTEM HARNESS 8. MAGNETIC SWITCH WITH 3+1 SYSTEM 9. CIRCUIT 11H, 7V MAGNETIC SWITCH 10. CRANKING BATTERY 11. CIRCUIT 11H 12. RED CABLE 13. 7V ISOLATED BATTERY MAGNETIC SWITCH 14. CIRCUIT 14FL 15. CIRCUIT 7 16. BLACK CABLE 17. CRANKING BATTERY 18. BATTERY BOX

s08210

18

1 POWER DISTRIBUTION AND GROUND SYSTEM

s08210

2 CAB ACCESSORIES

19

Table of Contents

1. DESCRIPTION.. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. ..21 1.1. CIGAR LIGHTER (CAB).. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . ..21 1.2. CLOCK (CAB).. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. .21 1.3. ELECTRIC WINDOW - RIGHT. .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . ..21 1.4. ELECTRIC WINDOW - RIGHT AND LEFT. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. .21 1.5. DEFROSTER FANS. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . ..21 1.6. ELECTRIC WINDSHIELD WIPERS INTERMITTENT WIPE AND WASH. . . . . . . . . . . . . . . . . . . . . . .21 1.7. ELECTRIC HORN. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. .21 1.8. MIRRORS - HEATED AND LIGHTED.. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. ..21 1.9. MIRRORS - MOTORIZED. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . .21 1.10. C.B. RADIO CAB POWER SOURCE. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. ..21 1.11. C.B. RADIO ACCOMMODATION PACKAGE. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .22 1.12. CAB RADIO AND SPEAKERS.. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . ..22 1.13. OWNER/OPERATOR SPARE SWITCH. .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .22 1.14. ELECTRIC LOCK - RIGHT AND LEFT.. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. ..22 1.15. INTERVISION DISPLAY. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. ..22 1.16. EATON VORAD COLLISION AVOIDANCE EVT-300. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. ..22 1.17. TEMPERATURE/COMPASS DISPLAY.. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. ..22 1.18. ROAD RELAY IV.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. .22 1.19. HEATED SEAT-DRIVER.. . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . .22 1.20. HEATED SEAT-PASSENGER.. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. .22 2. OPERATION. .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. .22 2.1. CIGAR LIGHTER (CAB).. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . ..23 2.2. CLOCK (CAB).. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. .23 2.3. ELECTRIC WINDOW - RIGHT (ONLY). .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . .23 Window Down Operation. . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . .23 Window Up Operation. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. .23 2.4. ELECTRIC WINDOW - RIGHT AND LEFT. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. .23 Right Window Down Operation. .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. .23 Right Window Up Operation. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. ..24 Left Window Down Operation.. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .24 Left Window Up Operation.. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. ..24 2.5. DEFROSTER FANS. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . ..24 2.6. ELECTRIC WINDSHIELD WIPERS - INTERMITTENT WIPE AND WASH. .. . .. . .. . .. . .. . .. . .. . .. .24 Two Speed Wiper With Intermittent Wiper And Washer Operation. . . . .. . . . . . . .. . . . . . . .. . . . .24 2.7. ELECTRIC HORN. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. .26 2.8. MIRRORS - HEATED AND LIGHTED.. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. ..26 2.9. MIRRORS - MOTORIZED. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . .26 2.10. C.B. RADIO CAB POWER SOURCE. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. ..26 2.11. C.B. RADIO ACCOMMODATION PACKAGE. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .26 2.12. CAB RADIO AND SPEAKERS.. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . ..26 2.13. OWNER/OPERATOR SPARE SWITCH. .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .27 With Fuse. .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. .27 Without Fuse.. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. .27 2.14. ELECTRIC LOCK - RIGHT AND LEFT.. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. ..27 2.15. INTERVISION DISPLAY. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. ..27

s08210

20

2 CAB ACCESSORIES

2.16. 2.17. 2.18. 2.19. 2.20.

EATON VORAD COLLISION AVOIDANCE EVT-300.. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .27 TEMPERATURE/COMPASS DISPLAY. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .27 ROAD RELAY IV. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .28 HEATED SEAT-DRIVER. . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . ..28 HEATED SEAT-PASSENGER. . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .28

3. TROUBLESHOOTING. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .28 3.1. TESTING CIGAR LIGHTER (CAB). .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .28 3.2. TESTING CLOCK (CAB). . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .29 3.3. TESTING ELECTRIC WINDOW - RIGHT.. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .30 3.4. TESTING ELECTRIC WINDOW - RIGHT AND LEFT. .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .32 3.5. TESTING DEFROSTER FAN(S).. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .37 3.6. TESTING WINDSHIELD WIPER AND WASHER SYSTEM. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .38 3.7. TESTING ELECTRIC HORN. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .42 3.8. HEATED AND LIGHTED MIRRORS. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . ..43 Testing Heated Mirrors. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..43 Testing Mirror Lights. . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. .44 3.9. MOTORIZED MIRRORS.. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .45 Testing Right Motorized Mirror. . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . .45 Testing Dual Axis Motorized Mirrors.. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .47 3.10. TESTING CB POWER SOURCE. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .49 3.11. TESTING RADIO-CB ACCOMMODATION PACKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 3.12. TESTING RADIO-CAB SPEAKERS.. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .51 3.13. TESTING OWNER/OPERATOR SPARE SWITCH (FUSED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 3.14. TESTING OWNER/OPERATOR SPARE SWITCH (NON-FUSED). . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .55 3.15. TESTING ELECTRIC LOCK RIGHT AND LEFT. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .56 3.16. TESTING INTERVISION CIRCUITS. . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . ..59 3.17. TESTING EATON VORAD COLLISION AVOIDANCE EVT-300 CIRCUITS. . . . . . . . . . . . . . . . . . . . . .61 3.18. TESTING TEMPERATURE/COMPASS DISPLAY CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 3.19. TESTING ROAD RELAY IV CIRCUITS. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .64 3.20. TESTING HEATED SEAT-DRIVER. . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . ..65 3.21. TESTING HEATED SEAT-PASSENGER. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .66 4. COMPONENT LOCATIONS.. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . ..67

s08210

2 CAB ACCESSORIES

21

1. DESCRIPTION
1.1. CIGAR LIGHTER (CAB)
The Cigar Lighter circuit provides power to the Cigar Lighter or other item plugged into the lighter socket. The socket is located to the right of the driver at the base of the wing panel.

1.2. CLOCK (CAB)


The Clock circuit provides power to an optional analog clock. The clock is located to the right of the driver in one of the four optional gauge openings of the wing panel.

1.3. ELECTRIC WINDOW - RIGHT


The right side electric window provides a means for the driver to operate the passengers side window from the drivers seat.

1.4. ELECTRIC WINDOW - RIGHT AND LEFT


The right and left side electric window provides a means for the driver to operate both the drivers and passengers side window from the drivers seat. It also allows the passenger to control the passengers side window.

1.5. DEFROSTER FANS


The single defroster or dual defroster options provide an increase in airow over the windshield.

1.6. ELECTRIC WINDSHIELD WIPERS INTERMITTENT WIPE AND WASH


Electric windshield wipers have a two-speed motor and intermittent wipe and wash feature, and are self parking when they are turned off.

1.7. ELECTRIC HORN


The electric horn is located in the grille of the truck and provides a means of signaling or warning other vehicle drivers.

1.8. MIRRORS - HEATED AND LIGHTED


Optional heated and lighted mirrors are available for the left and right side.

1.9. MIRRORS - MOTORIZED


Optional motorized right mirror, or dual axis motorized mirrors are available.

1.10. C.B. RADIO CAB POWER SOURCE


An optional Citizens Band radio power source is available in two styles. One style is the traditional cigar lighter socket, and the other is the terminal block style.

s08210

22

2 CAB ACCESSORIES

1.11. C.B. RADIO ACCOMMODATION PACKAGE


An optional Citizens Band radio accommodation package is available that provides a speaker, and speaker and power connections.

1.12. CAB RADIO AND SPEAKERS


An optional radio and front and rear speaker package is available. For tractors with a sleeper, speakers are also available.

1.13. OWNER/OPERATOR SPARE SWITCH


An optional owner/operator spare switch is available. Two different styles are available: one with a fused relay circuit, and one with a plain toggle switch.

1.14. ELECTRIC LOCK - RIGHT AND LEFT


Power locks, with controls in the driver and passenger doors, will lock or unlock all doors.

1.15. INTERVISION DISPLAY


The Intervision display is an optional electronic interface which displays vehicle information for drivers, eet managers and service technicians.

1.16. EATON VORAD COLLISION AVOIDANCE EVT-300


The EATON VORAD Collision Avoidance EVT-300 is an optional computerized collision warning system that uses forward-looking mounted radar and optional side-looking radar to constantly monitor vehicles ahead and in blind spot area, respectively.

1.17. TEMPERATURE/COMPASS DISPLAY


The optional temperature and compass display provides the driver with outside temperature and compass directions.

1.18. ROAD RELAY IV


The optional Cummins road relay IV provides the driver with an electronic engine monitoring and driver display system. The driver display module is mounted in driver side cutout of header panel.

1.19. HEATED SEAT-DRIVER


Optional heated seat is available for the driver.

1.20. HEATED SEAT-PASSENGER


Optional heated seat is available for the passenger.

2. OPERATION
Refer to CAB ACCESSORIES circuit diagrams in CTS-5298 or S08225.

s08210

2 CAB ACCESSORIES

23

2.1. CIGAR LIGHTER (CAB)


The cigar lighter receives power from 15A fuse F2-A with the key on or off. The cigar lighter is grounded at the left dash panel ground stud.

2.2. CLOCK (CAB)


The analog clock receives power from 10A fuse F10-A, with the key on or off. The clock is grounded through ground adapter (454).

2.3. ELECTRIC WINDOW - RIGHT (ONLY)


The right side electric window is controlled by the drivers right side window switch. To operate the window, the key must be in the on or accessory position. The circuit includes the electric window relay (1159), window switch (1158) and the right window motor. Power to the window switch is supplied from the B1 battery stud to the common terminal (30) of the window relay (1159). With the key in the on or accessory position, the relay is energized applying power to terminal 4 (and internally to terminal 3) at the electric window switch (1158). Note that switch terminals 4 and 3 are at 12V with key on and terminals 1 and 6 are always at ground. Window Down Operation With the window switch in the down position, power from switch terminal 5 is applied to the motor on circuit 83L. Circuit 83M from the motor to the switch terminal 2 becomes the ground circuit. With the switch in the down position, switch terminals 2 and 1 are connected, completing the path to ground. Window Up Operation With the window switch in the up position, power from switch terminal 2 is applied to the motor on circuit 83M. Circuit 83L from the motor to the switch terminal 5 becomes the ground circuit. With the switch in the up position, switch terminals 5 and 6 are connected, completing the path to ground.

2.4. ELECTRIC WINDOW - RIGHT AND LEFT


The right and left side electric windows are controlled by the drivers right and left side window switches. The passenger can also control the Right side window. To operate the windows, the key must be in the on or accessory position. The circuit includes the electric window relay (1138), drivers side right window switch (1040), drivers side left window switch (1039), passengers side window switch (1041), the right window motor and the left window motor. Power to the three window switches is supplied from the B1 battery stud to the common terminal (30) of the window relay (1138). With the key in the on or accessory position, the relay is energized applying power to terminal 4 (and internally to terminal 3) of the driver side right and passenger side window switches (1040) and (1041). The window relay also supplies power to the driver side left switch on terminal 28 and internally to terminal 1. Right Window Down Operation With the passengers side switch (1041) in the neutral position and the drivers side right window switch (1040) in the down position, power from switch terminal 5B is applied to the motor on circuit 83J through terminals 6 and 5B of switch (1041) to circuit 83M. Circuit 83L from the motor, through switch (1041) terminals 2B and 1, circuit 83K to switch (1040) terminal 2B becomes the ground circuit. With the passengers side switch in the down position, power from terminal 5B is applied to circuit 83M. Ground is supplied on circuit 83L through switch (1033), circuit 83K, and switch (1040) from circuit 83-GB.

s08210

24

2 CAB ACCESSORIES

Right Window Up Operation With the passengers side switch (1041) in the neutral position and the drivers side right window switch (1040) in the up position, power from switch terminal 2B is applied to the motor on circuit 83K through terminals 1 and 2B of switch (1041) to circuit 83L. Circuit 83M from the motor, through switch (1041) terminals 5B and 6, circuit 83J to switch (1040) terminal 5B becomes the ground circuit. With the passengers side switch in the up position power from terminal 2B is applied to circuit 83L. Ground is supplied on circuit 83M through switch (1033), circuit 83J, and switch (1040) from circuit 83-GB. Left Window Down Operation With the window switch in the down position, power from switch terminal 4 is applied to the motor on circuit 83N. Circuit 83F from the motor to the switch terminal 1 becomes the ground circuit. With the switch in the down position, switch terminals 2B and 1 are connected, completing the path to ground. Left Window Up Operation With the window switch in the up position, power from switch terminal 1 is applied to the motor on circuit 83F. Circuit 83N from the motor to the switch terminal 4 becomes the ground circuit. With the switch in the up position, switch terminals 2B and 4 are connected, completing the path to ground.

2.5. DEFROSTER FANS


Power for the defroster fan(s) is supplied from fuse F5B on circuits 86E and 78F to connector (313). When the defroster switch is in the high position, power from connector (313) ows through the switch to the high speed windings of the defroster motor(s). When the defroster switch is in the low position, power from connector (313) ows through the switch to the low speed windings of the defroster motor(s). Ground for the motors is provided on circuits 11GB, 11GAB, 11GAC and 76G.

2.6. ELECTRIC WINDSHIELD WIPERS - INTERMITTENT WIPE AND WASH


Two Speed Wiper With Intermittent Wiper And Washer Operation Table 3 Wiper Washer Switch Operation MOTION In Up FUNCTION If wiper is off, Turns wiper to low speed. If wiper is on in any mode, turns wiper off. If wiper is off, turns wiper on to high speed. If wiper is on, Increments wiper to next highest speed. If held more than one second wiper speed increases directly to high. Down If wiper is off, turns wiper on to low speed. If wiper is on, Increments wiper to next lowest speed.

SWITCH Top Toggle (ON/OFF)

s08210

2 CAB ACCESSORIES

25

Table 3

Wiper Washer Switch Operation (cont.) If held more than one second wiper enters its longest delay mode.

Bottom Button (WASH)

In

If pressed less than 1/2 second, wiper performs a single lowspeed dry wipe (mist function). If pressed and held more than 1/2 second, wiper continues in low speed and washes for 2 seconds or until released (whichever occurs later). After release wiper continues to cycle in low speed for 3 seconds, then wiper returns to previous state.

The electric windshield wiper with intermittent wipe and wash switch (1171) is an electronic device which controls the wiper relays and the washer pump depending on how the switch and washer button are pressed. Ignition switched power With the ignition switch on power from 10 amp fuse F10-B is applied to wiper-low speed delay relay (143) terminal 86, wiper-high speed delay relay (143) terminal 86, and windshield washer w/wiper delay switch (1171) terminal 1. Battery power Battery power from 15 amp fuse F4-D is applied to wiper-high speed delay relay (143) terminal 30, windshield washer pump (9) on circuit 87B, and windshield wiper motor connector (430) terminal A. Low Speed Wiper Operation When the wiper switch selects low wiper speed, a ground from the wiper switch (1171) terminal 3 is applied to wiper- low speed relay (143) terminal 85. This energizes the relay applying 12 volts from the closed contacts of high speed relay (142) terminal 87 to the low speed winding of the wiper motor through connector (430) terminal D. High Speed Wiper Operation When the wiper switch selects high wiper speed, a ground from the wiper switch (1171) terminal 4 is applied to wiper- high speed relay (142) terminal 85. This energizes the relay applying 12 volts from terminal 87 to the high speed winding of the wiper motor through connector (430) terminal E. The wiper switch also energizes the low speed relay (143), with a ground on circuit 82B, to open the park circuits and prevent 12 volts from being applied to the low speed winding of the wiper motor. Park Operation Note that power is always present at the P terminal of the crank motor. When the wipers are turned off and the wiper blades are not parked, the circuit between wiper motor P and S is closed. In this position, power at P goes through the contacts and out S, through the normally closed contacts of the wiper relay (143) and back to the low speed winding of the wiper motor. The motor continues to operate until the park switch rotates, opening the circuit between terminal S and P, and closing the circuit between S and X, parking the wipers and turning off operation. Windshield Washer Operation When the wiper switch selects the windshield washer, ground from switch (1171) is applied from terminal 5 to circuit 87A of the washer pump motor. Intermittent Wiper/Wash Operation The electronic wiper switch (1171) controls the washer and the low and high speed wiper circuits to perform intermittent wiping and washing as requested.

s08210

26

2 CAB ACCESSORIES

2.7. ELECTRIC HORN


Battery power from 15A fuse F5-C is always available to the horn relay (463)/R7 at the common terminal (30) and control coil (86). Depressing the horn closes the relay ground circuit energizing the relay and applying power to the horn.

2.8. MIRRORS - HEATED AND LIGHTED


Heated Mirror With the key in the on or accessory position, the heated mirror elements receive power from the ignition relay (462R1) through 10A fuse F5-A. Mirror Lights Power to the mirror lights is controlled by the cab and trailer lights relay (464R9). Refer to LIGHT SYSTEMS for that system. Power from cab and trailer lights relay (464R9) is applied to 15A fuse F8-C, which supplies power to operate the mirror lights.

2.9. MIRRORS - MOTORIZED


Right Motorized Mirror The right motorized mirror switch (437) receives power from ignition relay (462R1), through 10A fuse F5-A, when the key is in the on or accessory position. Momentarily positioning the switch down from the neutral position closes the circuit between switch contacts 1 - 2 and 4 - 5. This applies voltage to the motor on circuit 78F and grounds the motor through 78E. Momentarily positioning the switch up from the neutral position closes the circuit between switch contacts 23 and 56. This applies voltage to the motor on circuit 78E and grounds the motor through 78F. Dual Axis Motorized Mirrors The dual axis motorized mirror switch 1137 receives power from ignition relay (462R1), through 10A fuse F5A, on circuit 78C, through connector (1137), when the key is in the on or accessory position. Twisting the mirror control switch knob selects which mirror will be controlled. Positioning the L/R switch to the Left or Right position will cause the controlled mirror to move to the Left or Right. Positioning the U/D switch to the Up or Down position will cause the controlled mirror to move Up or Down. Ground for the circuits is supplied from GND Adapter (456) on circuit 78GA through connector (1137). Use the DUAL AXIS MOTORIZED MIRROR circuit diagrams in CTS-5298 or S08225 to determine which circuits are energized to move the mirrors.

2.10. C.B. RADIO CAB POWER SOURCE


Battery power from (B2) battery stud supplies power to the CB radio power receptacle. The circuit is protected by 20A fuse F5-D.

2.11. C.B. RADIO ACCOMMODATION PACKAGE


This option provides an accessory power CB radio connection. The circuit is protected by 10A fuse F5B and the connection is grounded through the right dash ground stud. An external speaker is also provided.

2.12. CAB RADIO AND SPEAKERS


Refer to the RADIO CAB SPEAKERS circuit diagrams in CTS-5298 or S08225 for radio and speaker installation.

s08210

2 CAB ACCESSORIES

27

2.13. OWNER/OPERATOR SPARE SWITCH


With Fuse This option provides switched battery power on circuit 14AQ for owner/operator connections. Power from the (B2) battery stud is applied, through 30A fuse F10A, to the spare accessory relay (167) common terminal. With the key switch in the on or accessory position the relay is energized applying the power to the spare accessory switch (517). When switch 517 is turned on, power is applied to circuit 14AQ. Without Fuse This option provides switched battery power on circuit 14AQ for owner/operator connections directly through the spare accessory switch (517).

2.14. ELECTRIC LOCK - RIGHT AND LEFT


Power from the (B1) battery adapter is applied through 10A fuse F-10A to terminals 85 and 87 of power lock relay (1139) and power lock relay unlock (1140). When driver switch (1042) or passenger switch (1043) are pushed to the unlock position, a ground from ground adapter (456) will be applied through terminal 2B and terminal 3 of the actuated switch to terminal 86 of the power lock relay unlock (1140). This will energize the relay, applying 12 volts to terminal 30 of the relay, circuits 81H, 81K and 81J to the left and right power locks. A ground from de-energized power lock relay (1139) will be on terminal 30, circuit 81D, 81E and 81F to the left and right power locks. This will unlock the doors. When driver switch (1042) or passenger switch (1043) are pushed to the lock position a ground from ground adapter (456) will be applied through terminal 2B and terminal 1 of the actuated switch to terminal 86 of the power lock relay (1139). This will energize the relay, applying 12 volts to terminal 30 of the relay, circuits 81D, 81E and 81F to the left and right power locks. A ground from de-energized power lock relay unlock (1140) will be on terminal 30, circuit 81H, 81J and 81K to the left and right power locks. This will lock the doors.

2.15. INTERVISION DISPLAY


The Intervision display receives battery power from the (B1) battery adapter through 5A fuse F10A. Switched ignition power is supplied from the (I2) ignition adapter through 5A fuse F10B. Ground for the display unit is supplied from the (G1) ground adapter. The unit connects to the truck data link on circuits 98G(+) and 98H(-).

2.16. EATON VORAD COLLISION AVOIDANCE EVT-300


The EATON VORAD Collision Avoidance EVT-300 CPU receives switched ignition power from the (I2) ignition adapter through 5A fuse F10B. Ground for the CPU is supplied from the (G1) ground adapter. The CPU is connected to the driver display unit on circuits 73U, 73V, 73W and 73X. The CPU is connected to the front antenna unit on circuits 73B, 73C, 73D and 73E. The CPU is connected to the right side sensor unit on circuits 73L, 73M and 73N. The CPU is connected to the right side display unit on circuits 73L, 73N and 73P. The CPU is connected to the truck data link on circuits 98YL9(+) and 98GN9(-), also 98EV(+) and 98EV(-).

2.17. TEMPERATURE/COMPASS DISPLAY


The temperature and compass display receives battery power from the (B2) battery adapter through 5A fuse F10B. Switched ignition power is supplied from the (I1) ignition adapter through 5A fuse F10A. Ground for the display unit is supplied from the (G3) ground adapter. The unit connects to the temperature sensor on circuits 41C and 41D. Also, the unit connects to the compass module on circuits 41F, 41H and 41J.

s08210

28

2 CAB ACCESSORIES

2.18. ROAD RELAY IV


The road relay display module receives battery power from the (B2) battery adapter through 5A fuse F10A. Switched ignition power is supplied from the (I1) ignition adapter through 5A fuse F10B. Ground for the display unit is supplied from the (G1) ground adapter. The unit connects to the truck data link on circuits 98E(+) and 98D(-).

2.19. HEATED SEAT-DRIVER


The driver heated seat receives switched ignition power from the (I2) ignition adapter through 10A fuse F10A. Ground for the heated seat is from the (G3) ground adapter.

2.20. HEATED SEAT-PASSENGER


The passenger heated seat receives switched ignition power from the (I2) ignition adapter through 10A fuse F10A. Ground for the heated seat is from the (G3) ground adapter.

3. TROUBLESHOOTING
Refer to the CAB ACCESSORIES circuit diagrams in CTS-5298 or S08225 for the following discussion. 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 laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to section in GROUP 08 - ELECTRICAL in the CTS-5000 Master Service Manual. D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid.

3.1. TESTING CIGAR LIGHTER (CAB)


Table 4 STEP 1. Testing Cigar Lighter (Cab) KEY Off ACTION Remove fuse F2-A and check for open condition. TEST POINTS F2-A SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse.

s08210

2 CAB ACCESSORIES

29

Table 4 Testing Cigar Lighter (Cab) (cont.) STEP 2. KEY Off ACTION Re-install fuse F2-A and measure voltage to gnd. at F2-A and circuit 14T. At cigar lighter socket, measure voltage of center electrical contact (circuit 84) to gnd. At cigar lighter socket, measure voltage from center electrical contact to outer electrical contact (circuit 84 to 84-G). Cigar lighter circuits check good. If lighter does not function, replace defective lighter or socket. TEST POINTS F2-A, 14T to gnd. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 14T or 14W, then repair. Locate cause of no or low voltage in circuit 84, then repair. Locate open or poor connection in circuit 84-G or 11-GD to ground, then repair.

3.

Off

Cigar Lighter, 84 to gnd. Cigar lighter, 84 to 84-G.

12 1.5 volts.

Go to next step.

4.

Off

12 1.5 volts.

Go to next step.

5.

Off

3.2. TESTING CLOCK (CAB)


Table 5 STEP 1. Testing Clock (Cab) KEY Off ACTION Remove fuse F10-A and check for open condition. TEST POINTS F10-A SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage in circuit 14N, then repair. Locate cause of no or low voltage in circuit 88F, then repair.

2.

Off

Re-install fuse F10-A and measure voltage at F10-A circuit 14N to ground. At analog clock connector (526), measure voltage at circuit 88F to ground.

F10- A, 14N to gnd.

12 1.5 volts.

Go to next step.

3.

Off

(526), 88F to gnd.

12 1.5 volts.

Go to next step.

s08210

30

2 CAB ACCESSORIES

Table 5 STEP 4.

Testing Clock (Cab) (cont.) KEY Off ACTION At connector (526) measure voltage from circuit 88F to circuit 88-GF. TEST POINTS (526), 88F to 88-GF. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 88-GF or 11-GAV to ground, then repair.

5.

Off

Analog clock circuits check good. If clock does not function properly, replace defective clock.

3.3. TESTING ELECTRIC WINDOW - RIGHT


Table 6 STEP 1. Testing Electric Window - Right KEY Off ACTION Remove 20A fuse F4-B and check for open condition. Re-install fuse F4-B. Remove relay from connector (1159). Measure voltage to ground at circuit 83. At connector (1159) measure voltage between circuits 83 and 12-GW. At connector (1159) measure voltage between circuits 12W and 12-G. Measure resistance of circuit 83D between connectors (1159) and (1158). Install relay in connector (1159). Turn key on. At connector (1158) measure voltage to ground at 83D. TEST POINTS F4-B SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage, then repair.

2.

Off

(1159), 83 to gnd.

12 1.5 volts.

Go to next step.

3.

Off

(1159), 83 to 12- GW.

12 1.5 volts.

Go to next step.

Locate open or poor connection in circuit 12-GW to ground, then repair. Locate cause of no or low voltage in circuit 12W, then repair. Repair open or poor connection in circuit 83D, then repair. Replace the relay in connector (1159).

4.

On

(1159), 12W to 12- G.

12 1.5 volts.

Go to next step.

5.

Off

83D between (1159) and (1158). (1158), 83D to gnd.

<5 ohms.

Go to next step.

6.

Off/ On

12 1.5 volts.

Go to next step.

s08210

2 CAB ACCESSORIES

31

Table 6 STEP 7.

Testing Electric Window - Right (cont.) KEY On ACTION At connector (1159) measure voltage between circuits 83D and 12-G. Remove window switch. With switch in neutral position measure resistance between terminals 1, 2 and 5. With switch in up position measure resistance between terminals 2 and 4. With switch in up position measure resistance between terminals 5 and 1. With switch in down position measure resistance between terminals 1 and 2. With switch in down position measure resistance between terminals 4 and 5. Disconnect motor at connector (1045). At connector (1158) measure resistance to gnd. at circuit 83L. At connector (1158) measure resistance to gnd. at circuit 83M. TEST POINTS (1159), 83D to 12-G. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 12-G ground path, then repair. Replace the switch.

8.

Off

Window switch, between 1, 2 and 5.

<1 ohm.

Go to next step.

9.

Off

Window switch, 2 to 4. Window switch, 5 to 1. Window switch, 1 to 2. Window switch, 4 to 5. (1158), 83L to gnd.

<1 ohm.

Go to next step.

Replace the switch.

10.

Off

<1 ohm.

Go to next step.

Replace the switch.

11.

Off

<1 ohm.

Go to next step.

Replace the switch.

12.

Off

<1 ohm.

Go to next step.

Replace the switch.

13.

Off

>100K ohms.

Go to next step.

Locate short to ground in circuit 83L, then repair.

14.

Off

(1158), 83M to gnd. (1045), 83L to gnd.

>100K ohms. 12 1.5 volts.

Go to next step. Go to next step.

Locate short to ground in circuit 83M, then repair. Locate open or poor connection in circuit 83L between connectors (1158) and (1045), then repair.

15.

Off/ On Connect (1158) to window switch. Turn key on. With switch in down position, at connector (1045) measure voltage to gnd. at circuit 83L.

s08210

32

2 CAB ACCESSORIES

Table 6 STEP 16.

Testing Electric Window - Right (cont.) KEY On ACTION With switch in down position, at connector (1045) measure voltage between circuits 83M and 83L. TEST POINTS (1045), 83M to 83L. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 83M between connectors (1158) and (1045), then repair.

17.

Off

Window control circuits check good. If window fails to operate, either the mechanical parts or the motor is defective.

3.4. TESTING ELECTRIC WINDOW - RIGHT AND LEFT


Table 7 STEP 1. Testing Electric Window - Right & Left KEY On ACTION Do any of the windows operate from any control? Does the left window operate correctly? TEST POINTS SPEC. Any window operates. Left window operates correctly. Right window operates correctly from both controls. F4-B <1 ohm. YES-IN SPEC. Go to next step. Go to next step. NO-OUT OF SPEC. Go to Step 4.

2.

On

Go to Step 9.

3.

On

Does the right window operate correctly from both the passenger and driver control?

Windows operate correctly

Go to Step 20.

4.

Off

Remove 20A fuse F4-B and check for open condition. Re-install fuse F4-B. Remove electric window relay from connector (1138). Measure voltage to ground at circuit 83.

Go to next step.

Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage, then repair.

5.

Off

(1138), 83 to gnd.

12 1.5 volts.

Go to next step.

s08210

2 CAB ACCESSORIES

33

Table 7 STEP 6.

Testing Electric Window - Right & Left (cont.) KEY Off ACTION At connector (1138) measure voltage between circuits 83 and 12-G. At connector (1138) measure voltage between circuits 12W and 12-G. TEST POINTS (1138), 83 to 12-G. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 12-G to ground, then repair. Locate cause of no or low voltage in circuit 12W, then repair. Replace the relay in connector (1138).

7.

On

(1138), 12W to 12-G.

12 1.5 volts.

Go to next step.

8.

Off/ On Install relay in connector (1138). Turn key on. Measure voltage to ground at circuit 83D . Off Remove driver side left window switch from connector (1039). Measure resistance from (1039) circuit 83H to ground.

(1138), 83D to gnd.

12 1.5 volts.

Relay and circuits check good. Go to next step.

9.

(1039), 83H to gnd.

Open circuit.

Locate short to ground in circuit 83H or 83C, then repair.

10.

Off/ On Turn key on. Measure voltage to ground from (1039), circuit 83H. On Measure voltage between (1039) circuit 83H and circuit 83-GBW.

(1039), 83H to gnd.

12 1.5 volts.

Go to next step.

Locate cause of no or low voltage on circuit 83H, then repair. Locate open or poor connection in circuit 83-GBW, 83GA or 11GAW to ground, then repair. Replace the switch.

11.

(1039), 83H to 83-GBW.

12 1.5 volts.

Go to next step.

12.

Off

With driver side left switch in up position measure resistance between switch terminals 2B and 4. With switch in up position measure resistance between switch terminals 5B and 1. With switch in down position measure resistance between terminals 1 and 2B.

Window switch, 2B to 4.

<1 ohm.

Go to next step.

13.

Off

Window switch, 5B to 1.

<1 ohm.

Go to next step.

Replace the switch.

14.

Off

Window switch, 1 to 2B.

<1 ohm.

Go to next step.

Replace the switch.

s08210

34

2 CAB ACCESSORIES

Table 7 Testing Electric Window - Right & Left (cont.) STEP 15. KEY Off ACTION With switch in down position measure resistance between terminals 4 and 5B. Disconnect motor at connector (1044). At connector (1039) measure resistance from 83F and 83N to ground. Connect (1039) to window switch. Turn key on. With switch in down position, at connector (1044) measure voltage to gnd. at circuit 83N. With switch in down position, at connector (1044) measure voltage between circuits 83N and 83F. TEST POINTS Window switch, 4 to 5B. (1039), 83F and 83N to gnd. SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

16.

Off

Open circuit.

Go to next step.

Locate short to ground in circuit 83F or 83N, then repair.

17.

Off/ On

(1044), 83N to gnd.

12 1.5 volts.

Go to next step.

Locate open or poor connection in circuit 83N between connectors (1039) and (1044), then repair. Locate open or poor connection in circuit 83F between connectors (1039) and (1044), then repair.

18.

On

(1044), 83N to 83F.

12 1.5 volts.

Go to next step.

19.

Off

Driver side left window control circuits check good. If window fails to operate, either the mechanical parts or the motor may be defective. Remove drivers side right window switch from connector (1040). Measure resistance from (1040) circuit 83E to ground. Turn key on. Measure voltage to ground from (1040), circuit 83E. (1040), 83E to gnd. Open circuit. Go to next step. Locate short to ground in circuit 83E, then repair.

20.

Off

21.

Off/ On

(1040), 83E to gnd.

12 1.5 volts.

Go to next step.

Locate cause of no or low voltage on circuit 83E, then repair.

s08210

2 CAB ACCESSORIES

35

Table 7 STEP 22.

Testing Electric Window - Right & Left (cont.) KEY On ACTION Measure voltage between (1040) circuit 83E and circuit 83-GB. TEST POINTS (1040), 83E to 83-GB. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 83-GB to ground, then repair. Replace the switch.

23.

Off

With driver side right switch in neutral position measure resistance between switch terminals 1, 2B and 5B. With switch in up position measure resistance between switch terminals 2B and 4. With switch in up position measure resistance between switch terminals 5B and 1. With switch in down position measure resistance between terminals 1 and 2B. With switch in down position measure resistance between terminals 4 and 5B. Measure resistance from connector (1040) circuit 83J and 83K to ground. Install a jumper between (1040) circuit 83J and 83K. Remove pasengers side window switch from connector (1041). Measure resistance between (1041) circuit 83J and 83K.

Window switch, between 1, 2B and 5B.

<1 ohm.

Go to next step.

24.

Off

Window switch, 2B to 4.

<1 ohm.

Go to next step.

Replace the switch.

25.

Off

Window switch, 5B to 1.

<1 ohm.

Go to next step.

Replace the switch.

26.

Off

Window switch, 1 to 2B. Window switch, 4 to 5B. (1040), 83J and 83K to gnd. (1041), between 83J and 83K.

<1 ohm.

Go to next step.

Replace the switch.

27.

Off

<1 ohm.

Go to next step.

Replace the switch.

28.

Off

Open circuit.

Go to next step.

Locate short to ground in circuit 83J or 83K, then repair. Locate open in circuit 83J or 83K, then repair.

29.

Off

<1 ohm.

Go to next step.

s08210

36

2 CAB ACCESSORIES

Table 7 Testing Electric Window - Right & Left (cont.) STEP 30. KEY Off ACTION Remove jumper from connector (1040) and reconnect driver side switch. Measure resistance from (1041) circuit 83D to ground. Turn key on. Measure voltage from (1041) circuit 83D to ground. With passenger side switch in neutral position measure resistance between switch terminals 1and 2B. With switch in neutral position measure resistance between switch terminals 6 and 5B. With switch in up position measure resistance between switch terminals 2B and 4. With switch in up position measure resistance between switch terminals 5B and 1. With switch in down position measure resistance between terminals 1 and 2B. With switch in down position measure resistance between terminals 4 and 5B. Disconnect motor at connector (1045). At connector (1041) measure resistance to gnd. at circuit 83L. TEST POINTS (1041), 83D to gnd. SPEC. Open circuit. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground in circuit 83D, then repair.

31.

Off/ On

(1041), 83D to gnd. Window switch, between 1 and 2B.

12 1.5 volts <1 ohm.

Go to next step. Go to next step.

Locate open in circuit 83D, then repair. Replace the switch.

32.

Off

33.

Off

Window switch, between 6 and 5B. Window switch, 2B to 4.

<1 ohm.

Go to next step.

Replace the switch.

34.

Off

<1 ohm.

Go to next step.

Replace the switch.

35.

Off

Window switch, 5B to 1.

<1 ohm.

Go to next step.

Replace the switch.

36.

Off

Window switch, 1 to 2B. Window switch, 4 to 5B. (1041), 83L to gnd.

<1 ohm.

Go to next step.

Replace the switch.

37.

Off

<1 ohm.

Go to next step.

Replace the switch.

38.

Off

Open circuit.

Go to next step.

Locate short to ground in circuit 83L, then repair.

s08210

2 CAB ACCESSORIES

37

Table 7 STEP 39.

Testing Electric Window - Right & Left (cont.) KEY Off ACTION At connector (1041) measure resistance from 83M to gnd. TEST POINTS (1041), 83M to gnd. (1044), 83M to gnd. SPEC. Open circuit. 12 1.5 volts. YES-IN SPEC. Go to next step. Go to next step. NO-OUT OF SPEC. Locate short to ground in circuit 83M, then repair. Locate open or poor connection in circuit 83M between connectors (1041) and (1045), then repair. Locate open or poor connection in circuit 83L between connectors (1041) and (1045), then repair.

40.

Off/ On Connect (1041) to window switch. Turn key on. With switch in down position, at connector (1045) measure voltage to gnd. at circuit 83M. On With switch in down position, at connector (1045) measure voltage between circuits 83M and 83L.

41.

(1045), 83M to 83L.

12 1.5 volts.

Go to next step.

42.

Off

Right window control circuits check good. If window fails to operate, either the mechanical parts or the motor may be defective.

3.5. TESTING DEFROSTER FAN(S)


Table 8 STEP 1. Testing Defroster Fan(s) KEY Off/ On ACTION Disconnect connector (313). Turn key on. At connector (313) measure the voltage between circuit 76F and gnd. At connector (313) measure the voltage between 76F and 76-G. TEST POINTS (313), 76F to gnd. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 76F or 86E, then repair. Locate open or poor connection in circuit 76-G, 11-GAC, 11GAB or 11-GB to ground, then repair.

2.

On

(313), 76F to gnd.

12 1.5 volts.

Go to next step.

s08210

38

2 CAB ACCESSORIES

Table 8 STEP 3.

Testing Defroster Fan(s) (cont.) KEY Off/ On ACTION Reconnect connector (313). Remove the red and orange wire from the fan. Turn the key on and turn the defroster switch to HI. Measure the voltage between the orange wire and the black wire. Turn the defroster switch to LO. Measure the voltage between the red wire and the black wire. TEST POINTS Orange wire to black wire. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open in black wire or orange wire or replace faulty switch.

4.

On

Red wire to black wire.

12 1.5 volts.

Replace faulty motor.

Locate open in black wire or replace faulty switch.

3.6. TESTING WINDSHIELD WIPER AND WASHER SYSTEM


NOTE Intermittent wipe/wash is controlled by circuitry inside switch (1171). If high/low speed wipe and wash work, but intermittent wipers and wash dont, the switch needs to be replaced. Perform this test if the wipers or wash do not work properly. Table 9 Testing Windshield Wiper and Washer System STEP 1. KEY On ACTION Do any of the washer/wiper functions work? TEST POINTS SPEC. Some washer/ wiper functions work. Washer works. High speed wipers work. Low speed wipers work. Wipers park correctly. Intermittent wipers work. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Go to Step 8.

2. 3.

On On

Does the windshield washer work? Do the wipers work correctly with high speed selected? Do the wipers work correctly with low speed selected? Do the wipers park correctly when they are turned off? Do the wipers work correctly with intermittent wipers selected?

Go to next step. Go to next step. Go to next step. Go to next step. Wipers and washer work correctly.

Go to Step 11. Go to Step 14.

4.

On

Go to Step 23.

5.

On

Go to Step 31.

6.

On

Go to next step.

s08210

2 CAB ACCESSORIES

39

Table 9 Testing Windshield Wiper and Washer System (cont.) STEP 7. KEY On ACTION Intermittent wipe/wash is controlled by circuitry inside switch (1171). If high/low speed wipe and wash work, but intermittent wipers dont, the switch needs to be replaced. Remove windshield washer w/wiper delay switch (1171). Measure resistance between circuit 12BC and gnd. Turn ignition on. At connector (1171) measure voltage between circuits 12BC and ground. At connector (1171) measure voltage between circuits 12BC and 82-GB. (1171), 12BC to gnd. Open circuit. Go to next step. Locate short to ground on circuit 12BC. TEST POINTS SPEC. YES- IN SPEC. NO-OUT OF SPEC.

8.

Off

9.

On

(1171), 12BC and ground.

12 1.5 volts.

Go to next step.

Locate cause of no or low voltage on circuit 12BC, check fuse F-10B, then repair. Locate open or poor connection in circuit 82-GB, then repair.

10.

On

(1171), 12BC and 82-GB.

12 1.5 volts.

Power circuits to switch check good. Replace switch. Go to next step.

11.

Off

Remove windshield washer w/wiper delay switch (1171). Remove windshield washer pump from connector (9). Measure resistance between circuit 87A and gnd. Install jumper from (1171), terminal 5 to ground. Measure resistance from (9) circuit 87A to ground.

(9), 87A to gnd.

Open circuit.

Locate short to ground on circuit 87A.

12.

Off

(9), 87A to gnd.

<1 ohm.

Remove jumper. Go to next step.

Locate open in circuit 87A.

s08210

40

2 CAB ACCESSORIES

Table 9 STEP 13.

Testing Windshield Wiper and Washer System (cont.) KEY Off ACTION Measure voltage between circuit 87B, connector (9) and gnd. TEST POINTS (9), 87B and gnd. SPEC. 12 1.5 volts. YES- IN SPEC. Circuits to washer pump motor check good. Replace switch (1171). Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 87B, then repair.

14.

Off

Remove windshield washer w/wiper delay switch (1171). Remove wiper-high speed relay from connector (142). Measure resistance on circuit 82J between (1171) and (142). Reconnect the wiper switch to (1171). Bench check wiper-high speed relay (142). Measure resistance from (142) circuit 12BB to ground. Turn ignition on and measure the voltage between (142) circuit 12BB and ground. Measure voltage between (142) circuit 82K and ground. Remove windshield wiper motor connector (430). Measure resistance between (430) circuit 82D and ground. Connect wiper high speed delay to (142). Turn ignition on and select high speed wiper. Measure voltage between (430) circuit 82D and ground.

82J, between (1171) and (142).

<1 ohm.

Locate open in circuit 82J, then repair.

15.

Off

Relay checks good. (142), 12BB to ground. (142), 12BB to ground. Open circuit. 12 1.5 volts.

Go to next step.

Replace relay.

16.

Off

Go to next step. Go to next step.

Locate short to ground in circuit 12BB, then repair. Locate cause of no or low voltage on circuit 12BB, then repair. Locate cause of no or low voltage on 82K. Locate short to ground on 82D.

17.

On

18.

Off

(142), 82K and gnd. (430), 82D and gnd.

12 1.5 volts. Open circuit.

Go to next step. Go to next step.

19.

Off

20.

Off/ On

(430), 82D and gnd.

12 1.5 volts

Go to next step.

Locate open on 82D.

s08210

2 CAB ACCESSORIES

41

Table 9 Testing Windshield Wiper and Washer System (cont.) STEP 21. KEY Off ACTION Measure resistance between (430) circuit 82-GC and ground. Reconnect all switches and relays. Turn ignition on and select high speed wipers. Remove wiper-low speed relay (143) and wiper high speed relay. Measure resistance of circuit 82A between (143) and (142). Turn ignition on. At connector (143), measure voltage to gnd. at circuit 12BA. Bench check wiper-low speed relay (143). Remove windshield washer w/wiper delay switch (1171). Measure resistance on circuit 82B between (1171) and (143). Reconnect the wiper switch to (1171). Bench check wiper-low speed delay relay (143). Remove connector (430) from the wiper motor. Measure resistance between 82E and gnd. Install a jumper between (143), circuit 82E and ground. Measure the resistance between (430), circuit 82E and ground. (430), 82E to gnd. 82J, between (1171) and (142). Circuit 82A (143)and (142). TEST POINTS (430), 82-GC and gnd. SPEC. <1 ohm. YES- IN SPEC. Go to next step. High speed wipers circuits check good. Go to next step. NO-OUT OF SPEC. Locate open on 82-GC. Replace wiper motor.

22.

Off

Motor turns at high speed.

23.

Off

<1 ohm.

Locate open or poor connection in circuit 82A, then repair.

24.

On

(143), 12BA to gnd.

12 1.5 volts.

Go to next step.

Locate open or poor connection in circuit 12BA, then repair. Replace relay.

25.

Off

Relay checks good. <1 ohm.

Go to next step. Go to next step.

26.

Off

Locate open in circuit 82J, then repair.

27.

Off

Relay checks good. Open circuit.

Go to next step.

Replace relay.

28.

Off

Go to next step.

Locate short to ground in circuit 82E. Locate open on circuit 82E.

29.

Off

(430), 82E and ground.

<1 ohm.

Go to next step.

s08210

42

2 CAB ACCESSORIES

Table 9 STEP 30.

Testing Windshield Wiper and Washer System (cont.) KEY Off ACTION Reconnect all switches and relays. Turn ignition on and select low speed wipers. Remove wiper low speed delay relay (143). Measure resistance between relay terminal 30 and 87A. (143), terminal 30 and 87A. TEST POINTS SPEC. Motor turns at low speed. YES- IN SPEC. Low speed wipers circuits check good. Install wiper low speed delay relay (143). Go to next step. Go to next step. NO-OUT OF SPEC. Replace wiper motor.

31.

Off

< 1 ohm.

Replace wiper low speed delay relay (143).

32.

Off

Remove connector (430) from wiper motor. Measure voltage between circuit 82C and gnd. Measure resistance between (430) circuit between circuit 82E and gnd. Measure resistance between (430) circuit between circuit 82E and 82F. If wipers do not park properly replace the wiper motor assembly.

(430), circuit 82C and gnd.

12 1.5 volts.

Locate cause of no or low voltage in circuit 82C.

33.

Off

(430), circuit 82E and gnd. (430), circuit 82E and 82F.

Open circuit.

Go to next step.

Locate short to ground in circuit 82E or 82F. Locate open in circuit 82E or 82F.

34.

Off

<1 ohm.

Go to next step.

35.

On

3.7. TESTING ELECTRIC HORN


Table 10 STEP 1. Testing Electric Horn KEY Off ACTION Remove 15A fuse F5-C and check for open condition. Re-install fuse F5-C. Remove relay from connector (463-R7). Measure voltage to ground at circuit 85/85D. TEST POINTS F5-C SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage from fuse, then repair.

2.

Off

(463)/R7, 85/ 85D to gnd.

12 1.5 volts.

Go to next step.

s08210

2 CAB ACCESSORIES

43

Table 10 STEP 3.

Testing Electric Horn (cont.) KEY Off ACTION With horn button depressed, at connector (463-R7) measure voltage between circuits 85 and 85C. TEST POINTS (463)/R7, 85 to 85C. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of open or poor connection in horn control circuit between relay and horn button ground, then repair. Go to next step.

4.

Off

At connector (463-R7) use test lead to jumper circuit 85 to 85B. With test leads, connect one side of horn to ground and the other side to B1 battery stud. Check for open in horn feed or ground circuit, then repair.

Does horn sound? Does horn sound?

Replace the horn relay. Go to next step.

5.

Off

Replace the horn.

6.

Off

3.8. HEATED AND LIGHTED MIRRORS


Testing Heated Mirrors Table 11 STEP 1. Testing Heated Mirrors KEY Off ACTION Check 15A fuse F5-A for open condition. TEST POINTS F5-A SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Go to Step 6.

2.

Off

Does the right side mirror work?

Right heated mirror works. Left heated mirror works. (1127), 78B to gnd. 12 1.5 volts.

Go to next step.

3.

Off

Does the left side mirror work? Disconnect connector (1127). Turn key on and measure voltage to gnd. at circuit 78B.

Heated mirrors work. Go to next step.

Go to next step.

4.

Off/ On

Locate open or poor connection in circuit 78B, then repair.

s08210

44

2 CAB ACCESSORIES

Table 11 STEP 5.

Testing Heated Mirrors (cont.) KEY On ACTION At connector (1127) measure voltage between circuits 78B and 11-GBM. At connector (1128) measure voltage to gnd. at circuit 78A. At connector (1128) measure voltage between circuits 78A and 11-GY. TEST POINTS Both (1127), 78B and 11GBM. Both (1128), 78A to gnd. SPEC. 12 1.5 volts. YES- IN SPEC. Replace heater element. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 11-GBM, then repair. Locate open or poor connection in circuit 78A, then repair. Locate open or poor connection in circuit 11-GY path to gnd., then repair.

6.

On

12 1.5 volts.

7.

On

Both (1128), 78B and 11GY.

121 .5 volts.

Replace heater element.

Testing Mirror Lights Table 12 STEP 1. Testing Mirror Lights KEY Off ACTION With headlight switch off, check 15A fuse F8-C for open condition. Check mirror light bulb(s) for open lament. Bulb OK? With headlight and trailer light switch on, disconnect connectors (1127) and (1128). Measure voltage to gnd. at circuit 58J and 58L. With headlight and trailer light switch on, disconnect connectors (1127) and (1128). Measure voltage at circuit 58J to circuit 11-GBM and 58L to 11-GY. (1127) and (1128), 58L and 58J to gnd. 12 1.5 volts. TEST POINTS F8-C SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Replace bulb.

2.

Off

Go to next step. Go to next step.

3.

On

Locate cause of no or low voltage in circuit 58J, 58L or other circuits from fuse F8-C, then repair. Locate open in circuit 11-GBM or 11-GY, then repair.

4.

On

(1127) and (1128), 58L to 11-GBM and 58J to 11-GY.

12 1.5 volts.

Circuits to mirror lights check good.

s08210

2 CAB ACCESSORIES

45

3.9. MOTORIZED MIRRORS


Testing Right Motorized Mirror Table 13 STEP 1. Testing Right Motorized Mirror KEY Off ACTION Check 15A fuse F5-A for open condition. TEST POINTS F5-A SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage in circuit 78C from fuse, then repair.

2.

Off/ On Disconnect connector (437) from motorized mirror switch. Turn key on. At connector (437) measure voltage to ground at circuit 78C. On At connector (437) measure voltage between circuits 78C and 78-GA. With switch (437) in up position, measure resistance between terminals 1 and 5. With switch (437) in up position, measure resistance between terminals 2 and 4. With switch (437) in down position, measure resistance between terminals 1 and 2. With switch (437) in down position, measure resistance between terminals 4 and 5. With switch (437) in neutral position, measure resistance between terminals 4 to 5.

(437), 78C to gnd.

12 1.5 volts.

Go to next step.

3.

(437), 78C to 78-GA.

12 1.5 volts.

Go to next step.

Locate open or poor connection in circuit 78-GA path to ground, then repair. Replace the switch.

4.

Off

Mirror switch, 1 to 5. Mirror switch, 2 to 4. Mirror switch, 1 to 2

<1 ohm.

Go to next step.

5.

Off

<1 ohm.

Go to next step.

Replace the switch.

6.

Off

<1 ohm.

Go to next step.

Replace the switch.

7.

Off

Mirror switch, 4 to 5.

<1 ohm.

Go to next step.

Replace the switch.

8.

Off

Mirror switch, 4 to 5.

>100K ohms.

Go to next step.

Replace the switch.

s08210

46

2 CAB ACCESSORIES

Table 13 STEP 9.

Testing Right Motorized Mirror (cont.) KEY Off ACTION With switch (437) in neutral position, measure resistance between terminals 5 and 6. With switch (437) in neutral position, measure resistance between terminals 1 and 2. With switch (437) in neutral position, measure resistance between terminals 2 and 3. Use diode test feature of uke meter to test the LED in the switch if it is not operating. Disconnect connector (1128). Turn key on. With switch in position that closes contacts between terminal 4 and 5, at (70) measure voltage to ground at circuit 78F. With switches still set, at (1128) measure voltage between circuits 78F and 78E. The control circuits to mirror motor check good. If the mirror still does not operate properly, replace the motor assembly. (1128), 78F to gnd. 12 1.5 volts. TEST POINTS Mirror switch, 5 to 6. SPEC. >100K ohms. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

10.

Off

Mirror switch, 1 to 2

>100K ohms.

Go to next step.

Replace the switch.

11.

Off

Mirror switch, 2 to 3.

>100K ohms.

Go to next step.

Replace the switch.

12.

Off

Go to next step.

13.

Off/ On

Go to next step.

Locate open or poor connection in circuit 78F, then repair.

14.

On

(1128), 78F to 78E.

12 1.5 volts.

Go to next step.

Locate open or poor connection in circuit 78E, then repair.

15.

Off

s08210

2 CAB ACCESSORIES

47

Testing Dual Axis Motorized Mirrors Table 14 STEP 1. Testing Dual Axis Motorized Mirrors KEY Off ACTION Check 15A fuse F5-A for open condition. TEST POINTS F5-A SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage in circuit 78C from fuse, then repair. Locate open or poor connection in circuit 78-GA path to gnd, then repair. Replace the switch.

2.

Off/ On

Disconnect connector (1137) from motorized mirror switch. Turn key on. At connector (1137) measure voltage to ground at circuit 78C. At connector (1137) measure voltage between circuits 78C and 78-GA.

(1137), 78C to gnd.

12 1.5 volts.

Go to next step.

3.

On

(1137), 78C to 78-GA.

12 1.5 volts.

Go to next step.

4.

Off

Turn the mirror switch (1137) knob to left position. Push the knob to up position, measure resistance from terminals (A to D) and H to C). Turn the mirror switch (1137) knob to left position. Push the knob to down position, measure resistance from terminals (A to C) and (H to D). Turn the mirror switch (1137) knob to left position. Push the knob to right position, measure resistance from terminals (A to B) and (H and C). Turn the mirror switch (1137) knob to left position. Push the knob to left position, measure resistance from terminals (A to C) and (H to B).

Mirror switch, (A to D) and (H to C).

<1 ohm.

Go to next step.

5.

Off

Mirror switch, (A to C) and (H and D).

<1 ohm.

Go to next step.

Replace the switch.

6.

Off

Mirror switch (A to B) and H and C).

<1 ohm.

Go to next step.

Replace the switch.

7.

Off

Mirror switch, (A to C) and (H and B).

<1 ohm.

Go to next step.

Replace the switch.

s08210

48

2 CAB ACCESSORIES

Table 14 STEP 8.

Testing Dual Axis Motorized Mirrors (cont.) KEY Off ACTION Turn the mirror switch (1137) knob to right position. Push the knob to up position, measure resistance from terminals (A to E) and (H to F). Turn the mirror switch (1137) knob to right position. Push the knob to down position, measure resistance from terminals (A to F) and (H to E). Turn the mirror switch (1137) knob to right position. Push the knob to left position, measure resistance from terminals (A to F) and (H to G). Turn the mirror switch (1137) knob to right position. Push the knob to right position, measure resistance from terminals (A to G) and (H to F). With switch (1137) in neutral position, measure resistance between all of the terminals. Reconnect connector (1137). Turn ignition key to ACC position. Verify operation of the left mirror. Verify operation of the right mirror. TEST POINTS Mirror switch, (A to E) and (H to F). SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

9.

Off

Mirror switch, (A to F) and (H to E).

<1 ohm.

Go to next step.

Replace the switch.

10.

Off

Mirror switch, (A to F) and (H to G).

<1 ohm.

Go to next step.

Replace the switch.

11.

Off

Mirror switch, (A to G) and (H to F).

<1 ohm.

Go to next step.

Replace the switch.

12.

Off

All mirror switch terminals. Check left mirror operation.

>100K ohms.

Go to next step.

Replace the switch.

13.

Off/ On

Left mirror operates correctly. Right mirror operates correctly.

Go to next step.

Go to Step 15.

14.

On

Mirror circuits check good.

Go to Step 17.

s08210

2 CAB ACCESSORIES

49

Table 14 Testing Dual Axis Motorized Mirrors (cont.) STEP 15. KEY On ACTION Disconnect connector (1127) going to the left mirror. Turn the switch knob to the "L" position. Have an assistant hold the switch in the up position. Measure voltage from middle pin of the three small connectors, to the next pin counter clockwise from the middle pin. Have an assistant hold the switch in the left position. Measure voltage between two outer pins of the three small connectors of connector (1127). Disconnect connector (1128) going to the right mirror. Turn the switch knob to the "R" position. Have an assistant hold the switch in the up position. Measure voltage from middle pin of the three small connectors, to the next pin counter clockwise from the middle pin. Have an assistant hold the switch in the left position. Measure voltage between two outer pins of the three small connectors of connector (1128). TEST POINTS (70), 58J to 78P. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuits 58J, 78R, or 78P, then repair.

16.

On

(1127), 78P to 78N.

12 1.5 volts.

Left mirror circuits check good.

Locate open or poor connection in circuit 78P or 78N, then repair. Locate open or poor connection in circuits 58L or 78F, then repair.

17.

On

(1128), 58L to 78F.

12 1.5 volts.

Go to next step

18.

On

(1128), 58L to 78E.

12 1.5 volts.

Right mirror circuits check good.

Locate open or poor connection in circuit 58L or 78F, then repair.

3.10. TESTING CB POWER SOURCE


Table 15 STEP 1. Testing CB Power Source KEY Off ACTION Remove 20A fuse F5-D and check for open condition. TEST POINTS F5-D SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse.

s08210

50

2 CAB ACCESSORIES

Table 15 STEP 2.

Testing CB Power Source (cont.) KEY Off ACTION Re-install fuse F5-D and measure voltage to gnd. at F5-D and circuit 14AA. At positive terminal of terminal block or cigar lighter socket, measure voltage (circuit 86K) to gnd. At terminal block or cigar lighter socket, measure voltage from circuit 86K to 86-GK. CB power source circuits check good. TEST POINTS F5-D, 14AA to gnd. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 14AA or 14W, then repair. Locate cause of no or low voltage in circuit 86K, then repair. Locate open or poor connection in circuit 86-GK or 11-GI to gnd., then repair.

3.

Off

Positive term. 86K to gnd. Power source 86K to 86-GK.

12 1.5 volts.

Go to next step.

4.

Off

12 1.5 volts.

Go to next step.

5.

Off

3.11. TESTING RADIO-CB ACCOMMODATION PACKAGE


Table 16 STEP 1. Testing Radio-CB Accommodation Package KEY Off ACTION Check fuse F5-B for open condition. TEST POINTS F5-B SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage in circuit 12M, then repair. Locate cause of no or low voltage in circuit 86E, then repair. Locate cause of no or low voltage in circuit 86AE, then repair.

2.

On

With ignition on, measure voltage to gnd. at F5-B and circuit 12M. Disconnect connector (428). Turn ignition on and measure voltage from circuit 86E coming from F5-B to gnd. Disconnect connector (525) and reconnect connector (428). Turn ignition on and at (525) measure voltage from circuit 86AE to gnd.

F5-B, 12M to gnd. (428), 86E to gnd.

12 1.5 volts.

Go to next step.

3.

Off/ On

12 1.5 volts.

Go to next step.

4.

Off/ On

(525), 86AE to gnd.

12 1.5 volts.

Go to next step.

s08210

2 CAB ACCESSORIES

51

Table 16 STEP 5.

Testing Radio-CB Accommodation Package (cont.) KEY Off ACTION At connector (525), measure voltage from circuit 86AE to 86-GE. TEST POINTS (525), 86AE to 86-GE. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 86-GE, 11-GAC, 11-GAB, or 11-GB to gnd., then repair. Replace defective speaker assembly.

6.

Off

Disconnect CB speaker connector, and measure resistance across connector terminals. CB power and speaker circuits check good.

Across CB speaker connector.

3.5 to 8 ohms.

Go to next step.

7.

Off

3.12. TESTING RADIO-CAB SPEAKERS


Table 17 STEP 1. Testing Radio-Cab Speakers KEY Off ACTION Check fuse F5-B for open condition. TEST POINTS F5-B SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage in circuit 12M, then repair. Locate cause of no or low voltage in circuit 86, then repair. Locate open or poor connection in circuit 86-GA or 11-GD to ground, then repair. Locate cause of overload condition, then repair. Replace fuse.

2.

On

With ignition on, measure voltage to gnd. at F5-B and circuit 12M.

F5-B, 12M to gnd.

12 1.5 volts.

Go to next step.

3.

Off/ On

Disconnect connector (426). Turn ignition on and measure voltage from circuit 86 to gnd. Disconnect connector (427) and measure voltage from (426) circuit 86 to (427) 86-GA.

(426), 86 to gnd.

12 1.5 volts.

Go to next step.

4.

On

(426), 86 to (427), 86-GA.

12 1.5 volts.

Go to next step.

5.

Off

Remove fuse F5-C and check for open condition.

F5-C

<1 ohm.

Go to next step.

s08210

52

2 CAB ACCESSORIES

Table 17 STEP 6.

Testing Radio-Cab Speakers (cont.) KEY Off ACTION Re-install fuse F5-C and measure voltage to ground at F5-C and circuit 14AM. At connector (426), measure voltage from circuit 88B to gnd. Was the right front speaker functional prior to being disconnected for this test? Disconnect connector (529), and measure resistance across right front speaker. Reconnect connector (529). At (426) measure resistance across circuits 86C and 86D. Was the left front speaker functional prior to being disconnected for this test? Disconnect connector (530), and measure resistance across left front speaker. Reconnect connector (530). At connector (426) measure resistance across circuits 86A and 86B. Was the right rear speaker functional prior to being disconnected for this test? Disconnect connector (528), and measure resistance across right rear speaker. Across right rear speaker. 3.5 to 8 ohms. Across left front speaker. 3.5 to 8 ohms. Across right front speaker. 3.5 to 8 ohms. TEST POINTS F5-C, 14AM to gnd. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 14AM, then repair. Locate cause of no or low voltage in circuit 88B, then repair.

7.

Off

(426), 88B to gnd.

12 1.5 volts.

Go to next step.

8.

Off

Go to Step Go to next step. 11.

9.

Off

Go to next step.

Replace defective speaker assembly. Locate open or poor connection in circuit 86C or 86D, then repair.

10.

Off

(426), 86C to 86D.

3.5 to 9 ohms.

Go to next step.

11.

Off

Go to Step Go to next step. 14.

12.

Off

Go to next step.

Replace defective speaker assembly. Locate open or poor connection in circuit 86A or 86B, then repair.

13.

Off

(426), 86A to 86B.

3.5 to 9 ohms.

Go to next step.

14.

Off

Go to Step Go to next step. 18.

15.

Off

Go to next step.

Replace defective speaker assembly.

s08210

2 CAB ACCESSORIES

53

Table 17 STEP 16.

Testing Radio-Cab Speakers (cont.) KEY Off ACTION Reconnect connector (528) and disconnect connector (489). Measure resistance across circuits 86U and 86T. Reconnect connector (489) and disconnect sleeper speaker connector (427). At (427) measure resistance across circuits 86W and 86V. Was the left rear speaker functional prior to being disconnected for this test? Disconnect connector (531), and measure resistance across left rear speaker. Reconnect connector (531) and disconnect connector (489). Measure resistance across circuits 86R and 86S. Reconnect connector (489) and disconnect sleeper speaker connector (427). At (427) measure resistance across circuits 86N and 86P. Power and speaker circuits check good. Reconnect all circuits. Across left rear speaker. 3.5 to 8 ohms. TEST POINTS (489), 86U to 86T. SPEC. 3.5 to 9 ohms. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 86U or 86T, then repair.

17.

Off

(427), 86W to 86V.

3.5 to 9 ohms.

Go to next step.

Locate open or poor connection in circuit 86W/86U or 86V/86T, then repair. Go to next step.

18.

Off

Go to Step 22.

19.

Off

Go to next step.

Replace defective speaker assembly. Locate open or poor connection in circuit 86R or 86S, then repair.

20.

Off

(489), 86R to 86S.

3.5 to 9 ohms.

Go to next step.

21.

Off

(427), 86N to 86P.

3.5 to 9 ohms.

Go to next step.

Locate open or poor connection in circuit 86N/86R or 86P/86S, then repair.

22.

Off

s08210

54

2 CAB ACCESSORIES

3.13. TESTING OWNER/OPERATOR SPARE SWITCH (FUSED)


Table 18 Testing Owner/Operator Spare Switch (Fused) STEP 1. KEY Off ACTION Remove fuse F10-A and check for open condition. TEST POINTS F10-A SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage in circuit 14AR, then repair. Locate cause of no or low voltage in circuit 14AS, then repair. Locate open or poor connection in circuit 12-GS or 11-GAL to panel lights gnd. adapter, then repair. Locate cause of no or low voltage in circuit 12S, then repair. Replace defective relay.

2.

Off

Re-install fuse F10-A, and measure voltage from circuit 14AR to ground. Remove relay from connector socket (167). Measure voltage to gnd. at circuit 14AS. At connector socket (167) measure voltage between circuits 14AS and 12-GS. At connector socket (167) measure voltage between circuits 12S and 12-GS. Bench test accessories relay (167) by measuring resistance from terminal 30 to 87A. Bench test accessories relay (167) by connecting +12 volts to terminal 86 of accessory relay, and ground to terminal 85. Measure resistance from terminal 30 to 87. Re-install accessory relay, and disconnect connector (517) from switch. Switch ignition on, and measure voltage from circuit 14AF to ground. At (517) measure voltage from circuit 14AF to 62-GU.

F10-A, 14AR to gnd.

12 1.5 volts.

Go to next step.

3.

Off

(167), 14AS to gnd.

12 1.5 volts.

Go to next step.

4.

Off

(167), 14AS to 12-GS.

12 1.5 volts.

Go to next step.

5.

Off

(167), 12S to 12-GS.

12 1.5 volts.

Go to next step.

6.

Off

Acc. relay, 30 to 87A.

<1 ohm.

Go to next step.

7.

Off

Energized acc. relay, 30 to 87.

<1 ohm.

Go to next step.

Replace defective relay.

8.

Off/ On

(517), 14AF to gnd.

12 1.5 volts.

Go to next step.

Locate cause of no or low voltage in circuit 14AF, then repair.

9.

On

(517), 14AF to 62-GU.

12 1.5 volts.

Go to next step.

Locate open or poor connection in circuit 62-GU, then repair.

s08210

2 CAB ACCESSORIES

55

Table 18 STEP 10.

Testing Owner/Operator Spare Switch (Fused) (cont.) KEY On ACTION Switch headlamps on, and at (517) measure voltage from circuit 62U to ground. With accessory switch in the on position, measure resistance across switch terminals that connect with cavity 5 and 6 of connector (517). With accessory switch in the off position, measure resistance across switch terminals that connect with cavity 5 and 6 of connector (517). Reconnect connector (517), switch ignition and accessories switch to on, and measure voltage at output of circuit 14AQ to ground. Spare switch circuits check good. TEST POINTS (517), 62U to gnd. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 62U, then repair. Replace defective switch.

11.

Off

Across switch terminals.

<1 ohm.

Go to next step.

12.

Off

Across switch terminals.

>100K ohms.

Go to next step.

Replace defective switch.

13.

Off/ On

(517), 14AQ to gnd.

12 1.5 volts.

Go to next step.

Locate cause of no or low voltage in circuit 14AQ, then repair.

14.

Off

3.14. TESTING OWNER/OPERATOR SPARE SWITCH (NON-FUSED)


Table 19 STEP 1. Testing Owner/Operator Spare Switch (Non-Fused) KEY Off ACTION Disconnect connector (517). Switch headlamps on, and measure voltage from circuit 62H to ground at (517). With headlights on, measure voltage from circuit 62H to 62-GH at (517). TEST POINTS (517), 62H to gnd. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 62H, then repair. Locate open or poor connection in circuit 62-GH, then repair.

2.

Off

(517), 62H to 62- GH.

12 1.5 volts.

Go to next step.

s08210

56

2 CAB ACCESSORIES

Table 19 STEP 3.

Testing Owner/Operator Spare Switch (Non-Fused) (cont.) KEY Off ACTION With accessory switch in the on position, measure resistance across switch terminals that connect with cavity 5 and 6 of connector (517). With accessory switch in the off position, measure resistance across switch terminals that connect with cavity 5 and 6 of connector (517). Spare switch circuits check good. Reconnect connector (517). TEST POINTS Across switch terminals. SPEC. <1 ohm. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Replace defective switch.

4.

Off

Across switch terminals.

>100K ohms.

Go to next step.

Replace defective switch.

5.

Off

3.15. TESTING ELECTRIC LOCK RIGHT AND LEFT


Table 20 STEP 1. Testing Electric Lock Right and Left KEY Off ACTION Remove power lock relayunlock (1140). Measure voltage from circuit 81A to ground. Bench check power lock relay-unlock (1140). TEST POINTS (1140), 81A to gnd. SPEC. 12 1.5 volts. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 81A, 81 or fuse F10-A, then repair. Replace defective relay.

2.

Off

Relay (1140).

Relay bench checks good. <1 ohm.

Go to next step.

3.

Off

At (1140), measure resistance between circuit 81-GB and ground. Remove power lock relay (1139). Measure voltage from circuit 81C to ground. Bench check power lock relay (1139).

(1140), 81-GB to gnd. (1139), 81C to gnd.

Go to next step. Go to next step.

Locate open in circuit 81-GB, then repair. Locate cause of no or low voltage in circuit 81C or 81B, then repair. Replace defective relay.

4.

Off

12 1.5 volts.

5.

Off

Relay (1139).

Relay bench checks good. <1 Ohm.

Go to next step.

6.

Off

At (1139), measure resistance between circuit 81-GA and ground.

(1139), 81-GA to gnd.

Go to next step.

Locate open in circuit 81-GA, then repair.

s08210

2 CAB ACCESSORIES

57

Table 20 STEP 7.

Testing Electric Lock Right and Left (cont.) KEY Off ACTION At (1140), measure reistance from circuit 81H to ground. TEST POINTS (1140), 81H to ground. SPEC. Open circuit. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground in circuit 81H, 81J, or 81K, left power lock or right power lock, then repair. Locate short to ground in circuits 81D, 81F, or 81E, left power lock or right power lock, then repair.

8.

Off

At (1139), measure reistance from circuit 81D to ground.

(1140), 81D to ground.

Open circuit.

Go to next step.

9.

Off

Remove connector (1046) from the left power lock and (1047) from the right power lock. Connect a jumper between connector (1046), circuits 81F and 81K. Measure the resistance between (1139) circuit 81D and (1140) circuit 81H. Connect a jumper between connector (1047), circuits 81E and 81J. Measure the resistance between (1139) circuit 81D and (1140) circuit 81H. Test each power lock by applying 12 volts to one terminal and gnd. to the other, then reverse polarity. (1139), 81D and (1140), 81H. <1 ohm.

Go to next step.

10.

Off

Go to next step.

Locate open in circuits 81D, 81F, 81H or 81K.

11.

Off

(1139), 81D and (1140), 81H.

<1 ohm.

Remove jumper. Go to next step.

Locate open in circuits 81D, 81E, 81H or 81J.

12.

Off

Each power lock.

Lock should actuate.

Reconnect Replace defective (1139) power lock. and (1140) to power locks.Go to next step. Go to next step. Replace switch (1042).

13.

Off

Remove driver switch (1042). With switch in the lock position, measure resistance between terminal 2B and 1. With switch in the unlock position, measure resistance between terminal 2B and 3.

Driver switch (1042), terminal 2B and 1. Driver switch (1042), terminal 2B and 3.

<1 Ohm

14.

Off

<1 Ohm

Go to next step.

Replace switch (1042).

s08210

58

2 CAB ACCESSORIES

Table 20 STEP 15.

Testing Electric Lock Right and Left (cont.) KEY Off ACTION At (1042), measure resistance between circuit 91-GG and ground. At (1042), measure resistance between circuit 81M and ground. At (1042), measure resistance between circuit 81N and ground. At (1042), install a jumper between circuit 81M and 81N. Measure resistance between (1139) circuit 81M and (1140) circuit 81N. Remove passenger switch (1043). With switch in the lock position, measure resistance between terminal 2B and 1. With switch in the unlock position, measure resistance between terminal 2B and 3. At (1043), measure resistance between circuit 81-GJ and ground. At (1043), measure resistance between circuit 81L and ground. At (1043), measure resistance between circuit 81P and ground. At (1043), install a jumper between circuit 81L and 81P. Measure resistance between (1139) circuit 81M and (1140) circuit 81N. TEST POINTS (1042), 91-GG and ground. (1042), 81M and ground. (1042), 81N and ground. (1139), 81M and (1140), 81N. SPEC. <1 ohm. YES- IN SPEC. Go to next step. Go to next step. Go to next step. Remove jumper. Go to next step. Go to next step. NO-OUT OF SPEC. Locate open in circuit 91-GG, 91-GC or 91-G. Locate short to gnd. in circuit 81M or 81L. Locate short to gnd. in circuit 81N or 81P. Locate open in circuit 81M or 81N, then repair.

16.

Off

Open circuit. Open circuit. <1 ohm.

17.

Off

18.

Off

19.

Off

Passenger switch (1043), terminal 2B and 1. Passenger switch (1043), terminal 2B and 3. (1043), 81-GG and ground. (1043), 81L and ground. (1043), 81P and ground. (1139), 81M and (1140), 81N.

<1 ohm.

Replace switch (1043).

20.

Off

<1 ohm.

Go to next step.

Replace switch (1043).

21.

Off

<1 ohm.

Go to next step. Go to next step. Go to next step. Remove jumper. Go to next step.

Locate open in circuit 81-GG, 81-GC or 81-G. Locate short to gnd. in circuit 81L or 81M. Locate short to gnd. in circuit 81P or 81N. Locate open in circuit 81L or 81P, then repair.

22.

Off

Open circuit. Open circuit. <1 ohm.

23.

Off

24.

Off

s08210

2 CAB ACCESSORIES

59

Table 20 STEP 25.

Testing Electric Lock Right and Left (cont.) KEY Off ACTION Remove (1043), install a jumper between circuit 81L and 81P. Measure resistance between (1139) circuit 81L and (1140) circuit 81P. Reconnect all connectors and relays. Power lock circuits check good. If power locks are not operating check for a mechanical failure in the lock mechanism. TEST POINTS (1139), 81L and (1140), 81P. SPEC. <1 ohm. YES- IN SPEC. Remove Jumper. Go to next step. NO-OUT OF SPEC. Locate open in circuit 81L or 81P, then repair.

26.

Off

3.16. TESTING INTERVISION CIRCUITS


Table 21 STEP 1. Testing InterVision Circuits KEY On ACTION Does the InterVision module have a visible display? 13M to gnd. 12 1.5 volts. TEST POINTS SPEC. YES- IN SPEC. Go to Step 6. Go to next step. NO-OUT OF SPEC. Go to next step.

2.

Off/ On Disconnect the InterVision display connector (1156). Turn ignition on, and measure voltage from circuit 13M to ground. On Measure voltage from circuit 13M to 11-GK. Measure voltage from circuit 14B to ground.

Locate cause of no or low voltage in circuit 13M, then repair.

3.

13M to 11-GK. 14B to ground.

12 1.5 volts. 12 1.5 volts.

Go to next step. Go to next step.

Locate open in circuit 11-GK, then repair. Locate cause of no or low voltage in circuit 14B, then repair. Locate cause of no or low voltage in circuit 62W, then repair.

4.

Off

5.

Off

With headlights on and panel lights all the way up, measure voltage from circuit 62W to ground.

62W to ground.

12 1.5 volts.

Power circuits check good. Replace InterVision module.

s08210

60

2 CAB ACCESSORIES

Table 21 STEP 6.

Testing InterVision Circuits (cont.) KEY Off ACTION Does the InterVision display show a problem receiving data from the data link? Disconnect data link pos. connector (514) and data link neg. connector (515). At (1156), measure resistance from circuit 98H(-) and 98G (+) to ground. Connect a jumper between data link pos. connector (514), cavity F and data link neg. connector (515), cavity F. At (1156), measure resistance between circuit 98H(-) and 98G (+). At (1156), measure resistance from circuits 91A and 91 to ground. Connect a jumper between RS-232 connector (1170), circuit 91A and circuit 91. At (1156), measure resistance between circuit 91A and 91. Connect a jumper between RS-232 connector (1170), circuit 91A and circuit 91-G. At (1156), measure resistance between circuit 91A and 91-G. (1156), 98H(-) and 98G (+) to ground. TEST POINTS SPEC. Display shows problem with data link. Open circuit. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. If InterVision is not working correctly, replace the module.

7.

Off

Go to next step.

Locate short to ground in circuit 98H(-) or 98G (+), then repair.

8.

Off

(1156), 98H(-) and 98G (+).

<1 ohm.

Data link circuits check good. Go to next step to check RS- 232 circuits. Go to next step.

Locate open in circuit 98H(-) or 98G (+), then repair.

9.

Off

(1156), 91A, 91 to ground.

Open circuit.

Locate short to ground in circuits 91A and 91, then repair. Locate open in circuit 91A or 91, then repair.

10.

Off

(1156), 91A and 91.

<1 ohm.

Go to next step.

11.

Off

(1156), 91A and 91-G.

<1 ohm.

All InterVision circuits check good. Replace InterVision module.

Locate open in circuit 91A or 91-G, then repair.

s08210

2 CAB ACCESSORIES

61

3.17. TESTING EATON VORAD COLLISION AVOIDANCE EVT-300 CIRCUITS


Table 22 Testing EATON VORAD Collision Avoidance EVT-300 Circuits STEP 1. KEY On ACTION Does the EATON VORAD Collision Avoidance EVT-300 module have a visible display? Disconnect the EATON VORAD Collision Avoidance EVT-300 CPU connector (1227). Turn ignition on, and measure voltage from circuit 73A to ground. Measure voltage from circuit 73A to 73GA. Press brake on. Measure voltage from circuit 73H to ground. With headlights on and panel lights all the way up, measure voltage from circuit 73J to ground. 73A to gnd. 12 1.5 volts. TEST POINTS SPEC. YES- IN SPEC. Go to Step 6. NO-OUT OF SPEC. Go to next step.

2.

Off/ On

Go to next step.

Locate cause of no or low voltage in circuit 73A, then repair.

3.

On

73A to 73GA.

12 1.5 volts. 12 1.5 volts.

Go to next step. Go to next step.

Locate open in circuit 73GA, then repair. Locate cause of no or low voltage in circuit 73H, then repair. Locate cause of no or low voltage in circuit 73J, then repair.

4.

Off

73H to ground.

5.

Off

73J to ground.

12 1.5 volts.

Power circuits check good. Replace EVT-300 CPU. Go to next step.

6.

Off

Does the Driver display show a problem receiving data from the data link?

Display shows problem with data link. (1227), 98EV(-) and 98EV(+) to ground. Open circuit.

If driver display is not working correctly, replace the display. Locate short to ground in circuit 98EV(-) or 98EV(+), then repair.

7.

Off

Disconnect data link pos. connector (514) and data link neg. connector (515). At (1227), measure resistance from circuit 98EV(-) and 98EV(+) to ground.

Go to next step.

s08210

62

2 CAB ACCESSORIES

Table 22 Testing EATON VORAD Collision Avoidance EVT-300 Circuits (cont.) STEP 8. KEY Off ACTION Connect a jumper between data link pos. connector (514), cavity F and data link neg. connector (515), cavity F. At (1227), measure resistance between circuit 98EV(-) and 98EV(+). Disconnect driver display data link connector (1228). At (1227), measure resistance from circuits 73U, 73V, 73W and 73X to ground. Connect a jumper between driver display data links connector (1228). At (1227), measure resistance between circuits 73U, 73V, 73W and 73X. TEST POINTS (1227), 98EV(-) and 98EV(+). SPEC. <1 ohm. YES- IN SPEC. Data link circuits check good. Replace EVT-300 CPU. Go to next step. NO-OUT OF SPEC. Locate open in circuit 98EV(-) or 98EV(+), then repair.

9.

Off

(1227), 73U, 73V, 73W and 73X to ground.

Open circuit.

Locate short to ground in circuits 73U, 73V, 73W and 73X, then repair. Locate open in circuits 73U, 73V, 73W and 73X, then repair.

10.

Off

(1227), circuits 73U, 73V, 73W and 73X.

<1 ohm.

Data link circuits check good. Replace driver display or EVT-300 CPU. Go to next step.

11.

Off

Disconnect front antenna data link connector (1239). At (1227), measure resistance from circuits 73B, 73C, 73D and 73E to ground. Connect a jumper between front antenna data links connector (1239). At (1227), measure resistance between circuits 73B, 73C, 73D and 73E

(1227), 73B, 73C, 73D and 73E to ground.

Open circuit.

Locate short to ground in circuits 73B, 73C, 73D and 73E, then repair. Locate open in circuits 73U, 73V, 73W and 73X, then repair.

12.

Off

(1227), circuits 73U, 73V, 73W and 73X.

<1 ohm.

Data link circuits check good. Replace front antenna or EVT-300 CPU.

s08210

2 CAB ACCESSORIES

63

3.18. TESTING TEMPERATURE/COMPASS DISPLAY CIRCUITS


Table 23 STEP 1. Testing Temperature/Compass Display Circuits KEY On ACTION Does the Temperature/ Compass module have a visible display? Disconnect the Temp/Comp display connector (1282). Turn ignition on, and measure voltage from circuit 41A to ground. Measure voltage from circuit 41A to 41G. Measure voltage from circuit 41B to ground. 41A to gnd. 12 1.5 volts. TEST POINTS SPEC. YES- IN SPEC. Go to Step 6. Go to next step. NO-OUT OF SPEC. Go to next step.

2.

Off/ On

Locate cause of no or low voltage in circuit 41A, then repair.

3.

On

41A to 41G.

12 1.5 volts. 12 1.5 volts.

Go to next step. Go to next step.

Locate open in circuit 41G., then repair. Locate cause of no or low voltage in circuit 41B, then repair.

4.

Off

41B to ground.

5.

Off

With headlights on and panel lights all the way up, measure voltage from circuit 41E to ground.

41E to ground.

12 1.5 volts.

Power Locate cause of circuits no or low voltage check in circuit 41E, then good. repair. Replace Temp/Comp module. Go to next step. If Temp/Comp is not working correctly, replace the module. Locate short to ground in circuits 41C and 41D, then repair. Locate open in circuits 41C and 41D, then repair.

6.

Off

Does the Temp/Comp display show a problem receiving data from the temp sensor? Disconnect temp sensor connector (1284). At (1282), measure resistance from circuits 41C and 41D to ground. Connect a jumper between temp sensor connector (1284). At (1282), measure resistance between circuits 41C and 41D. (1282), 41C and 41D to ground.

Display shows problem with temp sensor. Open circuit.

7.

Off

Go to next step.

8.

Off

(1282), circuits 41C and 41D.

<1 ohm.

Circuits check good. Replace temp sensor.

s08210

64

2 CAB ACCESSORIES

Table 23 STEP 9.

Testing Temperature/Compass Display Circuits (cont.) KEY Off ACTION Does the Temp/Comp display show a problem receiving data from the compass module? TEST POINTS SPEC. Display shows problem with compass module. (1282), 41F, 41H and 41J to ground. Open circuit. YES- IN SPEC. Go to next step. NO-OUT OF SPEC. If Temp/Comp is not working correctly, replace the module.

10.

Off

Disconnect compass module connector (1283). At (1282), measure resistance from circuits 41F, 41H and 41J to ground. Connect a jumper between temp sensor connector (1283). At (1282), measure resistance between circuits 41F, 41H and 41J.

Go to next step.

Locate short to ground in circuits 41F, 41H and 41J, then repair.

11.

Off

(1282), circuits 41F, 41H and 41J.

<1 ohm.

Circuits check good. Replace compass module.

Locate open in circuits 41F, 41H and 41J, then repair.

3.19. TESTING ROAD RELAY IV CIRCUITS


Table 24 Testing Road Relay IV Circuits STEP 1. KEY On ACTION Does the Road Relay IV module have a visible display? Disconnect the Road Relay IV display connector (662). Turn ignition on, and measure voltage from circuit 13PB to ground. Measure voltage from circuit 13PB to 11-GPD. Measure voltage from circuit 14B to ground. 13PB to gnd. 12 1.5 volts. TEST POINTS SPEC. YES- IN SPEC. Go to Step 6. Go to next step. NO-OUT OF SPEC. Go to next step.

2.

Off/ On

Locate cause of no or low voltage in 5A fuse F10B, circuit 13PB, then repair. Locate open in circuit 11-GPD, then repair. Locate cause of no or low voltage in 5A fuse F10A, circuit 14B, then repair.

3.

On

13PB to 11-GPD. 14B to ground.

12 1.5 volts. 12 1.5 volts.

Go to next step. Go to next step.

4.

Off

s08210

2 CAB ACCESSORIES

65

Table 24 Testing Road Relay IV Circuits (cont.) STEP 5. KEY Off ACTION With headlights on and panel lights all the way up, measure voltage from circuit 62EA to ground. TEST POINTS 62EA to ground. SPEC. 12 1.5 volts. YES- IN SPEC. Power circuits check good. Replace Road Relay IV module. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 62EA, then repair.

6.

Off

Does the Road Relay IV display show a problem receiving data from the data link? Disconnect data link pos. connector (514) and data link neg. connector (515). At (662), measure resistance from circuit 98D(-) and 98E(+) to ground. Connect a jumper between data link pos. connector (514), cavity F and data link neg. connector (515), cavity F. At (662), measure resistance between circuit 98D(-) and 98E(+). (662), 98D(-) and 98E(+) to ground.

Display shows problem with data link. Open circuit.

If Road Relay IV is not working correctly, replace the module. Locate short to ground in circuit 98D(-) or 98E(+), then repair.

7.

Off

Go to next step.

8.

Off

(662), 98D(-) and 98E(+).

<1 ohm.

Data link circuits check good. Replace Road Relay IV module.

Locate open in circuit 98D(-) or 98E(+), then repair.

3.20. TESTING HEATED SEAT-DRIVER


Table 25 STEP 1. Testing Heated Seat-Driver KEY Off ACTION Check fuse F10-A for open condition. TEST POINTS F10-A SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage in circuits 13EF, 13P, 13H, then repair.

2.

On

With ignition on, measure voltage to ground at F10-A and circuit 13EF.

F10-A, 13EF to gnd.

12 1.5 volts.

Go to next step.

s08210

66

2 CAB ACCESSORIES

Table 25 STEP 3.

Testing Heated Seat-Driver (cont.) KEY Off/ On ACTION Disconnect connector (1331). Turn ignition on and measure voltage, circuit 38A from terminal B to gnd. The driver seat heater OFF/ON/ HI/LO switch in seat, with switch in OFF position, measure resistance between terminals A and B. The driver seat heater OFF/ON/ HI/LO switch in seat, with switch in ON/HI position, measure resistance between terminals A and B. The driver seat heater OFF/ON/ HI/LO switch in seat, with switch in ON/LO position, measure resistance between terminals A and B. At connector (1331), measure resistance, circuit 38-G, terminals A to gnd. Reconnect connector (1331). Heated seat-driver circuits check good. TEST POINTS (1331), 38A to gnd. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 38A, then repair.

4.

Off

Driver seat heater switch A and B. Driver seat heater switch A and B. Driver seat heater switch A and B.

>100 K ohms.

Go to next step.

Replace defective driver seat heater switch.

5.

Off

100 ohms.

Go to next step.

Replace defective driver seat heater switch.

6.

Off

50 ohms.

Go to next step.

Replace defective driver seat heater switch.

7.

Off

(1331), 38-G, terminals A to gnd.

0 ohms.

Go to next step.

Locate open or poor connection in circuit 38-G to gnd, then repair.

8.

Off

3.21. TESTING HEATED SEAT-PASSENGER


Table 26 Testing Heated Seat-Passenger STEP 1. KEY Off ACTION Check fuse F10-A for open condition. TEST POINTS F10-A SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse.

s08210

2 CAB ACCESSORIES

67

Table 26 Testing Heated Seat-Passenger (cont.) STEP 2. KEY On ACTION With ignition on, measure voltage to ground at F10-A and circuit 13EG. Disconnect connector (1332). Turn ignition on and measure voltage, circuit 38B from terminal B to gnd. The passenger seat heater OFF/ON/ HI/LO switch in seat, with switch in OFF position, measure resistance between terminals A and B. The passenger seat heater OFF/ON/ HI/LO switch in seat, with switch in ON/HI position, measure resistance between terminals A and B. The passenger seat heater OFF/ON/ HI/LO switch in seat, with switch in ON/LO position, measure resistance between terminals A and B. At connector (1332), measure resistance, circuit 38-GB, terminals A to gnd. Reconnect connector (1332). Heated seat-passenger circuits check good. TEST POINTS F10-A, 13EG to gnd. (1332), 38B to gnd. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuits 13EG, 13P, 13H, then repair. Locate cause of no or low voltage in circuit 38B, then repair.

3.

Off/ On

12 1.5 volts.

Go to next step.

4.

Off

Passenger seat heater switch A and B. Passenger seat heater switch A and B.

>100K ohms.

Go to next step.

Replace defective passenger seat heater switch.

5.

Off

100 ohms.

Go to next step.

Replace defective passenger seat heater switch.

6.

Off

Passenger 50 ohms. seat heater switch A and B.

Go to next step.

Replace defective passenger seat heater switch.

7.

Off

(1332), 38-GB, terminals A to gnd.

0 ohms.

Go to next step.

Locate open or poor connection in circuit 38-GB to gnd, then repair.

8.

Off

4. COMPONENT LOCATIONS
B1 Battery Stud.. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . . . . . Power Distribution Panel B2 Battery Stud.. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . . . . . Power Distribution Panel (9) Washer Pump.. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . . . . . Washer Bottle (20) Horn Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Frt Engine Crossmember (76) Horn (Inline). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Front End Harness at Lower Left, Radiator (142) Wiper High Speed Delay Relay. . . . . . . . . . . . . . .. . . . . . Power Distribution Panel

s08210

68

2 CAB ACCESSORIES

(143) Wiper Low Speed Delay Relay. . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (167) Owner/Operator Spare Switch. . . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (313) Defroster Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Front Center Roof (426) Radio Connector #1. . . .. . . . .. . . .. . . .. . . . .. . . .. .. . . . . . Radio Pigtail to Cab Harness (428) Roof Connector #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Right Instrument Panel/Roof Conn. to Cab Harness (429) Roof Connector #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Rt Instrument Panel/Roof Conn. to Cab Harness. (430) Wiper Motor Connector. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Wiper Motor (437) Right Motorized Mirror Switch. .. . .. .. . .. . .. . ... . . . . . At Switch Cluster (450) Lt Door Courtesy Light. . . . .. . . . . . . .. . . . . . . .. . . .. . . . . . At Switch Cluster (451) Rt Door Courtesy Light. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Switch Cluster (453) Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel (454) Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel (455) Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel (456) Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Center Instrument Panel (463) R7 Horn Relay. . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . .. . . . . . Power Distribution Panel (489) Roof Connector #3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Lt Instrument Panel (494) I1 Ignition Adapter. .. . . . .. . . . .. . . . .. . . . .. . . . .. . .. . . . . . Behind Fuse Panel (495) I2 Ignition Adapter. .. . . . .. . . . .. . . . .. . . . .. . . . .. . .. . . . . . Behind Fuse Panel (497) B1 Battery Adapter. .. . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . Behind Fuse Panel (498) B2 Battery Adapter. .. . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . Behind Fuse Panel (499) Accessory Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Fuse Panel Right Side (501) Accessory Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Fuse Panel Right Side (503) LED Panel Lights Feed Adapter. . . . . . . . . . . . . .. . . . . . Behind Instrument Panel (504) LED Panel Lights Feed Adapter. . . . . . . . . . . . . .. . . . . . Behind Instrument Panel/Switch Breakout (506) LED Panel Lights Gnd Adapter. . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel/Switch Breakout (514) Data link Pos... . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . .. . . . . . Behind Instrument Cluster (515) Data link Neg... .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . ... . . . . . Behind Instrument Cluster (517) Spare Accessory Switch. .. . . . . .. . . . . .. . . . . .. . .. . . . . . At Switch Cluster (525) CB Radio Connection. . .. . . . . . . . .. . . . . . . . .. . . . .. . . . . . At CB Radio (528) Right Rear Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Speaker Pigtail (Inline) (529) Right Front Speaker.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . At Speaker Pigtail (Inline) (530) Left Front Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Speaker Pigtail (Inline) (531) Left Rear Speaker.. . . . .. . . . . .. . . . .. . . . .. . . . .. . .. . . . . . At Speaker Pigtail (Inline) (662) Road Relay Display Module Connector. . . . . .. . . . . . Behind Road Relay Display Module (1039) Drivers Side Left Window Switch. . . . . . . . . . .. . . . . . In Drivers Door (1040) Drivers Side Right Window Switch. . . . . . . . .. . . . . . In Drivers Door (1041) Passengers Side Window Switch. . . . . . . . . .. . . . . . Right Door (1042) Driver Lock Switch. . . .. . . . . . . . . . . . . . . .. . . . . . . .. . . . . . Left Door (1043) Passenger Lock Switch. . . . . . . . . . . . . . . . . . . . . .. . . . . . Right Door (1044) Left Power Window Motor. .. . .. .. .. .. .. .. .. ... . . . . . Left Door (1045) Right Power Window Motor. . . . . . . . . . .. . . . . . .. . . . . . Right Door (1046) Left Power Lock. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . .. . . . . . Left Door (1047) Right Power Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Right Door (1127) Left Mirror Connection. . . . . . .. . . . . . . . . . .. . . . . .. . . . . . Left Door Exterior (1128) Right Mirror Connection. . . . . . . . . . . . . . . . . . . . . .. . . . . . Right Door Exterior (1137) Dual Axis Motorized Mirrors.. .. .. .. .. .. .. .. ... . . . . . At Switch Cluster (1138) Right & Left Electric Window Relay. . . . . . . . .. . . . . . Power Distribution Panel (1139) Power Lock Relay. .. . .. . . .. . .. . .. . .. . .. . .. . . ... . . . . . Power Distribution Panel (1140) Power Lock Relay Unlock. . . .. . . .. . . .. . . .. .. . . . . . Power Distribution Panel (1156) InterVision Connector. . .. .. . .. . .. .. . .. . .. .. . ... . . . . . Behind InterVision Display (1158) Driver Right Window Switch. . . . . . . . . . . . . . . . .. . . . . . At Switch Cluster
s08210

2 CAB ACCESSORIES

69

(1159) Rt Electric Window Relay. . . . . . . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (1170) InterVision RS-232 Connector. . . . . . . . . . . . . . .. . . . . . Below Instrument Panel (1171) Windshield Washer W/Wiper Delay Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Switch Cluster (1226) VORAD CPU Ground Connector. . .. . .. . .. . .. . . . . . On Doghouse Storage Compartment (1227) VORAD CPU Connector. . . . . . . . . . . . . . . . . . . . .. . . . . . On Doghouse Storage Compartment (1228) VORAD Driver Display Unit Connector. . . . .. . . . . . On Instrument Wing Panel (1229) VORAD Right Side Display Unit Connector. .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . . On Apillar Panel (1230) VORAD Harness Connector To Right Side Sensor. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . . . . On Right Side Cab (1233A) J1939 VORAD Connector. . . . . . .. . . . . . . . . . .. . . . . . Below Instrument Panel (1239) VORAD Front Antenna Connector. . . . . . . . . .. . . . . . On Front Bumper (1240) VORAD Right Side Sensor Connector. . . . .. . . . . . On Right Side Fuel Tank Step (1281) Temp/Comp Roof Connector. . . . . . . . . . . . . . . .. . . . . . Above Windshield In Roof (1282) Temp/Comp Display Unit Connector. . . . . . . .. . . . . . Above Windshield (1283) Compass Module Connector. . . . . . . . . . . . . . . .. . . . . . Behind Fuse Panel (1284) Temp Sensor Connector. . . . . . . . . . . . . . . . . . . . .. . . . . . In Front Engine Compartment (1331) Drivers Heated Seat Connector. . . . . . . . . . . .. . . . . . In Drivers Seat (1332) Heated Passenger Seat Connector. . . . . . . . .. . . . . . In Passenger Seat

s08210

70

2 CAB ACCESSORIES

Figure 5

Instrument Panel Installation Showing Cigar Lighter and Aux. Power Source 1. 2. 3. 4. 5. WING PANEL L.H. INSTRUMENT PANEL AUX. POWER SOURCE LOCATION CIGAR LIGHTER LOCATION INSTRUMENT PANEL SUPPORT RAIL

s08210

2 CAB ACCESSORIES

71

Figure 6

Wing Instrument Panel Showing Analog Clock 1. 2. 3. 4. MAIN CAB HARNESS FUSE, 10 AMP AND CIRCUIT 88F INSTRUMENT WIRING, PART OF MAIN CAB HARNESS ANALOG CLOCK GAUGE (526)

s08210

72

2 CAB ACCESSORIES

Figure 7

Right Side Only Power Window Wiring 1. 2. 3. 4. 5. 6. 7. DOOR HARNESS (1045), CIR 83C AND 83D (1157), CIR 83C AND 83D RIGHT WINDOW MOTOR (1158), RIGHT WINDOW SWITCH INSTRUMENT WIRING HARNESS CAB HARNESS

s08210

2 CAB ACCESSORIES

73

Figure 8 Right Side Only, Power Window Switch and Power Feed 1. FUSE F4B, 25 AMP 2. ELECTRIC WINDOW RELAY (1159) 3. ELECTRIC WINDOW SWITCH (1158)

s08210

74

2 CAB ACCESSORIES

Figure 9 Electric Window/Electric Lock (Right Side Shown) Door Wiring 1. 2. 3. 4. 5. 6. 7. 8. (1049), ELECTRIC LOCK CONNECTOR (1033), ELECTRIC WINDOW CONNECTOR COURTESY LIGHT SWITCH (1041), ELECTRIC WINDOW SWITCH (1043), ELECTRIC LOCK SWITCH (1047), RIGHT POWER LOCK COURTESY LIGHT (1045), RIGHT WINDOW MOTOR

s08210

2 CAB ACCESSORIES

75

Figure 10

Electric Windows, Power Wiring 1.(1033), ELECTRIC WINDOW RIGHT DOOR CONNECTOR 2. (497), B1 BATTERY ADAPTER CONNECTOR 3. (499), A1 ACCESSSORY ADAPTER 4. (1138), ELECTRIC WINDOW RELAY 5. (503), PANEL LIGHTS FEED ADAPTER 6. (455), GROUND ADAPTER 7. (1034), ELECTRIC WINDOW LEFT DOOR CONNECTOR 8. LEFT COURTESY LIGHT & DOOR SWITCH CONNECTOR 9. ELECTRIC WINDOW HARNESS 10. FUSE F4B, 20A 11. RIGHT COURTESY LIGHT & DOOR SWITCH CONNECTOR

s08210

76

2 CAB ACCESSORIES

Figure 11

Electric Lock, Power Wiring 1. (1049), ELECTRIC LOCK RIGHT DOOR CONNECTOR 2. (497), B1 BATTERY ADAPTER CONNECTOR 3. FUSE F1A, 10A 4. (1140), POWER LOCK RELAY-UNLOCK 5. (1139), POWER LOCK RELAY 6. (456), GROUND ADAPTER 7. (503), PANEL LIGHTS FEED ADAPTER 8. (1048), ELECTRIC LOCK LEFT DOOR CONNECTOR 9. LEFT COURTESY LIGHT & DOOR SWITCH CONNECTOR 10. ELECTRIC LOCK HARNESS 11. RIGHT COURTESY LIGHT & DOOR SWITCH CONNECTOR

s08210

2 CAB ACCESSORIES

77

Figure 12

Windshield Wiper/Washer Wiring 1. 2. 3. 4. 5. 6. 7. CHASSIS HARNESS WASHER BOTTLE (3), DASH PANEL CONNECTOR POWER DISTRIBUTION CENTER TO WIPER/WASHER SWITCH TO POWER DISTRIBUTION CENTER WASHER HARNESS

s08210

78

2 CAB ACCESSORIES

Figure 13 Wiper Motor and Connector 1. TO POWER DISTRIBUTION CENTER (THROUGH ENGINE HARNESS) 2. WIPER MOTOR

s08210

2 CAB ACCESSORIES

79

Figure 14 Wiper Switch Wiring 1. SWITCH PANEL 2. WIPER/WASHER SWITCH (1171) 3. MAIN CAB WIRING

s08210

80

2 CAB ACCESSORIES

Figure 15

Wiper Wiring at Power Distribution Center 1. 2. 3. 4. 5. (143), WIPER-HIGH SPEED DELAY RELAY (142), WIPER-LOW SPEED DELAY RELAY TO CAB WIRING TO CAB WIRING FUSE F4D, 15A

s08210

2 CAB ACCESSORIES

81

Figure 16 Horn Wiring at Power Distribution Center 1. 2. 3. 4. (B1), BATTERY STUD (B2), BATTERY STUD FUSE F-5C, 15A HORN RELAY (463R7)

s08210

82

2 CAB ACCESSORIES

Figure 17

Horn Button Assembly (Slip Ring) 1. 2. 3. 4. CIRCUIT 85C MAIN CAB WIRING HARNESS CIRCUIT 85C HORN BUTTON ASSEMBLY

s08210

2 CAB ACCESSORIES

83

Figure 18

Horn Installation 1. 2. 3. 4. 5. 6. STANDARD ELECTRIC HORN, HIGH NOTE OPTIONAL ELECTRIC HORN, LOW NOTE ENGINE FRONT MOUNTING BRACKET ENGINE FRONT CROSSMEMBER LEFT SIDE MEMBER (76), CIRCUITS 85B AND 85G

s08210

84

2 CAB ACCESSORIES

Figure 19

Heated, Lighted, and Motorized Mirror (Right Door Shown) 1. HEATED, LIGHTED AND MOTORIZED MIRROR 2. (1128) MIRROR CONNECTOR 3. ANTENNA CONNECTOR

s08210

2 CAB ACCESSORIES

85

Figure 20 Power Circuits for Heated, Lighted, and Motorized Mirrors 1. 2. 3. 4. 5. 6. 7. (973) MIRROR POWER CONNECTOR (437) RIGHT MOTORIZED MIRROR SWITCH (1054) RIGHT DOOR COURTESY LIGHT AND MIRROR CONNECTION (1116) MIRROR LIGHTS CONNECTOR (456) GROUND ADAPTER (504) PANEL LIGHT FEED ADAPTER (1050) LEFT DOOR COURTESY LIGHT AND MIRROR CONNECTION

s08210

86

2 CAB ACCESSORIES

Figure 21

Power Circuits for Dual Axis Mirrors 1. 2. 3. 4. 5. (973) MIRROR POWER CONNECTOR (1137) DUAL AXIS MOTORIZED MIRROR SWITCH (1054) RIGHT DOOR COURTESY LIGHT AND MIRROR CONNECTION (456) GROUND ADAPTER (1050) LEFT DOOR COURTESY LIGHT AND MIRROR CONNECTION

s08210

2 CAB ACCESSORIES

87

Figure 22

CB Radio Accommodation Wiring 1. 2. 3. 4. 5. 6. 7. (525) CB RADIO POWER CONNECTION CB ANTENNA CONNECTION CB SPEAKER CONNECTION CB SPEAKER LEFT DOOR ANTENNA CONNECTION ANTENNA MULTIPLEXER RIGHT DOOR ANTENNA CONNECTION

s08210

88

2 CAB ACCESSORIES

Figure 23 Entertainment Radio Wiring 1. ENTERTAINMENT RADIO 2. RIGHT REAR SPEAKER 3. RIGHT FRONT SPEAKER 4. LEFT FRONT SPEAKER 5. LEFT REAR SPEAKER 6. ANTENNA MULTIPLEXER 7. RADIO CONNECTOR #1 (426) 8. ROOF CONNECTOR #2 (428) 9. ROOF CONNECTOR #3 (489) 10. RADIO CONNECTOR #2 (427) 11. ANTENNA CONNECTOR

s08210

2 CAB ACCESSORIES

89

Figure 24 InterVision Wiring 1. 2. 3. 4. TO FUSE F10A INTERVISION DISPLAY MODULE (1156) INTERVISION DISPLAY MODULE CONNECTION INTERVISION HARNESS

s08210

90

2 CAB ACCESSORIES

Figure 25

InterVision RS-232 Wiring 1. TO INTERVISION DISPLAY MODULE 2. (1170) RS-232 CONNECTOR

s08210

2 CAB ACCESSORIES

91

Figure 26

Owner Operator Spare Switch 1. 2. 3. 4. RELAY (167) FUSE F10A (517) OWNER/OPERATOR SPARE SWITCH INSTRUMENT WIRING HARNESS

s08210

92

2 CAB ACCESSORIES

Figure 27 EATON VORAD Collision Avoidance EVT-300 Circuits Front Antenna 1. EATON VORAD SPEED SENSOR TRANSMITTER FRONT ANTENNA 2. FRONT ANTENNA WIRING HARNESS

s08210

2 CAB ACCESSORIES

93

Figure 28 EATON VORAD Collision Avoidance EVT-300 Circuits Side Sensor W/51, 72 Pro Sleeper 1. EATON VORAD SIDE SENSOR 2. SIDE SENSOR WIRING HARNESS

s08210

94

2 CAB ACCESSORIES

Figure 29

EATON VORAD Collision Avoidance EVT-300 Circuits Side Sensor W/Daycab 1. EATON VORAD SIDE SENSOR W/PAINTED STEPS 2. SIDE SENSOR WIRING HARNESS 3. EATON VORAD SIDE SENSOR W/ALUMINUM STEPS

s08210

2 CAB ACCESSORIES

95

Figure 30 EATON VORAD Collision Avoidance EVT-300 Circuits Side Sensor Chassis Skirt 1. CHASSIS SKIRT 2. EATON VORAD SIDE SENSOR 3. SIDE SENSOR WIRING HARNESS

s08210

96

2 CAB ACCESSORIES

Figure 31

EATON VORAD Collision Avoidance EVT-300 Circuits Driver Display Unit 1. EATON VORAD COLLISION AVOIDANCE DRIVER DISPLAY/CONTROL ELECTRONIC CONTROL 2. INSTRUMENT PANEL

s08210

2 CAB ACCESSORIES

97

Figure 32

EATON VORAD Collision Avoidance EVT-300 Circuits Side Display Unit 1. A-PILLAR TRIM COVER 2. EATON VORAD SIDE DISPLAY MODULE INSTRUMENT

s08210

98

2 CAB ACCESSORIES

Figure 33

EATON VORAD Collision Avoidance EVT-300 Circuits CPU 1. 2. 3. 4. LOWER COVER CONSOLE PANEL EATON VORAD COLLISION AVOIDANCE CPU ELECTRONIC CONTROL ARROW C, SEE NEXT FIGURE CENTER CONSOLE INSTRUMENT PANEL

s08210

2 CAB ACCESSORIES

99

Figure 34 EATON VORAD Collision Avoidance EVT-300 Circuits CPU 1. 2. 3. 4. EATON VORAD MAIN WIRING HARNESS EATON VORAD GROUND JUMPER HARNESS VIEW IN DIRECTION OF ARROW C CENTER CONSOLE INSTRUMENT PANEL

s08210

100

2 CAB ACCESSORIES

Figure 35 EATON VORAD Collision Avoidance EVT-300 Circuits Wiring Harness 1. EATON VORAD SIDE DISPLAY MODULE INSTRUMENT 2. A-PILLAR 3. EATON VORAD COLLISION AVOIDANCE DRIVER DISPLAY/CONTROL ELECTRONIC CONTROL 4. INSTRUMENT PANEL 5. EATON VORAD MAIN WIRING HARNESS 6. EATON VORAD CAB SIDE SENSOR WIRING HARNESS CONNECTOR 7. FRONT END WIRING HARNESS CONNECTOR 8. CENTER CONSOLE INSTRUMENT PANEL 9. EATON VORAD COLLISION AVOIDANCE CPU WIRING HARNESS CONNECTOR

s08210

2 CAB ACCESSORIES

101

Figure 36 EATON VORAD Collision Avoidance EVT-300 Circuits Side Sensor Wiring Harness W/51 Pro Sleeper 1. EATON VORAD SLEEPER BOX SIDE SENSOR WIRING HARNESS CONNECTOR 2. EATON VORAD SLEEPER BOX WIRING HARNESS 3. EATON VORAD CAB SIDE SENSOR WIRING HARNESS CONNECTOR

s08210

102

2 CAB ACCESSORIES

Figure 37 EATON VORAD Collision Avoidance EVT-300 Circuits Side Sensor Wiring Harness W/Daycab 1. 2. 3. 4. EATON VORAD CAB SIDE SENSOR WIRING HARNESS CONNECTOR EATON VORAD CAB WIRING HARNESS TRAILER SOCKET EATON VORAD CAB SIDE SENSOR WIRING HARNESS CONNECTOR

s08210

2 CAB ACCESSORIES

103

Figure 38 EATON VORAD Collision Avoidance EVT-300 Circuits Side Sensor Wiring Harness W/72 Pro Sleeper 1. EATON VORAD SLEEPER BOX SIDE SENSOR WIRING HARNESS CONNECTOR 2. EATON VORAD SLEEPER BOX WIRING HARNESS

s08210

104

2 CAB ACCESSORIES

Figure 39

Temperature/Compass Cab Wiring Harness 1. 2. 3. 4. COMPASS MODULE SENSOR GAUGE CAB OUTSIDE TEMPERATURE SENSOR INSTRUMENT WIRING HARNESS FRONT END CONNECTOR CAB BASE HARNESS

s08210

2 CAB ACCESSORIES

105

Figure 40

Temperature/Compass Wiring Harness 1. 2. 3. 4. COMPASS MODULE SENSOR GAUGE ROOF HARNESS CAB OUTSIDE TEMPERATURE SENSOR INSTRUMENT WIRING HARNESS CAB BASE HARNESS

s08210

106

2 CAB ACCESSORIES

Figure 41

Temperature/Compass Temp Sensor Wiring Harness 1. OUTSIDE TEMPERATURE SENSOR GAUGE CIRCUITS 41C & 41D 2. FRONT END WIRING HARNESS

s08210

2 CAB ACCESSORIES

107

Figure 42

Temperature/Compass Display 1. ROOF WIRING HARNESS 2. TEMPERATURE/COMPASS DISPLAY MODULE

s08210

108

2 CAB ACCESSORIES

Figure 43

Road Relay IV Wiring Harness Driver Display Unit 1. CIRCUITS 14B & 13PB 2. CIRCUIT 14B TO (497) B1 BATTERY ADAPTER 3. CIRCUIT 13PB TO (495) I2 IGNITION ADAPTER 4. 5 AMP FUSES F10A & F10B 5. CAB BASE HARNESS 6. CIRCUIT 11GPD TO (453) GROUND ADAPTER 7. CIRCUIT 62EA TO (504) LED PANEL LIGHTS FEED ADAPTER 8. ROAD RELAY IV ELECTRICAL HARNESS 9. CIRCUIT 98D(-) TO (515) DATA LINK NEG. 10. CIRCUIT 98E(+) TO (514) DATA LINK POS.

s08210

2 CAB ACCESSORIES

109

Figure 44

Road Relay IV Wiring Harness Driver Display Unit 1. 2. 3. 4. 5. 6. ROAD RELAY IV ROOF WIRING HARNESS TO CONNECTOR (662) CUMMINS ROAD RELAY IV ENGINE MONITORING DISPLAY ELECTRONIC GAUGE CAB ROOF HARNESS CAB BASE HARNESS ROAD RELAY IV ELECTRICAL HARNESS ROAD RELAY IV POWER (662M) TO CONNECTOR (662F) ROOF WIRING HARNESS

s08210

110

2 CAB ACCESSORIES

Figure 45

Road Relay IV Wiring Harness Driver Display Unit 1. ROAD RELAY IV ROOF WIRING HARNESS TO CONNECTOR (662) 2. CUMMINS ROAD RELAY IV ENGINE MONITORING DISPLAY ELECTRONIC GAUGE

Figure 46

Heated Seat-Driver/Passenger

s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

111

Table of Contents

1. DESCRIPTION. . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . ..113 1.1. BATTERY POWER. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. ..113 Remote Start Terminal.. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . .113 1.2. CHARGING CIRCUITS. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . ..113 With 3+1 Isolated Battery System.. . .. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . ..113 1.3. CRANKING MOTOR CIRCUITS.. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. ..113 Cranking Motor. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . ..113 Cranking Motor Circuits. .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. .113 Cranking Motor Thermal Overcrank Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .113 2. OPERATION.. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. ..114 2.1. BATTERY POWER. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. ..114 Remote Start Terminal.. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . .114 2.2. CHARGING CIRCUITS. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . ..114 With 3+1 Isolated Battery System.. . .. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . ..114 2.3. CRANKING MOTOR CIRCUITS.. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. ..114 Cranking Motor. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . ..114 Cranking Motor Circuits. .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. .114 Cranking Motor Thermal Overcrank Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .115 3. TROUBLESHOOTING. . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. .115 3.1. BATTERIES AND CABLES.. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. ..115 Battery Test Procedure. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..116 Battery Cable Voltage Loss Test. . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . .117 3.2. STARTING MOTOR SYSTEM CIRCUITS AND COMPONENTS. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . ..119 Starter Solenoid Circuit Test - Part 1. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . .119 Starter Solenoid Circuit Test - Part 2. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .120 Starter Magnetic Switch Circuit Test - Part 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Starter Magnetic Switch Circuit Test - Part 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Starter Motor Replacement Test. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Testing Thermal Overcrank Protection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .125 3.3. VEHICLE CHARGING SYSTEM. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .126 Batteries Undercharged. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .126 Alternator Tests. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .127 Alternator Wiring Test.. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .127 Alternator Replacement Test Voltage Output Test. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .128 Alternator Replacement Test Amperage Output Test. . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .129 Alternator Replacement Test Replacement. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .130 4. COMPONENT LOCATIONS. .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .130

s08210

112

3 BATTERY, CHARGING AND CRANKING SYSTEMS

s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

113

1. DESCRIPTION
1.1. BATTERY POWER
The vehicle batteries, connected in parallel, provide power via the positive battery cable which is connected to the cranking motor solenoid "B" terminal. Depending upon battery box location, some vehicles have two positive cables to the cranking motor. The negative battery terminals are connected to the cranking motor ground terminal, which is connected to the frame rail. The engine and cab are also connected by ground cables to the cranking motor ground. An optional 3+1 isolated battery system is available. Refer to POWER DISTRIBUTION AND GROUND SYSTEM section for discussion about this system. Remote Start Terminal An optional remote start terminal allows an external battery power source to either charge the vehicle batteries or assist in cranking the engine.

1.2. CHARGING CIRCUITS


The Delco 22-SI, 12 volt, 100-ampere capacity alternator is standard on this family of vehicles. Other alternators are available as options. The alternator output "B" terminal is connected to the start magnetic switch B terminal and to the crank motor solenoid B terminal. With 3+1 Isolated Battery System On vehicles with this system, 7 volt output from the alternator R terminal is used to energize the isolated battery magnetic switch whenever the alternator is operating. (Refer to the POWER DISTRIBUTION AND GROUND SYSTEM section for information on the 3+1 system.)

1.3. CRANKING MOTOR CIRCUITS


Cranking Motor The Delco MT41 Series cranking motor is used with the standard engine in the 5000i series truck, and the Delco MT42 series cranking motor is standard for the 9000i series vehicles. It provides the rotation of the engine crank via the ywheel needed to start the engine. Cranking Motor Circuits The cranking motor circuits provide power to the cranking motor to turn over the crankshaft of the engine. If all other systems are operational, the engine will start. Cranking Motor Thermal Overcrank Protection On vehicles with thermal overcrank protection (optional system), excessive cranking will cause cranking motor temperature to reach a pre-set thermal overcrank limit, and the thermal switch will open causing the motor to dis-engage. This protects the starting motor from heat damage. When the crank motor cools, the switch closes permitting the crank motor to operate again.

s08210

114

3 BATTERY, CHARGING AND CRANKING SYSTEMS

2. OPERATION
Refer to CHARGING AND CRANKING circuit diagrams in CTS-5298 or S08225.

2.1. BATTERY POWER


Vehicle batteries are connected in parallel with the positive battery cable connected to the cranking motor solenoid "B" terminal. Depending upon battery box location, some vehicles have two positive cables to the cranking motor. The additional cable reduces the voltage drop during cranking. The negative battery terminals are connected to the cranking motor ground terminal, which is connected to the frame rail. The engine and cab are also connected by ground cables to the cranking motor ground. An optional 3 +1 isolated battery system is available. Refer to POWER DISTRIBUTION AND GROUND SYSTEM for this system. Remote Start Terminal The remote starter terminal allows an external battery power source to either charge the vehicle batteries or assist in cranking the engine. Connect the external source positive cable to the remote start terminal and the external source negative cable to vehicle frame rail. To use an external power source to charge the deep cycle battery (with 3+1 system) at the same time as the cranking batteries, a jumper must be used to connect the positive deep cycle battery terminal to the positive terminal of the cranking batteries.

2.2. CHARGING CIRCUITS


The Delcotron Integral Charging systems are high-output alternators, with an internal diode rectier and voltage regulator, producing direct current (DC) to operate vehicle electrical system and charge vehicle batteries. The Delco 22-SI alternator (100A, 115A or 145A) uses brushes and slip rings. The alternator output B terminal is connected to the start magnetic switch B terminal and to the crank motor solenoid B terminal. For a complete discussion on operating principles for alternators, refer to GROUP 08 - ELECTRICAL in the CTS-5000 Master Service Manual for the specic alternator being serviced. With 3+1 Isolated Battery System On vehicles with this system, 7 volt output from the alternator R terminal is used to energize the isolated battery magnetic switch whenever the alternator is operating. (Refer to POWER DISTRIBUTION AND GROUND SYSTEM section for the 3+1 system.)

2.3. CRANKING MOTOR CIRCUITS


Cranking Motor For complete information on operation and servicing this cranking motor and optional cranking motors used on these vehicles, refer to GROUP 08 - ELECTRICAL in the CTS-5000 Master Service Manual. Cranking Motor Circuits With the key in the start position, ignition voltage from start feed adapter (509) is applied through circuit 17B to energize the starter magnetic switch.
s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

115

Battery power from the (B1) battery stud (circuit 14A) is always present at the B terminal of the magnetic switch. With the start magnetic switch energized, battery power is applied through circuit 17C to energize the crank motor solenoid. With the crank motor solenoid energized, the solenoid engages the cranking motor and battery power causes the motor to rotate. When the starter switch is released, a spring returns the solenoid to the released position. Cranking Motor Thermal Overcrank Protection On vehicles with thermal overcrank protection (optional system), the start magnetic switch control coil ground circuit 17D is connected to the normally closed thermal switch (275). The thermal switch is located in the end of the cranking motor. The thermal switch is grounded at the engine ground stud. If excessive cranking causes cranking motor temperature to reach pre-set thermal overcrank limits, the thermal switch opens causing the start magnetic switch to de-energize, turning off power to the cranking motor solenoid S terminal, dis-engaging the cranking motor. When the crank motor cools, the switch closes permitting the crank motor to operate again.

3. TROUBLESHOOTING
Refer to CHARGING AND CRANKING circuit diagrams in CTS-5298 or S08225. 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 laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual. D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit, by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid.

3.1. BATTERIES AND CABLES


The standard battery system for 5000 and 9000 conventionals consists of three 12V maintenance free batteries. All optional batteries installed are also maintenance free.

WARNING When handling batteries, always wear face or eye protection, have water supply available, assure good ventilation, and be sure no open ames are present.

s08210

116

3 BATTERY, CHARGING AND CRANKING SYSTEMS

Battery Test Procedure Battery Test Conguration Figure below. Test each battery separately. 1. Disconnect both battery terminals at each battery. Check each battery visually. 2. Examine the hydrometer eye (if no eye go to next step). a. Eye shows green - go to step 4. b. Eye shows dark - recharge, then go to step 3. c. Eye shows yellow - replace battery.

3. Apply a 300A load for 15 seconds. Turn off load and wait one minute. a. If 12.4V or more - go to step 4. b. If less than 12.4V - recharge then repeat step 3. 4. Apply a test load equal to 50% of the battery CCA rating at 0F (-18C). After 15 seconds,with the load still applied, measure and record terminal voltage ________. Turn the load off. 5. Estimate the battery temperature. If measured voltage does not meet or exceed the value shown in the following table, replace the battery. Table 27 Battery Temperature Table Temp. Min. Volts 70F / 21C 9.6V 50F / 10C 9.4V 30F / 1C 9.1V 15F / 9C 8.8V 0F / 18C 8.5V

6. Clean all cable ends and terminals of the battery with a wire brush.

s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

117

Figure 47

Battery Test Conguration

Battery Cable Voltage Loss Test Refer to Battery Cable Voltage Loss Test Figure below. Slow cranking is often caused by high resistance in the battery cables or connections, especially in cold weather. After all batteries check good (Battery Test Procedure) and terminals are clean and tight, check the battery cables. To do this place a specic load on the batteries at the starter. This load will be supplied by the adjustable carbon pile. The voltage drop in the positive cable plus the voltage drop in the negative cable equals the difference between the battery voltage and the starter voltage due to the cables. The maximum acceptable loss has been calculated only for the specic load specied in the test. 1. Tighten nuts holding battery cables to the solenoid and starter terminals. NOTE The solenoid BAT terminal is at battery voltage when batteries are connected. 2. Connect carbon pile positive lead to start solenoid B terminal and negative lead to starter ground terminal (Battery Cable Voltage Loss Test Figure).

s08210

118

3 BATTERY, CHARGING AND CRANKING SYSTEMS

3. Connect voltmeter from the starter solenoid B terminal to battery positive post. 4. Adjust load to 500A, quickly read and record positive cable voltage. Turn off the load and allow carbon pile to cool. 5. Connect voltmeter from negative battery post to starter ground terminal. Attach ground lead directly to stud and not the cable end. 6. Adjust load to 500A, read and record negative cable voltage. Turn off the load. Positive Cable Voltage Loss (step 4) ________ plus Negative Cable Voltage Loss (step 6) ________ equals Total Cable Loss ________. If system loss is 0.6V or less, go to STARTING MOTOR SYSTEM CIRCUITS AND COMPONENTS. If system loss is greater than 0.6V, repair or replace cable(s) with excessive voltage loss and retest.

Figure 48 Battery Cable Voltage Loss Test

s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

119

To check the interconnecting cables between the batteries, while cranking, measure the terminal voltage of each battery by touching voltmeter leads to the post of each battery (refer to the Figure below). If the difference between any two battery readings in the same battery box is more than 0.5 volt or any cable is warm to the touch, replace the interconnecting cables.

Figure 49 Measure Terminal Voltage of Each Battery

3.2. STARTING MOTOR SYSTEM CIRCUITS AND COMPONENTS


Starter Solenoid Circuit Test - Part 1 Starter shifting in and out, or not pulling in, is often caused by high resistance in the starter solenoid circuit. When the solenoid circuit has excessive voltage loss, the starter pinion sometimes may not engage the ywheel. If it does engage, it may drop out too soon when battery voltage drops. The solenoid circuit includes the starter magnetic switch and leads connected to the starter solenoid. On vehicles with overcrank protection, refer to Testing Thermal Overcrank Protection System before performing this test. 1. Disconnect circuit 17C from the starter solenoid S terminal. Connect the carbon pile positive lead to circuit 17C and negative lead to the starter ground. Connect the voltmeter positive lead to the solenoid battery stud and the negative lead to the starter motor ground stud (not to carbon pile clamp). 2. Have an assistant push the start button or turn key switch. The magnetic switch should energize with a clicking sound. If the switch doesnt "click," either the switch is defective (refer to Starter Magnetic Switch Circuit Test) or there is no voltage from the key switch circuit.

3. Adjust the carbon pile to 100 amp load. Measure and record cable voltage. Release the start button or key switch. If the reading is more than .5 volt lower than the value shown in the table in Battery Test Procedure, perform that test and Battery Cable Voltage Loss Test.
s08210

120

3 BATTERY, CHARGING AND CRANKING SYSTEMS

4. Move the voltmeter negative lead from the starter motor ground stud to the end of circuit 17C that is connected to the carbon pile. Do not connect to carbon pile clamp. 5. Push and hold the start button again and re-adjust the carbon pile load to 100 amps. Read and record voltage to the solenoid. Release the start button or key switch. Cable Voltage (step 3) ________ minus Solenoid Voltage (step 5) ________ equals Circuit Loss = ________ If circuit loss is 1.0 volt or less, go toStarter Magnetic Switch Circuit Test - Part 1. If circuit loss is more than 1.0 volt, go toStarter Solenoid Circuit Test - Part 2.

Figure 50

Starter Solenoid Circuit Test Part 1

Starter Solenoid Circuit Test - Part 2 If the voltage loss in Test 1 was more than 1 volt, the loss is excessive. The loss may be from loose terminals, corrosion, or a worn out start magnetic switch. To locate the problem: 1. Leave carbon pile connected as in Part 1. 2. Connect DMM positive lead to solenoid BAT stud and negative lead to large terminal of magnetic switch. If voltage shows on meter, move meter lead to the other large magnetic switch terminal. 3. Push start button with key on or turn key switch to start position. Turn on and adjust carbon pile to 100 amp load. Read and record rst wire voltage loss. Release start switch. 4. Connect DMM positive lead to other (opposite) large terminal on magnetic switch and negative lead to circuit 17C (not to carbon pile clamp).
s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

121

5. Push start button or turn key switch to start position. Turn on and adjust carbon pile to 100 amp load. Read and record second wire voltage loss. Release start switch. First Wire Loss (step 3) ________ plus Second Wire Loss (step 5) ________ equals Total Wiring Loss = _________(0.8V maximum loss) If circuit loss is 0.8 volt or less, go to step 6. If circuit loss is more than 0.8 volt, repair or replace wire, then go to step 6. 6. Connect DMM across the two large magnetic switch terminals (battery voltage will show immediately). 7. Push start button or turn key switch to start position. Turn on and adjust carbon pile to 100 amp load. Read and record ________ voltage loss across the magnetic switch. 8. If the voltage drop is greater than 0.2 volt, replace the magnetic switch. 9. Remove carbon pile. Leave circuit 17C disconnected (use tape to insulate) to perform Starter Magnetic Switch Circuit Test - Part 1 (below).

s08210

122

3 BATTERY, CHARGING AND CRANKING SYSTEMS

Figure 51

Starter Solenoid Circuit Test - Part 2

Starter Magnetic Switch Circuit Test - Part 1 A magnetic switch that does not close or drops out too soon can be caused by high resistance or an open in the control circuit. 1. Disconnect circuit 17C from start solenoid S terminal and insulate with tape. Connect voltmeter positive lead to the starter solenoid BAT stud and negative lead to the starter motor ground stud.

2. Have an assistant push the start button (with key on) or turn key to start position.You should hear the magnetic switch relay click." If not, proceed anyway. Read and record battery cable voltage. Release start switch. 3. Connect the voltmeter positive lead to the small magnetic switch terminal and the negative lead to the switch ground screw. (Magnetic switch is internally grounded through the mounting.) 4. Have an assistant push the start button (with key on) or turn key to start position. Read and record magnetic switch voltage. Release the start switch. Battery Cable Voltage (step 2) ________
s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

123

minus Magnetic Switch Voltage (step 4) ________ equals Control Circuit Wiring Loss = ________ If circuit loss is 1.0 volt or less and the magnetic switch closes, circuit is OK. If circuit loss is 1.0 volt or less and the magnetic switch doesnt close, replace the switch and repeat the test. If circuit loss is more than 1.0 volt, go to Starter Magnetic Switch Circuit Test - Part 2 (below).

Figure 52 Starter Magnetic Switch Circuit Test - Part 1 Starter Magnetic Switch Circuit Test - Part 2 If Starter Magnetic Switch Circuit Test - Part 1 has shown a voltage loss greater than 1.0V, perform this test using a digital multimeter (DMM). Leave circuit 17C disconnected from the starter solenoid. 1. With the key on and start button depressed or key switch in start position, and the voltmeter leads in the positions shown for each step: a. Measure magnetic switch to starter motor ground. If reading is within 1.0 volt of battery voltage, repair magnetic switch ground. If reading is not within 1.0 volt of battery voltage, go to Step B. b. Measure and record ______ solenoid to key voltage. c. Measure and record ______ key switch voltage.

d. Measure and record ______ key to start button voltage. e. Measure and record ______ start button voltage. f. Measure and record ______ start button to magnetic switch voltage.
s08210

124

3 BATTERY, CHARGING AND CRANKING SYSTEMS

TOTAL ______ (1.0V MAX. ALLOWED) If greater than 1.0 volt, repair or replace any circuit or component with excess voltage loss. If any of the circuits or component checks (B through F) show full battery voltage with the start button depressed or key switch in start position, then an open circuit exists in the portion of the circuit between the DMM leads. Repair that portion and connect circuit 17B to the starter solenoid.

Figure 53

Starter Magnetic Switch Circuit Test - Part 2

Starter Motor Replacement Test A. Cold Weather Start Magnetic Switch Problems If all previous battery tests have been performed, the vehicle batteries and starter wiring have been checked. The starter magnetic switch can fail to "hold in" during cold weather cranking due to low voltage, even though the switches and circuits check OK. With this failure you will hear the starter failing to stay engaged with the ywheel. It is caused by low system voltage releasing the magnetic switch. If this condition exists, have an assistant clamp a heavy battery jumper cable between the two big (5/16") studs on the magnetic switch while cranking. Caution - The studs are battery voltage and the engine should crank when the jumper is connected. Remove jumper to stop cranking. If the engine cranks properly with jumper in place, replace the magnetic switch and make sure starter mounting bolts are tight. B. Checking Available Voltage At Starter If all previous battery tests have been performed, the vehicle batteries and starter wiring have been checked, but the engine still cranks slowly, check available voltage at the starter.
s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

125

1. While cranking engine, measure voltage between the starter BATT terminal and starter ground. a. If voltage is 9.0 volts or more, the problem must be in the starter (or engine). Replace the starter. b. If the voltage is less than 9.0 volts, go to Battery Cable Voltage Loss Test. 2. Check the interconnecting cable between the batteries.

Figure 54

Starter Motor Replacement Test

Testing Thermal Overcrank Protection System Table 28 STEP 1. Testing Thermal Overcrank Protection System KEY Off ACTION Remove connector (275) from thermal switch and measure resistance across switch terminals (engine must be cool). With key in start position, at connector (275) measure voltage to gnd. at circuit 17B. TEST POINTS Thermal switch, across terminals. (275), 17B to gnd. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the thermal switch.

2.

On

12 1.5 volts.

Go to next step.

Go to Starter Solenoid Circuit Test - Part 1.

s08210

126

3 BATTERY, CHARGING AND CRANKING SYSTEMS

Table 28 STEP 3.

Testing Thermal Overcrank Protection System (cont.) KEY On ACTION With key in start position, at connector (275) measure voltage between circuits 17B and 17-G. Thermal overcrank circuits check good. TEST POINTS (275), 17B to 17-G. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Repair open in circuit 17-G.

4.

Off

3.3. VEHICLE CHARGING SYSTEM


Batteries Undercharged Before beginning test procedures: check battery cables and alternator wiring (especially grounds) for clean, tight connections. Wires and connectors should not be damaged or corroded. Perform the following checks before removing the alternator from the vehicle. 1. Accessories having been left on for an extended time. 2. Check alternator drive belt tension (refer to GROUP 12 - ENGINE, Cooling in the CTS-5000 Master Service Manual for belt tension specications). As a general rule, if the alternator fan can be rotated by pulling on the fan with one nger, the belt is too loose. 3. Inspect for defective batteries as described in GROUP 08 - ELECTRICAL, Battery Section in the CTS-5000 Master Service Manual. 4. Wiring defects. Visually check wiring, clamps, and connections for clean, tight connections, free of damage and corrosion. 5. With the engine OFF, check voltage to ground at the BAT terminal of the alternator. A zero reading indicates an open in circuit 2, between the alternator and batteries. 6. A defective component or wiring defect may be causing a small current drain that is less than the fuse rating for the circuit so the fuse does not open. To locate the unwanted current drain: NOTE Batteries should be fully charged for the following test. a. KEY OFF- Turn all accessories and controls off. Disconnect circuit 2 from the alternator B terminal. b. To check the entire system for current drains, insert the DMM leads in the COM and 10A fused jack on the meter. Set the meter to DC Amps. Connect the meter in series with the alternator (if the meter leads are not connected with correct polarity, a (-) amp reading will be present. c. Some current draw will be present. If the current draw is less than 0.3A move the lead from the 10A jack to the 320mA jack to read the exact current ow.

d. Refer to the Battery Power Distribution circuit diagrams in CTS-5298 or S08225. Remove the battery feed fuses one at a time, while monitoring the meter for any change in current ow. Note that some circuits (such as clock or radio or engine computer, etc.) should be drawing some current. Look for current draw in circuits that should not be active.
s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

127

7. Perform Alternator Wiring Test. Alternator Tests The alternator output must reach the batteries and accessory loads with a minimum amount of voltage loss. Any loss slows the rate of charge to the batteries and can cause the batteries to be undercharged. Discharged batteries can damage the starter and cause vehicle electrical components to operate improperly. Most alternators control the maximum system voltage using a voltage regulator. Maximum voltage output is available at the alternator BAT terminal, but if any voltage is lost in the wiring, something less than the maximum will reach the batteries and load devices. The greatest losses occur when the charging system is outputting at the maximum rated level (amps). Alternator Wiring Test Instead of using alternator current output this test uses the same amount of current but draws it from the batteries (must be fully charged). Using the carbon pile load, the current ows in reverse through the circuit without the engine running. 1. Without the engine running, connect the carbon pile to the alternator output terminal and ground. NOTE Alternator output is at battery voltage. 2. Connect voltmeter between alternator output terminal and positive battery terminal. 3. Adjust the carbon pile to alternator rated output (amps). Rated output is stamped on the case or on a tag. 4. Read voltmeter and record positive circuit voltage loss. Immediately turn the carbon pile off. 5. Move the voltmeter connections to between the alternator, ground and negative battery terminal. Adjust carbon pile to rated output (amps) of the alternator. 6. Read voltmeter and record negative circuit voltage loss. Immediately turn carbon pile off. Positive Circuit Loss Voltage (step 4) ________ plus Negative Circuit Loss Voltage (step 6) ________ equals System Loss ________ If system loss is 0.7V or less, go toAlternator Replacement Test If system loss is greater than 0.7V, repair circuit(s) with excessive voltage loss and retest. Then go to Alternator Replacement Test.

s08210

128

3 BATTERY, CHARGING AND CRANKING SYSTEMS

Figure 55

Alternator Wiring Test

Alternator Replacement Test Voltage Output Test If the wiring tests have been performed (circuits OK), adjust alternator belt and tighten mounting bolts and ground connections. Batteries must be near full charge with more than 12.4 volts no load voltage. Voltage Output Test 1. With vehicle at shop temperature, connect voltmeter between alternator B (+) and G (-) terminals. 2. With NO electrical loads turned on, start the engine. Fast idle engine until voltage stabilizes (does not increase) for 2 minutes. 3. Check and record alternator output voltage _______V (should not exceed 15.5 volts). 4. If voltage reading is above 15.5V, replace the alternator.

s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

129

Figure 56

Alternator Replacement Test

Alternator Replacement Test Amperage Output Test 1. With vehicle at shop temperature, connect carbon pile and clamp-on ammeter as shown (see Figure above). Clamp around all wires connected to alternator B terminal. (To use an ammeter without an induction clamp, disconnect circuits to alternator B terminal and connect meter shunt between alternator B+ terminal and all circuits previously removed.)

CAUTION Do not connect an ammeter without a high current shunt.

s08210

130

3 BATTERY, CHARGING AND CRANKING SYSTEMS

2. With NO electrical loads turned on, start the engine, and speed up and maintain a high RPM. 3. Turn on and adjust carbon pile until ammeter reads its highest value and record ______A. 4. Turn off carbon pile and engine. 5. If reading is zero (no output), the rotor should be magnetized with the alternator hooked up normally. To do this, momentarily connect a jumper lead from the alternator B terminal to the indicator R terminal. This will restore normal residual magnetism. 6. Repeat steps 2, 3, and 4. If output is still zero, replace alternator. Alternator Replacement Test Replacement Replace alternator if either of the following exists: A. Output voltage exceeded 15.5V. B. Output current is not within 10% of the alternator rated output stamped on the alternator.

4. COMPONENT LOCATIONS
B1 Battery Stud. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . ... . . . . . Power Distribution Panel B2 Battery Stud. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . ... . . . . . Power Distribution Panel B Alternator Stud. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . .. . . . . . Back of Alternator G Alternator Stud. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . ... . . . . . Back of Alternator B Cranking Motor Solenoid Stud. . . . . . . . . . . . . . . . . . . .. . . . . . Back of Cranking Motor Solenoid M Cranking Motor Solenoid Stud. . . . . . . . . . . . . . . . . . . .. . . . . . Back of Cranking Motor Solenoid R Alternator Stud. . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . .. . . . . . Back of Alternator S Cranking Motor Solenoid Stud. . . . . . . . . . . . . . . . . . . .. . . . . . Back of Cranking Motor Solenoid (1) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Left Side of Engine Cowl (2) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Right Side of Engine Cowl, Above Conn. 3 (3) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Right Side of Engine Cowl, Below Conn. 2 (40) Key Switch. .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . ... . . . . . Behind Left Side of Instrument Panel (275) Thermo Overload Switch. . . . . . . . . . . . . . . . . . . . . .. . . . . . At the Cranking Motor (509) Start Feed Adapter. .. . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . 6" Left of Fuse Panel, Near Heater Control

s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

131

Figure 57

Cab Wiring

s08210

132

3 BATTERY, CHARGING AND CRANKING SYSTEMS

1. 150A MEGAFUSE 2. TO (B1) BATTERY STUD 3. START MAG SWITCH 4. NO BUS BAR WITH 3+1 BATTERY SYSTEM 5. TO HEATER 6. (3) ENGINE HARNESS CONNECTOR 7. (2) CHASSIS HARNESS CONNECTOR 8. RIGHT HAND DASH GROUND STUD 9. FUSE BLOCK GROUND STUD 10. (B2) BATTERY STUD 11. (B1) BATTERY STUD 12. KEY SWITCH 13. LEFT HAND DASH GROUND STUD 14. (1) FRONT END HARNESS CONNECTOR 15. GROUND CIRCUITS 16. DASH PANEL

s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

133

Figure 58 Cab Wiring 3+1 System 1. CIRCUIT 14A FROM START MAG SWITCH 2. 3+1 CAB HARNESS CONNECTS TO 3+1 ENGINE HARNESS 3. CIRCUIT 14A FROM 3+1 MAG SWITCH

s08210

134

3 BATTERY, CHARGING AND CRANKING SYSTEMS

Figure 59

Chassis Wiring 3+1 System (Typical)

s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

135

1. 2. 3. 4. 5. 6. 7. 8. 9.

3+1 BATTERY SYSTEM HARNESS SEE FIGURE BELOW SEE VIEW BELOW CIR 14A TO B2 BATTERY STUD CIRCUIT 7 CIRCUIT 7 SEE VIEW ABOVE 3+1 BATTERY SYSTEM HARNESS

s08210

136

3 BATTERY, CHARGING AND CRANKING SYSTEMS

Figure 60

Chassis Wiring 3+1 System and Battery Cable Connections

s08210

3 BATTERY, CHARGING AND CRANKING SYSTEMS

137

1. DEEP CYCLE BATTERY 2. RED CABLE TO 7V MAGNETIC SWITCH 3. CRANKING BATTERY 4. GROUND 5. CIRCUITS 4A & 7 6. SEE FIGURE ABOVE 7. 3+1 BATTERY SYSTEM HARNESS 8. MAGNETIC SWITCH WITH 3+1 SYSTEM 9. CIRCUIT 11H, 7V MAGNETIC SWITCH 10. CRANKING BATTERY 11. CIRCUIT 11H 12. RED CABLE 13. 7V ISOLATED BATTERY MAGNETIC SWITCH 14. CIRCUIT 14FL 15. CIRCUIT 7 16. BLACK CABLE 17. CRANKING BATTERY 18. BATTERY BOX

s08210

138

3 BATTERY, CHARGING AND CRANKING SYSTEMS

s08210

4 ELECTRICAL TROUBLESHOOTING ETHER START

139

Table of Contents

1. DESCRIPTION. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .141 2. OPERATION.. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .141 3. TROUBLESHOOTING. .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .141 4. COMPONENT LOCATIONS. .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .142

s08210

140

4 ELECTRICAL TROUBLESHOOTING ETHER START

s08210

4 ELECTRICAL TROUBLESHOOTING ETHER START

141

1. DESCRIPTION
Use with Circuit Diagram Book CTS-5298 or S08225. When activated, the ether start system injects a measured amount of ether into the engine intake system to assist starting. The system will only function if the engine temperature is less than approximately 40F (5C).

2. OPERATION
The ether start switch on the instrument panel receives ignition voltage from 10A fuse F10-A (location may vary) when the key is on. The switch is a momentary-on (normally open) type switch. When the switch is closed, power is applied to the ether control valve coil. If the thermo switch is closed, a measured amount of ether is injected into the engine intake system. The ether control valve coil is grounded through the ether thermo switch mounted on the side of the engine block, which closes at less than 40F (5C) and opens when engine block temperature exceeds 50F (10C).

3. TROUBLESHOOTING
1. 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. 2. Before beginning these test procedures, check any light or indicator lamp laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. 3. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual. 4. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit, by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. 5. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid. Refer to circuit diagram ETHER START in CTS-5298 or S08225. Table 29 STEP 1. 2. Ether Start Table KEY Off Off ACTION Check ether cylinder for ether. Check fuse F10-A [location may vary]. F10-A TEST POINTS SPEC. Ether in cylinder. Fuse OK? YES- I N SPEC. Go to next step. Go to next step. NO-OUT OF SPEC. Replace with new cylinder. Locate cause of overload condition, then correct. Replace 10A fuse.

s08210

142

4 ELECTRICAL TROUBLESHOOTING ETHER START

Table 29 STEP 3.

Ether Start Table (cont.) KEY Off ACTION Remove circuit 21A from thermo switch and jumper 21A to engine ground. Test operation of ether start system. Remove ether switch (600) and measure voltage from circuit 21H to ground. Use ohmmeter to measure resistance across switch (600) terminals 5 and 6 with switch depressed. Reconnect connector (600) and remove connector (72). At connector (72), measure voltage to ground at cir. 21 with ether switch depressed. At connector (72), measure voltage between cir. 21 and 21A with ether switch depressed. (72), 21 to gnd. 10 to 12 volts. 21H to gnd. Ether system works? 10 to 12 volts. TEST POINTS SPEC. YES- I N SPEC. Go to next step. NO-OUT OF SPEC.

4.

On

Replace thermo switch. Go to next step.

Leave jumper in place and go to next step. Locate cause of no or low voltage in cir. 21H from fuse F10-A, then repair. Replace switch and reconnect 21, 21H, and 21A. Test operation.

5.

On

6.

Off

(600), terminals 5 and 6.

< 5 ohms. .

Go to next step.

7.

Off

Go to next step. Go to next step. Locate open in cir. 21 between ether switch and connector (72), then repair. Test operation. Locate open in cir. 21A between ether control valve and thermo switch, then repair. Test operation.

8.

On

9.

On

(72), 21 to 21A.

10 to 12 volts.

Replace ether control valve assembly.

4. COMPONENT LOCATIONS
(1) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Left Side of Engine Cowl (2) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Right Side of Engine Cowl, Above Connector 3 (3) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Right Side of Engine Cowl, Below Connector 2 (72) Ether Start At Dash Panel. . . . . . . . . . . . . . . . . . . . . .. . . . . . Front End Harness (494) I1 Ignition Adapter. .. . . . .. . . . .. . . . .. . . . .. . . . .. . .. . . . . . Behind Fuse Panel (504) L2 Panel Light Feed Adapter. .. . .. . .. . .. . .. . ... . . . . . Behind Instrument Panel/Switch Breakout (506) L4 Panel Lights Gnd Adapter. . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel/Switch Breakout (600) Ether Start On/Off Switch. . .. . .. . .. . .. . .. . .. . ... . . . . . At Switch Cluster

s08210

4 ELECTRICAL TROUBLESHOOTING ETHER START

143

Figure 61 Ether Start Cab Wiring 1. 2. 3. 4. 5. 6. 7. ETHER START SWITCH (600) CONNECTOR (3) CONNECTOR (2) FUSE F10A ETHER START SWITCH (600) CIRCUIT 21, PART OF MAIN CAB HARNESS TO FRONT END HARNESS (1)

s08210

144

4 ELECTRICAL TROUBLESHOOTING ETHER START

Figure 62

Ether Start Chassis and Valve Wiring 1. 2. 3. 4. CIRCUITS 21 AND 21A CONNECTOR (72) ETHER BOTTLE FRONT END HARNESS

s08210

4 ELECTRICAL TROUBLESHOOTING ETHER START

145

Figure 63 Ether Start Engine Wiring Cummins ISM 1. 2. 3. 4. 5. 6. THERMOSTAT SWITCH ENGINE HARNESS ENGINE HARNESS CIRCUIT 21A CONNECTOR (NOT LISTED) THERMOSTAT SWITCH

s08210

146

4 ELECTRICAL TROUBLESHOOTING ETHER START

Figure 64

Ether Start Engine Wiring Cummins N-14 1. ENGINE HARNESS 2. CIRCUIT 21A 3. THERMOSTATIC SWITCH

s08210

4 ELECTRICAL TROUBLESHOOTING ETHER START

147

Figure 65 Ether Start Engine Wiring Cummins AHD 1. CIRCUIT 21A 2. ENGINE HARNESS 3. THERMOSTATIC SWITCH

s08210

148

4 ELECTRICAL TROUBLESHOOTING ETHER START

Figure 66 Ether Start Engine Wiring Caterpillar C-10, C-12 1. 2. 3. 4. THERMOSTATIC SWITCH CONNECTOR (NOT LISTED) CIRCUIT 21A ENGINE HARNESS

s08210

4 ELECTRICAL TROUBLESHOOTING ETHER START

149

Figure 67

Ether Start Engine Wiring Caterpillar 3406E 1. 2. 3. 4. ENGINE HARNESS THERMOSTAT SWITCH CONNECTOR (NOT LISTED) CIRCUIT 21A

s08210

150

4 ELECTRICAL TROUBLESHOOTING ETHER START

Figure 68 Ether Start Engine Wiring Detroit Diesel Series 60 1. 2. 3. 4. ENGINE HARNESS THERMOSTAT SWITCH CONNECTOR (NOT LISTED) ENGINE HARNESS

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

151

Table of Contents

1. DESCRIPTION. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .153 1.1. HORTON ENGINE FAN CONTROLS. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .153 1.2. KYSOR ENGINE FAN CONTROLS.. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .153 2. OPERATION.. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .153 2.1. CATERPILLAR C-10, C-12 AND 3406E. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 ADEM III ECM Fan Control. .. . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . .153 Horton Engine Fan.. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .154 Kysor Engine Fan.. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .155 Kysor Engine Fan.. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .155 2.2. DETROIT DIESEL SERIES 60. . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .156 Horton Engine Fan Controls.. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .156 Kysor Engine Fan Controls. .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .157 2.3. CUMMINS N14E. . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .158 Horton Engine Fan Controls With ECM Control System. .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .158 Kysor Engine Fan Controls With ECM Control System. . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .158 2.4. CUMMINS ISM AND AHD. . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .158 Horton Engine Fan Controls With ECM Control System. .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .158 Kysor Engine Fan Controls With ECM Control System. . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .159 2.5. INTERNATIONAL I6 HEUI.. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .159 Horton Engine Fan Controls With ECM Control System. .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .159 Kysor Engine Fan Controls With ECM Control System. . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .160 3. TROUBLESHOOTING. .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .160 3.1. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH CATERPILLAR C10, C-12 AND 3406E. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .160 Testing Fan Solenoid and Circuits.. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .160 Testing A/C Compressor High Pressure Switch (228) and Circuits.. .. . .. . .. .. . .. . .. .. . .. .162 Testing (Optional) Engine Fan Override Switch (659). . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .163 3.2. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH DETROIT DIESEL SERIES 60 DDEC III. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .164 Testing Fan Solenoid and Circuits.. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .164 Testing A/C Compressor High Pressure Switch (228) and Circuits.. .. . .. . .. .. . .. . .. .. . .. .165 3.3. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH CUMMINS M11 AND N14 CELECT. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .166 Testing Fan Solenoid and Circuits.. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .166 Testing A/C Compressor High Pressure Switch (228) and Circuits.. .. . .. . .. .. . .. . .. .. . .. .167 3.4. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH CUMMINS ISM AND AHD. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .168 Testing Fan Solenoid and Circuits.. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .168 Testing A/C Compressor High Pressure Switch (228) and Circuits.. .. . .. . .. .. . .. . .. .. . .. .169 Testing (Optional) Engine Fan Override Switch (659). . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .169 3.5. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH INTERNATIONAL I6 HEUI ENGINE. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .170 Testing Fan Solenoid and Circuits.. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .171 Testing A/C Compressor High Pressure Switch (228) and Circuits.. .. . .. . .. .. . .. . .. .. . .. .171

s08210

152

5 ELECTRICAL TROUBLESHOOTING FANS

4. COMPONENT LOCATIONS. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..172

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

153

1. DESCRIPTION
1.1. HORTON ENGINE FAN CONTROLS
The ECM is used to control the Horton engine cooling fan. Other fan control components include: Horton fan clutch assembly. A Normally Open (N.O.) Fan Solenoid (227). A Normally Closed (N.C.) Air Conditioning (A/C) High Pressure Switch (228). An optional engine fan override switch (659).

The fan solenoid relay is controlled by the ECM using information from the coolant temperature sensor, retarder solenoid status and A/C high pressure switch. The optional engine fan override switch allows the driver to disable the control voltage from the ECM and keep the fan turned on. An indicator will light during the time the fan would normally be off.

1.2. KYSOR ENGINE FAN CONTROLS


The ECM is used to control the Kysor engine cooling fan. Other fan control components include: A Kysor Fan clutch assembly. A Normally Open (N.C.) Fan Solenoid (227). A Normally Closed (N.C.) Air Conditioning (A/C) High Pressure Switch (228). An optional engine fan override switch (659).

The solenoid relay is controlled by the ECM using information from the coolant temperature sensor, retarder solenoid status and A/C high pressure switch. The optional engine fan override switch allows the driver to disable the control voltage from the ECM and keep the fan turned on.

2. OPERATION
2.1. CATERPILLAR C-10, C-12 AND 3406E
ADEM III ECM Fan Control Refer to circuit diagram HORTON AND KYSOR ENGINE FAN WITH C10, C12, and 3406E ENGINES circuits in CTS-5298 or S08225. The ECM uses inputs from the engine coolant temperature sensor, retarder solenoid status and the A/C high pressure switch (228) to determine when the fan should be on. To turn the fan on, the ECM applies OV to the fan solenoid relay. To turn the fan off, the ECM applies 12V to the fan solenoid relay. The ECM turns the fan on under the following conditions: If the engine speed is less than 2250 RPM and any of the following conditions exists: Engine not running or

s08210

154

5 ELECTRICAL TROUBLESHOOTING FANS

During engine cranking or Coolant temperature sensor is greater than 205F (96C) for C-10 and C-12 or Coolant temperature sensor is greater than 216F (102C) for 3406E or Intake manifold air temperature is greater than 180F (82C) or Intake manifold air temperature is greater than 151F (66C) with boost pressure greater than 10 psi (70kPa). There is an active diagnostic code for the coolant temperature sensor or

The retarder solenoid signal is active (high mode) for more than 2 seconds (dependent upon customer programming) or A/C high pressure switch open or EC is counting (dependent upon customer programming) or

The ECM turns the fan off under the following conditions: Engine speed is greater than 2250 RPM or all of the following conditions exists: Coolant temperature sensor is less than 198F (92C) for C-10 and C-12 or Coolant temperature sensor is less than 207F (97C) for 3406E and The fan has been on for 30 seconds and Engine retarder ON strategy is not active and A/C high pressure switch is not active.

NOTE Once the ECM has turned the fan on, the fan will remain on for a minimum of 30 seconds to avoid unnecessary fan clutch cycling (except at engine start-up: it will run for only two seconds after the engine has reached the programmed low idle (700750 rpm). When the ECM energizes the fan solenoid, it causes the fan solenoid to energize. This disengages the fan clutch. Horton Engine Fan Horton Fan Clutch Assembly - The fan clutch is engaged by air pressure supplied by the fan solenoid. The fan clutch is spring loaded off and air pressure is required to overcome the spring and engage the clutch. Horton Normally Open Fan Solenoid (227) -The N.O. fan solenoid (227) supplies air pressure to engage the fan clutch when the solenoid is not energized. Energizing the solenoid turns off the air pressure to the fan clutch, causing the fan clutch to disengage. When the optional engine fan override switch is not installed, the solenoid is energized by a 12V signal on circuit 23A from ECM connector (400) terminal 28. The solenoid ground circuit, 23GA, is grounded through circuit 11GC. When the optional engine fan override switch is installed, the solenoid is energized by a 12V signal on circuit 23A from ECM connector (400) terminal 28 through switch (659). The solenoid ground circuit, 23GA, is grounded through circuit 11GC. The engine fan override switch has an indicator LED which will light during the time the fan would normally be off, when the override switch is on. The 12V signal on circuit 23A from ECM connector (400) terminal 28 will ow through the LED in switch (659). The LED is grounded through circuit 23GY.

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

155

The engine fan override switch is illuminated with an LED. 12 volts from the panel feed adapter (503) is supplied on circuit 62M. Ground for the LED is supplied on circuit 11GR. Kysor Engine Fan When the optional engine fan override switch is installed, the solenoid is energized by a 12V signal on circuit 23A from ECM connector (400) terminal 28 through switch (659). The solenoid ground circuit, 23GA, is grounded through circuit 11GC. Kysor Fan/Clutch Assembly The fan clutch is disengaged by air pressure supplied by the fan solenoid. The fan clutch is spring loaded on and air pressure is required to overcome the spring and disengage the fan clutch. Kysor Normally closed (N.C.) Fan Solenoid (227) The N.C. fan solenoid (227) does not supply air pressure to disengage the fan clutch when the solenoid is not energized. Energizing the solenoid turns on the air pressure to the fan clutch, causing the fan clutch to disengage. When the optional engine fan override switch is not installed, the solenoid is energized by a 12V signal on circuit 23A from ECM connector (400) terminal 28. The solenoid ground circuit, 23GA, is grounded through circuit 11GC. The engine fan override switch has an indicator lamp which will light during the time the fan would normally be off, when the override switch is on. The 12V signal on circuit 23A from ECM connector (400) terminal 28 will ow through the LED in switch (659). The LED is grounded through circuit 23GY. The engine fan override switch is illuminated with an LED. 12 volts from the panel feed adapter (503) is supplied on circuit 62M. Ground for the LED is supplied on circuit 11GR. Kysor Engine Fan When the optional engine fan override switch is installed, the solenoid is energized by a 12V signal on circuit 23A from ECM connector (400) terminal 28 through switch (659). The solenoid ground circuit, 23GA, is grounded through circuit 11GC. Kysor Fan/Clutch Assembly The fan clutch is disengaged by air pressure supplied by the fan solenoid. The fan clutch is spring loaded on and air pressure is required to overcome the spring and disengage the fan clutch. Kysor Normally Closed (N.C.) Fan Solenoid (227) The N.C. fan solenoid (227) does not supply air pressure to disengage the fan clutch when the solenoid is not energized. Energizing the solenoid turns on the air pressure to the fan clutch, causing the fan clutch to disengage. When the optional engine fan override switch is not installed, the solenoid is energized by a 12V signal on circuit 23A from ECM connector (400) terminal 28. The solenoid ground circuit, 23GA, is grounded through circuit 11GC. The engine fan override switch has an indicator lamp which will light during the time the fan would normally be off, when the override switch is on. The 23V signal on circuit 23A from ECM connector (400) terminal 28 will ow through the LED in switch (659). The LED is grounded through circuit 23GY. The engine fan override switch is illuminated with an LED. 12 volts from the panel feed adapter (503) is supplied on circuit 62M. Ground for the LED is supplied on circuit 11GR.

s08210

156

5 ELECTRICAL TROUBLESHOOTING FANS

2.2. DETROIT DIESEL SERIES 60


Horton Engine Fan Controls Refer to circuit diagram HORTON AND KYSOR ENGINE FAN WITH SERIES 60 ENGINE circuits in CTS-5298 or S08225. The ECM controls the Horton fan system. The Horton fan clutch is spring-loaded so the fan is off. Air pressure from a normally open (N.O.) fan solenoid is used to engage the fan clutch. The ECM controls the fan solenoid (227) by opening or closing the solenoid ground. The ECM turns the fan on when at least one of the following conditions occur: Oil temperature above DDEC III factory set limits. Coolant temperature above DDEC III factory set limits. Air temperature above DDEC III factory set limits. Air conditioning (A/C) compressor high pressure switch is open. The fan will remain on a minimum of 3 minutes after the switch closes. Oil temperature sensor fails. Coolant temperature sensor fails. Air temperature sensor fails. Pressure governor switch is active. Engine brake is on in 6 cylinder position. Fan will remain on a minimum of 30 seconds.

Horton Fan Solenoid (227) The normally open (N.O.) fan solenoid supplies air pressure to engage the fan clutch. When the solenoid is not energized, the fan clutch is engaged. The solenoid receives ignition power from 10A fuse F9A, whenever the key is on. The solenoid coil ground is connected by circuit 23D to ECM connector (273) terminal A2. A2 is an ECM digital output terminal. ECM connector (273) terminal A2 is either low (ground) or high (12 volts). When the ECM wants the fan off, terminal A2 and circuit 23D are low (ground). This grounds the fan solenoid causing it to energize and air pressure necessary to engage the fan is turned off. When the ECM wants the fan on, ECM connector (273) terminal A2 and circuit 23D are high (12 volts), causing the fan solenoid (227) to be de-energized (no ground). with the solenoid de-energized, air pressure from the normally open solenoid engages the fan clutch. AC High Pressure Switch (228) This switch is normally closed and opens when A/C compressor head pressure exceeds 300 psi. The switch closes when the head pressure drops below 210 psi. Digital input circuit 23C from ECM connector (273) terminal F1 is connected to one side of the A/C pressure switch. The other switch terminal is connected by circuit 23GB to ground. With the switch in its normally closed position, circuit 23C is low (ground). When the switch is open, circuit 23C is high (5V). When the ECM sees circuit 23C high, it causes fan solenoid circuit 23D to be at a HIGH state (12V), which de-energizes the fan solenoid, engaging the fan clutch. When this occurs, the fan clutch will remain engaged for a minimum of three minutes after the A/C pressure switch returns to a closed position, to reduce fan cycling.

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

157

Kysor Engine Fan Controls The ECM controls the Kysor fan system. The Kysor fan clutch is spring-loaded so the fan is on. Air pressure from a normally closed (N.C.) fan solenoid is used to disengage the fan clutch. The ECM controls the fan solenoid (227) by opening or closing the solenoid ground. The ECM turns the fan on when at least one of the following conditions occur: Oil temperature above DDEC III factory set limits. Coolant temperature above DDEC III factory set limits. Air temperature above DDEC III factory set limits. Air conditioning (A/C) compressor high pressure switch is open (International installed switch and circuits). The fan will remain on a minimum of 3 minutes after the switch closes. Oil temperature sensor fails. Coolant temperature sensor fails. Air temperature sensor fails. Pressure governor switch is active. Engine brake is on in 6 cylinder position. Fan will remain on a minimum of 30 seconds.

The International installed components include the fan clutch, fan solenoid (227), and the A/C high pressure switch (228). Kysor Fan Solenoid (227) The normally closed (N.C.) fan solenoid supplies air pressure to disengage the fan clutch. When the solenoid is not energized, the fan clutch is engaged. The solenoid receives power from 10A fuse F9A, whenever the key is on. The solenoid coil ground is connected by circuit 23D to ECM connector (273 terminal A2. A2 is an ECM digital output terminal. ECM connector (273) terminal A2 is either low (ground) or high (12 volts). When the ECM wants the fan off, terminal A2 and circuit 23D are low (ground). This grounds the fan solenoid causing it to energize and to provide the air pressure necessary to disengage the fan. When the ECM wants the fan on, ECM connector (273) terminal A2 and circuit 23D are high (12 volts), causing the fan solenoid (227) to be de-energized (no ground). With the solenoid de-energized, there is no air pressure from the normally closed solenoid applied to the fan clutch, which is spring loaded on. AC High Pressure Switch (228) This switch is normally closed and opens when A/C compressor head pressure exceeds 300 psi. The switch closes when the head pressure drops below 210 psi. Digital input circuit 23C from ECM connector (273) terminal F1 is connected to one side of the A/C pressure switch. The other switch terminal is connected by circuit 23GB to ground. With the switch in its normally closed position, circuit 23C is low (ground). When the switch is open, circuit 23C is high (5V). When the ECM sees circuit 23C high, it causes fan solenoid circuit 23D to be at a HIGH state (12V), which de-energizes the fan solenoid, engaging the fan clutch. When this occurs, the fan clutch will remain engaged for a minimum of three minutes after the A/C pressure switch returns to a closed position, to reduce fan cycling.

s08210

158

5 ELECTRICAL TROUBLESHOOTING FANS

2.3. CUMMINS N14E


Horton Engine Fan Controls With ECM Control System Refer to circuit diagram HORTON AND KYSOR ENGINE FAN WITH N14E ENGINES circuits in CTS-5298 or S08225. To turn the fan off: The ECM applies 12 volts through the 21way ECM Interface connector (251) to circuit 23D to the fan solenoid (227), causing the solenoid to energize, turning off the air pressure which keeps the fan engaged. The fan is spring loaded in the disengaged position. Turning the fan on: The fan is turned on two ways: A. When the ECM senses the engine coolant has reached the preset temperature limit, the ECM turns off the voltage to circuit 23D. This causes the fan solenoid to de-energize, which applies air pressure to the fan clutch engaging the fan. B. The second way the fan is turned on is when the A/C compressor head pressure exceeds 300 psi, the A/C high pressure switch (228) opens and removes the ground on circuit 23C to ECM connector terminal T. The ECM will turn off 12 volts on circuit 23D. This causes the fan solenoid to de-energize, which applies air pressure to the fan clutch engaging the fan. When the A/C head pressure drops below 210 psi, the switch closes, the ECM applies 12 volts to circuit 23D which energizes the fan solenoid and the fan turns off. Kysor Engine Fan Controls With ECM Control System To turn the fan off: The ECM applies 12 volts through the 21way ECM interface connector (251) to circuit 23D to the fan solenoid (227), causing the solenoid to energize, turning on the air pressure which overrides the fan clutch spring, turning the fan off. Turning the fan on: The fan is turned on two ways: A. When the ECM senses the engine coolant has reached the preset temperature limit, the ECM turns off the voltage to circuit 23D. This causes the fan solenoid to de-energize, which applies air pressure to the fan clutch engaging the fan. B. The second way the fan is turned on is when the A/C compressor head pressure exceeds 300 psi, the A/C high pressure switch (228) opens and removes the ground on circuit 23C to ECM connector terminal T. The ECM will turn off 12 volts on circuit 23D. This causes the fan solenoid to de-energize, which applies air pressure to the fan clutch engaging the fan. When the A/C head pressure drops below 210 psi, the switch closes, the ECM applies 12 volts to circuit 23D which energizes the fan solenoid and the fan turns off.

2.4. CUMMINS ISM AND AHD


Horton Engine Fan Controls With ECM Control System Refer to circuit diagram HORTON AND KYSOR ENGINE FAN WITH AHD and ISM ENGINES circuits in CTS-5298 or S08225. To turn the fan off: When the optional engine fan override switch is not installed, the ECM applies 12 volts on circuit 23A from ECM connector (1093) terminal 28 circuit 23D to the fan solenoid (227), causing the solenoid to energize, turning off the air pressure that keeps the fan engaged. The fan is spring loaded in the disengaged position. The solenoid is grounded through circuit 23GA and 11GC.

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

159

When the optional engine fan override switch is installed, the solenoid is energized by 12 volts on circuit 23A from ECM connector (1093) terminal 28 through switch (659), which then applies the voltage on circuit 23D to the fan solenoid (227), causing the solenoid to energize, turning off the air pressure that keeps the fan engaged. The fan is spring loaded in the disengaged position. The solenoid is grounded through circuit 23GA and 11GC. The engine fan override switch has an indicator lamp which will light, during the time the fan would normally be off, when the override switch is on. The 12V signal on circuit 23A from ECM connector (400) terminal 28 will ow through the LED in switch (659). The LED is grounded through circuit 23GY. The engine fan override switch is illuminated with an LED. 12 volts from the panel feed adapter (503) is supplied on circuit 62M. Ground for the LED is supplied on circuit 11GR. Turning the fan on: The fan is turned on two ways: A. When the ECM senses the engine coolant has reached the preset temperature limit, the ECM turns off the voltage to circuit 23D. This causes the fan solenoid to de-energize, which applies air pressure to the fan clutch engaging the fan. B. The second way the fan is turned on is when the A/C compressor head pressure exceeds 300 psi, the A/C high pressure switch (228) opens the fan solenoid circuit. This causes the fan solenoid to de-energize, which applies air pressure to the fan clutch engaging the fan. When the A/C head pressure drops below 210 psi, the switch closes, energizing the fan solenoid and the fan turns off. Kysor Engine Fan Controls With ECM Control System To turn the fan off: The ECM applies 12 volts through the 21way ECM interface connector (251) to circuit 23A, which is connected to the normally closed A/C high pressure switch (228), which then applies the voltage on circuit 23D to the fan solenoid (227), causing the solenoid to energize, turning on the air pressure which overrides the fan clutch spring, turning the fan off. When the optional engine fan override switch is not installed, the solenoid is energized by a 12V signal on circuit 23A from ECM connector (400) terminal 28. The solenoid ground circuit, 23GA, is grounded through circuit 11GC. When the optional engine fan override switch is installed, the solenoid is energized by a 12V signal on circuit 23A from ECM connector (400) terminal 28 through switch (659). The solenoid ground circuit 23GA, is grounded through circuit 11GC. The engine fan override switch has an indicator lamp which will light when the override switch is on. The 12V signal on circuit 23A from ECM connector (400) terminal 28 will ow through the LED in switch (659). The LED is grounded through circuit 23GY. The engine fan override switch is illuminated with an LED. 12 volts from the panel feed adapter (503) is supplied on circuit 62M. Ground for the LED is supplied on circuit 11GR.

2.5. INTERNATIONAL I6 HEUI


Horton Engine Fan Controls With ECM Control System Refer to circuit diagram HORTON AND KYSOR ENGINE FAN WITH I6 HUEI ENGINES circuits in CTS-5298 or S08225.

s08210

160

5 ELECTRICAL TROUBLESHOOTING FANS

To turn the fan off: The ECM applies a ground through the gray engine connector, pin 8, to fan control connector (1075) terminal A. Circuit 97EFS, from engine fan control connector (1075) terminal A, connects to the fan solenoid (227), causing the solenoid to energize, turning off the air pressure that keeps the fan engaged. The fan is spring loaded in the disengaged position. 12 volts is supplied to fan solenoid connector (227), terminal A from key switch (40) through circuit 13, circuit 13U, fuse F9A, circuit 23 and circuit 23D. Turning the fan on: The fan is turned on two ways: A. When the ECM senses the engine coolant has reached the preset temperature limit, the ECM removes the ground from circuit 97EFS. This causes the fan solenoid to de-energize, which applies air pressure to the fan clutch engaging the fan. B. The second way the fan is turned on is when the A/C compressor head pressure exceeds a preset limit the A/C high pressure switch (228) opens and signals the EC to engage the fan. When the A/C head pressure drops below a preset limit the switch closes, signaling the ECM to turn the fan off. Kysor Engine Fan Controls With ECM Control System To turn the fan off: The ECM applies a ground on circuit 97EFS from engine fan control connector (1075) terminal A to the fan solenoid (227), causing the solenoid to energize, turning on the air pressure which overrides the fan clutch spring, turning the fan off. 12 volts is supplied to fan solenoid connector (227), terminal A from key switch (40) through circuit 13, circuit 13U, fuse F9A, circuit 23 and circuit 23D. Turning the fan on: The fan is turned on similarly to the Horton fan except air pressure is removed when the solenoid is de-energized. This permits the fan clutch spring to engage the fan.

3. TROUBLESHOOTING
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 laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual. D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit, by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid.

3.1. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH CATERPILLAR C10, C-12 AND 3406E
Testing Fan Solenoid and Circuits Refer to HORTON and KYSOR ENGINE FAN WITH C10, C12 AND 3406E ENGINES circuit diagram in CTS-5298 or S08225.
s08210

5 ELECTRICAL TROUBLESHOOTING FANS

161

Before beginning this test procedure, inspect all connectors for loose or damaged pins, wires, etc. International OEM connector (400) mates with Caterpillar ECM OEM connector. This is an AMP 40pin connector, with the International side having female terminals (sockets) and the Caterpillar side having pins. NOTE No tests in this manual require testing into the Caterpillar OEM connector. When testing the International side of connector (400), never insert meter probes into the sockets, as the probes will damage the sockets. Always use test leads of the type described in Inspecting Electrical Connectors, Test Leads of this manual. The test leads must t snugly into the sockets without expanding the sockets. NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting. Table 30 STEP 1. Testing Fan Solenoid and Circuits KEY Off ACTION Disconnect connector (227) from the solenoid pigtail. Measure resistance from (227) terminal B to ground. Disconnect connector (400). Insure the optional "engine fan override switch" (659) is in the off position. Measure resistance from (400) terminal 11 to (227) terminal A. Measure resistance from (400) terminal 11 to ground. Reconnect (227) to solenoid. Install a jumper from (400) terminal 28 to 12 volts. Does the solenoid energize? TEST POINTS (227), terminal B to gnd. SPEC. <5 ohms. YES- IN SPEC. NO-OUT OF SPEC.

Go to next Locate open or poor connection in circuit step. 23-GA or 11-GC between connector (227) and ground, then repair. Go to next Locate open or poor connection in circuit step. 23A and 23B or "fan override switch" (659) between connector (227) and (400), then repair. Go to next Locate short to ground step. in circuit 23A or 23B, then repair.

2.

Off

(400), terminal 11 to (227) terminal A.

<5 ohms.

3.

Off

(400), terminal 11 to gnd.

>100K ohms

4.

On

Sole- noid Go to next Replace fan solenoid. enerstep. gizes

s08210

162

5 ELECTRICAL TROUBLESHOOTING FANS

Table 30 STEP 5.

Testing Fan Solenoid and Circuits (cont.) KEY Off ACTION Disconnect connector (400). Insure the optional engine fan override switch is in the off position. Measure resistance from (400) terminal 11 to (227) terminal A. Reconnect connectors. The fan control circuits and components check good. TEST POINTS (400), terminal 11 to (227) terminal A. SPEC. <5 ohms YES- IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 23A and 23B between connector (227) and (400), then repair.

6.

Off

Testing A/C Compressor High Pressure Switch (228) and Circuits Refer to HORTON & KYSOR ENGINE FAN WITH C10, C12 and 3406E ENGINES circuit diagram in CTS-5298 or S08225. Before beginning this test procedure, inspect all connectors for loose or damaged pins, wires, etc. NOTE Perform the preceding test, Testing Fan Solenoid and Circuits, before performing this test. Table 31 STEP 1. Testing A/C Compressor High Pressure Switch (228) and Circuits KEY Off ACTION Disconnect connectors (228) and (400). At A/C pressure switch, measure resistance across the switch terminals. (If you suspect the switch is not opening at 300 PSI, replace switch.) Measure resistance from (400) terminal 5, circuit 97-G, to (228) terminal B, circuit 23-G. Measure resistance from (400) terminal 41 to (228) terminal A, circuit 23C. TEST POINTS A/C pressure switch. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace switch.

2.

Off

(400) terminal 5 to (228) terminal B. (400) terminal 41 to (228) terminal A.

<5 ohms.

Go to next step.

Locate open in circuit 23-G or 97-G between (400) and (228), then repair. Locate open in circuit 23C between (400) and (228), then repair.

3.

Off

>5 ohms.

Go to next step.

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

163

Table 31 STEP 4.

Testing A/C Compressor High Pressure Switch (228) and Circuits (cont.) KEY Off ACTION Measure resistance from (400) terminal 41 to ground. The A/C high pressure switch circuits check good. Reconnect (400) and (228). If you suspect the A/C switch is not working properly, replace the switch and test system operation. TEST POINTS (400), terminal 41 to ground. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground in circuit 23C, then repair.

5.

Off

Testing (Optional) Engine Fan Override Switch (659) Refer to HORTON & KYSOR ENGINE FAN WITH C-10, C-12 and 3406E ENGINES circuit diagram in CTS-5298 or S08225. This switch is intended to last the life of the truck. If it is determined to be defective it should be replaced. It is not a repairable item. Table 32 STEP 1. Testing (Optional) Engine Fan Override Switch (659) KEY Off ACTION Disconnect connectors (659). With the switch in the "Off" position, measure the resistance between terminals 4 and 5. With the switch in the "On" position, measure the resistance between terminals 5 and 6. Connect 12 volts to terminal 7 and ground to terminal 8. Does the LED illuminate? Connect 12 volts to terminal 7 and ground to terminal 8. Does the LED illuminate? TEST POINTS Engine Fan Override Switch (659), terminals 4 and 5. Engine Fan Override Switch (659), terminals 5 and 6. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace switch.

2.

Off

<5 ohms.

Go to next step.

Replace switch.

3.

Off

LED illuminates.

Go to next step. Go to next step.

Replace switch.

4.

Off

LED illuminates.

Replace switch.

s08210

164

5 ELECTRICAL TROUBLESHOOTING FANS

Table 32 STEP 5.

Testing (Optional) Engine Fan Override Switch (659) (cont.) KEY Off ACTION Connect 12 volts to terminal 6 and ground to terminal 1. Does the LED illuminate? Switch tests good. Reconnect switch. TEST POINTS SPEC. LED illuminates. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace switch.

6.

Off

Switch operates correctly.

Identify problems with circuit 62M to panel feed adapter or circuits 11-GR or 23-GY to ground.

3.2. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH DETROIT DIESEL SERIES 60 DDEC III
Testing Fan Solenoid and Circuits Refer to HORTON & KYSOR ENGINE FAN WITH SERIES 60 ENGINES circuit diagram in CTS-5298 or S08225. Before beginning this test procedure, inspect all connectors for loose or damaged pins, wires, etc. Table 33 STEP 1. Testing Fan Solenoid and Circuits KEY Off ACTION Check 10A fuse F9-A for open condition. Fuse OK? TEST POINTS F9-A SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. NOTE: A blown fuse will cause fan to be engaged all the time. Locate cause of no or low voltage in circuit 23 from fuse, then repair.

2.

Off/ On

Disconnect fan solenoid at connector (227). Turn key on and measure voltage to ground at circuit 23 of connector (227). At solenoid side of connector (227) jumper black wire to gnd. and apply 12V to red wire. Does solenoid energize?

(227), 23 to gnd.

12 1.5 volts.

Go to next step.

3.

Off

Go to next step.

Replace the fan solenoid.

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

165

Table 33 Testing Fan Solenoid and Circuits (cont.) STEP 4. KEY Off ACTION With (227) still disconnected, remove connector (273) from ECM. At connector (273) terminal A2 measure resistance to ground. With (227) still disconnected, at connector (273) terminal A2 measure voltage to ground. Connect (227) to fan solenoid At connector (273) use test lead to jumper terminal A2 to gnd. Turn key on. Does solenoid energize? TEST POINTS (273), A2 to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground in circuit 23D, between connectors (273) and (227), then repair. Locate short in circuit 23D to unwanted voltage source, then repair. Locate open or poor connection in circuit 23D between connectors (273) and (227), then repair.

5.

On

(273), A2 to gnd.

<1 volt.

Go to next step.

6.

Off/ On

Fan solenoid and circuit check good. Go to following test, Testing A/C Compressor High Switch Pressure Switch (228) and Circuits.

Testing A/C Compressor High Pressure Switch (228) and Circuits Refer to HORTON and KYSOR ENGINE FAN WITH SERIES 60 ENGINES circuit diagram in CTS-5298 or S08225. Before beginning this test procedure, inspect all connectors for loose or damaged pins, wires, etc. NOTE Perform preceding test, Testing Solenoid and Circuits, before performing this test. Table 34 STEP 1. Testing A/C Compressor High Pressure Switch (228) and Circuits KEY Off ACTION Remove connector (273) from ECM. Disconnect connector (228) from A/C pressure switch. At connector (273) terminal F1, measure resistance to gnd. With A/C pressure switch disconnected, measure resistance between switch terminals. TEST POINTS (273), F1 to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground in circuit 23C between connectors (273) and (228), then repair.

2.

Off

A/C pressure switch.

<5 ohms.

Go to next step.

Replace switch.

s08210

166

5 ELECTRICAL TROUBLESHOOTING FANS

Table 34 Testing A/C Compressor High Pressure Switch (228) and Circuits (cont.) STEP 3. KEY Off ACTION At connector (228) measure resistance to ground at circuit 23-GB. TEST POINTS (228), 23-GB to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 23-GB or path to ground at neg. battery terminal, then repair. Locate open or poor connection in circuit 23C between connectors (273) and (228), then repair.

4.

Off

Connect (228) to switch. At connector (273) terminal F1, measure resistance to ground. A/C high pressure switch and circuits check good. If you suspect that the A/C high pressure switch is not opening at the correct pressure, replace the switch and retest.

(273), F1 to gnd.

<5 ohms.

Go to next step.

5.

Off

3.3. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH CUMMINS M11 AND N14 CELECT
Testing Fan Solenoid and Circuits Refer to HORTON and KYSOR ENGINE FAN WITH N14 ENGINE circuit diagram in CTS-5298 or S08225. Before beginning this test procedure, inspect all connectors for loose or damaged pins, wires etc. Table 35 STEP Testing Fan Solenoid and Circuits KEY ACTION TEST POINTS (227), terminal B to gnd. SPEC. YES - IN SPEC. Go to next step. NO-OUT OF SPEC.

1.

Off

Disconnect connector (227) from the solenoid pigtail. Measure resistance from (227) terminal B to ground. Disconnect connector (251). Measure resistance from (251) terminal C to (227) terminal A. Measure resistance from (251) terminal C to ground.

<5 ohms.

Locate open or poor connection in circuit 23-GA or 11-GU between connector (227) and ground, then repair. Locate open or poor connection in circuit 23A between connector (227) and (251), then repair. Locate short to ground in circuit 23D, then repair.

2.

Off

(251), terminal C to (227) terminal A. (251), terminal C to gnd.

<5 ohms.

Go to next step.

3.

Off

>100K ohms.

Go to next step.

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

167

Table 35 Testing Fan Solenoid and Circuits (cont.) STEP KEY ACTION TEST POINTS SPEC. YES - IN SPEC. Go to next step. NO-OUT OF SPEC.

4.

On

Reconnect (227) to solenoid. Install a jumper from (251) terminal C to 12 volts. Does the solenoid energize? Reconnect connectors. The fan control circuits and components check good.

Solenoid energizes.

Replace fan solenoid.

5.

Off

Testing A/C Compressor High Pressure Switch (228) and Circuits Refer to HORTON and KYSOR ENGINE FAN WITH N14 ENGINE circuit diagram in CTS-5298 or S08225. Before beginning this test procedure, inspect all connectors for loose or damaged pins, wires etc. NOTE Perform preceding test, Testing Fan Solenoid and Circuits, before performing this test. Table 36 STEP 1. Testing A/C Compressor High Pressure Switch (228) and Circuits KEY Off ACTION Disconnect connectors (251), (252) and (190). At A/C pressure switch, measure resistance across the switch terminals. (If you suspect the switch is not opening at 300 PSI, replace switch.) Measure resistance from (251) terminal T to (228) terminal A. Measure resistance from (251) terminal T to ground. Measure resistance from (252) terminal 10 to (228) terminal B. TEST POINTS A/C pressure switch. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace switch.

2.

Off

(251), terminal T to (228) terminal A. (251), terminal T to gnd. (252) terminal 10 to (228) terminal B.

<5 ohms.

Go to next step. Go to next step. Go to next step.

Locate open in circuit 23C between (251) and (228), then repair. Locate short to ground in circuits 23C, then repair. Locate open in circuit 23-GB or 97-G between (252) and (228), then repair.

3.

Off

>100K ohms. <5 ohms.

4.

Off

s08210

168

5 ELECTRICAL TROUBLESHOOTING FANS

Table 36 Testing A/C Compressor High Pressure Switch (228) and Circuits (cont.) STEP 5. KEY Off ACTION Measure resistance from (190) terminal V to (228) terminal B. TEST POINTS (190) terminal V to (228) terminal B. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open in circuit 23-GB or 97-GA between (252) and (190). Repair condition.

6.

Off

Reconnect connectors. The A/C pressure switch circuits and components check good.

3.4. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH CUMMINS ISM AND AHD
Testing Fan Solenoid and Circuits Refer to HORTON and KYSOR ENGINE WITH AHD and ISM ENGINE circuit diagram in CTS-5298 or S08225. Before beginning this test procedure, inspect all connectors for loose or damaged pins, wires, etc. Table 37 STEP 1. Testing Fan Solenoid and Circuits KEY Off ACTION Disconnect connector (227) from the solenoid pigtail. Measure resistance from (227) terminal B to ground. Disconnect connector (251). Measure resistance from (251) terminal C to (227) terminal A. Measure resistance from (251) terminal C to ground. Reconnect (227) to solenoid. Install a jumper from (251) terminal C to 12 volts. Does the solenoid energize? Reconnect connectors. The fan control circuits and components check good. TEST POINTS (227), terminal B to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 23-GA or 11-GU between connector (227) and ground, then repair. Locate open or poor connection in circuit 23A between connector (227) and (251), then repair. Locate short to ground in circuit 23D, then repair. Replace fan solenoid.

2.

Off

(251), term. C to (2274) term. A. (251), terminal C to gnd.

<5 ohms.

Go to next step.

3.

Off

>100K ohms. Solenoid energizes.

Go to next step. Go to next step.

4.

On

5.

Off

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

169

Testing A/C Compressor High Pressure Switch (228) and Circuits Refer to HORTON and KYSOR ENGINE WITH AHD and ISM ENGINE circuit diagram in CTS-5298 or S08225. Before beginning this test procedure, inspect all connectors for loose or damaged pins, wires, etc. NOTE Perform preceding test, Testing Fan Solenoid and Circuits, before performing this test. Table 38 STEP 1. Testing A/C Compressor High Pressure Switch (228) and Circuits KEY Off ACTION TEST POINTS SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace switch.

Disconnect connectors A/C (251), (252) and (190). pressure At A/C pressure switch, switch. measure resistance across the switch terminals. (If you suspect the switch is not opening at 300 PSI, replace switch.) Measure resistance from (251) terminal T to (228) terminal A. Measure resistance from (251) terminal T to ground. Measure resistance from (252) terminal 10 to (228) terminal B. Measure resistance from (190) terminal V to (228) terminal B. Reconnct connectors. The A/C pressure switch circuits and components check good. (251) terminal T to (228) terminal A. (251), terminal T to gnd. (252) terminal 10 to (228) terminal B. (190) terminal V to (228) terminal B.

2.

Off

<5 ohms.

Go to next step. Go to next step. Go to next step. Go to next step.

Locate open in circuit 23C between (251) and (228), then repair. Locate short to ground in circuits 23C, then repair. Locate open in circuit 23-GB or 97-G between (252) and (228), then repair. Locate open in circuit 23-GB or 97-GA between (252) and (190). Repair condition.

3.

Off

>100K ohms. <5 ohms.

4.

Off

5.

Off

<5 ohms.

6.

Off

Testing (Optional) Engine Fan Override Switch (659) Refer to HORTON and KYSOR ENGINE FAN WITH AHD and ISM ENGINE circuit diagram in CTS-5298 or S08225. This switch is intended to last the life of the truck. If it is determined to be defective it should be replaced. It is not a repairable item.

s08210

170

5 ELECTRICAL TROUBLESHOOTING FANS

Table 39 STEP 1.

Testing (Optional) Engine Fan Override Switch (659) KEY Off ACTION Disconnect connectors (659). With the switch in the "Off" position, measure the resistance between terminals 4 and 5. With the switch in the "On" position, measure the resistance between terminals 5 and 6. Connect 12 volts to terminal 7 and ground to terminal 8. Does the LED illuminate? Connect 12 volts to terminal 7 and ground to terminal 8. Does the LED illuminate? Connect 12 volts to terminal 6 and ground to terminal 1. Does the LED illuminate? Switch tests good. Reconnect switch. TEST POINTS Engine Fan Override Switch (659), terminals 4 and 5. Engine Fan Override Switch (659), terminals 5 and 6. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace switch.

2.

Off

<5 ohms.

Go to next step.

Replace switch.

3.

Off

LED Go to illuminates. next step. LED Go to illuminates. next step. LED Go to illuminates. next step. Switch operates correctly.

Replace switch.

4.

Off

Replace switch.

5.

Off

Replace switch.

6.

Off

Identify problems with circuit 62M to panel feed adapter or circuits 11-GR or 23-GY to ground.

3.5. ENGINE COOLING FAN CONTROLS, HORTON AND KYSOR WITH INTERNATIONAL I6 HEUI ENGINE
Refer to HORTON and KYSOR ENGINE FAN WITH I6 HEUI ENGINE circuit diagrams in CTS-5298 or S08225. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. CEC module connector (379) mates with the ECM connector. This is a 60pin connector, with the chassis side having female terminals (sockets) and the engine side having pins. NOTE No tests in this manual require testing into the black ECM connector. When testing the chassis side of connector (379), never insert meter probes into the sockets, as the probes will damage the sockets. Always use breakout box (ZTSE-4445) as described in International Engine/Vehicle Manual EGES-175.

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

171

Testing Fan Solenoid and Circuits Table 40 STEP 1. Testing Fan Solenoid and Circuits KEY Off ACTION Disconnect connector (227) from the solenoid pigtail. Disconnect connector (1075) from the engine fan control connector. Measure resistance from (227) terminal B to (1075) terminal A. Measure resistance from (227) terminal B to ground. Disconnect connector (228). Measure resistance from (228) terminal B to ground. Turn on key switch. Measure voltage from (227) terminal A to ground. TEST POINTS (227), terminal B to (1075) terminal A. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97EFS between connector (227) and connector (1075), then repair.

2.

Off

(227), terminal B to ground. (228), terminal B to ground. (227) terminal A to ground.

>100K ohms. >100K ohms.

Go to next step. Go to next step. Go to next step.

Locate short to ground in circuit 97EFS then repair. Locate short to ground in circuits 23D, 23B, 23, 13U or 13, then repair. Locate open or poor connection in circuits between connector (227) and key switch (40), and circuit 23B, then repair. Replace fan solenoid.

3.

Off

4.

On

12 1.5 volts.

5.

On

Reconnect (227) to solenoid, install a jumper from (1075) terminal A to ground. Does the solenoid energize? The fan solenoid switch circuits check good. Reconnect (227) and (1075).

Solenoid Go to energizes. next step.

6.

Off

Testing A/C Compressor High Pressure Switch (228) and Circuits Refer to HORTON and KYSOR ENGINE FAN WITH I6 HEUI ENGINE circuit diagrams in CTS-5298 or S08225. Before beginning this test procedure, inspect all connectors for loose or damaged pins, wires, etc. NOTE Perform preceding test, Testing Fan Solenoid and Circuits, before performing this test.

s08210

172

5 ELECTRICAL TROUBLESHOOTING FANS

Table 41 STEP 1.

Testing A/C compressor High Pressure Switch (228) and Circuits KEY Off ACTION Disconnect connectors (228) and (379). At A/C pressure switch, measure resistance across the switch terminals. (If you suspect the switch is not opening at 300 PSI, replace switch.) Measure resistance from (379) terminal 33, circuit 23A to (228) terminal A. Measure resistance from (379) terminal 33 to ground. Turn on key switch. Measure voltage from (228) terminal B to ground. The A/C high pressure switch circuits check good. Reconnect (379) and (228). If you suspect the A/C switch is not working properly, replace the switch and test system operation. TEST POINTS A/C pressure switch. SPEC. YES-IN SPEC. NO-OUT OF SPEC. Replace switch.

<5 ohms. Go to next step.

2.

Off

(379) terminal 33 to (228) terminal A. (379) terminal 33 to ground. (228) terminal B to ground.

<5 ohms. Go to next step. >100K ohms. 12 1.5 volts. Go to next step. Go to next step.

Locate open in circuit 23A between (400) and (228), then repair. Locate short to ground in circuit 23A, then repair. Locate open or poor connection in circuits between connector (228) and key switch (40), then repair.

3.

Off

4.

On

5.

Off

4. COMPONENT LOCATIONS
(2) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Right Side of Engine Cowl, Above Connector 3 (3) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Right Side of Engine Cowl, Below Connector 2 (227) Fan Solenoid. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . ... . . . . . At Front of Engine (Outside Dash Panel, Left Side, with Cummins ISM and AHD) (228) A/C Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On A/C Compressor (251) CELECT 21Way ECM Connector. . . . . . . . . . .. . . . . . At Engine Harness Near ECM (With M11E and N14E) (273) Detroit Diesel ECM Connector . . . . . . . . . . . . . . .. . . . . . To ECM Mounted on Dash Engine Side (With Detroit Diesel) (379) CEC Module Connector. . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Engine (With I6 HEUI) (400) OEM Interface Connector. . . . . . . . . . . . . . . . . . . . .. . . . . . On Engine (With C-10, C-12 and 3406E) (659) Engine Fan Override Switch. . . . . . . . . . . . . . . . . .. . . . . . At Switch Cluster (1074) Engine Fan Control Connector. . . . . . . . . . . . . .. . . . . . On Engine (With I6 HEUI) (1093) ECM Interface Connector. . . . . . . . . . . . . . . . . . . .. . . . . . On Engine (With ISM and AHD)

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

173

Figure 69

Engine Wiring at Dash Panel, With Fan Solenoid

s08210

174

5 ELECTRICAL TROUBLESHOOTING FANS

1. SEE FOLLOWING FIGURES FOR DETROIT DIESEL SERIES 60 OR CUMMINS N14E ENGINE HARNESS 2. ENGINE HARNESS 3. CONNECTOR (3) 4. CIRCUIT 23, CONNECTOR (2) 5. FAN SOLENOID 6. FAN SOLENOID CONNECTOR (227)

Figure 70

Engine Fan Wiring, Detroit Diesel Series 60 1. 2. 3. 4. 5. ECM CONNECTOR TO OTHER SIDE OF ENGINE TO ENGINE WIRING AT DASH PANEL ENGINE HARNESS TO TRANSMISSION

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

175

Figure 71 Engine Fan Wiring, Detroit Diesel Series 60 1. ENGINE HARNESS TO OTHER SIDE OF ENGINE 2. HIGH PRESSURE CUTOUT CIRCUITS 23C AND 23GB (228) 3. AIR HOSE TO FAN

s08210

176

5 ELECTRICAL TROUBLESHOOTING FANS

Figure 72

Engine Fan Wiring, Cummins N14E 1. A/C HIGHPRESSURE CUT-OUT CIRCUITS 23 AND 23D (228) 2. TO FAN SOLENOID 3. 21WAY ECM CONNECTOR (251)

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

177

Figure 73 Engine Fan Wiring, Caterpillar C10, C12 1. 2. 3. 4. 5. 6. ECM CONNECTOR (400) GROUND STUD CIRCUIT 11GS CIRCUITS 23C AND 23G A/C HIGH PRESSURE CUT-OUT (228) ENGINE HARNESS TO ENGINE WIRING AT DASH PANEL

s08210

178

5 ELECTRICAL TROUBLESHOOTING FANS

Figure 74

Engine Fan Wiring, Caterpillar 3406E 1. 2. 3. 4. ECM CONNECTOR (400) GROUND STUD CIRCUIT 11GC AND 23GA ENGINE HARNESS TO OTHER SIDE OF ENGINE TO ENGINE WIRING AT DASH PANEL

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

179

Figure 75

Engine Fan Wiring, Caterpillar 3406E (Viewed From Top of Engine) 1. 2. 3. 4. CIRCUIT 77C ENGINE HARNESS FAN CIRCUITS TO ENGINE WIRING AT DASH PANEL A/C HIGH PRESSURE CUTOUT (228)

s08210

180

5 ELECTRICAL TROUBLESHOOTING FANS

Figure 76

Engine Fan Wiring, Cummins ISM 1. 2. 3. 4. 5. 6. 31WAY INTERFACE CONNECTOR (1093) 50WAY OEM INTERFACE CONNECTOR (1091) A/C HIGH PRESSURE CUTOUT CIRCUITS 23A AND 23D (228) TO FAN CIRCUITS, ENGINE WIRING AT DASH PANEL TO ENGINE WIRING AT DASH PANEL

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

181

Figure 77

Engine Fan Wiring, Cummins AHD 1. 2. 3. 4. 5. A/C HIGH PRESSURE CUT-OUT CIRCUITS 23A AND 23D (228) 50WAY ECM OEM CONNECTOR (1091) 31WAY ECM INTERFACE CONNECTOR TO FAN SOLENOID CIRCUITS AT ENGINE WIRING ON DASH ENGINE HARNESS TO OTHER SIDE OF ENGINE

s08210

182

5 ELECTRICAL TROUBLESHOOTING FANS

Figure 78

Engine Fan Wiring, International I6 HEUI 1. 2. 3. 4. TO FAN SOLENOID CIRCUITS AT ENGINE WIRING ON DASH ENGINE FAN CONTROL CONNECTOR (1075) CEC CONNECTOR (379) TO ENGINE WIRING ON DASH

s08210

5 ELECTRICAL TROUBLESHOOTING FANS

183

Figure 79 Engine Fan Wiring, International I6 HEUI 1. 2. 3. 4. A/C HIGH PRESSURE CUT-OUT SWITCH CIRCUITS 23A AND 23B (228) JUMPER WITH NO A/C ENGINE HARNESS

s08210

184

5 ELECTRICAL TROUBLESHOOTING FANS

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

185

Table of Contents

1. DESCRIPTION. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .187 2. OPERATION.. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .188 2.1. ECM POWER CIRCUITS.. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .188 2.2. VEHICLE SPEED SENSOR. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .188 2.3. COOLANT LEVEL SENSOR. . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .188 2.4. ATA DATALINK CONNECTOR.. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .189 2.5. J1939 DATA LINK. . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .189 2.6. CRUISE CONTROL. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .189 2.7. SERVICE BRAKE SWITCH.. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .190 2.8. CLUTCH SWITCH.. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .190 2.9. VEHICLE SPEED SENSOR. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .190 2.10. SPEEDOMETER/TACHOMETER CONNECTOR. . .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. .190 2.11. THROTTLE POSITION SENSOR.. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .191 2.12. ENGINE BRAKE. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .191 2.13. ANTILOCK BRAKE SYSTEM. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .192 2.14. IDLE SHUTDOWN TIMER. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .192 3. TROUBLESHOOTING. .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .193 3.1. DETERMINING FAULT CODES.. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .193 Reading Flash Codes .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .193 3.2. IMPORTANT STEPS BEFORE TESTING. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .195 3.3. INSPECTING ELECTRICAL CONNECTORS. . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .195 Visual Inspection. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .195 Performing Electrical Tests At International Connection (400) To ECM.. .. .. .. .. .. .. .. .. 196 Test Leads.. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .196 Replacing International Components. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .196 3.4. TESTING HELLA RELAY. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .196 3.5. TESTING ELECTRICAL POWER SUPPLY TO ECM. .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .197 Testing Switched Power Supply To ECM. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .197 Testing Unswitched Battery Feed To ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..197 3.6. DIAGNOSTIC CONNECTOR (137) AND DATA LINK CIRCUITS. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .198 Testing Diagnostic Connector Power and Ground Circuits. . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .198 Testing Diagnostic Connector and Speedometer/Tachometer Positive and Negative Data Link Circuits.. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .199 3.7. THROTTLE POSITION SENSOR (TPS). . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .201 Testing Throttle Position Sensor (TPS) and Circuits. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .201 3.8. VEHICLE SPEED SENSOR (VSS). .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .202 Inspecting And Adjusting the Adjustable Vehicle Speed Sensor (VSS). . . . . . . . . . . . . . . . . .202 Testing Vehicle Speed Sensor (VSS).. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .202 Testing Vehicle Speed Sensor (409). .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .203 Testing Vehicle Speed Sensor To ECM Circuits. .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .203 3.9. CRUISE AND PTO CONTROLS. . . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .204 Testing Cruise On/Off Switch and Circuits. . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .205 Testing Cruise Set/Resume Switch and Circuits. . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .205 3.10. CLUTCH SWITCH (55).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 206 Testing Clutch Switch and Circuits.. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .206

s08210

186

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Adjusting Clutch Switch. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . ..207 3.11. SERVICE BRAKE SWITCH (141). . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . .207 Testing Service Brake Switch and Circuits.. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. ..207 3.12. LOW COOLANT SENSOR.. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. .208 Testing Low Coolant Sensor.. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . ..209 3.13. ENGINE BRAKE CONTROLS. . . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. .210 Testing Engine Brake Switches and Circuits. . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . .210 Testing J1922 Circuits. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .211 4. COMPONENT LOCATIONS. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..212

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

187

1. DESCRIPTION
The C-10, C-12 and 3406E engines use the ADEM III electronic controller. This controller provides engine and vehicle functions including: ENGINE FUNCTIONS A. Electronic Governing* B. Fuel/Air Ratio Control* C. Injection Timing Control* D. Service Diagnostics** E. Torque Rise Shaping* F. Trip Data Recording*

*Caterpillar System **Caterpillar/International System VEHICLE FUNCTIONS A. Cruise Control* B. Data Links* C. Engine Brake Controls* D. Engine Protection System* E. Idle Shutdown Timer* F. Progressive Shifting*

G. PTO Controls* H. Vehicle Speed Limiting* *Caterpillar/International System Certain programmable parameters that affect the engine electronic control systems may be changed with electronic service tools. The parameters are stored in the system Electronic Control Module (ECM) and are protected from unauthorized change by passwords. The programmable parameters are either System Parameters or Customer Parameters. System Conguration Parameters are set at the factory and affect emissions and horsepower ratings within a family of engines. Factory passwords must be obtained and used to change System Conguration Parameters. Customer Selectable Parameters are variable, and are used to specify operating parameters for: cruise control, PTO operation, vehicle speed limits, progressive shifting, type of engine protection system, RPM and horsepower ratings within the engine family . Customer passwords are needed to change Customer Parameters.

s08210

188

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Since each C-10, C-12 or 3406E control system is electronically programmable to individual owner specications, the operating parameters will vary from vehicle to vehicle. Some of these parameters may cause the engine to operate in a way that the driver (or service technician) does not expect, if proper training has not taken place. This may lead to power or performance complaints and/or service time, when the engine is operating correctly. International provides an ATA Diagnostic connector (137) for connecting an Electronic Service Tool (EST) to the electronic engine control system. The Diagnostic connector is located on the instrument panel left side.

2. OPERATION
Refer to CATERPILLAR C-10 and C-12 and 3406E ENGINE circuit diagrams CTS-5298 or S08225. This section describes specic electrical operation of International installed circuits and components, referencing specic circuits, connectors and components by number.

2.1. ECM POWER CIRCUITS


With the key switch on, the ECM receives (12 volt DC) operating power from the vehicle batteries through International engine harness connector (400) terminal 70. Battery power to the ECM comes fuse F6-D, when the key switch is in the ignition position. Battery power from the (+) battery terminal of the cranking motor solenoid is always applied on circuits 97B and 97C through connector (400) terminals 52 and 53 to the ECM. These circuits are protected by fuses (217) and (218). Refer to 12V CHARGING and CRANKING WITH CATERPILLAR C-10, C-12 and 3406E ENGINES circuit diagrams CTS-5298 or S08225. The ECM uses this power to maintain a portion of memory used for customer trip data accumulators. Disconnecting this circuit does not affect engine operation or factory/customer parameters or logged diagnostic codes. Refer to the Caterpillar Troubleshooting Manual for additional information on this feature.

2.2. VEHICLE SPEED SENSOR


The ECM receives the AC signal from the vehicle speed sensor (1099) on circuits 97AJ and 97AK, through connector (1093), and sends a signal to the vehicle speedometer. The ECM also sends the signal to drive the vehicle tachometer. Two types of sensors are available. The threaded (adjustable) sensor is used on most transmissions. A push-in (non-adjustable) sensor may be used on some transmissions.

2.3. COOLANT LEVEL SENSOR


The coolant level switch is a uid level actuated switch that sends two signals to the ECM, thus providing a warning when coolant is being lost. It is mounted in the coolant surge tank. The coolant level switch is an electronic switch that operates on the electrostatic or capacitance principle and cannot be tested with a multimeter. The probe extends into the coolant and produces a change in capacitance when coolant displaces air immediately surrounding the probe. This change is converted in the switch to an on/off solid state switch closure indicating the absence or presence of coolant. The switch is electrically insulated providing a slick, non-fouling surface as well as good electrical characteristics to prevent current ow into the coolant. The low
s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

189

coolant level switch connects to the engine harness at connector (249). Four circuits from connector (402) connect the low coolant switch to the ECM through the 21way ECM connector (400). The coolant level switch (402) receives a 5 volt signal on circuit 34B(5V) from the ECM (400). When the coolant level is above the probe, the switch sends a high signal (3.5 volts minimum) on circuit 34A and a low signal (0.5 volt maximum) on circuit 34 to the ECM (400). When the coolant level is below the probe, the switch sends a low signal (0.5 volt maximum) on circuit 34A and a high signal (3.5 volts minimum) on circuit 34 to ECM (251). The low coolant level switch is grounded through circuit 34G to ECM (251). NOTE The low coolant level switch cannot be tested with a multimeter in the ohmmeter mode. This is due to the fact that the switch is an electronic switch and not a mechanical switch.

2.4. ATA DATALINK CONNECTOR


Connector (137) is located on left instrument panel. Four of the six connector cavities have terminals. Those terminals and connecting circuits are as follows: A. Circuit 98A(+) is the positive data link connection, and it is fed by the positive data link connector (514), connector (190), circuit 98B(+) and circuit 98(+) coming from the ECM connector (400). B. Circuit 98C(-) is the negative data link connection, and it is fed by the negative data link connector (515), circuit 98B(-), connector (190), and circuit 98B(-) coming from the ECM connector (400). C. Circuit 97DL is a 12 volt feed and is fed from bat stud (B1) circuit 14W, circuit 14AA, 20A fuse F5D, and circuit 97DL. Thus it provides power for the electronic service tool. D. Circuits 11GR and 11GT connect to the panel light ground adapter (506) and provide a ground for the electronic service tool.

2.5. J1939 DATA LINK


The ADEM III controller provides a J1939 data link for use with some types of transmissions and service tools. A. Circuit 98YL(+) is the positive data link connection. It originates from ECM connector (400), terminal 50. The circuit is connected to J1939 terminating resistor connector (1098), terminal A and J1939 backbone connector (1097), terminal A. B. Circuit 98GN(-) is the negative data link connection. It originates from ECM connector (400), terminal 34. The circuit is connected to J1939 terminating resistor connector (1098), terminal C and J1939 backbone connector (1097), terminal B. C. Circuit 98SHD is the data link shield connection. It originates from ECM connector (400), terminal 42. The circuit is connected to J1939 terminating resistor connector (1098), terminal B and J1939 backbone connector (1097), terminal C.

2.6. CRUISE CONTROL


The cruise control switches are used as idle controls when the vehicle road speed is not present (this is a customer selected parameter). Refer to the Operators Manual furnished with the vehicle for cruise control operating instructions. Refer to circuit diagram CATERPILLAR C-10, C-12 or 3406E CRUISE CONTROL in CTS-5298 or S08225.

s08210

190

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

The cruise on/off switch is lighted to allow for easy location in the dark. Cruise on/off switch circuit 97AE is an input to the ECM at connector (400) terminal 20. The ground side of the on/off switch is connected through circuits 97GC, 97GB, 97GA and 97G to connector (400) terminal 5. With the switch on, the ECM sees 0 volts at connector (400) terminal 20. With the switch off, the ECM sees 5 volts at connector (400) terminal 20. The cruise set/resume switch is lighted to allow for easy location in the dark. Set/resume switch terminal 2 is connected to the ECM through circuits 97GB, 97GA and 97G to the connector (400) terminal 5. Set/resume switch Set terminal 3 is an input (circuit 97AB) to the ECM through connector (400) terminal 35. Set/resume switch Resume terminal 1 is an input (circuit 97AA) to the ECM through connector (400) terminal 44. With the set/resume switch in the set position, the ECM sees 0 volts at connector (400) terminal 35 and 5 volts at terminal 44. In resume position, the ECM sees 5 volts at connector (400) terminal 35 and 0 volts at terminal 44. In the set/resume neutral position, the ECM sees 5 volts at both connector (400) terminals 35 and 44.

2.7. SERVICE BRAKE SWITCH


Circuit 97AL is an input to the ECM through connector (400) terminal 45. The ground or common side of the service brake switch is connected through circuits 97GF, 97GA and 97G to connector (400) terminal 29. With service brakes released (switch closed), the ECM sees 0 volts at connector (400) terminal 5. Applying the brakes opens the switch, and the ECM sees 5 volts at terminal 14.

2.8. CLUTCH SWITCH


This normally open switch is adjusted to be closed while the clutch pedal is released. The clutch switch connects to the cab harness at connector (294). Clutch switch circuit 97AH is an input to the ECM through connector (400) terminal 22. The ground side of the clutch pedal switch is grounded through circuits 97GH, 97GA, and 97G to connector (400) terminal 5. With the drivers foot off the clutch pedal (switch closed), the ECM sees 0 volts at terminal 22. When the driver depresses the clutch pedal (switch opens), the ECM sees 5 volts at terminal 22.

2.9. VEHICLE SPEED SENSOR


Connector (409) is located at the rear of the transmission. The sensor contains a permanent magnet that creates a magnetic eld that is interrupted by the teeth on the speedometer output gear. As the rotating speedometer gear teeth repeatedly interrupt the sensor magnetic eld, a variable AC voltage is generated and transmitted to the ECM. From sensor connector (409) circuits 97AJ and 97AK carry the signal to ECM connector (400) terminals 32 and 33.

2.10. SPEEDOMETER/TACHOMETER CONNECTOR


Data link positive connector (514) terminal C is connected by circuit 47/48(+) to speedometer/tachometer connector (421). Data link positive connector (514) terminal A is connected by circuit 98A(+) to the ATA data link connector (137) terminal A. ATA data link connector (137) can be used to access information on the data link using an electronic service tool. Data link negative connector (515) terminal C is connected by circuit 47/48(-) to speedometer/tachometer connector (421). Data link negative connector (515) terminal A is connected by circuit 98C(-) to the ATA data link connector (137) terminal B. ATA data link connector (137) can be used to access information on the data link using an electronic service tool.
s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

191

2.11. THROTTLE POSITION SENSOR


The pedal mounted Throttle Position Sensor (TPS) is used to provide a throttle signal to the ECM. Sensor output is a constant frequency signal with a pulse width that varies with throttle position. This output signal is referred to as either Duty Cycle or a Pulse Width Modulated (PWM) signal and is expressed as a percentage between 0 and 100%. The pedal mounted throttle position sensor is attached directly to the throttle pedal assembly and requires no adjustment. This sensor can be replaced separately from the throttle pedal assembly, however, an incorrectly calibrated pedal mounted throttle position sensor assembly cannot be calibrated the pedal assembly must be replaced. Refer to circuit diagram CATERPILLAR C-10, C-12, or 3406E CRUISE CONTROL in CTS-5298 or S08225. The TPS connects to the cab harness at three-pin connector (404). When the ECM is powered (key switch on), the TPS receives operating voltage (8 volts) at terminal A on circuit 99A which is connected to ECM connector (400) terminal 4. TPS terminal B is grounded by circuit 99GA, 97GA, 97G through ECM connector (400) terminal 5. TPS terminal C outputs the variable throttle position signal on circuit 99 to ECM connector (400) terminal 66. The pedal mounted TPS should produce a Duty Cycle of 10 to 22 percent at low idle and 75 to 90 percent at full throttle. An electronic service tool can be used to monitor the signal. The percent duty cycle is translated in the ECM into a throttle position percentage of 3 to 100%.

2.12. ENGINE BRAKE


These Caterpillar engines come with an engine brake. This manual discusses only engine brake control circuits and components installed by International: the engine brake on/off switch (434), the engine brake selector switch (433) and the connecting circuits. The International installed clutch switch (294) and service brake switch (141) also provide inputs to the engine brake control system. For a complete description of engine brake operation, refer to the appropriate Caterpillar Service Manual. There are two owner selected engine brake operation modes, which are COAST and LATCH. If the COAST mode (standard mode) is selected, the engine brake operates when: Engine speed is over 800 rpm. The drivers foot is off the throttle pedal (throttle position less than 7%). Clutch pedal is not depressed. The service brake pedal is depressed (engine brake only operates while service brake is applied). The cruise control switch can be in the on position, although it will be disabled by applying the service brake.

If the LATCH mode is selected, the engine brake operates when: Engine speed is over 800 rpm. The drivers foot is off the throttle pedal (throttle position less than 7%). Clutch pedal is not depressed. The cruise control switch must be off.
s08210

192

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

The engine brake operates when the driver applies the service brake, but the engine brake continues to operate (latches on, so to speak) after the driver takes his foot off the brake. The engine brake stays engaged (latched on) until one of the other ECM inputs changes: clutch pedal depressed, throttle pedal depressed, engine speed drops below 800 rpm or the brake pedal is depressed a second time.

Control of the engine brake is shared by the driver and the ECM. The driver turns the engine brake on or off and selects how much engine brake is desired (number of cylinders). The ECM monitors certain engine parameters, then enables the engine brake system when all conditions are acceptable. An on/off switch (434) is used to enable (turn on) the engine brake control system. With the on/off switch closed, the circuit between ECM connector (400) terminal 5 and the engine brake selector switch terminal 2 is complete. The engine brake selector switch (433) has three circuits: Low, Medium and a common or ground circuit connected to the engine brake on/off switch. Selector switch terminal 2 is connected by circuit 24A to the engine brake on/off switch (434) at terminal 5. When the on/off switch is on, the circuit between the engine brake selector switch (433) terminal 2 and ECM connector (400) terminal 5 is complete. With the selector switch (433) in the Low position, the ECM sees a 0 volt signal at connector (400) terminal 23 and a 5 volt signal at terminal 40. With the selector switch (433) in the Medium position, the ECM sees a 0 volt signal at connector (400) terminal 40 and a 5 volt signal at terminal 23. With the selector switch (433) in the High position, the ECM sees a 0 volt signal at connector (400) terminals 40 and 23.

2.13. ANTILOCK BRAKE SYSTEM


On vehicles with Antilock Brakes (ABS), the ABS controller is connected to the ECM through J1922 connector (403). This connection allows the ABS controller to communicate with the ECM by serial data circuits 98Z(+) and 98Y(-). These circuits are a twisted wire pair. This allows the ECM to turn off the engine brake when the ABS system detects that a vehicle wheel is encountering a slippery road surface.

2.14. IDLE SHUTDOWN TIMER


This feature helps improve fuel consumption by limiting idle time. The shutdown time is a customer specied parameter, and may be from 3 to 1440 minutes. Programming the time to zero shuts the timer off. The timer is activated and the countdown (from the customer selected time) begins when: The vehicle speed is zero. The engine is warmed up. The engine is not under load (with or without the park brake set).

Ninety seconds before the programmed time is reached, the Yellow Serv/Check Engine light will begin to ash rapidly. If the driver moves the clutch (294) or service brake (141) pedal during this 90second time period, the clutch switch (294) or the brake switch (141) contacts will open up and the timer will be overridden until it is reset. The timer is reset and begins counting over by moving the vehicle a short distance.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

193

A code (Override of Idle Shutdown Timer) will be logged when the driver overrides the timer within the 90second time period. If the timer is activated and allowed to shut down the engine, then a code (Idle Shutdown Timed Out) will be set. These codes record an event they do not indicate a fault in the system. IMPORTANT Note that the system shuts the engine down, but does not turn off power to the vehicle.

3. TROUBLESHOOTING
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 laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual. D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid. During normal vehicle start-up, turning the key to the on position causes the Serv/Check Engine light to come on as a system test. The light remains on for about six seconds, then goes off. If the Serv/Check Engine light stays on after the initial start-up, the ECM has detected a problem with the system. All C-10, C-12 and 3406E equipped vehicles have a yellow Serv/Check Engine light located in the left gauge cluster. This light communicates engine status. If during vehicle operation, the Serv/Check Engine light comes on, that indicates an active fault is present. The light will remain on, but blink approximately every ve seconds for a brief 1/2 second.

3.1. DETERMINING FAULT CODES


The EZ-Tech, PRO-LINK 9000, or Caterpillar electronic service tools (EST) can be used to identify logged fault codes. Refer to the EST manual for operating instructions. The yellow Serv/Check Engine light can be used to read fault codes by following the procedure in the following paragraph. Reading Flash Codes KEY ON ENGINE OFF PROCEDURE NOTE All Caterpillar ash codes are two digit numbers. 1. Turn the key to the on position. The yellow Serv/Check Engine light will turn on for approximately ve seconds, then turn off for several more seconds, then begins to FLASH any logged codes.
s08210

194

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

2. The yellow Serv/Check Engine light will FLASH the rst digit. At the end of rst digit there is a one or two second pause. 3. The yellow Serv/Check Engine light will FLASH the second digit. At the end of the second digit there will be a two or three second pause before the next fault code number is FLASHED. 4. The second and all successive fault codes will FLASH until all codes have been FLASHED. It will stop FLASHING after the last code has been ashed. To see the fault codes again, repeat the process. 5. Flash code 55 indicates that there are no logged diagnostic codes. For a listing of Caterpillar Flash codes, refer to the Caterpillar Electronic Troubleshooting manual. Codes are also listed in the EZ- Tech or PRO-LINK 9000 manual. ENGINE RUNNING PROCEDURE NOTE All Caterpillar ash codes are two digit numbers. 6. Begin procedure with engine off. 7. Start engine and allow to run at low idle for about 30 seconds. 8. Turn cruise on/off switch to off position. 9. Hold cruise set/resume switch in either position until codes begin to FLASH, then release. 10. The yellow Serv/Check Engine light will FLASH the rst digit. At the end of the rst digit there is a one or two second pause. 11. The yellow Serv/Check Engine light will FLASH the second digit. At the end of the second digit there will be a two or three second pause before the next fault code number is FLASHED. 12. The second and all successive fault codes will FLASH until all codes have been FLASHED. It will stop FLASHING after the last code has been ashed. To see the fault codes again, repeat steps 4 through 6. 13. Flash code 55 indicates that there are no logged diagnostic codes. For a listing of Caterpillar ash codes, refer to the Caterpillar Electronic Troubleshooting manual. Codes are also listed in the EZ-Tech or PRO-LINK 9000 manual. This section includes diagnostic tables for International installed circuits and components that are part of the Caterpillar electronic engine control system. To begin the process, refer to the appropriate Caterpillar Electronic Troubleshooting Manual and follow their directions. If the Caterpillar diagnostics indicate that an International circuit is suspect, use the diagnostic tables included in this section for a step-by-step procedure. Refer to the appropriate circuit diagram for CATERPILLAR C-10, C-12 or 3406E ENGINES IN CTS-5298 or S08225. The EZ-Tech or PRO-LINK 9000 ESTs with the Caterpillar programs can be used to read fault codes, customer and engine parameters and monitor various switches and sensors.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

195

3.2. IMPORTANT STEPS BEFORE TESTING


1. Gather information by talking to the driver 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 problem. Is the complaint due to misunderstood customer selected parameters? Use an EST to review customer selected parameters. 3. Check for and record any logged fault codes. a. Do the logged codes correlate to probable causes? b. Were the codes logged about the same time as the symptoms appeared? Were the codes logged repeatedly? c. Are the logged codes related to other symptoms? Do they have a common cause?

4. Avoid Preconceived Ideas! Eliminate any non-electrical causes for the problem rst (contaminated fuel, clogged air lters, etc.).

3.3. INSPECTING ELECTRICAL CONNECTORS


Visual Inspection The troubleshooting guide requires checking specic connectors. Use the following steps to determine if the connector is causing the problem. If a defective condition is found, make the necessary corrections and continue the process. 1. Check the connector lock mechanism or retaining screw. Make sure the connector is capable of properly locking the connector together. 2. Perform a 10 pound pull-test on each terminal/wire in the connector. Each terminal/wire assembly should easily withstand 10 pounds of pull and remain in the connector. This test determines (A) if the wire is properly in the terminal and (B) if the terminal is properly inserted into the connector. Correct any defects noted. 3. Visually inspect wiring. Inspect for worn or damaged wires. Check for pinched or damaged harness. 4. Visually inspect connectors. Verify that pins and sockets are free of corrosion, dirt or other contaminants and damage. Verify correct alignment and location of terminals in the connector. 5. Check individual pins and sockets. This is especially important with an intermittent symptom. Using a new pin, insert the pin into each socket, one at a time, checking for a good grip on the pin by the socket. Repeat for each pin on the mating side of the connector, using a new female terminal for the test. 6. Inspect Engine Ground Stud. Inspect this ground and other related grounds for clean, tight connections that are free of corrosion and/or other defective conditions.

s08210

196

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Performing Electrical Tests At International Connection (400) To ECM International OEM connector (400) mates with Caterpillar ECM connector J1. This is a Deutsch 40pin connector, with the International side having female terminals (sockets) and the Caterpillar side having pins. NOTE No tests in this manual require testing into the Caterpillar J1 connector. When testing the International side of connector (400), never insert meter probes into the sockets, as the probes will damage the sockets. Always use test leads of the type described in Test Leads, in the following paragraph. The test leads must t snugly into the sockets without expanding the sockets. Test Leads To construct test leads, attach an insulated alligator clip to a suitable length of 16 gauge wire. On the other end, use Deutsch HDT-4800 Crimp Tool to install male terminal 1651958C1. Signal Reading Probes, Caterpillar part number 7X1710, can also be used. Replacing International Components When replacing electrical switches, connectors (including pins and sockets), relays or other components, use only approved International replacement parts. Many of the switches have gold or silver plated contacts and some of the connectors have gold plated terminals. By using correct replacement parts, you maintain the design integrity of the system. All of the relays and other solenoids installed by International are suppressed to prevent voltage spikes from damaging electrical components. Again, use only International replacements for these components.

3.4. TESTING HELLA RELAY


International circuits use suppressed Hella 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 in the vehicle. 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 Test Procedure 1. With relay removed, measure resistance between terminals 30 and 87A. If resistance is less than 5 ohms, go to step 2; otherwise replace the relay. 2. Measure resistance between terminals 30 and 87. If resistance is 100K ohms or more, go to step 3; otherwise replace the relay. 3. Using 12V battery source and test leads, connect (+) lead to terminal 85 and (-) lead to terminal 86. If relay energizes with an audible click sound, go to step 4; otherwise replace the relay. 4. While relay is energized, measure resistance between terminals 30 and 87. If resistance is less than 5 ohms, go to step 5; otherwise replace the relay. 5. While relay is energized, measure resistance between terminals 30 and 87A. If resistance is 100K ohms or more, the relay is good; otherwise replace relay.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

197

3.5. TESTING ELECTRICAL POWER SUPPLY TO ECM


Procedure for Testing Switched Power Supply To ECM tests the switched battery power circuits to the ECM (key on). Procedure for Testing Unswitched Battery Feed To ECM tests the unswitched battery power circuits to the ECM. Testing Switched Power Supply To ECM NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting. Table 42 Testing Switched Power Supply To ECM STEP 1. KEY Off ACTION Remove and check fuse F6-D for open condition. Fuses OK? TEST POINTS F6-D SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse(s). Loacate cause of incorrect voltage on circuit 13D.

2.

Off/ On

Disconnect connector (400) from ECM. Re-install fuse F6-D. Turn key on and measure voltage to ground at terminal 70, circuit 97L. Switched voltage to ECM checks good. At connector (400), measure voltage between terminals 5 (circuit 97-G) and 70 (circuit 97L).

(400), 97L to gnd.

12 1.5 volts.

Go to next step.

3.

On

(400), between 97-G and 97L.

12 1.5 volts.

ECM gnd. circuit 97-GB checks good.

Locate open or poor connection in ground circuit 97-GB, between connector (400) and engine ground stud, then repair.

Testing Unswitched Battery Feed To ECM NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting.

s08210

198

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Table 43 STEP 1.

Testing Unswitched Battery Feed To ECM KEY Off ACTION Disconnect connector (400) from ECM. Check inline fuses (217) and (218) for open condition. At terminal 52, circuit 97B, measure voltage to ground. TEST POINTS Inline fuses (217) and (218). (400), 97B to gnd. SPEC. Not open. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuses. Locate cause of no or low voltage in circuit 97B from cranking motor "B" terminal, then repair. Locate cause of no or low voltage in circuit 97B from cranking motor "B" terminal, then repair. Locate open or poor connection in circuit 97-GB between conn. (400) and cylinder head ground, then repair. Locate open or poor connection in circuit 97-GJ between conn. (400) and cylinder head ground, then repair.

2.

Off

12 1.5 volts.

Go to next step.

3.

Off

At terminal 53, circuit 97C, measure voltage to ground.

(400), 97C to ground.

12 1.5 volts.

Go to next step.

4.

Off

At connector (400), measure voltage between terminal 65, circuit 97-GB and terminal 52, circuit 97B. At connector (400), measure voltage between terminal 67, circuit 97-GJ and terminal 52, circuit 97B.

(400) between 97-GB and 97B.

12 1.5 volts

Go to next step.

5.

Off

(400) between 97-GJ and 97B.

12 1.5 volts.

Unswitched battery feed to ECM checks good.

3.6. DIAGNOSTIC CONNECTOR (137) AND DATA LINK CIRCUITS


Testing Diagnostic Connector Power and Ground Circuits Table 44 STEP 1. Testing Diagnostic Connector Power and Ground Circuits KEY Off ACTION Remove and check 20A fuse F5-D for open condition. Is fuse open? TEST POINTS F5-D SPEC. <1 ohm. YES-IN SPEC. Go to next step NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace the fuse.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

199

Table 44 STEP 2.

Testing Diagnostic Connector Power and Ground Circuits (cont.) KEY On ACTION Re-install fuse F5-D. At connector (137), measure voltage from circuit 97DL to ground. At connector (137), measure voltage between circuit 97DL and circuit 11-GR. TEST POINTS (137), 97DL to ground. (137) between 97DL and 11-GR. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 97DL, then repair. Locate open or poor connection in circuit 11-GR, 11-GT to panel light adapter (506), then repair.

3.

On

12 1.5 volts.

Power and gnd. circuits to diagnostic conn. (137) check good.

Testing Diagnostic Connector and Speedometer/Tachometer Positive and Negative Data Link Circuits NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting. NOTE A multimeter cannot be used to measure the voltage of the signal on these circuits. Table 45 Testing Diagnostic Connector and Speedometer/Tachometer Positive and Negative Data Link Circuits STEP 1. KEY Off ACTION Disconnect conn. (400) from ECM, and (421) from speedometer unit. If other devices are connected at data link connectors (514) and (515), disconnect them. At conn. (137) measure resistance from terminal A, circuit 98A(+) to ground. At conn. (137) measure resistance from terminal B, circuit 98C(-) to ground. At conn. (137) measure resistance between terminal A, circuit 98A(+) and terminal B, circuit 98C(-). TEST POINTS (137), 98A (+) to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground, then repair.

2.

Off

(137), 98C(-) to gnd. (137) between 98A(+) and 98C(-).

>100K ohms. >100K ohms.

Go to next step. Go to next step.

Locate short to ground, then repair. Locate short circuit between circuits connected to terminal A 98A(+), 98(+), 47/48(+) and terminal B98C(-), 98B(-), 47/48(-), then repair.

3.

Off

s08210

200

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Table 45 Testing Diagnostic Connector and Speedometer/Tachometer Positive and Negative Data Link Circuits (cont.) STEP 4. KEY Off ACTION At connector (400), use test lead to jumper terminal 8, circuit 98(+) to gnd. At connector (137) terminal A, circuit 98A(+) measure resistance to ground. TEST POINTS (137), 98A(+) to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 98A(+) between connectors (514) and (137) or open or poor connection in circuit 98(+) between connectors (514) and (400), then repair. Locate open or poor connection in circuit 47/48(+) between connectors (421) and (514), then repair. Locate open or poor connection in circuit 98C(-) between connectors (515) and (137), or open or poor connection in circuit 98B(-) between connectors (515) and (400), then repair. All data link circuits check good.

5.

Off

With jumper still in place at terminal 7, circuit 98(+), measure resistance to ground at circuit 47/48(+) and connector (421).

(421), 47/48(+) to gnd.

<5 ohms.

Go to next step.

6.

Off

At connector (400) use test lead to jumper terminal 8, circuit 98(+) to terminal 9, circuit 98B(-). At conn. (137) measure resistance between terminal A, circuit 98A(+) and terminal B, circuit 98C(-).

(137) between 98A(+) and 98C(-).

<5 ohms.

Go to next step.

7.

Off

With jumper still in place, at connector (421) measure resistance between 47/48(-) and ground.

(421), 47/48 (-) to gnd.

<5 ohms. Locate open in circuit 47/48 (-) between conn. (421) and (515), then repair.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

201

3.7. THROTTLE POSITION SENSOR (TPS)


Testing Throttle Position Sensor (TPS) and Circuits NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting. Table 46 STEP 1. Testing Throttle Position Sensor (TPS) and Circuits KEY Off ACTION Disconnect TPS from cab harness at conn. (404). At TPS side of (404) measure resistance to gnd. at terminals A, B and C (red, black and white wires). Disconnect conn. (400) from ECM. At (404) measure resistance between terminals A, B and C (circuits 99E, 99-G and 99). There should be no continuity between the three terminals. At conn. (400), use test lead to jumper terminal 29 (circuit 97-G) to gnd. At conn. (404) and terminal B (circuit 99-GA) measure resistance to ground. At conn. (400), use test lead to jumper terminal 29 to 37 (circuit 97-G to 99). At connector (404) measure resistance between terminals B and C (circuit 99-GA to 99). At conn. (400), use test lead to jumper terminal 29 to 35 (circuit 97-G to 99E). At conn. (404) measure resistance between terminals B and A (circuit 99-GA and 99E). TEST POINTS (404), A, B, and C to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the throttle position sensor.

2.

Off

(404) between 99E, 99-G and 99.

>100K ohms.

Go to next step.

Locate short circuit, then repair.

3.

Off

(404), 99-GA to gnd.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 99-GA path to ground, then repair.

4.

Off

(404), 99-GA to 99.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 99 between connectors (404) and (400), then repair. Locate open or poor connection in circuit 99E between connectors (404) and (400), then repair.

5.

Off

(404), 99-GA to 99E.

<5 ohms.

Go to next step.

s08210

202

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Table 46 STEP 6.

Testing Throttle Position Sensor (TPS) and Circuits (cont.) KEY Off/ On ACTION Connect (400) at ECM. Turn ignition on. At conn. (404) measure voltage between terminals A and B (circuit 99E and 99-GA). Replace the throttle position sensor and reconnect connectors. Test system operation and note if defect is still present. TPS works OK? TEST POINTS (404), 99E to 99-GA. SPEC. 8 0.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Have Caterpillar dealer diagnose the ECM.

7.

Off

End test.

Have Caterpillar dealer diagnose the ECM.

3.8. VEHICLE SPEED SENSOR (VSS)


Inspecting And Adjusting the Adjustable Vehicle Speed Sensor (VSS) 1. Disconnect engine harness connector (250) from the sensor. Loosen the locknut and remove the sensor. The harness connector and sensor should be free of damage or corrosion. Remove any metal shavings or debris from the sensor. 2. To install the adjustable sensor, turn in until the sensor contacts the transmission speedometer gear, then back out one full turn. Tighten locknut to 15 ft-lbs. (20.3 Nm). This assures that the sensor is adjusted properly for the next test. Testing Vehicle Speed Sensor (VSS) To perform this test construct two test leads using terminals (1680205C1) and suitable length of 16GA wire.

WARNING A jack must never be used alone to support vehicle. The jack may lower and serious injury could result. Always support vehicle with oor jacks. Always block wheels to prevent vehicle from moving.

WARNING EXTREME CAUTION should be used to prevent personal injury resulting from contact with rotating vehicle wheels when connecting test leads.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

203

Testing Vehicle Speed Sensor (409) Table 47 STEP 1. Testing Vehicle Speed Sensor (409) KEY Off ACTION Inspect VSS for damage and proper adjustment before performing this test. Disconnect engine harness connector (409) from VSS and use test leads to measure resistance between terminal A and B of the sensor. VSS, A to B TEST POINTS SPEC. YES-IN SPEC. Go to next step. 600 to Go to next 800 ohms step. for the adjustable sensor. 1500 3500 ohms for the push-in sensor. >100K ohms. Go to next step. Go to next step. Replace the vehicle speed sensor (VSS). NO-OUT OF SPEC.

2.

Off

3.

Off

Measure resistance to ground at both terminals (A and B) of the sensor VSS sensor output test: This test checks for proper AC voltage output signal from VSS sensor. Improper sensor adjustment will cause low, erratic or no output. Block front wheels and place rear axles on oor stands. Use AC voltmeter with sufcient length leads to avoid personal contact with rotating vehicle wheels during test. Connect meter leads to sensor test leads. Run engine at idle speed with transmission in high gear. Measure voltage across the two sensor terminals.

VSS, A and B to gnd.

Replace the vehicle speed sensor (VSS).

4.

Off

5. 6.

Off Off

Go to next step. Go to next step.

7.

On

VSS, A to B.

>2.0 volts AC.

The vehicle speed sensor checks good.

If sensor was properly adjusted, replace the sensor.

Testing Vehicle Speed Sensor To ECM Circuits This procedure tests the International speed sensor circuits between connectors (409) and (400).

s08210

204

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting. Table 48 Testing Vehicle Speed Sensor To ECM Circuits STEP 1. KEY Off ACTION Disconnect conn. (409) from VSS and (400) from the ECM. At conn. (409) measure resistance to gnd. at both terminals. At (409) measure resistance between terminals. TEST POINTS (409) both terminals to gnd. SPEC. >100 K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground in circuit (97AK or 97AJ, then repair. Locate short circuit between circuits 97AJ and 97AK, between connectors (409) and (400), then repair. Locate open or poor connection in circuit 97AK, then repair.

2.

Off

(409), between terminals.

>100K ohms.

Go to next step.

3.

Off

At conn. (400) use test lead to jumper terminal 33 to ground. At conn. (409) measure resistance to ground at circuit 97AK. At conn. (400) use test lead to jumper terminal 32 to ground. At conn. (409) measure resistance to ground at circuit 97AJ.

(409), 97AK to gnd.

<5 ohms.

Go to next step.

4.

Off

(409), 97AJ to gnd.

<5 ohms.

Vehicle speed circuits and VSS check good.

Locate open or poor connection in circuit 97AJ, then repair.

3.9. CRUISE AND PTO CONTROLS


Refer to Caterpillar Electronic Troubleshooting Guide to diagnose a cruise system malfunction. The EZ-Tech or Pro-Link Electronic Service Tools (EST) can be used to monitor system parameters relating to Cruise Control operation. Use the EST to monitor operation of system switches, including the Cruise On/Off, Set/Resume, service brake and clutch switch. NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

205

Testing Cruise On/Off Switch and Circuits Table 49 Testing Cruise On/Off Switch and Circuits STEP 1. KEY Off ACTION Disconnect conn. (435) from cruise on/off switch. With switch in the on position measure resistance between terminals 5 and 6. Disconnect conn. (400) from ECM. Measure the resistance between conn. (435), terminal 6 and ground. TEST POINTS Across cruise on/off switch. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

(435), 97-GC to ground.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 97-GC, or 97-GB between conn. (435) and ground, then repair. Locate open or poor connection in circuit 97AE between connectors (435) and (400), then repair.

3.

Off

At conn. (400) use test lead to jumper terminal 59 (circuit 97AE) to terminal 5 (circuit 97-G). At connector (435), measure resistance between circuits 97AE and 97-GC.

(435), 97AE to 97-GC.

<5 ohms.

Cruise on/off switch and circuits to (400) check good.

Testing Cruise Set/Resume Switch and Circuits NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting. Table 50 STEP 1. Testing Cruise Set/Resume Switch and Circuits KEY Off ACTION Remove conn. (436) from cruise set/resume switch. With switch in neutral position, measure resistance between switch terminal 2 and terminals 1 and 3. TEST POINTS Set/ resume switch, 2 to 1 and 2 to 3. SPEC. >100K ohms YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace set/ resume switch.

2.

Off

With switch in resume Set/resume <2 ohms. position, measure resistance switch, 1 between switch terminals 1 to 2. and 2.

Go to next step.

Replace set/ resume switch.

s08210

206

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Table 50 STEP 3.

Testing Cruise Set/Resume Switch and Circuits (cont.) KEY Off ACTION With switch in set position, measure resistance between switch terminals 2 and 3. Disconnect conn. (400) from ECM. Measure the resistance between conn. (436) terminal 2 and ground. At conn. (400), use test lead to jumper terminal 5 (circuit 97-G) to 44 (circuit 97AA). At conn. (436) measure resistance between circuits 97AA and 97-GB. At conn. (400) use test lead to jumper terminal 5 (circuit 97-G) to 35 (circuit 97AB). At conn. (436) measure resistance between circuits 97AB and 97-GB. TEST POINTS Set/ resume switch 2 to 3. (436), 97-GB to ground. (436), 97AA to 97-GB. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace set/ resume switch.

4.

Off

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 97-GB, then repair. Locate open or poor connection in circuit 97AA between connectors (436) and (400), then repair. Locate open or poor connection in circuit 97AB between connectors (436) and (400), then repair.

5.

Off

<5 ohms.

Go to next step.

6.

Off

(436) 97AB to 97-GB.

<5 ohms.

The set/ resume switch and circuits test good.

3.10. CLUTCH SWITCH (55)


Testing Clutch Switch and Circuits NOTE If the vehicle is equipped with an Allison transmission, this switch is replaced with a jumper connection. Table 51 STEP 1. Testing Clutch Switch and Circuits KEY Off ACTION At (294) disconnect clutch switch lead from cab harness. With clutch pedal released, measure resistance across clutch switch pigtail connector (A to B). Switch should read closed. TEST POINTS Clutch switch, A to B. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. If switch is not adjusted properly, adjust and retest. Refer to Adjusting Clutch Switch. If switch is adjusted properly, replace the switch.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

207

Table 51 Testing Clutch Switch and Circuits (cont.) STEP 2. KEY Off ACTION Depress clutch pedal while measuring resistance across clutch switch pigtail (294) terminal A to B. TEST POINTS Clutch switch, A to B. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. If sw. is not adjusted properly, adjust and retest. Refer to Adjusting Clutch Switch. If switch is adjusted properly, replace the switch. Locate open condition in cirucit 97AH between connectors (294) and (400), then repair. Locate open or poor connection in circuit 97AH, 97-GH, 97-GA or 97-G betweeen connectors (294) and (400), then repair. Locate short circuit between circuit 97AH and circuit 97-GE, then repair.

3.

Off

Disconnect connector (400) from ECM. At connector (400) use test lead to jumper terminal 22 (circuit 97AH) to ground. At connector (294) measure resistance to ground at circuit 97AH. At connector (400), use test lead to jumper terminal 5 (circuit 97-G) to 22 (circuit 97AH). At clutch switch harness (294) measure resistance between circuit 97-GH and 97AH. Remove jumper from connector (400), but do not connect. At clutch switch harness (294), measure resistance between circuits 97AH and 97-GE.

(294), 97AH to ground.

<5 ohms.

Go to next step.

4.

Off

(294), 97-GH to 97AH.

<5 ohms.

Go to next step.

5.

Off

(294), 97AH to 97-GE.

>100K ohms.

The clutch switch adjustment and circuits check OK.

Adjusting Clutch Switch The clutch switch should be mounted so that the switch actuator makes contact with the clutch pedal arm when the arm is depressed 0.5 inch at the point of actuator contact. The bracket can be bent forward or backward for adjustment. An audible click (switch closing) should be heard when the pedal is released.

3.11. SERVICE BRAKE SWITCH (141)


Testing Service Brake Switch and Circuits NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting.

s08210

208

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Table 52 STEP 1.

Testing Service Brake Switch and Circuits KEY Off ACTION Remove conn. (141) from service brake switch. With brakes released, measure resistance to ground at each switch terminal (not the harness connector side). With (141) removed from service brake switch, and service brakes released, measure resistance across switch terminals. With vehicle air pressure >80 PSI, apply service brakes while measuring resistance across the brake switch terminals. Disconnect conn. (400) from ECM and do not reconnect (141) to switch. Use test lead to jumper conn. (400) terminal 45 (circuit 97AL) to gnd. At brake switch (141), measure resistance to gnd. at circuit 97AL. At conn. (400), use test lead to jumper terminal 5 (circuit 97-G) to terminal 45 (circuit 97AL). Measure resistance between conn. (141) circuit 97AL and 97-GF. With conn. (400) disconnected and jumpers removed, at (141) measure resistance between circuits 97AL and 97-GF. TEST POINTS Brake switch to gnd. at each terminal. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the brake switch.

2.

Off

Across switch terminals.

<2 ohms.

Go to next step.

Replace the brake switch.

3.

Off

Across switch terminals.

>100K ohms.

Go to next step.

Replace the brake switch.

4.

Off

(141), 97AL to ground.

<5 ohms.

Go to next step.

Locate open or poor connection condition in circuit 97AL between connectors (141) and (400), then repair. Locate open or poor conn. in circuit 97-GF, 97-GA, or 97-G between connectors (141) and (400), then repair. Locate short circuit between circuit 97AL and circuit 97-GF, then repair.

5.

Off

(141), 97-GF to 97AL.

<5 ohms.

Go to next step.

6.

Off

(141), 97AL to 97-GF.

>100K ohms.

The brake switch and circuits check OK.

3.12. LOW COOLANT SENSOR


NOTE If the customer has elected to turn Engine Protection Feature off, this sensor is not active.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

209

Testing Low Coolant Sensor NOTE Do not use meter to test low coolant sensor. It may cause damage to the circuit board located in the sensor. NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting. Table 53 STEP 1. Testing Low Coolant Sensor Circuits KEY Off ACTION Disconnect connector (400) from Cummins connector. Disconnect (402) from low coolant switch. At connector (400) measure resistance between terminals 2, 5, 49 and 54 (circuits 34, 97-G, 34A, and 34) and all other terminals in (400). TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short between any circuits where resistance between terminals is less than 100K ohms, then repair.

>100K (400) between 34B, ohms. 97-G, 34A and 34 and all other circuits.

2.

Off

(400), 34, At (4001) measure 97-G, 34A, resistance to ground and 34 to gnd. at terminals 2, 5, 49 and 54 (circuits 34, 97-G, 34A, and 34). At (400) measure voltage to ground at terminals 2, 5, 49 and 54 (circuits 34, 97-G, 34A, and 34). (400), circuits 34, 97-G, 34A, and 34 to gnd.

>100K ohms.

Go to next step.

Locate short to ground in any circuit(s) where resistance is less than 100K ohms, then repair. Locate short to unwanted voltage source in any circuit(s) where voltage is more than 1.5V, then repair. Locate open or poor connection in circuit(s) if resistance is more than 5 ohms, then repair.

3.

On

<1.5 volts.

Go to next step.

4.

Off

Measure resistance of circuits 34, 34A, 97-G and 34B between connectors (400) and (402).

34, 34A, 97-G, and 34B between (400) and (402)

<5 ohms

Go to next step.

5.

Off

The low coolant switch circuits check good. If problem is still present, replace low coolant switch. If problem persists, have a Caterpillar dealer diagnose ECM operation.

s08210

210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

3.13. ENGINE BRAKE CONTROLS


Testing Engine Brake Switches and Circuits NOTE Disconnecting (400) from the ECM will cause incremental amounts of Trip Data to be lost. An Event Recorder Data Lost code may also be logged. The loss of this data will not affect engine operation, but will affect the accuracy of the data. Ask the owner/operator if they want data recorded before disconnecting. Table 54 STEP 1. Testing Engine Brake Switches and Circuits KEY Off ACTION Remove conn. (434) from on/off switch. Use ohmmeter to test the switch. In the on position, continuity should be present between terminals 5 and 6. Use ohmmeter to test the switch. In the off position, no continuity should be present between terminals 5 and 6. Measure resistance between conn. (434) terminal 6 and ground. TEST POINTS Engine brake switch, 5 to 6. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace engine brake on/off switch.

2.

Off

Engine brake switch, 5 to 6. (434), 24-G to gnd.

>100K ohms.

Go to next step.

Replace engine brake on/off switch.

3.

Off

<5 ohms.

Go to next step.

Locate open or poor connection in circuit(s) 24-G, 97-GA, 97-G, between connectors (434) and (400), then repair. Locate open or poor connection in circuit 24A between connectors (434) and (433), then repair. Replace the switch.

4.

Off

Remove conn. (433) from engine brake selector switch. Measure resistance of circuit 24A between connectors (434) and (433). Use ohmmeter to test selector switch in position 1, continuity between terminals 2 and 3. Use ohmmeter to test selector switch in position 2, continuity between terminals 2 and 6.

24A between (434) and (433).

<5 ohms.

Go to next step.

5.

Off

Engine brake switch, 2 to 3. Engine brake switch, 2 to 6.

<2 ohms.

Go to next step.

6.

Off

<2 ohms.

Go to next step.

Replace the switch.

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

211

Table 54 STEP 7.

Testing Engine Brake Switches and Circuits (cont.) KEY Off ACTION Use ohmmeter to test selector switch in position 3, continuity between terminals 2, 3 and 6. Remove connector (400), use test lead to jumper terminal 40 (circuit 24AE) to ground. At connector (433) measure resistance to ground at circuit 24AE. At connector (400), install jumper between terminals 40 and 23 (circuits 24AE and 24AF). At (433) measure resistance between circuits 24AE and 24AF. Remove jumper from connector (400), but do not reconnect (400) yet. With on/off switch off, at connector (433) measure resistance to gnd. at circuits 24A, 24AE and 24AF. At connector (433) measure resistance between circuits 24A, 24AE and 24AF. TEST POINTS Engine brake switch, 2, 3 and 6. (433), 24AE to ground. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

8.

Off

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 24AE between connectors (433) and (400), then repair. Locate open or poor connection in circuit 24AF between connectors (433) and (400), then repair. Locate short to ground, then repair.

9.

Off

(433), 24AE to 24AF.

<5 ohms.

Go to next step.

10.

Off

(433), 24A, 24AE and 24AF to ground.

>100K ohms.

Go to next step.

11.

Off

(433) between 24A, 24AE and 24AF.

>100K ohms.

The cruise control switches and circuits check good.

Locate short between circuits, then repair.

Testing J1922 Circuits Table 55 Testing J1922 Circuits STEP 1. KEY Off ACTION Remove ECM conn. (400) and J1922 conn. (403). Measure resistance between circuits 98Y(-) and 98Z(+). TEST POINTS (400) between 97Y(-) and 98Z(+). SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short between circuits, then repair.

s08210

212

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Table 55 Testing J1922 Circuits (cont.) STEP 2. KEY Off ACTION At conn. (400), install jumper between terminals 1 and 14. Measure resistance between conn. (403), circuits 98Y(-) and 98Z(+). With jumper still in place, at conn. (403) measure resistance between circuits 98Y(-) and 98Z(+) to ground. J1922 circuits check good. Remove jumper, reconnect (403) and (400). TEST POINTS (403), 98Y(-) and 98Z(+). SPEC. <5 ohms. YES-IN SPEC. Go to next step NO-OUT OF SPEC. Locate open or poor connection in circuits 98Y(-) and 98Z(+), between connectors (403) and (400), then repair. Locate short between (403) circuits and ground, then repair.

3.

Off

Between (403) and ground.

>100K ohms.

Go to next step.

4.

Off

4. COMPONENT LOCATIONS
(1) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Left Side of Engine Cowl (2) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Right Side of Engine Cowl, Above Conn. 3 (3) Dash Panel Connector.. . .. . .. .. . .. .. . .. .. . .. .. . ... . . . . . Right Side of Engine Cowl, Below Conn. 2 (94) Back-Up Light Switch.. . .. .. . .. . .. .. . .. .. . .. .. . ... . . . . . On Transmission (137) 6Way Data Link Connector. . . . . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (141) Ser. Brake Switch/Cruise Switch. . . . . . . . . . . . .. . . . . . Dash Panel, Left Side, Engine Side. (190) Cab Overlay to Engine Harness. . . . . . . . . . . . . .. . . . . . Right Instrument Panel (217) Inline Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Near ECM (218) Inline Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Near ECM (227) Fan Solenoid. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . ... . . . . . At Front of Engine (228) Refrigerant Pressure Switch. . . . . . . . . . . . . . . . . .. . . . . . On A/C Compressor (229) Engine Oil Temp Sender. . .. . .. .. . .. . .. . .. .. . ... . . . . . Left Side of Engine (275) Thermal Overcrank Protection. . . . . . . . . . . . . . . .. . . . . . At the Cranking Motor (294) Clutch Switch Connector. . . . . . . . . . . . . . . . . . . . . .. . . . . . Near Clutch Switch (400) OEM Interface Connector. . . . . . . . . . . . . . . . . . . . .. . . . . . On Engine (402) Low Coolant Level.. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . . . . . In Instrument Panel to Left of Tachometer (403) J1922 Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Dash Panel Right Side (404) Throttle Position Sensor. . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Left Instrument Panel (409) Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Transmission to Engine Harness (420) Right Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Gauge Cluster (421) Speedo./Tach. Module. . . .. . . .. . .. . . .. . . .. . . .. .. . . . . . Behind Speedo./Tach. Gauge (422) Speedo./Tach. Module. . . .. . . .. . .. . . .. . . .. . . .. .. . . . . . Behind Speedo./Tach. Gauge (423) Left Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Left Gauge Cluster (424) Left Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Left Gauge Cluster (514) Data Link Positive.. . . .. . . .. . . .. . . .. . . .. . . .. .. . . . . . Behind Instrument Panel/Behind Cluster (515) Data Link Negative.. .. .. .. . .. .. .. .. . .. .. .. ... . . . . . Behind Instrument Panel/Behind Cluster (640) Stop Light Switch. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . .. . . . . . Dash Panel, Left Side Engine Compartment

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

213

Figure 80

Engine Wiring, Cab Effects

s08210

214

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

1. DASH PANEL (VIEWED FROM INSIDE ENGINE COMPARTMENT 2. (141) BRAKE SWITCH 3. (640) STOP LIGHT SWITCH 4. (190) ELECTRONIC ENGINE CONNECTOR 5. RIGHT HAND DASH PANEL GROUND STUD 6. (3) ENGINE CONNECTOR 7. (2) CHASSIS HARNESS CONNECTOR 8. POWER DISTRIBUTION PANEL 9. RUN RELAY 10. SWITCHES 11. RIGHT GAUGE CLUSTER 12. SPEEDOMETER/TACHOMETER CLUSTER 13. LEFT GAUGE CLUSTER 14. (514) DATA LINK CONNECTOR 15. (515) DATA LINK CONNECTOR 16. (137) DATA LINK 17. FRONT END HARNESS CONNECTOR 18. THROTTLE PEDAL 19. (267) THROTTLE PEDAL CONNECTOR 20. CLUTCH SWITCH 21. (294) CLUTCH SWITCH CONNECTOR

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

215

Figure 81

Engine Wiring at Dash Panel 1. (190) ELECTRONIC ENGINE CONNECTOR 2. RH DASH PANEL GROUND STUD 3. (3) CHASSIS HARNESS CONNECTOR 4. (2) CAB/ENGINE HARNESS CONNECTOR 5. CIRCUIT 17D USED WITH THERMAL OVERCRANK SYSTEM 6. START MAGNETIC SWITCH 7. CIRCUIT 17C 8. CIRCUIT 17B 9. CIRCUIT 14 10. CIRCUIT 14A TO (B1) BATTERY STUD 11. (402) LOW COOLANT LEVEL SWITCH 12. ENGINE HARNESS

s08210

216

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Figure 82 Engine Wiring, C10 & C12

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

217

1. GROUND STUD 2. CIRCUIT 11GR, RADIATOR GROUND 3. (228) A/C PRESSURE SWITCH CONNECTOR 4. TO ENGINE WIRING AT DASH PANEL 5. (1097) BACKBONE FOR J1939 6. ETHER THERMOCOUPLE CIRCUIT 21A 7. J1922 DATALINK CONNECTOR 8. (1098) TERMINATION RESISTOR FOR J1939 9. TRANSMISSION TEMPERATURE GAUGE CONNECTOR 10. (229) ENGINE OIL TEMPERATURE GAUGE CONNECTOR 11. (275) THERMAL OVERCRANK CONNECTOR 12. (400) INTERNATIONAL ECM CONNECTOR 13. CIRCUIT 17C 14. CIRCUIT 97/97A 15. FUSIBLE LINK 16. CIRCUIT 11GS 17. CIRCUIT 2G

s08210

218

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Figure 83 Engine Wiring, C10 and C12 1. CIRCUITS 2 and 2G 2. TO ENGINE WIRING AT DASH PANEL 3. CIRCUIT 77C TO A/C COMPRESSOR CLUTCH (228)

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

219

Figure 84

Engine Wiring, C10 and C12

s08210

220

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

1. CIRCUIT 2 2. CIRCUIT 14 3. CIRCUIT A2 4. CIRCUIT 2-G 5. CIRCUIT 2-G 6. CIRCUIT 2 7. CIRCUIT 14 8. CIRCUIT 2-G 9. CIRCUIT 2 10. CIRCUIT 14 11. CIRCUIT 14 12. CIRCUIT 2 13. CIRCUIT 2-G

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

221

Figure 85 Engine Wiring, 3406E

s08210

222

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

1. FRAME GROUND STRAP 2. CIRCUITS 30 & 30GA ENGINE OIL TEMP. 3. CIRCUITS 17D & 17G THERMAL OVERCRANK 4. TO OTHER SIDE OF ENGINE 5. TO ENGINE WIRING AT DASH PANEL 6. J1922 CONTROL DATA LINK CONNECTOR 7. (1097) J1939 BACKBONE 8. (1098) J1939 TERM. RESISTOR 9. TO TRANSMISSION 10. CIRCUIT 21 ETHER START 11. (400) NAVISTAR ECM CONNECTOR 12. GROUND STUD 13. CIRCUIT 17C 14. FUSIBLE LINK 15. CIRCUIT 97/97A 16. CIRCUIT 11-GS 17. CIRCUIT 2-G

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

223

Figure 86 Engine Wiring, 3406E 1. GENERATOR 2. TO OTHER SIDE OF ENGINE 3. FAN SOLENOID AIR HOSE

s08210

224

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

Figure 87

Engine Wiring, 3406E 1. 2. 3. 4. CIRCUIT CIRCUIT CIRCUIT CIRCUIT 14 2 2-G 2 and 14

s08210

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

225

Figure 88

Engine Wiring, Transmission Effects 1. TO ENGINE HARNESS 2. BACKUP LIGHT SWITCH (94) CIRCUITS 71 and 71A 3. VEHICLE SPEED SENSOR

s08210

226

6 CATERPILLAR C-10, C-12 AND 3406E ENGINES

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

227

Table of Contents

1. DESCRIPTION. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .229 2. OPERATION.. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .229 2.1. ECM POWER CIRCUITS.. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .230 2.2. SHUTDOWN OVERRIDE/DIAGNOSTIC SWITCH. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .230 2.3. ATA DATA LINK CONNECTOR. . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .230 2.4. IDLE SHUTDOWN FEATURE. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .231 2.5. COOLANT LEVEL PROBE. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .231 2.6. ELECTRONIC ACCELERATOR PEDAL ASSEMBLY. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .231 2.7. CRUISE CONTROL. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .232 2.8. VEHICLE SPEED SENSOR (VSS). .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .232 2.9. CLUTCH SWITCH.. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .232 2.10. SERVICE BRAKE SWITCH. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .232 2.11. IDLE TIMER/PARK BRAKE SWITCH.. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .233 2.12. ENGINE BRAKE. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .233 2.13. ANTILOCK BRAKE INTERFACE. . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .233 3. TROUBLESHOOTING. .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .233 3.1. DETERMINING FAULT CODES.. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .234 Diagnostic OnOff/Shutdown Override Switch. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .234 EZ-Tech and PRO-LINK 9000 Electronic Service Tools (EST).. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .235 3.2. INSPECTION.. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .235 Before Troubleshooting. .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .235 Testing Relays. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .235 3.3. ACCELERATOR PEDAL (TPS/IVS). . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .236 Testing Throttle Position Sensor (TPS). . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .236 Testing Idle Validation Switch (IVS).. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .237 Testing Accelerator Pedal (TPS/IVS) Circuits. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .238 3.4. DIAGNOSTIC CONNECTOR (137) AND DATA LINK CIRCUITS INCLUDING SPEEDOMETER/TACHOMETER INPUT CIRCUITS.. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .240 Testing Diagnostic Connector Power and Ground Circuits. . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .240 Testing ATA Data Link Circuits.. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .240 3.5. CRUISE/PTO CONTROL SYSTEM AND RELATED COMPONENTS.. . . .. . .. . . .. . .. . . .. . .. . . .. . .242 Testing Clutch Switch.. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .242 Testing Service Brake Switch And Circuits.. . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .243 Testing Cruise On/Off Switch. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .244 Testing Cruise Set/Resume Switch And Circuits. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .245 3.6. VEHICLE SPEED SENSOR (VSS). .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .247 Inspecting And Adjusting the Adjustable Vehicle Speed Sensor (VSS). . . . . . . . . . . . . . . . . .247 Testing Vehicle Speed Sensor (VSS).. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .247 Testing Vehicle Speed Sensor (VSS) Circuits To ECM. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .248 3.7. ENGINE BRAKE SYSTEM.. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .249 Testing Engine Brake Switches and Circuits. . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .249 3.8. DIAGNOSTIC ON/OFF/SHUTDOWN OVERRIDE SWITCH (260). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251 Testing Diagnostic On/Off/Shutdown Override Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251 3.9. PARK BRAKE (IDLE TIMER) SWITCH (268). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252 Testing Park Brake Switch (268) and Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252

s08210

228

7 DETROIT DIESEL SERIES 60 ENGINES

3.10. TESTING LOW COOLANT SENSOR CIRCUITS. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. ..253 3.11. ECM POWER SUPPLY (SWITCHED AND UNSWITCHED). . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..254 Testing Unswitched Battery Power To ECM At Connector (676). . . . . . . . . . . . . . . . . . . . . . . . . . .254 Testing Switched Battery Power To ECM.. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . ..255 4. COMPONENT LOCATIONS. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..255

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

229

1. DESCRIPTION
The Detroit Diesel Electronic Control system (DDEC III) provides an electronic fuel control system, electronic engine protection and other operational controls. DDEC III is standard on Series 60 engines and provides many engine/vehicle functions including: Cruise/PTO Controls Automatic Idle Shutdown Timer (3100 Minutes) Engine Diagnostics Engine Protection System Engine Cooling System Engine Brake Control Speedometer/Tachometer Input Signals ABS/Traction Control Interface

Refer to Detroit Diesel manual furnished with the vehicle for additional feature information. Since each Series 60 DDEC III system is electronically programmable to individual owner specications, the operating parameters will vary from vehicle to vehicle. These parameters include: maximum cruise speed, maximum road speed settings and many others. The brain of the DDEC III system is the Electronic Control Module (ECM), located on the left side of the engine. The ECM receives inputs from the following International components: Vehicle Speed Sensor (VSS) Throttle Position Sensor (TPS) Service Brake Switch Park Brake Switch Clutch Switch Low Coolant Level Sensor Cab Switches

The ECM receives inputs from sensors and switches, then outputs signals to the injectors, engine brake relay and other system components.

2. OPERATION
The ECM is connected to the International electrical system at two points (or three points with antilock brakes installed). A. International engine harness 30way ECM connector (273) connects to ECM. This connector links the International switches, sensors and data links and supplies ignition power to the ECM. B. ECM power cable connector (676) supplies unswitched battery power and a ground path to the ECM.

s08210

230

7 DETROIT DIESEL SERIES 60 ENGINES

C. Additionally, with ABS/traction control system, the International 2way J1922 data link connector (403) connects the circuits to ECM communications connector (1160) and is used to provide communications between the ECM and the ABS/traction control system controller. Refer to the DETROIT SERIES 60 ENGINE SYSTEMS circuit diagrams in CTS-5298 or S08225.

2.1. ECM POWER CIRCUITS


Power is supplied at all times from the positive battery terminal to the ECM over two circuits. The rst circuit consists of circuit 14A from the battery positive terminal, a 15A fuse, circuit 14D, connector (675), and circuit 14D to the ECM power connector (676). The second circuit consists of circuit 14B from the battery positive terminal, a 15A fuse, circuit 14C, connector (675), and circuit 14C to the ECM power connector (676). The ECM is grounded through circuits 11GA, 11GB, and 11GC to a splice. From the splice the circuits are grounded through circuit 11G, connector (N/L) and circuit 11G to the negative battery cable. When the key switch is in the ignition or start position, power is applied to circuit 13Z, 5A fuse F6D, circuit 13D, connector (2), and circuit 13D to the ECM (273).

2.2. SHUTDOWN OVERRIDE/DIAGNOSTIC SWITCH


The lighted two-position momentary engine shutdown override/diagnostic switch (260) is a dual function switch. The switch overrides the engine shutdown and enables the on-board diagnostics. The switch is connected to the negative battery terminal by way of circuits 97GD and 97GA, connector (190), circuits 97GA and 97G, connector (N/L), circuits 97G and 11G, connector (N/L) and circuit 11G to the negative battery terminal. The switch is connected to the ECM by way of circuit 97AU, connector (190), and circuit 97AU to ECM (273). Closing the switch causes the voltage state of circuit 97AU to change to ground, indicating to the ECM that the switch has been toggled to the on position. Thus the ECM will switch modes to display fault codes or the absence of codes by ashing the engine warning light and the stop engine light. The red stop engine light will ash the active codes and the yellow engine warning light will ash the inactive codes.

2.3. ATA DATA LINK CONNECTOR


The six pin ATA data link connector (137) allows an electronic service tool (EST) to communicate with the ECM. The data link carries serial data transmissions between the ECM and the electronic service tool and between the ECM and the speedo/tachometer and the EST. The ATA data link connector (137), which is located on the left instrument panel, has circuits in four of the six cavities. The data link circuits are a twisted wire pair because twisting the wires helps shield them from interference. The circuits are as follows: A. Circuit 98A(+) is the positive data link connection and it is fed by the positive data link connector (514), the jumper bus bar, circuit 98(+), connector (190), and circuit 98(+) coming from the ECM connector (273). B. Circuit 98C(-) is the negative data link connection and it is fed by the negative data link connector (515), the jumper bus bar, circuit 98B(-), connector (190), and circuit 98B(-) coming from the ECM connector (273). C. Circuit 97D is a 12 volt circuit and is fed from B1 Battery Stud to circuit 14W and 14AA, through 20A fuse F5D. Thus it provides power for the electrical service tool.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

231

D. Circuits 97GR and 11GT are connected to the panel lights ground adapter (506), and provide a ground for the electronic service tool.

2.4. IDLE SHUTDOWN FEATURE


The customer selectable idle shutdown feature shuts down the engine (does not shut down power to the cab) after a customer selected (programmed) length of time between 3 and 100 minutes. The timer (an ECM function) begins counting when the parking brake is set (which closes the park brake switch [268]), the engine temperature is above 104F/40C, the engine speed is at idle rpm, and the ECM does not see any clutch or brake pedal operation. If these conditions are present, the ECM counts down the customer selected length of time until 90 seconds before the scheduled engine shutdown is to occur. At this time the yellow engine warning light begins to ash rapidly. The idle timer can be disabled by depressing the accelerator pedal. This will allow the idle timer to be overridden if longer idle time is wanted. The shutdown timing sequence can be re-started by releasing and re-applying the parking brake. If the idle timer shuts the engine down, fueling is stopped, but ignition voltage is still present to the ECM on circuit 13D at connector (273). NOTE The key switch must be cycled to off and back to on before the engine will start. NOTE The engine is shut down, but power to the cab is not turned off.

2.5. COOLANT LEVEL PROBE


The low coolant level probe is connected through the Navistar engine harness connector (278) circuit 34 to ECM (273). A signal from the ECM is sent to the probe on this circuit. The other side of the probe is connected to ground through circuits 34G, 97G, connector (N/L), circuits 97G and 11G, connector (N/L), and circuit 11G to battery ground. When coolant level is below the probe, the circuit resistance changes, indicating to the ECM that the coolant level is below the critical level.

2.6. ELECTRONIC ACCELERATOR PEDAL ASSEMBLY


DDEC engines use an electronic accelerator pedal assembly that includes a throttle position sensor (TPS) and idle validation switch (IVS) function. The TPS/IVS sensor assembly is not serviceable and if defective must be replaced. The TPS acts like a potentiometer. Movement of the pedal results in a variable signal being sent to the ECM. This signal is proportional to the pedal position. A ve volt signal from the ECM (273) is sent through circuit 99A, connector (190), and circuit 99A to the potentiometer of TPS/IVS (267). The variable potentiometer wiper signal (varies with pedal position) is returned from the TPS/IVS (267) over circuit 99, connector (190), and circuit 99 to the ECM (273). The TPS/IVS (267) potentiometer is grounded through circuit 99R, connector (190) and circuit 99R to the ECM (273). The IVS is used to verify when the accelerator pedal is in the idle position. One side of the idle validation switch (273) is connected to circuit 99B, connector (190), and circuit 99B to the ECM (273). The ECM sets this input at 5 volts and when the throttle is at idle a ground is applied to this input by the idle validation switch (267). This ground pulls the input voltage down to nearly zero, telling the ECM that the accelerator pedal is in the idle position. The ground path that is applied by the IVS (267) is through circuits 99GA and 97GA, connector (190), circuits 97GA and 97G, connector (N/L), circuit 97G and 11G, connector (N/L), and circuit 11G to the negative battery terminal.

s08210

232

7 DETROIT DIESEL SERIES 60 ENGINES

The ECM analyzes the signals received from the TPS/IVS, making certain that the signals fall within certain parameters. For example, if the IVS signal indicates that the pedal is in the idle position, the ECM expects to see a TPS signal that indicates no throttle (or very little) is being applied. If the ECM does not see a logical response from both, a fault code will be logged. The TPS/IVS timing cannot be checked using a multimeter.

2.7. CRUISE CONTROL


The cruise control operates when vehicle speed is greater than 20 mph and engine speed is greater than 1100 rpm. The vehicle speed signal used by the ECM to control the cruise system comes from the International installed vehicle speed sensor. The PTO mode is activated when vehicle speed is zero and the park brake is set (park brake switch [268] contacts open). Releasing the park brake disables the PTO controls. The cruise control and PTO systems share the same components, which include a cruise on/off switch (435), cruise set/resume switch (436), service brake switch (141), park brake switch (268), clutch pedal switch (294) and vehicle speed sensor (250). The lighted cruise on/off switch (435) is connected by circuit 97AE, connector (190), and circuit 97AE to the ECM (273). The other side of switch (435) is connected through circuits 97GC, 97GB, 97GA, connector (190), circuits 97GA and 97G, connector (N/L), circuits 97G and 11G, connector (N/L), and circuit 11G to negative battery stud. With the switch in the on position, the voltage state at the ECM input changes to ground, telling the ECM that the switch is in the on position. The lighted set/resume switch (436) is connected by circuit 97AB, connector (190), and circuit 97AB to the ECM (273). The switch is also connected by circuit 97AA, connector (190) and circuit 97AA to the ECM (273). The switch (436) is connected to the panel lights ground adapter (506) by way of circuits 62GK and 11GP. With the switch held in the set position, circuit 97AB is switched to ground signaling the ECM (273). With the switch held in the resume position, circuit 97AA is switched to ground, signaling the ECM (273).

2.8. VEHICLE SPEED SENSOR (VSS)


The vehicle speed sensor (250) feeds a VSS signal to the ECM (273) by way of circuits 97AJ and 97AK. Two types of sensors may be used. The threaded (adjustable sensor is used on most transmissions. A new push-in sensor (non-adjustable) is used on some transmissions.

2.9. CLUTCH SWITCH


The clutch switch (294) is a normally open (N.O.) switch that is adjusted so that its contacts are closed when the clutch pedal is in the released position. Depressing the clutch pedal causes the switch contacts to open. The clutch switch is connected by circuit 97AH, connector (190), and circuit 97AH to the ECM (273). The other side of the switch is connected through circuits 97GH, 97GA, connector (190), circuit 97GA and 97G, connector (N/L), circuits 97G and 11G, connector (N/L), and circuit 11G to negative battery stud.

2.10. SERVICE BRAKE SWITCH


The service brake switch (141) is a normally closed (N.C.) air operated switch. Its contacts are closed when the brakes are not applied and its contacts open up when the brakes are applied. One terminal of the service brake switch (141) is connected to circuit 97AL, connector (190), circuit 97AL and the ECM (273). The other terminal of the switch is connected to ground by way of circuit 97GF and 97GA, connector (190), circuits 97GA and 97G, connector (N/L), circuits 97G and 11G, connector (N/L), and circuit 11G to the negative terminal of the batteries.
s08210

7 DETROIT DIESEL SERIES 60 ENGINES

233

2.11. IDLE TIMER/PARK BRAKE SWITCH


The idle timer/park brake switch (268) is an air operated normally closed (N.C.) switch. Its contacts are closed when the parking brakes are applied, and its contacts open up when the brakes are released. One terminal of the idle timer switch (268) is connected to circuit 97AV, connector (190), circuit 97AV and the ECM (273). The other terminal of the switch is connected to ground by way of circuits 97GE and 97GA, connector (190), circuits 97GA and 97G, connector (N/L), circuits 97G and 11G, connector (N/L), and circuit 11G to the negative terminal of the batteries.

2.12. ENGINE BRAKE


The driver controls the engine brake on/off and selector switches but the ECM enables or disables the system by way of a relay in response to the engine throttle position. The ECM enables the relay whenever the engine speed is 150 rpm greater than idle rpm, and the throttle is in the idle position. The engine brake can provide braking when the vehicle is in the cruise control mode. For example, if the vehicle is in the cruise control mode, going down hill, and the engine brake is selected, the ECM will control the engine brake with respect to the cruise control set speed. The amount of braking will not exceed the number of cylinders selected at the brake selector switch. The lighted two position engine brake on/off switch (434) receives a ground signal on circuits 24GA and 97GA, connector (262), circuits 97GA and 97G, connector (N/L), circuits 97G and 11G, connector (N/L), and circuit 11G to the negative terminal of the batteries. In the on position a ground signal is sent from the switch on circuit 24AJ to the engine brake selector switch (433). When switch (433) is placed in the rst position, a ground is applied to circuit 24AE, connector (190) and circuit 24AE to the ECM (273). This tells the ECM to enable the brake solenoid for two of the cylinders. When switch (433) is placed in the second position, a ground is applied to circuit 24AF, connector (190) and circuit 24AF to the ECM (273). This tells the ECM to enable the brake solenoids for four of the cylinders. When switch (433) is placed in the third position, a ground is applied to circuit 24AE, connector (190) and circuit 24AE to the ECM (273) and circuit 24AF, connector (190), and circuit 24AF to the ECM (273). This tells the ECM to enable the brake solenoids for all six of the cylinders.

2.13. ANTILOCK BRAKE INTERFACE


If the vehicle is equipped with antilock brakes, information is shared with ABS controller module (766) over a pink wire, connector (403), and circuit 98Z(+) to the ECM (1160). Information is also shared by the ABS module (766) over a light blue wire, connector (403) and circuit 98Y(-) to the ECM (1160).

3. TROUBLESHOOTING
Refer to the DETROIT SERIES 60 ENGINE SYSTEMS circuit diagrams in CTS-5298 or S08225. 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 laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks.

s08210

234

7 DETROIT DIESEL SERIES 60 ENGINES

C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in the GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual. D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit, by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid.

3.1. DETERMINING FAULT CODES


The ECM continuously monitors itself and other system components, including sensors, injectors, connectors and associated wiring. The yellow Engine Warning Light is turned on if a minor fault occurs. A fault code is also logged. This indicates the problem should be diagnosed as soon as possible. The ECM turns on the yellow Engine Warning Light and the red Stop Engine Light and stores a fault code if a major fault is detected. If this occurs, the vehicle should be brought to a safe stop and the engine shut down. A diagnostic check may be performed using the diagnostic on/off switch, the EZ-Tech or Pro-Link 9000 EST. Diagnostic OnOff/Shutdown Override Switch The diagnostic on/off switch is used to signal the ECM to ash the yellow Engine Warning light and the red Stop Engine light to ash codes. The red Stop Engine light will ash the ACTIVE codes and the yellow Engine Warning light will ash the INACTIVE codes. If no fault codes are logged, the code "25" will be ashed out on the yellow Engine Warning Light. For example, the yellow Engine Warning light blinks out: FLASH, FLASH. The rst digit is a 2, then a half-second pause: FLASH, FLASH, FLASH, FLASH, FLASH. The second digit is a 5. Code 25 is System OK. The diagnostic on/off switch is used to ash codes in the following circumstances: A. When the engine is not running and the ignition switch is on, toggling and releasing the diagnostic on/off switch will ash out the engine codes. Toggling then releasing the diagnostic on/off switch a second time will stop the ECM from ashing the codes. B. When the engine is idling and not in an "engine protection condition," toggling and releasing the diagnostic on/off switch will ash out the engine codes. Toggling then releasing the diagnostic on/off switch a second time will stop the ECM from ashing the codes. NOTE All Series 60 fault codes are 2 digits. The Detroit Diesel Troubleshooting Manual contains ash code descriptions and diagnostic procedures. If the fault code(s) or symptoms indicate a need to troubleshoot an International installed circuit or component, procedures are included in this chapter or other CTS-5000 Master Service Manual sections.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

235

EZ-Tech and PRO-LINK 9000 Electronic Service Tools (EST) The EZ-Tech or the PRO-LINK 9000 electronic service tools (EST) with a Series 60 program can be used to read logged fault codes and monitor many of the system switches and operating parameters. Refer to the EZ-Tech and PRO-LINK 9000 manuals for information on using the EST. International vehicles include an 6-way diagnostic connector used to access the system with an EST. The diagnostic tables in this section are not designed for specic symptoms, but designed to test those circuits and components installed by International. Use DDEC III diagnostics procedures to identify the suspect circuit or system, then use the procedures included in this section to troubleshoot the specic International circuit.

3.2. INSPECTION
NO TESTS in this section require testing "into" the DDEC ECM. Before Troubleshooting A. Before troubleshooting, make sure that the vehicle batteries are fully charged!Check battery cables and grounds for clean, tight connections free of damage and corrosion. Many of the voltage tests included in the procedures will give misleading readings if the batteries are not fully charged. B. Before troubleshooting a particular circuit, inspect connectors for pushed back, loose or damaged (spread or bent), or corroded terminals, or wires with cut strands, etc. The wires and connections must be free of damage or corrosion. When some connectors corrode, a light white residue will be present that must be removed. C. Before troubleshooting, inspect the suspect circuit grounds for clean, tight connections free of damage or corrosion. Testing Relays International circuits use suppressed relays for controlling power to load devices (Figure 69). The suppression feature (a resistor circuit parallel to the relay coil) prevents voltage spikes from damaging electronic components in the vehicle. These relays must be replaced with approved International parts.

Figure 89

Typical Relay

s08210

236

7 DETROIT DIESEL SERIES 60 ENGINES

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 Test Procedure 1. With relay removed, measure resistance between terminals 30 and 87A. If resistance is less than 5 ohms, go to step 2; otherwise replace the relay. 2. Measure resistance between terminals 30 and 87. If resistance is 100K ohms or more, go to step 3; otherwise replace the relay. 3. Using 12V battery source and test leads, connect (+) lead to terminal 85 and (-) lead to terminal 86. If relay energizes with an audible click sound, go to step 4; otherwise replace the relay. 4. While relay is energized, measure resistance between terminals 30 and 87. If resistance is less than 5 ohms, go to step 5; otherwise replace the relay. 5. While relay is energized, measure resistance between terminals 30 and 87A. If resistance is 100K ohms or more, the relay is good; otherwise replace relay. Refer to the appropriate circuit diagrams in CTS-5298 or S08225.

3.3. ACCELERATOR PEDAL (TPS/IVS)


Inspect the TPS circuits and connectors as outlined in Before Troubleshooting. The following 3 tests, Testing Throttle Position Sensor (TPS)), Testing Idle Validation Switch (IVS) and Testing Accelerator Pedal (TPS/IVS) Circuits, check the TPS/IVS connection and related International cab and engine harness connections leading to the ECM. These tests should be performed if a DDEC III fault code indicates a problem in the circuits or if the EZ-Tech or PRO-LINK 9000 indicates that the TPS/IVS is not working properly while monitoring switches. NOTE The following 3 tests must be performed in sequence. Testing Throttle Position Sensor (TPS) This test checks the TPS circuits in the accelerator pedal assembly. This test will identify if the resistance of the pedal circuits is within specications. Table 56 STEP 1. Testing Throttle Position Sensor (TPS) KEY Off ACTION Disconnect the accelerator pedal from cab harness connector (267). At the pedal side of (267) measure resistance between terminals A and C with the pedal in the idle position, then with the pedal fully depressed. Resistance should be TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace TPS/IVS sensor.

2000 to At accelerator 3000 ohms. pedal A to C.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

237

Table 56 STEP

Testing Throttle Position Sensor (TPS) (cont.) KEY ACTION 2000 to 3000 ohms in all positions. TEST POINTS SPEC. YES-IN SPEC. NO-OUT OF SPEC.

2.

Off

With the pedal at idle, at connector (267) measure resistance between terminals B and C. With pedal at full throttle position, at connector (267) measure resistance between terminals B and C. Resistance must be 1000 ohms less than reading at idle position and must be 250 to 1500 ohms. At accelerator pedal and connector (267), measure resistance to the metal part of pedal assembly and terminals A, B, C, D and E.

1500 to At accelerator 3000 ohms. pedal B to C. 250 to At accelerator 1500 ohms, pedal B and 1000 to C. less than idle position reading. Accelerator pedal metal to terminals. >100K ohms.

Go to next step.

Replace TPS/IVS sensor.

3.

Off

Go to next step.

Replace TPS/IVS sensor.

4.

Off

APS sensor checks good. Go to Testing Idle Validation Switch (IVS).

Replace APS/IVS sensor.

Testing Idle Validation Switch (IVS) Perform preceding test before performing this test. This test checks the IVS circuits in the accelerator pedal assembly. Table 57 STEP 1. Testing Idle Validation Switch (IVS) KEY Off ACTION With accelerator pedal still disconnected at connector (267) and the pedal at idle, measure resistance between terminal F and E on the accelerator pedal. TEST POINTS At accelerator pedal F to E. SPEC. <125 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace TPS/IVS sensor.

s08210

238

7 DETROIT DIESEL SERIES 60 ENGINES

Table 57 STEP 2.

Testing Idle Validation Switch (IVS) (cont.) KEY Off ACTION At connector (267), measure resistance between terminals E and F while slowly depressing the pedal (idle to full throttle). After approximately 10 of travel the resistance should be 100K ohms or more. The TPS and IVS functions check good. NOTE: This test is not able to check the timing function between the two functions. TEST POINTS At accelerator pedal E to F after 10 of travel. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace TPS/IVS sensor.

3.

Off

Go to Testing Accelerator Pedal (TPS/IVS) Circuits following.

Testing Accelerator Pedal (TPS/IVS) Circuits Inspect TPS/IVS circuits and connectors as outlined in Before Troubleshooting. This test checks the cab and engine harness TPS/IVS circuits for opens, shorts to ground, shorts to "hot" circuits and shorts to other circuits in the harness and checks the circuits for continuity. Perform the two preceding tests before performing this test. Table 58 STEP 1. Testing Accelerator Pedal (TPS/IVS) Circuits KEY Off ACTION With accelerator pedal disconnected from the cab harness at (267), disconnect connector (273) from the ECM. At International ECM connector (273), measure resistance to gnd. at terminals E1, C3, D2 and A3 (circuits 99B, 99R, 99 and 99A). At harness and connector (273) measure resistance between terminals E1, C3, D2, A3 (99B, 99R, 99 and 99A) and all other terminals in connector (273). TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground, then repair.

>100K (273), 99B, 99R, ohms. 99 and 99A to gnd.

2.

Off

(273), 99B, 99R, 99 and 99A to all cir. in conn.

>100K ohms.

Go to next step.

Locate short between circuits, then repair.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

239

Table 58 STEP 3.

Testing Accelerator Pedal (TPS/IVS) Circuits (cont.) KEY Off ACTION At harness and connector (273) measure voltage to ground at terminals E1, C3, D2, A3 (circuits 99B, 99R, 99 and 99A). At harness and connector (267) measure resistance to ground at terminal F (circuit 99-GA). TEST POINTS (273), 99B, 99R, 99 and 99A to gnd. (267), 99-GA to gnd. SPEC. <1 volt. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to unwanted voltage source, then repair.

4.

Off

<5 ohms.

Go to next step.

Locate open or poor connection in gnd. path between connector (267) terminal F and negative battery terminal, then repair. Locate open or poor connection in circuit 99B between connectors (273) and (267), then repair.

5.

Off

At connector (273) use test lead to jumper terminal E1 (circuit 99B) to negative battery terminal. At connector (267) measure resistance between terminals E and F (circuit 99B and 99-GA). At connector (273) use test lead to jumper terminal C3 (circuit 99R) to negative battery terminal. At connector (267) measure resistance between terminals A and F (cir. 99R and 99-GA). At connector (273) use test lead to jumper terminal D2 (cir. 99) to negative battery terminal. At connector (267) measure resistance between terminals B and F (cir. 99 and 99-GA). At connector (273) use test lead to jumper terminal A3 (cir. 99A) to gnd. At connector (267) measure resistance between terminals C and F (cir. 99A and 99-GA).

(267), 99B to 99-GA.

<5 ohms.

Go to next step.

6.

Off

(267), 99R to 99-GA.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 99R between connectors (273) and (267), then repair.

7.

Off

(267), 99 to 99-GA.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 99 between connectors (273) and (267), then repair.

8.

Off

(267), 99A to 99-GA.

<5 ohms.

TPS/IVS circuits between (273) and (267) check good.

Locate open or poor connection in circuit 99A between connectors (273) and (267), then repair.

s08210

240

7 DETROIT DIESEL SERIES 60 ENGINES

3.4. DIAGNOSTIC CONNECTOR (137) AND DATA LINK CIRCUITS INCLUDING SPEEDOMETER/TACHOMETER INPUT CIRCUITS
Make sure batteries are fully charged and inspect circuits and connectors as outlined in Before Troubleshooting. Testing Diagnostic Connector Power and Ground Circuits This table checks the power and ground circuits to the diagnostic connector (137). Table 59 STEP 1. Testing Diagnostic Connector Power and Ground Circuits KEY Off ACTION Remove 5A fuse F9-C and check for open condition. Fuse OK? Re-install fuse F9-C. At diagnostic connection (137) measure voltage to ground at terminal C (circuit 97DL). At connector (137) measure voltage between terminals C and E (circuits 97DL and 97-GR). The power and ground circuits to diagnostic connector (137) check good. Proceed to following table. TEST POINTS F9-C SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of oveload condition, then repair. Replace fuse. Locate cause of no or low voltage in circuit 97DL from fuse, then repair. Locate open or poor connection in ground circuit between connector (137) and (506) ground adapter, then repair.

2.

On

(137), 97DLto gnd.

10 to 12 volts.

Go to next step.

3.

On

(137), 97DL to 97-GR.

10 to 12 volts.

Go to next step.

4.

On

Testing ATA Data Link Circuits This test checks the data link circuits between ECM connector (273) and the diagnostic connector (137) and the speedometer/tachometer connector (421). Table 60 Testing ATA Data Link Circuits STEP 1. KEY Off ACTION Disconnect ECM connector (273) from ECM and (421) from speedometer/ tachometer unit. If any other devices are connected to the data link connectors (515) and TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

241

Table 60 Testing ATA Data Link Circuits (cont.) STEP KEY ACTION (514) disconnect these devices. 2. On At connector (137) measure resistance to gnd. at terminal A, circuit 98A(+). At connector (137) measure resistance to ground at terminal B, circuit 98C(-). At connector (137) measure resistance between terminals A and B, circuits 98A(+) and 98C(-). Measure voltage to ground at connector (137) terminals A, circuit 98A(+) and B, circuit 98C(-). At ECM connector (273) use test lead to jumper terminal C1, circuit 98B(-) to gnd. At connector (137) measure resistance to ground at terminal B, circuit 98C(-). At connector (421) measure resistance to ground at circuit 47/48(-). (137), 98A(+) to gnd. (137), 98C(-) to gnd. (137), 98A(+) to 98C(-). >100K ohms. Go to next step. Locate short to ground in circuit, then repair. TEST POINTS SPEC. YES-IN SPEC. NO-OUT OF SPEC.

3.

On

>100K ohms.

Go to next step.

Locate short to ground in circuit, then repair.

4.

On

>100K ohms.

Go to next step.

Locate short between the positive data link circuit and the negative data link circuit, then repair. Locate short to unwanted voltage source, then repair.

5.

On

(137), 98A(+) to gnd. and 98C(-) to gnd. (137), 98C(-) to gnd.

<1 volt.

Go to next step.

6.

Off

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 98B(-) or 98C(-) between connectors (273) and (137), then repair. Locate open or poor connection in circuit 47/48(-) between connectors (515) and (421), then repair. Locate open or poor connection in circuit 98A(+) or 98(+) between connectors (273) and (137), then repair.

7.

Off

(421), 47/48(-) to gnd.

<5 ohms.

Go to next step.

8.

Off

At ECM connector (273) use test lead to jumper terminal C1 to C2, circuit 98B(-) to 98(+). At connector (137) measure resistance between terminals A and B, circuit 98A(+) to 98C(-).

(137), 98A(+) to 98C(-).

<5 ohms.

Go to next step.

s08210

242

7 DETROIT DIESEL SERIES 60 ENGINES

Table 60 STEP 9.

Testing ATA Data Link Circuits (cont.) KEY Off ACTION At connector (421) measure resistance to ground at circuit 47/48(+). TEST POINTS (421), 47/48(+) to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 47/48(+) between connectors (514) and (421), then repair.

10.

Off

The data link circuits between connectors (273) and (137) and (421) check good.

3.5. CRUISE/PTO CONTROL SYSTEM AND RELATED COMPONENTS


Inspect TPS/IVS circuits and connectors as outlined in Before Troubleshooting. IMPORTANT The following cruise control test procedures must be performed in the sequence that they appear in this manual. Each test relies on information from the previous test procedure. NOTE The clutch switch is a normally open switch, adjusted to be closed when the pedal is in the released (foot off) position. NOTE Use the EZ-Tech or PRO-LINK 9000 EST to check clutch switch operation. If the EST indicates the clutch switch is not operating properly, perform this procedure. Testing Clutch Switch Table 61 STEP 1. Testing Clutch Switch KEY Off ACTION Visually check clutch switch adjustment. The switch should be adjusted to open with an audible click when the pedal is depressed 0.5 inch (13 mm). Is clutch switch adjusted properly? Disconnect clutch switch pigtail from cab harness at connector (294). With pedal released, measure resistance across pigtail connector terminals. Depress clutch pedal and measure resistance across pigtail connector terminals. Clutch switch, across terminals. <5 ohms. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Adjust clutch switch.

2.

Off

Go to next step.

If switch is properly adjusted, replace the switch.

3.

Off

Clutch switch, across terminals.

>100K ohms.

Go to next step.

If switch is properly adjusted, replace the switch.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

243

Table 61 STEP 4.

Testing Clutch Switch (cont.) KEY Off ACTION At cab side of connector (294), measure resistance of 97-GH to gnd. TEST POINTS (294), 97-GH to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in gnd. path for circuit 97-GH between connector (294) and negative battery terminal, then repair. Locate open or poor connection in circuit 97AH between connectors (273) and (294), then repair.

5.

Off

Disconnect ECM connector (273) from ECM. Use test lead to jumper terminal J2 , (circuit 97AH) to ground. At connector (294) measure resistance to gnd. at circuit 97AH.

(294), 97AH to gnd.

<5 ohms.

The clutch switch and circuits check good.

Testing Service Brake Switch And Circuits Inspect circuits and connectors as outlined in Before Troubleshooting. NOTE Use the EZ-Tech or PRO-LINK 9000 EST to check service brake switch operation. If the EST indicates the service brake switch is not operating properly, perform this procedure. NOTE Vehicle air brake system must be fully charged for this test. Table 62 Testing Service Brake Switch And Circuits STEP 1. KEY Off ACTION Remove harness connector (141) from service brake switch. Measure resistance to ground at both service brake switch terminals. At service brake switch, measure resistance between the two terminals with brakes released. At service brake switch, measure resistance between the two terminals with brakes applied. TEST POINTS Service brake switch, terminals to gnd. Service brake switch, across terminals. Service brake switch, across terminals. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace service brake switch.

2.

Off

<2 ohms.

Go to next step.

Replace service brake switch.

3.

Off

>100K ohms.

Go to next step.

Replace service brake switch.

s08210

244

7 DETROIT DIESEL SERIES 60 ENGINES

Table 62 Testing Service Brake Switch And Circuits (cont.) STEP 4. KEY Off ACTION At service brake switch harness connector (141), measure resistance to gnd. at circuit 97-GF. TEST POINTS (141), 97-GF to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in gnd. path for circuit 97-GF between connector (141) and negative battery terminal, then repair. Locate short to gnd. in circuit 97AL between connectors (273) and (141) then repair.

5.

Off

Remove ECM connector (273) from the ECM. At connector (273) measure resistance to gnd. at terminal G2, (circuit 97AL). Use test lead to jumper terminal G2 to gnd. At connector (141) measure resistance to ground at circuit 97AL.

(273), 97AL to gnd.

>100K ohms.

Go to next step.

6.

Off

(141), 97AL to gnd.

<5 ohms.

The service brake switch and circuits check good.

Locate open or poor connection in circuit 97AL between connectors (273) and (141) then repair.

Testing Cruise On/Off Switch Inspect circuits and connectors as outlined in Before Troubleshooting. NOTE Use the EZ-Tech or PRO-LINK 9000 EST to check cruise on/off switch operation. If the EST indicates the cruise on/off switch is not operating properly, perform this procedure. Table 63 Testing Cruise On/Off Switch STEP 1. KEY Off ACTION Remove connector (435) from on/off switch. With switch in position, measure resistance between terminals 5 and 6. With switch in position, measure resistance between terminals 5 and 6. To test switch panel light function, connect 12V lead to terminal 7 and gnd. terminal 8. Does light turn on?
s08210

TEST POINTS Cruise on/off switch, 5 to 6.

SPEC. <2 ohms.

YES-IN SPEC. Go to next step.

NO-OUT OF SPEC. Replace cruise on/off switch.

2.

Off

Cruise on/off switch, 5 to 6.

>100K ohms.

Go to next step.

Replace cruise on/off switch.

3.

Off

Go to next step.

Replace cruise on/off switch.

7 DETROIT DIESEL SERIES 60 ENGINES

245

Table 63 STEP 4.

Testing Cruise On/Off Switch (cont.) KEY Off ACTION Disconnect ECM connector (273) from the ECM. At connector (273) measure resistance from terminal F2, (circuit 97AE) to gnd. At connector (435), measure resistance to gnd. at circuit 97-GC. TEST POINTS (273), 97AE to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to gnd in circuit 97AE between connectors (273) and (435), then repair.

5.

Off

(435), 97-GC to gnd.

<5 ohms.

Go to next step.

Locate open or poor connection in gnd. path to negative battery terminal for circuit 97-GC, then repair. Locate open or poor connection in circuit 97AE between connectors (273) and (435), then repair.

6.

Off

Connect (435) to cruise on/off switch and turn switch to position. At connector (273) measure resistance of F2, (circuit 97AE) to gnd.

(273), 97AE to gnd.

<5 ohms.

The cruise on/off switch and circuits check good.

Testing Cruise Set/Resume Switch And Circuits Inspect circuits and connectors as outlined in Before Troubleshooting. NOTE Use the EZ-Tech or PRO-LINK 9000 EST to check set/resume switch operation. If the EST indicates the set/resume switch is not operating properly, perform this procedure. Table 64 STEP 1. Testing Cruise Set/Resume Switch And Circuits KEY Off ACTION Remove connector (436) from cruise set/resume switch. With switch in set position, measure resistance between terminals 2 and 3. With switch in neutral position, measure resistance between terminals 1, 2, and 3. With switch in resume position, measure resistance between terminals 1 and 2. TEST POINTS Cruise set/ resume switch, 2 to 3. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace cruise set/ resume switch.

2.

Off

Cruise set/ resume switch, between 1, 2 and 3. Cruise set/ resume switch, between 1 and 2.

>100K ohms.

Go to next step.

Replace cruise set/ resume switch.

3.

Off

<5 ohms.

Go to next step.

Replace cruise set/ resume switch.

s08210

246

7 DETROIT DIESEL SERIES 60 ENGINES

Table 64 STEP 4.

Testing Cruise Set/Resume Switch And Circuits (cont.) KEY Off ACTION To test switch light function, connect 12V lead to terminal 7 and gnd. terminal 8. Does LED light turn on? At connector (436) measure resistance to ground at circuit 97-GB. (436), 97-GB to gnd. <5 ohms. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace cruise set/ resume switch.

5.

Off

Go to next step.

Locate open or poor connection in circuit 97-GB to gnd. at negative battery terminal, then repair. Locate short to ground in circuit 97AA, then repair.

6.

Off

Disconnect ECM connector (273) from the ECM. Measure resistance G3, (circuit 97AA), to ground. Measure resistance from J1, (circuit 97AB), to ground. With set/resume switch disconnected, at connector (273) measure resistance between terminal G3 and J1, (circuit 97AA to 97AB). At connector (273), measure voltage from J1, (circuit 97AB), to ground. At connector (273), measure voltage from G3, (circuit 97AA), to ground.

(273), 97AA to gnd.

>100K ohms

Go to next step.

7.

Off

(273), 97AB to gnd. (273), 97AA to 97AB

>100K ohms >100K ohms.

Go to next step. Go to next step.

Locate short to ground in circuit 97AB, then repair. Locate short between circuits 97AA and 97AB, then repair.

8.

Off

9.

On

(273), 97AB to gnd. (273), 97AA to gnd.

<1 volt.

Go to next step. Go to next step.

Locate short to unwanted voltage source, then repair. Locate short to unwanted voltage source, then repair. Locate open or poor connection in circuit 97AA between connectors (436) and (273), then repair.

10.

On

<1 volt.

11.

Off

(436), At connector (273) use 97AA to test lead to jumper terminal G3, circuit 97AA, 97-GB. to ground. At connector (436) measure resistance between circuits 97AA and 97-GB. At connector (273) use test lead to jumper terminal J1, (circuit 97AB), to ground. At connector (436) measure resistance between circuits 97AB and 97-GB. (436), 97AB to 97-GB.

<5 ohms.

Go to next step.

12.

Off

<5 ohms.

The cruise set/ resume switch and circuits check good.

Locate open or poor connection in circuit 97AB between connectors (436) and (273), then repair.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

247

3.6. VEHICLE SPEED SENSOR (VSS)


Inspect circuits and connectors as outlined in Before Troubleshooting. When monitoring engine functions using the EZ-Tech or PRO-LINK 9000 EST, if the vehicle is moving, EZ-Tech or PRO-LINK 9000 will display vehicle speed if the system is working properly. Inspecting And Adjusting the Adjustable Vehicle Speed Sensor (VSS) 1. Disconnect engine harness connector (250) from the sensor. Loosen the locknut and remove the sensor. The harness connector and sensor should be free of damage or corrosion. Remove any metal shavings or debris from the sensor. 2. To install the sensor, turn in until the sensor contacts the transmission speedometer gear, then back out one full turn. Tighten locknut to 15 ft-lbs. (20.3 Nm). This assures that the sensor is adjusted properly for the next test. Testing Vehicle Speed Sensor (VSS) To perform this test construct two test leads using terminals (1680205C1) and suitable length of 16GA wire.

WARNING A jack must never be used alone to support vehicle. The jack may lower and serious injury could result. Always support vehicle with oor jacks. Always block wheels to prevent vehicle from moving.

WARNING EXTREME CAUTION should be used to prevent personal injury resulting from contact with rotating vehicle wheels when connecting test leads.

Table 65 STEP 1.

Testing Vehicle Speed Sensor (VSS) KEY Off ACTION With VSS (250), disconnected, use test lead to measure resistance to ground at both sensor terminals. Use test leads and measure resistance between VSS (250) sensor terminals. TEST POINTS VSS terminals to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace VSS (Refer to Inspecting and Adjusting the Vehicle Speed Sensor (VSS) preceding. Replace VSS, refer to Inspecting and Adjusting the Vehicle Speed Sensor (VSS) preceding.

2.

Off

VSS between terminals.

600 to Go to next 900 step. ohms with adjustable speed sensor. 1500 to 3500 with

s08210

248

7 DETROIT DIESEL SERIES 60 ENGINES

Table 65 STEP

Testing Vehicle Speed Sensor (VSS) (cont.) KEY ACTION TEST POINTS SPEC. YES-IN SPEC. NO-OUT OF SPEC.

non-adjustable sensor. 3. Off Block front wheels and place rear axles on oor stands. Use AC voltmeter with sufcient length leads to avoid personal contact with rotating vehicle wheels during this test. Connect meter leads to test leads. Run engine at idle speed, with transmission in high gear. Measure voltage across the two sensor terminals. VSS across terminals >2.0 Volts AC. Go to next step. Go to next step.

4.

Off

5.

Off

VSS checks good.

Replace VSS, refer to Inspecting and Adjusting the Vehicle Speed Sensor (VSS) preceding. NOTE: Improper adjustment will cause low, erratic, or no sensor output.

Testing Vehicle Speed Sensor (VSS) Circuits To ECM Table 66 STEP 1. Testing Vehicle Speed Sensor (VSS) Circuits To ECM KEY Off ACTION TEST POINTS SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground, then repair.

(273), With VSS sensor (250) 97AJ to disconnected, remove gnd. ECM connector (273) from ECM. At connector (273) measure resistance to ground at terminal E2, (ciruit 97AJ). At connector (273) measure resistance to ground at terminal E3, (circuit 97AK). At connector (273) measure resistance between terminals E2 and E3, (circuits 97AJ and 97AK). (273), 97AK to gnd. (273), 97AJ to 97AK.

2.

Off

>100K ohms.

Go to next step.

Locate short to ground, then repair.

3.

Off

>100K ohms.

Go to next step.

Locate short between circuits 97AJ and 97AK, then repair.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

249

Table 66 Testing Vehicle Speed Sensor (VSS) Circuits To ECM (cont.) STEP 4. KEY Off ACTION At connector (273) measure voltage from E2, (circuit 97AJ), to ground. At connector (273) measure voltage from E3, circuit 97AK, to ground. At connector (250), use test leads to connect circuit 97AJ to gnd. At connector (273) measure resistance from E2, (circuit 97AJ), to ground. At connector (250), use test leads to connect circuit 97AK to ground. At connector (273) measure resistance from E3, (circuit 97AK), to ground. TEST POINTS (273), 97AJ to gnd. (273), 97Ak to gnd. (273), 97AJ to gnd. SPEC. <1 volt. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to unwanted voltage source, then repair. Locate short to unwanted voltage source, then repair. Locate open or poor connection in circuit 97AJ between connectors (250) and (273), then repair. Locate open or poor connection in circuit 97AK between connectors (250) and (273), then repair.

5.

Off

<1 volt.

Go to next step.

6.

Off

<5 ohms

Go to next step.

7.

Off

(273), 97AK to gnd.

<5 ohms.

The VSS circuits between connectors (273) and (250) check good.

3.7. ENGINE BRAKE SYSTEM


Inspect circuits and connectors as outlined in Before Troubleshooting. Testing Engine Brake Switches and Circuits Table 67 STEP 1. Testing Engine Brake Switches and Circuits KEY Off ACTION Remove connector (434) from on/off switch. With switch in position measure resistance between terminals 5 and 6. With switch in position, measure resistance between terminals 5 and 6. TEST POINTS Engine brake on/off switch, 5 to 6. Engine brake on/off switch, 5 to 6. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

>100K ohms.

Go to next step.

Replace the switch.

s08210

250

7 DETROIT DIESEL SERIES 60 ENGINES

Table 67 Testing Engine Brake Switches and Circuits (cont.) STEP 3. KEY Off ACTION To test switch light function, connect 12V lead to terminal 7, and gnd. to terminal 8. Does LED light turn on? At connector (434) measure resistance to ground at circuit 24-GA. (434), 24-GA to gnd. <5 ohms. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

4.

Off

Go to next step.

Locate open or poor connection in circuit 24-GA or path to ground at negative battery terminal, then repair. Locate open or poor connection in circuit 24AJ between connectors (434) and (433), then repair.

5.

Off

Reconnect on/off switch to connector (434) and place in position. Remove connector (433) from engine brake selector switch. At (433) measure resistance from 24AJ to gnd. With engine brake selector switch in 6 cyl. position, measure resistance between terminals 2 and 6. With engine brake selector switch in 6 cyl. position, measure resistance between terminals 2 and 3. With engine brake selector switch in 2 cyl. position, measure resistance between terminals 2 and 3. With engine brake selector switch in 4 cyl. position, measure resistance between terminals 2 and 6. To test switch light function, connect 12V lead to terminal 7, and gnd. terminal 8. Does LED light turn on?

(433), 24AJ to gnd.

<5 ohms.

Go to next step.

6.

Off

Engine brake selector switch, 2 to 6. Engine brake selector switch, 2 to 3. Engine brake selector switch, 2 to 3. Engine brake selector switch, 2 to 6.

<5 ohms.

Go to next step.

Replace the switch.

7.

Off

<5 ohms.

Go to next step.

Replace the switch.

8.

Off

<5 ohms.

Go to next step.

Replace the switch.

9.

Off

<5 ohms.

Go to next step.

Replace the switch.

10.

Off

Go to next step.

Replace the switch.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

251

Table 67 STEP 11.

Testing Engine Brake Switches and Circuits (cont.) KEY Off ACTION Remove connector (273) from the ECM. At connector (273) measure resistance to gnd. at terminal K2. At connector (273) measure resistance to gnd at terminal K3. At connector (273) measure resistance between terminals K2 and K3. At connector (273) measure voltage at terminal K2 to ground. At connector (273) measure voltage at terminal K3 to ground. At connector (273) use test lead to jumper K2 to gnd. At connector (433) measure resistance to gnd. at circuit 24AE. At connector (273) use test lead to jumper K3 to gnd. At connector (433) measure resistance to gnd. at circuit 24AF. TEST POINTS (273), K2 to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground. in circuit, then repair.

12.

Off

(273), K3 to gnd. (273), K2 to K3.

>100K ohms. >100K ohms.

Go to next step. Go to next step.

Locate short to ground in circuit, then repair. Locate short between circuits 24AF and 24AE, then repair. Locate short to unwanted voltage source, then repair. Locate short to unwanted voltage source, then repair. Locate open or poor connection in circuit 24AE between connectors (273) and (433) then repair. Locate open or poor connection in circuit 24AF between connectors (273) and (433) then repair.

13.

Off

14.

On

(273), K2 to gnd. (273, K3 to gnd. (433), 24AE to gnd.

<1 volt.

Go to next step. Go to next step. Go to next step.

15.

On

<1 volt.

16.

Off

<5 ohms.

17.

Off

(433), 24AF to gnd.

<5 ohms.

The engine brake switches and circuits check good.

3.8. DIAGNOSTIC ON/OFF/SHUTDOWN OVERRIDE SWITCH (260)


Refer to Operation Section for operation description. Testing Diagnostic On/Off/Shutdown Override Switch Inspect circuits and connectors as outlined in Before Troubleshooting.

s08210

252

7 DETROIT DIESEL SERIES 60 ENGINES

Table 68 STEP 1.

Testing Diagnostic On/Off - Shutdown Override Switch KEY Off ACTION Remove connector (260) from the on/off shutdown override switch. With switch in on position, measure resistance between terminals 5 and 6. With switch in off position, measure resistance between terminals 5 and 6. To test switch light function, connect 12V lead to terminal 7, and ground terminal 8. Does LED light turn on? At connector (260) measure resistance of circuit 97-GD to ground. (260), 97-GD to gnd. <5 ohms. TEST POINTS Shutdown override switch, 5 to 6. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

Shutdown override switch, 5 to 6.

>100K ohms.

Go to next step.

Replace the switch.

3.

Off

Go to next step.

Replace the switch.

4.

Off

Go to next step.

Locate open or poor connection in circuit 97-GD or path to ground at negative battery terminal, then repair. Locate open or poor connection in circuit 97AU between connectors (273) and (260), then repair.

5.

Off

Remove connector (273) from ECM. At (273) use test lead to jumper terminal G1 to ground. At connector (260) measure resistance from circuit 97AU to ground.

(260), 97AU to gnd.

<5 ohms.

The shutdown override/ diagnostic switch and circuits check good.

3.9. PARK BRAKE (IDLE TIMER) SWITCH (268)


Inspect circuits and connectors as outlined in Before Troubleshooting. Testing Park Brake Switch (268) and Circuits NOTE Vehicle air system must be fully charged for this test.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

253

Table 69 STEP 1.

Testing Park Brake Switch (268) and Circuits KEY Off ACTION Remove connector (268) from the park brake switch. With park brake applied, measure resistance across switch terminals. With park brake applied, measure resistance to gnd at both switch terminals. Release park brake and measure resistance between switch terminals. TEST POINTS Park brake switch, across terminals. Park brake switch, terminals to gnd. Park brake switch, across terminals. (268), 97-GE to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

>100K ohms.

Go to next step.

Replace the switch.

3.

Off

>100K ohms.

Go to next step.

Replace the switch.

4.

Off

At connector (268) measure resistance of 97-GE to ground.

<5 ohms

Go to next step.

Locate open or poor connection in circuit 97-GE or path to ground at negative battery terminal, then repair. Locate short to ground in circuit 97AV between connectors (273) and (268), then repair. Locate short to unwanted voltage source in circuit 97AV, then repair. Locate open or poor connection in circuit 97AV between connectors (273) and (268), then repair.

5.

Off

Remove connector (273) from ECM. At connector (273) measure resistance of H2 to ground. At connector (273) terminal H2, measure voltage to ground. Connect (268) to park brake switch, and apply park brake. At connector (273) measure resistance to ground at terminal H2.

(273), H2 to gnd.

>100K ohms.

Go to next step.

6.

On

(273), H2 to gnd.

<1 volt.

Go to next step.

7.

Off

(273), H2 to gnd.

<5 ohms.

Park brake (idle timer) switch (268) and circuits check good.

3.10. TESTING LOW COOLANT SENSOR CIRCUITS


When Detroit Diesel diagnostic codes are logged indicating a low coolant condition or a coolant sensor circuit fault check for proper coolant levels. If coolant levels are not low, this test should be performed.

s08210

254

7 DETROIT DIESEL SERIES 60 ENGINES

Table 70 STEP 1.

Testing Low Coolant Sensor and Circuits KEY Off ACTION Disconnect ECM connector (273) from the ECM and disconnect (278) from the coolant probe. Measure the resistance from (273) terminal H3, circuit 34, to ground. At (278), place a jumper between terminals A and B. Measure the resistance between ECM connector (273) terminal H3 and ground. Replace coolant probe. If problem persists have a Detroit Diesel dealer diagnose ECM operation. TEST POINTS (273) circuit 34 to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short in circuit 34, then repair.

2.

Off

(273) terminal H3 and gnd.

<5 ohms.

Low coolant circuits check good. Go to next step.

Locate open in circuits 34 or 34-G, then repair.

3.

Off

3.11. ECM POWER SUPPLY (SWITCHED AND UNSWITCHED)


Inspect ECM power and ground circuits and connectors as outlined in Before Troubleshooting. Testing Unswitched Battery Power To ECM At Connector (676) Table 71 STEP 1. Testing Unswitched Battery Power To ECM At Connector (676) KEY Off ACTION Remove and check the two 15A power fuses located near batteries for open condition. Re-install two 15A fuses. At connector (676) measure voltage to ground at terminal A. TEST POINTS Fuses near batteries. (676), A to gnd. SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse(s). Locate cause of no or low voltage in circuit 14C or 14B from battery, then repair.

2.

Off

12 1.5 volts.

Go to next step.

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

255

Table 71 STEP 3.

Testing Unswitched Battery Power To ECM At Connector (676) (cont.) KEY Off ACTION At connector (676) measure voltage to ground at terminal C. At connector (676) measure voltage between terminal C and terminal B, D, and E. TEST POINTS (676), C to gnd. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 14D or 14A from battery, then repair. At terminal (B, D, or E) where less than battery voltage is present, locate open in circuit between connector (676) and negative battery terminal, the repair.

4.

Off

(676), C to B, D, and E.

12 1.5 volts.

ECM power connector circuits test good.

Testing Switched Battery Power To ECM Table 72 Testing Switched Battery Power To ECM STEP 1. KEY Off ACTION Remove and check fuse F6-D for open condition. TEST POINTS F6-D. SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Go to next step.

2.

Off/ On

Re-install fuse F6-D. Remove connector (273) from ECM. Turn key on and at (273) terminal B3 measure voltage to ground. At fuse F6-D/circuit 13D, measure voltage to ground.

(273), B3 to gnd.

12 1.5 volts.

Switched voltage circuit to ECM connector (273) is good. Locate open in circuit 13D, then repair.

3.

On

F6-D/ 13D to gnd.

12 1.5 volts.

Locate cause of no or low voltage at fuse F6-D, then repair.

4. COMPONENT LOCATIONS
(B1) Battery Stud. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . . Power Distribution Panel (B2) Battery Stud. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . . Power Distribution Panel (2) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Right Side of Engine Cowl, Above Connector 3 (3) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Right Side of Engine Cowl, Below Connector 2 (94) Back-Up Light Switch. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . . . . . On Transmission (137) 6-Way Data Link Connector. . . . . . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (141) Ser. Brake Switch/Cruise Switch. . . . . . . . . . . . .. . . . . . Dash Panel, Lt. Side, Engine Side (190) Cab Overlay to Elect. Eng. Harness. . . . . . . . .. . . . . . Right Instrument Panel (227) Fan Solenoid.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . . . . . At Front of Engine
s08210

256

7 DETROIT DIESEL SERIES 60 ENGINES

(228) Refrigerant Pressure Switch. . . . . . . . . . . . . . . . . .. . . . . . On A/C Compressor, On Engine (235) Transmission Oil Temp. (Inline).. . . . .. . . . . .. . .. . . . . . On Front of Transmission (250) Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Transmission (260) Det. Diesel Eng. Override Diag. On/Off Switch . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. ... . . . . . At Switch Cluster (267) Detroit Diesel Throttle Pos. Sensor. . . . . . . . . .. . . . . . On Engine (268) Det. Diesel Idle Timer/Park Brake Sw. . . . . . .. . . . . . Behind Switch Cluster (273) Detroit Diesel ECM Connector. . . . . . . . . . . . . . . .. . . . . . To ECM Mounted on Dash Engine Side (278) Detroit Diesel Low Coolant Switch. . . . . . . . . . .. . . . . . To Engine Harness (294) Clutch Switch Connector. . . . . . . . . . . . . . . . . . . . . .. . . . . . Near Clutch Switch (403) J1922 Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Dash Panel Right Side (1160) ECM Comm. W/ Series 60 Detr. . . . . . . . . . . . .. . . . . . Inline near ECM (433) Engine Brake Selector Switch. . . . . . . . . . . . . . . .. . . . . . At Switch Cluster (434) Engine Brake On/Off Switch. . . . . . . . . . . . . . . . . .. . . . . . At Switch Cluster (435) Cruise On/Off Switch . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . At Switch Cluster (436) Cruise Set/Resume Switch. .. . . . . . . . . . . . . . . . . .. . . . . . At Switch Cluster (494) I1 Ignition Adapter. .. . . . .. . . . .. . . . .. . . . .. . . . .. . .. . . . . . Behind Fuse Panel (504) L2 Panel Light Feed Adapter. .. . .. . .. . .. . .. . ... . . . . . Behind Instrument Panel/Switch Breakout (506) L4 Panel Lights Ground Adapter. . . . . . . . . . . . .. . . . . . Behind Instrument Panel/Switch Breakout (514) Data Link - Positive. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel/Behind Cluster (515) Data Link - Negative. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel/Behind Cluster (640) Stop Light Switch. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . .. . . . . . Dash Panel, Left Side, Engine Compartment (675) ECM Power (Inline) W/Series 60. . . . . . . . . . . . .. . . . . . Near ECM (676) ECM 6-Way Power Connector. . . . . . . . . . . . . . . .. . . . . . Near ECM

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

257

Figure 90

Engine Wiring

s08210

258

7 DETROIT DIESEL SERIES 60 ENGINES

1. DASH PANEL (VIEWED FROM INSIDE ENGINE COMPARTMENT) 2. (141) BRAKE SWITCH 3. (640) STOP LIGHT SWITCH 4. (190) ELECTRONIC ENGINE CONNECTOR 5. RIGHT HAND DASH PANEL GROUND STUD 6. (3) ENGINE CONNECTOR 7. (2) CHASSIS HARNESS CONNECTOR 8. POWER DISTRIBUTION PANEL 9. B1 AND B2 BATTERY STUDS 10. SWITCHES 11. RIGHT GAUGE CLUSTER 12. SPEEDOMETER / TACHOMETER CLUSTER 13. LEFT GAUGE CLUSTER 14. (514) DATA LINK CONNECTOR 15. (515) DATA LINK CONNECTOR 16. (137) DATA LINK 17. FRONT END HARNESS CONNECTOR 18. THROTTLE PEDAL 19. (267) THROTTLE PEDAL CONNECTOR 20. (268) IDLE TIMER PARK BRAKE SWITCH 21. CLUTCH SWITCH 22. (294) CLUTCH SWITCH CONNECTOR

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

259

Figure 91

Engine Wiring 1. (190) ELECTRONIC ENGINE CONNECTOR 2. RH DASH PANEL GROUND STUD 3. (3) CHASSIS HARNESS CONNECTOR 4. (2) CAB/ENGINE HARNESS CONNECTOR 5. CIRCUIT 14A TO (B1) BATTERY STUD 6. START MAGNETIC SWITCH 7. CIRCUIT 17D USED WITH THERMAL OVERCRANK SYSTEM 8. (402) LOW COOLANT LEVEL SWITCH 9. LH DASH PANEL GROUND STUD 10. (1) FRONT END HARNESS CONNECTOR 11. (410) FAN SOLENOID RELAY 12. ENGINE HARNESS

s08210

260

7 DETROIT DIESEL SERIES 60 ENGINES

Figure 92

Engine Wiring

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

261

1. TO BATTERY CABLE AND STARTER HARNESS 2. CIRCUIT 97G 3. ECM CONNECTOR (273) 4. J1939 & J1922 CONNECTOR (1160) 5. ECM POWER CONNECTOR (676) 6. ECM 7. CIRCUIT 21A 8. CIRCUITS 11GA, 11GU, 11GS & 2G 9. STARTER 10. ECM 11. TO OTHER SIDE OF ENGINE 12. TO ENGINE WIRING AT DASH PANEL 13. TO TRANSMISSION 14. CIRCUIT 17C 15. FUSIBLE LINK, CIRCUIT 2 16. TO FRAME GROUND 17. TO ECM 18. CIRCUIT 11GS 19. CIRCUIT 11GA 20. CIRCUIT 2G 21. CIRCUIT 11GU

s08210

262

7 DETROIT DIESEL SERIES 60 ENGINES

Figure 93

Engine Wiring 1. 2. 3. 4. 5. CIRCUIT 77C TO OTHER SIDE OF ENGINE CIRCUITS 23 & 23D JUMPER USED WITHOUT AIR CONDITIONING AIR LINE TO FAN CLUTCH (FROM FAN SOLENOID)

s08210

7 DETROIT DIESEL SERIES 60 ENGINES

263

Figure 94

Engine Wiring, Alternator Effects 1. 2. 3. 4. CIRCUIT 2 ENGINE HARNESS CIRCUIT 2-G CIRCUIT A2

s08210

264

7 DETROIT DIESEL SERIES 60 ENGINES

Figure 95

Engine Wiring, Transmission Effects 1. 2. 3. 4. 5. 6. TO ENGINE TRANSMISSION OIL TEMPERATURE CONNECTOR (235) BACK-UP LIGHT SWITCH (94) CIR 97AJ & 971K VEHICLE SPEED SENSOR NEUTRAL POSITION SWITCH

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

265

Table of Contents

1. DESCRIPTION. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .267 2. OPERATION.. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .267 2.1. ECM POWER CIRCUITS.. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .268 2.2. ATA DATA LINK CONNECTOR. . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .268 2.3. DIAGNOSTIC ON/OFF SWITCH. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .269 2.4. IDLE/DIAGNOSTIC SWITCH. .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .269 2.5. ELECTRONIC ACCELERATOR PEDAL ASSEMBLY. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .269 2.6. COOLANT LEVEL SWITCH.. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .270 2.7. CRUISE CONTROL. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .270 2.8. CLUTCH SWITCH.. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .271 2.9. VEHICLE SPEED SENSOR. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .271 2.10. ENGINE BRAKE. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .271 2.11. ANTILOCK BRAKE INTERFACE. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .272 2.12. GAUGES AND WARNING LIGHTS. . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .272 3. TROUBLESHOOTING. .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .272 3.1. ONBOARD DIAGNOSTICS WITH ENGINE RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .272 3.2. PERFORMING A DIAGNOSTIC CHECK WITH THE ENGINE OFF. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .273 3.3. COMPULINKTM.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .274 3.4. EZ-TECH OR PRO-LINK ELECTRONIC SERVICE TOOL (EST). .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .274 3.5. INSPECTING INTERNATIONAL ENGINE HARNESS ECM CONNECTOR (252). . . . . . . . . . . . . . .275 3.6. RELAYS.. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .277 3.7. TESTING RELAY. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .277 3.8. ACCELERATOR PEDAL TPS/IVS.. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .278 Testing Throttle Position Sensor (TPS). . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .278 Testing Idle Validation Switch (IVS).. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .279 Testing Accelerator Pedal (TPS/IVS) System for "Short or Open" Circuits. . . . . . . . . . . . . .280 Testing TPS/IVS Circuits for Continuity. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .281 Accelerator/ECM Calibration.. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .283 3.9. LOW COOLANT SWITCH. .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .283 Testing Low Coolant Level Switch and Circuits.. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .283 3.10. POWER SUPPLY CIRCUITS TO ECM.. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .284 Testing Unswitched Battery Power Circuits and ECM Ground Circuit. . . . . . . . . . . . . . . . . . . .284 Testing Switched Ignition Power To ECM . .. . .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .285 3.11. SERVICE BRAKE AND CLUTCH SWITCHES. .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. .286 Testing Clutch Switch.. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .286 Testing Clutch Switch Circuits for Open and Short Condition. . .. . .. . . .. . .. . . .. . .. . . .. . .287 Testing Clutch Switch Circuits For Continuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288 Testing Service Brake Switch (141). . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. .289 Testing Service Brake Switch Circuits for "Open and Short" Condition.. .. . .. .. . .. .. . .. .290 Testing Service Brake Switch Circuits for Continuity. .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .291 3.12. ENGINE BRAKE. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .292 Testing Engine Brake Components and Circuits. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .292 Testing Engine Brake Switches. . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .292 3.13. ATA DATA LINK CONNECTOR (137) AND SPEEDOMETER/TACHOMETER INPUT CIRCUITS. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .293

s08210

266

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Testing Diagnostic Connector Power and Ground Circuits. . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . .293 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit. . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . .. . . . . . .294 3.14. DIAGNOSTIC SWITCHES. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. ..295 Testing Diagnostic On/Off Switch and Circuit. . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . .296 Testing Idle/Diagnostic Switch (243) and Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297 3.15. CRUISE CONTROL. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .299 Testing Cruise Control On/Off Switch and Circuits. .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ..299 Testing Cruise Set/Resume Switch and Circuits. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .301 3.16. VEHICLE SPEED SENSOR.. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..302 Inspecting and Adjusting the Vehicle Speed Sensor (VSS).. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . .302 Testing Vehicle Speed Sensor. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . ..303 Testing Vehicle Speed Sensor Circuits To ECM. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. .304 4. COMPONENT LOCATIONS. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..305

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

267

1. DESCRIPTION
The N14 controller provides many engine/vehicle functions including: Cruise/PTO Controls Tachometer/Speedometer Input To Gauges Idle Shutdown Adjustable Low Idle Speed (In-Cab) Engine Cooling Fan Control Self Diagnostics Engine Protection System Engine Brake Control

Refer to the Cummins Engine Manual furnished with the vehicle for additional feature information. Since each engine control system is electronically programmable to individual owner specications, the operating parameters will vary from vehicle to vehicle. These parameters include: maximum cruise speed, shift schedules, governor type (automotive type or variable speed), idle RPM, full engine shutdown as part of the engine protection system and many others. The electronic control module (ECM) is the control center of the CELECT system. The ECM receives input from Cummins and International sensors and switches, processes the information, then used electrical signals to control engine and vehicle functions. The ECM receives inputs from International installed components including: Vehicle Speed Sensor (VSS) Throttle Position Sensor (TPS) Idle Validation Switch (IVS) Service Brake Switch Clutch Switch Low Coolant Level Switch ABS/Traction Control Controller CELECT Cab Switches

The ECM receives information from the sensors and switches and sends signals to the injectors, fuel shutoff valve and engine brake relay.

2. OPERATION
Refer to Cummins N14 CELECT ENGINE CONTROLS circuit diagrams in CTS-5298 or S08225. The ECM is connected to the International electrical system at three points (or four points with antilock brakes installed).

s08210

268

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

A. International engine harness 28way ECM connector (252) connects to ECM port B. This connector links International sensors, switches and the diagnostic connector to the ECM. B. International 21way connector (251) connects to the Cummins sensor harness. This connector links the International installed engine brake components, low coolant switch, fan controls and switched voltage to the ECM. C. The International ECM power connector (216) connects to the Cummins actuator harness. This connector supplies the unswitched power to the ECM and provides an ECM ground circuit to the engine ground stud. D. Additionally, with ABS/traction control system, the International ECM connector (252), connects to the Cummins sensor harness located near the front of the ECM. J1922 Data Link connector (403) connects to the ABS system.

2.1. ECM POWER CIRCUITS


Power is supplied at all times to the ECM from the cranking motor solenoid B+ terminal. Circuits 97B and 97C deliver power on the International harness through the ECM power connector (225) and the Cummins harness to the ECM. The Cummins harness has a 10A inline fuse in each circuit. The ECM is grounded through the Cummins harness, ECM power harness connector (225) and circuit 97G to the engine ground stud. The engine ground stud is connected to the cranking motor ground stud, frame rail and negative battery terminal. Turning the key switch to the ignition or start position applies power to circuit 13, 13Z, 5A fuse F6D and circuit 13D to the 21way ECM connector (251).

2.2. ATA DATA LINK CONNECTOR


The six pin ATA data link connector (137) allows an electronic service tool (EST) to communicate with the ECM. The data link carries serial data transmissions between the ECM and the electronic service tool, and between the ECM and the speedo/tachometer cluster. Thus, the ECM provides vehicle and engine information to the speedo/tachometer and the EST. The ATA data link connector (137), which is located on the left instrument panel, has circuits in four of the six cavities. The data link circuits are a twisted wire pair because twisting the wires helps shield them from interference. The circuits are as follows: Circuit 98A(+) is the positive data link connection, and it is fed by the positive data link connector (514), the jumper bus bar, circuit 98(+), connector (190), and circuit 98(+) coming from the ECM connector (252). Circuit 98C(-) is the negative data link connection, and it is fed by the negative data link connector (515), the jumper bus bar, circuit 98B(-), connector (190) and circuit 98B(-) coming from the ECM connector (252). Circuit 97DL is a 12 volt feed and is fed from the battery adapter (498), circuit 14BK and 20A fuse F5D. Thus it provides power for the electronic service tool. Circuit 11GR, 11GT is connected to the panel lights ground adapter (506), and provides a ground for the electronic service tool.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

269

2.3. DIAGNOSTIC ON/OFF SWITCH


A lighted diagnostic on/off switch is provided for on-board diagnostics. The switch is connected to the ECM common/ground connection by way of ECM connector (252), circuits 97G and 97GA, connector (190), and circuits 97GA and 97GE. Moving the switch to the on position, closing the switch, applies the ground to circuit 97AM, connector (190) and circuit 97AM to the Cummins engine connector (251). This tells the ECM that the diagnostic on/off switch has been turned on. Thus the ECM will switch modes to display fault codes or the absence of codes by ashing the engine warning light and the stop engine light.

2.4. IDLE/DIAGNOSTIC SWITCH


The lighted two-position momentary idle/diagnostic switch is a dual function switch. The switch adjusts the low engine idle speed and is also used during on-board diagnostics (when the diagnostic switch is in the on position) to move through the diagnostic fault code list. The engine idle speed can be adjusted by the switch in increments of 25 rpm by toggling the switch. Maximum idle speed is 800 rpm and minimum idle speed is 550 rpm. When the idle has been changed and the key turned off, the new setting is saved in memory. This feature is owner selected and can be turned off with an electronic service tool. The switch is connected to the ECM common/ground connection by way of ECM connector (252), circuits 97G and 97GA, connector (190) and circuits 97GA and 97GD. Momentarily placing the switch in the increment position applies ground to circuit 97AV, connector (190) and circuit 97AV to the ECM (252). This causes the engine idle rpm to increase 25 rpm. Momentarily placing the switch in the decrement position applies ground to circuit 97AU, connector (190) and circuit 97AU to the ECM (252). This causes the engine idle rpm to decrease 25 rpm.

2.5. ELECTRONIC ACCELERATOR PEDAL ASSEMBLY


CELECT engines utilize an electronic accelerator pedal assembly that includes an integrated throttle position sensor (TPS) and idle validation switch (IVS). The accelerator pedal assembly is serviceable, to the extent that the IVS switch is replaceable without replacing the whole assembly. The TPS is attached to the accelerator pedal and acts like a potentiometer. Movement of the pedal results in a variable signal being sent to the ECM that is proportional to pedal position. A 5 volt signal from the ECM connector (252) is applied to circuit 99A, connector (190), circuit 99A and the TPS/IVS (267). The variable wiper signal (varies with pedal position) from TPS/IVS (267) is returned to the ECM over circuit 99, connector (190), circuit 99 and ECM connector (252). This variable signal tells the ECM the position of the accelerator pedal. The TPS (267) is grounded through circuit 99GA, connector (190) and circuit 99GA to the ECM (252). NOTE Any time the accelerator pedal sensor (TPS) is disconnected from the ECM with the key switch on, the TPS and ECM must be recalibrated. The IVS is used to indicate when accelerator pedal is in the low idle position and when the pedal is not in the low idle position. A ground path from the ECM connector (252), circuits 97G and 97GA, connector (190), circuits 97GA and 99GA is applied to the TPS/IVS (267). When the accelerator is in the low idle position, the IVS (267) applies a ground signal to circuit 99B, connector (190) and circuit 99B to the ECM (252). When the accelerator is not in the idle position, the IVS (267) applies a ground signal to circuit 99C, connector (190) and circuit 99C to the ECM (252).

s08210

270

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

The ECM analyzes the signals received from the TPS and IVS to make certain that the signals fall within certain parameters. For example: if the IVS signal indicates that the accelerator pedal is in the idle position, the ECM expects to see a TPS signal that indicates that no throttle is applied. If it does not see a logical response from both, a fault code may be logged. The ECM and accelerator pedal must be calibrated to one another for proper engine response. Therefore, the ECM and accelerator pedal must be calibrated when the accelerator pedal is initially installed, when an accelerator pedal is replaced, when a new calibration is downloaded to the ECM, or when the accelerator pedal wiring is disconnected at the pedal, the cab oor, or the ECM connector. To recalibrate the ECM and the accelerator pedal, move the key switch to ignition position, slowly move the accelerator pedal from idle position to fully depressed position and then release. Repeat this cycle two more times to assure proper calibration.

2.6. COOLANT LEVEL SWITCH


The coolant level switch is a uid level actuated switch that sends two signals to the ECM, thus providing a warning when coolant is being lost. It is mounted in the coolant surge tank. The coolant level switch is an electronic switch that operates on the electrostatic or capacitance principle and cannot be tested with a multimeter. The probe extends into the coolant and produces a change in capacitance when coolant displaces air immediately surrounding the probe. This change is converted in the switch to an on/off solid state switch closure indicating the absence or presence of coolant. The switch is electrically insulated providing a slick, non-fouling surface as well as good electrical characteristics to prevent current ow into the coolant. The low coolant level switch connects to the engine harness at connector (249). Four circuits from connector (249) connect the low coolant switch to the ECM through the 21way ECM connector (251). The coolant level switch (249) receives a 5 volt signal on circuit 34B(5V) from the ECM (251). When the coolant level is above the probe, the switch sends a high signal (3.5 volts minimum) on circuit 34A and a low signal (0.5 volt maximum) on circuit 34 to the ECM (251). When the coolant level is below the probe, the switch sends a low signal (0.5 volt maximum) on circuit 34A and a high signal (3.5 volts minimum) on circuit 34 to ECM (251). The low coolant level switch is grounded through circuit 34G to ECM (251). NOTE The low coolant level switch cannot be tested with a multimeter in the ohmmeter mode. This is due to the fact that the switch is an electronic switch and not a mechanical switch.

2.7. CRUISE CONTROL


The cruise control system has three modes of operation: off, standby and active. The off position of the on/off switch turns cruise control off. The standby mode occurs when the driver switches the cruise control on/off switch to the on position. The driver can then achieve the active mode by toggling the set/resume switch after reaching the desired road speed. Once the system is active, the driver can accelerate beyond the set speed by depressing the accelerator pedal. When the pedal is released, cruise control is reactivated when the vehicle speed reaches the previously set speed. Cruise is deactivated and returns to the standby mode in several ways: the brake or clutch pedal is depressed, the engine speed (rpm) drops below 1000 rpm, or the vehicle speed (mph) drops below 30 mph. The resume switch can be used to reactivate cruise at the previous set speed or the set switch can be used to establish a new set speed.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

271

While in the active mode, the coast feature is used to decrease vehicle speed and establish a new lower set speed. By holding select switch in the coast position, vehicle speed decreases until the switch is released; the speed at release becomes the new set speed. While in the active mode, the accelerate feature is used to increase the vehicle speed and establish a new higher speed. By holding the select switch in the accel position, vehicle speed increases until the switch is released; the speed at release becomes the new set speed. The lighted cruise control on/off switch (435) receives a ground signal on circuits 97GC, 97GA, connector (259), circuits 97GA, 97G and 11G from the negative battery terminal. In the on position, a ground signal is sent from the switch on circuit 97AE, connector (190) and circuit 97AE to ECM connector (252) terminal 2. This indicates to the ECM that the cruise control switch is in the on position. In the off position, circuit 97AE returns to its 12 volt value, indicating to the ECM that the switch is off. The lighted cruise set/resume switch is a momentary switch. This switch receives a ground signal on circuits 97GB, 97GA, connector (259), circuits 97GA, 97G and 11G from the negative battery terminal. The cruise selector switch sends a ground signal from the switch on circuit 97AB, connector (190) and circuit 97AB to the ECM connector (252) terminal 12 while in the set/accel position. In the resume/coast position, the switch sends a ground signal by way of circuit 97AA, connector (190) and circuit 97AA to the ECM connector (252) terminal 22.

2.8. CLUTCH SWITCH


The clutch switch (294) is a N.O. momentary switch and its contacts are held closed when the clutch pedal is released. The switch is provided a ground path over circuits 97GH, 97GA, connector (259), circuits 97GA, 97G and 11G from the negative battery terminal. The clutch switch (294) sends a ground signal by way of circuit 97AH, connector (190) and circuit 97AH to the ECM connector (252) terminal 4 while the clutch pedal is released.

2.9. VEHICLE SPEED SENSOR


The vehicle speed sensor (250) feeds a VSS signal to the ECM (252) by way of circuits 97A and 97AK. Two types of sensors are available. The threaded (adjustable) sensor is used on most transmissions. A push-in (non-adjustable) sensor is used on some transmissions.

2.10. ENGINE BRAKE


The lighted engine brake on/off switch (434) receives a ground signal on circuits 24G, 97GA, connector (259), circuits 97GA, 97G and 11G from the negative battery terminal. In the on position, a ground signal is sent from the switch on circuit 24AD to engine brake selector switch (433). When lighted switch (433) is placed in the rst position, a ground is applied to circuit 24AE, connector (190), and circuit 24AE to the ECM (252). This tells the ECM to enable the brake solenoid for the front two and rear two cylinders on the N14E engine when braking is called for. When switch (433) is placed in the second position, a ground is applied to circuit 24AF, connector (190) and circuit 24AF to the ECM (252). This tells the ECM to enable the brake solenoid for the center two cylinders on the N14E engine when braking is called for. When switch (433) is placed in the third position, a ground is applied to circuit 24AF and 24AE to the ECM (252). This tells the ECM to enable all solenoids and use all cylinders for braking.
s08210

272

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

2.11. ANTILOCK BRAKE INTERFACE


If the vehicle is equipped with antilock brakes, information is shared with ABS controller module over a J1922 data link through connector (403), circuits 98Z and circuit 98Y(-) to the ECM (251).

2.12. GAUGES AND WARNING LIGHTS


Refer to separate gauge and warning lights sections in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual for information on speedometer, tachometer, gauges and warning lights.

3. TROUBLESHOOTING
Refer to Cummins N14 CELECT ENGINE CONTROLS circuit diagrams in CTS-5298 or S08225. This section includes troubleshooting charts for International installed circuits and components that are part of the CELECT Electronic Control system. To begin the troubleshooting process, refer to the appropriate Cummins manual and follow their directions. If the Cummins diagnostics (fault codes) indicate that the suspect circuits are International circuits or components, then use the charts in this section. The EZ-Tech or Pro-Link 9000 EST can also be used to determine if the International switches and components are working properly. If they are not, use a Fluke digital multimeter (DMM) to troubleshoot the circuits. If the Cummins diagnostic codes or the EZ-Tech or the Pro-Link indicates a problem with International installed circuits, the diagnostic tables in this chapter provide step-by-step test procedures. 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 laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual. D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit, by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid.

3.1. ONBOARD DIAGNOSTICS WITH ENGINE RUNNING


All CELECT vehicles have a yellow Engine Warning light and a red Engine Stop light located in the telltale lights in the instrument cluster. Every time the key is turned to the ignition position, the lights come on for several seconds as a system self-test and then turn off. If the warning lights remain on, it is an indication that the ECM has detected a problem. The CELECT system can show and record certain problems. The problems are shown as fault codes. The fault codes are recorded in the ECM.
s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

273

If a fault is detected (becomes active) during vehicle operation, the driver is alerted by the illumination of either the yellow Engine Warning light or the red Stop Engine light. The yellow Service/Check Engine light may also be illuminated. The yellow Engine Warning light turns on to warn the driver of an active component or system fault that should be serviced as soon as possible to solve the problem, but the situation is not considered an emergency. The red Stop Engine light turns on to warn the driver that there is a major CELECT system problem and the vehicle should be stopped and engine shut down as soon as is safely possible. The yellow Service/Check Engine light (engine protection system) turns on to warn the driver that: A. Coolant temperature is out of range. B. Oil temperature is out of range. C. Oil pressure is out of range. D. Intake manifold temperature is out of range. E. Engine coolant level is below the acceptable level.

3.2. PERFORMING A DIAGNOSTIC CHECK WITH THE ENGINE OFF


A diagnostic check may be performed using the Diagnostic On/Off switch and Idle/ Diagnostic Inc/Dec switch. Any error codes will be ashed through the red Engine Stop light and yellow Engine Warning light. If no errors are found, both lights will stay on while the diagnostics switch is on. Consult the Cummins Operation and Maintenance Manual furnished with the vehicle for exact procedures and fault code information. To determine the fault codes use the following procedure: 1. Begin the procedure with the engine off. 2. Place the switch key in the off position. 3. Turn the diagnostic on/off switch to the on position. 4. Turn the key switch to run position (not crank). 5. Yellow Engine Warning light will ash once. 6. There will be a one to two second pause. 7. Red Engine Stop light will ash code with one or two seconds between digits. 8. Yellow Engine Warning light will ash indicating the end of that fault code, and then start over and repeat the same fault code. 9. To go to the second fault code, move the Idle/Diagnostic Inc/Dec switch to the Inc position and then release it. The process will then repeat itself as indicated in steps 5 through 8. 10. To move back to the last or previous fault code, move the Idle/Diagnostic Inc/Dec switch to the Dec position and then release it. The process will then repeat itself as indicated in steps 5 through 8.

s08210

274

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

11. To stop the diagnostics procedure, correct the faults or move the diagnostic on/off switch to off, and turn the vehicle key switch to the off position. NOTE Cummins CELECT engine diagnostics must be run with the engine NOT RUNNING. If BOTH the yellow Engine Warning and red Engine Stop lights come on momentarily and then go out, it is an indication that engine faults are present. If BOTH the yellow Engine Warning and red Engine Stop lights come on and stay on, it is an indication that no engine faults are present. NOTE All Cummins fault codes are 3 digits. For example, the yellow Engine Warning light ashes once. The red Engine Stop light ashes: FLASH Digit number one is 1. Then there is a pause. FLASH FLASH Digit number two is 2. Then there is pause. FLASH FLASH FLASH. Digit number three is 3. Yellow Engine Warning lamp ashes once. The fault code is 123

3.3. COMPULINKTM
CELECT vehicles have a data link connected to the ATA data link connector (137) The Cummins CompulinkTM electronic service tool can be connected to the connector to program owner-specied information into the engine, monitor the system, and aid in troubleshooting the engine. Consult the Cummins CELECT Troubleshooting and Repair Manual. The CompulinkTM may be available at the nearest Cummins Authorized Service Center. CompulinkTM must be used with a CELECT service cartridge to communicate with a CELECT engine. A PACE or PT PACER cartridge will not work properly. NOTE On the Cummins CompulinkTM, since no alpha characters are available, use the up arrow and down arrow to move through the alphabet.

3.4. EZ-TECH OR PRO-LINK ELECTRONIC SERVICE TOOL (EST)


The EZ-Tech or Pro-Link 9000 EST with the heavy duty standard program can also be used with the International data link to read active and inactive fault codes through the data link. The use of the DDR or specic codes are not discussed in this manual as the information is part of the EZ-Tech or Pro-Link 9000 documentation. The EZ-Tech or Pro-Link 9000 can also be used to monitor operation of various switches and controls and perform other diagnostic tasks. The specic capabilities and operating instructions are included in the EZ-Tech or Pro-Link 9000 documentation.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

275

3.5. INSPECTING INTERNATIONAL ENGINE HARNESS ECM CONNECTOR (252)


1. Remove connector (252) from the ECM, rst removing the two capscrews. Carefully pull the connector straight out of the ECM. The connector pins are numbered (see Figure below) and correspond to the numbers on the circuit diagrams.

Figure 96

OEM Connector "B"

2. Inspect the connector for pushed back or expanded terminals in the following manner: a. Insert the tool (Cummins part number 3823383) into each Amp connector (Tool In Connector Figure) Do not force the tool into the connector. b. A terminal that is not pushed back or expanded will have a surface to tool gap (Tool In Connector Figure) of approximately 0.050 inch (1.3 mm). If the tool touches the connector, replace the terminal. c. Push the tool into the terminal until the tool touches the connector (Surface Tool Gap Figure). Slowly remove the tool from the terminal. A small resistance (6 to 10 ounces) must be felt (Tool Touching Connector Figure). If the resistance is not felt, the terminal is expanded and must be replaced.

d. Repeat steps A through C to check for pushed back or expanded terminals for all terminals in the ECM connector. e. Inspect the connector pins in the ECM. If the pins are bent (Inspect Connector Pins Figure), have a Cummins dealer replace the ECM.

s08210

276

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Figure 97

Tool In Connector

Figure 98

Surface Tool Gap

Figure 99

Tool Touching Connector

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

277

Figure 100 Inspect Connector Pins

3.6. 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 in the vehicle. These relays must be replaced with the correct International part. Relays used in exposed areas such as the engine compartment are sealed relays and have a different part number than those in the cab. The part number is embossed on the relay. There is also a circuit diagram of the relay located on the relay body. The terminals are numbered on the relay in the same manner as in the circuit diagrams. To test the relay, refer toTesting Relay.

3.7. TESTING RELAY


Table 73 STEP 1. Testing Relay KEY Off ACTION With relay removed, measure resistance between terminals 30 and 87. Measure resistance between terminals 30 and 87A. Connect 12V lead to terminal 85 and ground lead to terminal 86. Does relay energize with audible click? With relay energized (step 3), measure resistance between terminals 30 and 87. Energized <2 ohms. relay, 30 to 87. TEST POINTS Relay, 30 to 87. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the relay.

2.

Off

Relay, 30 to 87A.

<2 ohms.

Go to next step. Go to next step.

Replace the relay.

3.

Off

Replace the relay.

4.

Off

Relay tests good.

Replace the relay.

s08210

278

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

3.8. ACCELERATOR PEDAL TPS/IVS


The following four tests check the throttle position sensor (TPS), the idle validation switch (IVS) and the related International cab and engine harness circuits connected to the ECM. NOTE The following four tests, Testing Throttle Position Sensor (TPS), Testing Idle Validation Switch (IVS), Testing Accelerator Pedal (TPS/IVS) System for Short or Open Circuits and Testing TPS/IVS Circuits for Continuity must be performed in sequence. The tests should be performed if a Cummins fault code indicates a problem in the circuits or if the CompulinkTM EZ-Tech or Pro-Link 9000 EST indicates that the TPS/IVS is not working properly while monitoring switches. If CompulinkTM detects a fault with the IVS circuits while monitoring switches, the display would show Idle Validation Switch = Fault. If a fault is present while monitoring Percent Of Throttle, the percent displayed does not indicate actual throttle position. NOTE Testing Throttle Position Sensor (TPS) and Testing Idle Validation Switch (IVS) check operation of the APS and IVS, but do not check the timing between the two functions. Testing Throttle Position Sensor (TPS) This test checks the TPS circuits in the accelerator pedal assembly. This test will help identify if the resistances are within specications and if there are any opens or shorts in the TPS, but will not verify the correct switching of the IVS and TPS. Table 74 STEP 1. Testing Throttle Position Sensor (APS) KEY Off ACTION TEST POINTS SPEC. 2000 to 3000 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the TPS/IVS sensor, then recalibrate (refer to Accelerator/ ECM Calibration).

Disconnect accelerator TPS, A to pedal from cab harness at C. connector (267). At pedal side of (267) measure resistance between terminals A and C with the pedal in the idle position, then with the pedal fully depressed. With the pedal in the idle position, at pedal, measure resistance between terminals B and C. TPS, B to C.

2.

Off

1500 to 3000 ohms.

Go to next step.

Replace the TPS/IVS switch then recalibrate (refer to Accelerator/ ECM Calibration). Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibration).

3.

Off

With the pedal in the TPS, B to full throttle position, at C. pedal, measure resistance between terminals B and C. Is reading 1000 ohms less than reading at idle position, and between 250 and 1500 ohms?

250 to 1500 ohms, and < idle position reading -1000 ohms.

Go to next step.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

279

Table 74 STEP 4.

Testing Throttle Position Sensor (APS) (cont.) KEY Off ACTION At the accelerator pedal, measure resistance between gnd. (metal part of pedal) and terminals A, B, C, D and E. The TPS sensor checks good. Proceed to Testing Idle Validation Switch (IVS below), which checks the idle validation portion of the accelerator pedal. TEST POINTS TPS, A, B, C, D and E to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibration).

5.

Off

Testing Idle Validation Switch (IVS) This test checks the IVS circuits in the accelerator pedal assembly. Perform Testing Throttle Position Sensor (TPS) above, before performing this test. Table 75 STEP 1. Testing Idle Validation Switch (IVS) KEY Off ACTION Disconnect accelerator pedal from cab harness at connector (267). At pedal side of (267) measure resistance between terminals F and E with pedal in idle position. Is it <125 ohms? At pedal measure resistance between terminals F and E while slowly depressing the pedal (idle to full throttle). After approximately 10 degrees of travel, is the resistance 100K ohms or more? Remove connector (252) from ECM. At pedal measure resistance between terminals F and D while the pedal is at idle position. TEST POINTS TPS/ IVS, F to E. SPEC. <125 ohms YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the TPS/IVS switch, then recalibrate. Refer to Accelerator/ ECM Calibration.

2.

Off

TPS/ IVS, F to E.

>100K ohms.

Go to next step.

Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibration).

3.

Off

TPS/ IVS, F to D.

>100K ohms.

Go to next step.

Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibration).

s08210

280

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 75 STEP 4.

Testing Idle Validation Switch (IVS) (cont.) KEY Off ACTION At pedal measure resistance between terminals F and D while slowly depressing the pedal (idle to full throttle). After approximately 10 degrees of travel the resistance should be less than 125 ohms. At pedal measure resistance between metal part of accelerator pedal and terminals D, E and F. The TPS/IVS pedal assembly checks good. Note that this test is not able to check the timing between TPS and IVS functions. TEST POINTS TPS/ IVS, F to D. SPEC. <125 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibration).

5.

Off

TPS/ IVS, metal to D, E, and F.

>100K ohms

Go to next step.

Replace the TPS/IVS sensor, then recalibrate (refer to Acceleration/ ECM Calibration).

6.

Off

Testing Accelerator Pedal (TPS/IVS) System for "Short or Open" Circuits This test checks the cab and engine harness TPS/IVS circuits for opens, shorts to ground, shorts to "hot" circuits and shorts to other circuits in the harness. NOTE Perform Testing Throttle Position Sensor (TPS) and Testing Idle Validation Switch (IVS) before performing this test. Table 76 STEP 1. Testing Accelerator Pedal (TPS/IVS) System for Short or Open Circuits KEY Off ACTION With (267) disconnected, disconnect connector (252) from ECM and inspect ECM connector. Refer to Inspecting International Engine Harness ECM Connector (252). TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate the ECM to TPS/IVS.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

281

Table 76 Testing Accelerator Pedal (TPS/IVS) System for Short or Open Circuits (cont.) STEP 2. KEY Off ACTION At connector (252) use test leads and measure resistance to gnd. at terminals 6, 9, 10, 11, 18 and 19 (circuits 99B, 99C, 97-G, 99, 99A and 99-G). Do not use probes or leads other than Cummins P/N 3822758 or the connector could be damaged. At connector (252) use test leads and measure resistance between terminals 6, 9, 11, 18 and 19 (circuits 99B, 99C, 99, 99A and 99-G) and all other terminals in (252). At connector (252) use test leads and measure voltage to gnd. at terminals 6, 9, 10, 11, 18 and 19 (circuits 99B, 99C, 97-G, 99, 99A and 99-G). TEST POINTS (252), 99B, 99C, 97-G, 99, 99A and 99-G to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground, in circuit where terminal resistance is less than 100K ohms, then repair.

3.

Off

(252), between 99B, 99C, 99, 99A, 99-G and all other cir. in conn. (252), 99B, 99C, 97-G, 99, 99A and 99-G to gnd.

>100K ohms.

Go to next step.

Locate short between any circuits where resistance between terminals is less than 100K ohms, then repair.

4.

On

<1.5 volts.

Go to Test Locate short to unwanted voltage Chart source in any circuit below. where more than 1.5 volts is present, then repair. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal.

Testing TPS/IVS Circuits for Continuity This test checks the individual TPS and IVS circuits (cab and engine harness) for correct resistance while disconnected from the accelerator pedal assembly and ECM. NOTE Perform the preceding three tests before performing this test. Table 77 Testing TPS/IVS Circuits for Continuity STEP 1. KEY Off ACTION At ECM connector (252) use test lead to jumper terminal 11 to 18 (circuit 99 to 99A). At connector (267) measure resistance between terminals B and C (circuit 99 to 99A). Do not use probes or leads TEST POINTS (267), 99 to 99A. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of out-of-specication resistance in either circuit 99 or 99A(5V), then repair. Refer to Accelerator/ ECM Calibration to

s08210

282

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 77 Testing TPS/IVS Circuits for Continuity (cont.) STEP KEY ACTION other than Cummins P/N 3822758 or the ECM connector could be damaged. 2. Off (267), At connector (252) use 99-G to test lead to jumper 99. terminal 11 to 19 (circuit 99 to 99-G). At connector (267) measure resistance between terminals A and B (circuit 99-G to 99). (267), 99 At connector (252) use to 99C. test lead to jumper terminal 11 to 9 (circuit 99 to 99C). At connector (267) measure resistance between terminals B and D (circuit 99 to 99C). (267), 99 At connector (252) use to 99B. test lead to jumper terminal 11 to 6 (circuit 99 to 99B). At connector (267) measure resistance between terminals B and E (circuit 99 to 99B). (267), 99 At connector (252) use to 99-GA. test lead to jumper terminal 11 to 10 (cir. 99 to 97-G). At connector (267) measure resistance between terminals B and F (circuit 99 to 99-GA). < 5 ohms. Go to next step. TEST POINTS SPEC. YES-IN SPEC. NO-OUT OF SPEC. recalibrate ECM/ accelerator pedal.

Locate cause of out-of-specication resistance in circuit 99-G, then repair. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate cause of out-of-specication resistance in circuit 99C, then repair. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate cause of out-of-specication resistance in circuit 99B, then repair. Refer to Accelerator/ ECM Calibration then recalibrate ECM/ accelerator pedal. Locate cause of out-of-specication resistance in circuit 99-GA or 97-G, then repair. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal.

3.

Off

< 5 ohms.

Go to next step.

4.

Off

< 5 ohms.

Go to next step.

5.

Off

< 5 ohms.

Go to next step.

6.

Off

If all four of these tests have been performed and defects were not noted, the TPS and IVS circuits check good. If the problem is still present, replace the accelerator pedal. If this does not correct the problem, have Cummins
s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

283

Table 77 STEP

Testing TPS/IVS Circuits for Continuity (cont.) KEY ACTION dealer diagnose the ECM operation. TEST POINTS SPEC. YES-IN SPEC. NO-OUT OF SPEC.

Accelerator/ECM Calibration The electronic accelerator pedal assembly and the ECM must be calibrated when: A. The pedal assembly is initially installed. B. The pedal assembly or sensor is replaced. C. The accelerator pedal is disconnected (at any point in the circuitry) and the key switch is placed in the on position. To recalibrate the accelerator pedal and ECM: A. The vehicle key must be in the on position. B. Depress the accelerator pedal slowly through the complete range of movement, then release. Slowly depress and release, three times in this manner. This completes the calibration process.

3.9. LOW COOLANT SWITCH


First check for proper coolant levels. If coolant levels are not low, this test would be performed if Cummins diagnostic codes were logged indicating a low coolant condition or other circuit fault. This test procedure requires a VOM to check the International harness for opens, shorts to ground, or shorts to other circuits in the International harness. The low coolant sensor has complex circuits and a VOM should not be used to test the sensor as it may damage the circuits. Testing Low Coolant Level Switch and Circuits Table 78 STEP 1. Testing Low Coolant Level Switch and Circuits KEY Off ACTION Disconnect 21-way connector (251) from Cummins connector. Disconnect (249) from low coolant switch. At connector (251) measure resistance between terminals J, K, L and M (circuits 34B[5V], 34-G, 34A, and 34) and all other terminals in (251). TEST POINTS (251) between 34B/(5V), 34-G, 34A and 34 and all other circuits. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short between any circuits where resistance between terminals is less than 100K ohms, then repair.

s08210

284

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 78 STEP 2.

Testing Low Coolant Level Switch and Circuits (cont.) KEY Off ACTION At (251) measure resistance to ground at terminals J, K, L and M (circuits 34B[5V], 34-G, 34A, and 34). At (251) measure voltage to ground at terminals J, K, L and M (circuits 34B[5V], 34-G, 34A and 34). Measure resistance of circuits 34, 34A, 34-G and 34B(5V) between connectors (249) and (251). The low coolant switch circuits check good. If problem is still present, replace low coolant switch. If problem persists, have Cummins dealer diagnose ECM operation. TEST POINTS (251), 34B (5V), 34-G, 34A, and 34 to gnd. (251), 34B/(5V), 34-G, 34A and 34 to gnd. 34, 34A, 34-G, and 34B(5V) between (249) and (251) SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground in any circuit(s) where resistance is less than 100K ohms, then repair. Locate short to unwanted voltage source in any circuit(s) where voltage is more than 1.5V, then repair. Locate open or poor connection in circuit(s) if resistance is more than 5 ohms, then repair.

3.

On

<1.5 volts.

Go to next step.

4.

Off

<5 ohms

Go to next step.

5.

Off

3.10. POWER SUPPLY CIRCUITS TO ECM


This test checks the unswitched battery power feed to the ECM and the ECM ground circuit that is part of the Battery Feed Harness. Check the two 15A Cummins fuses before performing this test. NOTE Batteries must be fully charged before performing this test. Testing Unswitched Battery Power Circuits and ECM Ground Circuit Table 79 Testing Unswitched Battery Power Circuits and ECM Ground Circuit STEP 1. KEY Off ACTION Check ECM power harness connector at starter (circuit 97, 97A and 97-G) and at connector (225) for clean, tight connections. Connections good? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Correct poor connections.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

285

Table 79 STEP 2.

Testing Unswitched Battery Power Circuits and ECM Ground Circuit (cont.) KEY Off ACTION Check the two 15 amp fuses located in the engine harness for open condition. Disconnect ECM power connector (225) from Cummins engine harness. Measure voltage to gnd. at circuits 97 and 97A. Battery voltage present? At connector (225) measure voltage between circuits 97 and 97-G. Battery voltage present? At connector (225) measure voltage between circuits 97 and 97-G while cranking engine. Unswitched battery power circuits and ECM ground circuit at connector (225) checks good. TEST POINTS ECM fuses. SPEC. <5 ohms. YES-IN SPEC. Go to next step. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then correct. Replace with correct rated fuse. Locate cause of low or no voltage in circuit 97 or 97A from B+ terminal or starter, then repair.

3.

Off

(225), 97 and 97A to gnd.

12 1.5 volts.

4.

Off

(225), 97 to 97-G.

12 1.5 volts.

Go to next step.

Locate open or high resistance in circuit 97-G between (225) and engine gnd. stud, then repair. Locate cause of excess voltage drop in cranking circuit, then repair.

5.

On

(225), 97 to 97-G while cranking.

>7 volts.

Go to next step.

6.

Off

Testing Switched Ignition Power To ECM Table 80 Testing Switched Ignition Power To ECM STEP 1. KEY Off ACTION Check 5A fuse F6-D for open condition. Measure voltage to ground at input circuit (13Z to F6-D fuse). TEST POINTS F6-D. SPEC. <1 ohm. YES-IN SPEC. Go to next step. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage in 13Z.

2.

On

13Z to gnd.

12 1.5 volts.

s08210

286

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 80 Testing Switched Ignition Power To ECM (cont.) STEP 3. KEY ACTION TEST POINTS (251), A to gnd. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open in circuit 13D between fuse and connector (251), and repair.

Off/On Disconnect engine harness 21-pin ECM connector (251) from Cummins harness. Turn key on, measure voltage to gnd. at connector (251) terminal A (circuit 13D). Off Measure voltage between terminal A (circuit 13D and terminal G (circuit 11-GK).

4.

(251), A to G.

12 1.5 volts.

Switched ignition voltage circuit to ECM checks good.

Locate open in circuit 11-GK between engine ground and connector (251), then repair.

3.11. SERVICE BRAKE AND CLUTCH SWITCHES


This test would be performed if the Electronic Service Tool (EST) displayed an incorrect switch position or Cummins diagnostic codes indicate a problem may be present. Testing Clutch Switch Table 81 STEP 1. Testing Clutch Switch KEY Off ACTION Disconnect clutch switch connector (294) from cab harness. With clutch pedal released, measure resistance between the pigtail terminals. With clutch pedal depressed to the bottom of the free travel position (approx. 1.7 inches or 43 mm from pedal stop plate), the u-bolt plate should touch the switch actuator arm. When the clutch pedal returns to the stop, the switch should actuate (to closed position) with an audible click. Is clutch switch adjusted properly? TEST POINTS Clutch switch across pigtail terminals (294). SPEC. <2 ohms. YES-IN SPEC. Go to Step 3. NO-OUT OF SPEC. Check switch adjustment. Go to next step.

2.

Off

Replace and adjust clutch switch. Go to Step 1.

Adjust clutch switch. Go to Step 1.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

287

Table 81 STEP 3.

Testing Clutch Switch (cont.) KEY Off ACTION Depress clutch pedal and measure resistance between clutch switch pigtail connector (294) terminals. TEST POINTS Clutch switch across pigtail terminals (294). SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. If switch is not properly adjusted, adjust and retest. If switch was properly adjusted, replace the switch. Replace the clutch switch, then adjust.

4.

Off

Check clutch switch for short to gnd. With switch disconnected, measure resistance to gnd. at each switch terminal.

Clutch switch each pigtail to gnd.

>100K ohms.

Clutch switch checks good. Perform Testing Clutch Switch Circuits for "Open and Short" Condition.

Testing Clutch Switch Circuits for Open and Short Condition Perform Testing Clutch Switch before performing this test.

CAUTION When testing at ECM connector (252), do not use probes or leads other than Cummins test lead, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 82 Testing Clutch Switch Circuits for "Open and Short" Condition STEP 1. KEY Off ACTION With clutch switch disconnected, remove ECM connector (252) from the ECM. Refer to Inspecting Navistar Engine Harness ECM Connector (252) and inspect connector. ECM harness connector or ECM pins OK? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal.

s08210

288

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 82 Testing Clutch Switch Circuits for "Open and Short" Condition (cont.) STEP 2. KEY Off ACTION Turn all CELECT cab switches to off or neutral position and set service brake using trailer hand valve. Use test leads and measure resistance to gnd. at connector (252) terminal 4 and 10 (circuit 97AH and 97-G). With CELECT cab switches still in off or neutral position and service brake set, use test leads and measure resistance between terminals 4 and 10 (circuit 97AH and 97-G) and all other terminals in connector (252). At connector (252), use test leads and measure voltage to gnd. at terminals 4 and 10 (circuit 97AH and 97-G). TEST POINTS (252), 97AH and 97-G to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to gnd. in circuit where resistance at terminal was less than 100K ohms, then repair.

3.

Off

(252), 97AH and 97-G and all other circuits.

>100K ohms.

Go to next step.

Locate short between circuits, then repair.

4.

On

(252), 97AH and 97-G to gnd.

<1.5 volts.

The clutch switch circuits are free of short circuits. Perform Testing Clutch Switch Circuits for Continuity

Locate short to unwanted voltage source in circuit with more than 1.5 volts, then repair. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal.

Testing Clutch Switch Circuits For Continuity

CAUTION When testing at ECM connector (252), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

289

Table 83 STEP 1.

Testing Clutch Switch Circuits For Continuity KEY Off ACTION At ECM connector (252) use test lead to jumper terminal 4 (circuit 97AH) to ground. At clutch switch connector (294) measure resistance of 97AH to ground. At ECM connector (252) use test lead to jumper terminal 4 to 10 (circuit 97AH to 97-G). At clutch switch connector (294) measure resistance between circuits 97AH and 97-GF. The clutch switch circuits and switch check good. TEST POINTS (294), 97AH to gnd. SPEC. <5 ohms YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97AH between connectors (252) and (294), then repair. Locate open or poor connection in circuit 97-GH, 97-GA or 97-G between connectors (252) and (294), then repair.

2.

Off

(294), 97AH to 97-GF.

<5 ohms.

Go to next step.

3.

Off

Testing Service Brake Switch (141) Table 84 STEP 1. Testing Service Brake Switch (141) KEY Off ACTION Remove connector (141) from brake switch. With brakes released, measure resistance across switch terminals. Switch should be closed. Apply service brakes and measure resistance across the brake pressure switch. Switch should be open. NOTE: Sufcient air pressure must be present to apply service brakes for this test step. Measure resistance to gnd. at both brake switch terminals with service brakes applied, and with brakes released. Both should be isolated from ground at all times. TEST POINTS Brake pressure switch across terminals. Brake pressure switch across terminals. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the brake switch.

2.

Off

>100K ohms.

Go to next step.

Replace the brake switch.

3.

Off

Brake pressure switch both terminals to gnd.

>100K ohms.

Reconnect (141) to brake switch. Perform Testing Service Brake Switch Circuits for "Open

Replace the brake switch.

s08210

290

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 84 STEP

Testing Service Brake Switch (141) (cont.) KEY ACTION TEST POINTS SPEC. YES-IN SPEC. and Short" Condition NO-OUT OF SPEC.

Testing Service Brake Switch Circuits for "Open and Short" Condition Perform Testing Service Brake Switch (141) before performing this test.

CAUTION When testing at ECM connector (252), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 85 Testing Service Brake Switch Circuits for "Open and Short" Condition STEP 1. KEY Off ACTION With connector (141) disconnected from brake switch, remove connector (252) from the ECM. Refer to Inspecting International Engine Harness ECM Connector (252) to inspect connector. ECM connector and ECM pins OK? Turn all CELECT cab switches to off or neutral position and disconnect clutch switch. Use test leads and measure resistance to gnd. at connector (252) terminals 13 and 10 (circuits 97AL and 97-G). Use test leads and measure resistance between terminal 13 and 10 (circuits 97AL and 97-G) and all other terminals in connector (252). At connector (252), use test leads and measure voltage to ground at (252), 97AL and 97-G to gnd. >100K ohms. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness connector terminals if damaged. If ECM pins damaged, have Cummins dealer replace ECM.

2.

Off

Go to next step.

Locate short to ground. in circuit where resistance at terminal was less than 100K ohms, then repair.

3.

Off

(252), 97AL to 97-G and all other circuits.

>100K ohms.

Go to next step.

Locate short between any circuit where resistance between terminals is less than 100K ohms, then repair.

4.

On

(252), 97AL and

<1.5 volts.

The brake switch

Locate short to unwanted voltage source in circuit

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

291

Table 85 STEP

Testing Service Brake Switch Circuits for "Open and Short" Condition (cont.) KEY ACTION terminals 13 and 10 (circuits 97AL and 97-G). TEST POINTS 97-G to gnd. SPEC. YES-IN SPEC. NO-OUT OF SPEC.

with more than 1.5 volts, circuits then repair. are free of short circuits. Perform Testing Service Brake Switch Circuits for Continuity.

Testing Service Brake Switch Circuits for Continuity

CAUTION When testing at ECM connector (252), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 86 STEP 1.

Testing Service Brake Switch Circuits for Continuity KEY Off ACTION At ECM connector (252) use test lead to jumper terminal 13 (cir. 97L) to gnd. At brake switch connector (141) measure resistance to ground at circuit 97AL. At ECM connector (252) use test lead to jumper terminal 13 to terminal 10 (circuits 97AL to 97-G). At brake switch connector (141) measure resistance between circuits 97AL and 97-GF. The service brake switch circuits and switch check good. TEST POINTS (141), 97AL to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97AL between connectors (252) and (141), then repair.

2.

Off

(141), 97AL to 97-GF.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 97-GF, 97-GA, or 97-G between connectors (252) and (141), then repair.

3.

Off

s08210

292

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

3.12. ENGINE BRAKE


In the event the engine brake fails to operate, the following test chart provides a systematic series of steps to check the switches and circuits that are installed by International. Testing Engine Brake Components and Circuits Table 87 Testing Engine Brake Components and Circuits STEP 1. KEY Off ACTION Remove engine brake on/off switch from connector (434). Measure resistance to ground at connector (434), circuit 24-G. With on/off switch removed, refer to Testing Engine Brake Switches and use ohmmeter to check switch. Switch good? Remove connector (433) from selector switch. Measure resistance of circuit 24AD between connectors (434) and (433). Refer to Testing Engine Brake Switches and test the selector switch. Switch good? Re-install connector (434) to engine brake on/off switch and place in on position. Re-install conn. (433) to engine brake switch and place in position 3. Disconnect 21-way conn. (252) from engine harness. At connector (252) measure resistance from pin 5 and 28 to ground (circuit 24AE and 24AF to ground). (252), 24AE and 24AF to gnd. <1 ohm. 24AD between (434) and (433). <5 ohms. TEST POINTS (434), 24-G to gnd. SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 24-G, 97-GA or 97-G, then repair.

2.

Off

Go to next step.

Replace the switch.

3.

Off

Go to next step.

Locate open or poor connection in circuit 24AD between connectors (434) and (433), then repair. Replace the switch.

4.

Off

Go to next step.

5.

Off

Go to next step.

6.

On

Engine brake circuits and components check good.

Locate open or poor connection in circuit 24AE or 24AF between connectors (433) and (252), then repair.

Testing Engine Brake Switches 1. Testing Engine Brake On/Off Switch


s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

293

a. With switch in on position, resistance between terminals 5 and 6 and between 2 and 3 should be less than 5 ohms. b. With switch in off position, resistance should be 100K ohms or more. c. To test the LED in the switch, connect B+ test lead to terminal 7 and ground terminal 8. LEDs should illuminate.

2. Testing Engine Brake Selector Switch With N14E Engine. a. With switch in 3 position, resistance between terminals 2 and 3 and 6 should be less than 5 ohms. b. With switch in 1 position, resistance between terminals 2 and 3 should be less than 5 ohms. c. With switch in 2 position, resistance between terminals 2 and 6 should be less than 5 ohms.

d. To test the LED in the switch, connect B+ test lead to terminal 7 and ground terminal 8. LEDs should illuminate.

3.13. ATA DATA LINK CONNECTOR (137) AND SPEEDOMETER/TACHOMETER INPUT CIRCUITS
This following series of tests provide charts for testing: [1] The Data Link circuits between the ECM and ATA Data Link connector (137) and the speedometer/tachometer connector (421). [2] The power and ground circuits to the ATA Data Link connector (137). Testing Diagnostic Connector Power and Ground Circuits Table 88 Testing Diagnostic Connector Power and Ground Circuits STEP 1. KEY Off ACTION Remove and check 20A fuse F5-D for open condition. Re-install fuse. At connector (137) measure voltage to at terminal C (circuit 97DL) to gnd. At connector (137) measure voltage between terminals C and E (circuits 97DL and 11-GR). TEST POINTS F5-D. SPEC. <1 ohm YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace 5A fuse. Locate cause of no or low voltage in circuit 97DL from fuse F9-C, then repair. Locate open or poor connection in circuit 11-GR between connector (137) and G1 ground adapter (453), then repair.

2.

On

(137), 97DL to gnd. (137), 97DL to 11-GR.

12 1.5 volts.

Go to next step.

3.

On

12 1.5 volts.

Go to next step.

4.

On

The power and gnd. circuits to the ATA data link connector (137) check good.

s08210

294

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit

CAUTION When testing at ECM connector (252), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 89 Unit STEP 1.

Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer KEY Off ACTION Disconnect ECM connector (252) from the ECM. Refer to Inspecting International Engine Harness ECM Connector (252) and inspect connector. ECM harness connector OK? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short circuit to ground in circuit where resistance is less than 100K ohms, then repair.

2.

Off

Disconnect connector (421) from speedometer/ tachometer unit and if additional devices have been connected to (514) and (515) data link connectors, they must be disconnected. At connector (252), using test leads, measure resistance to gnd. at terminals 8 and 27 (circuit 98B[-] and 98[+]). At connector (252) use test leads and measure resistance between terminals 8 and 27 (circuit 98B[-] and 98[+]) and all other terminals in connector. At connector (252) use test leads and measure voltage to gnd. at terminals 8 and 27 (circuits 97B[-] and 98[+]).

(252), 98B(-) and 98(+) to gnd.

>100K ohms.

Go to next step.

3.

On

(252), 98B(-) and 98(+) and all other circuits in conn. (252), 98B(-) and 98(+) to gnd.

>100K ohms.

Go to next step.

Locate short between circuits where resistance between terminals is less than 100K ohms, then repair. Locate short to unwanted voltage source in circuit where more than 1.5 volts is present at terminal, then repair.

4.

On

<1.5 volts

Go to next step.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

295

Table 89 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit (cont.) STEP 5. KEY Off ACTION At connector (252) use test lead to jumper terminal 8 (cir. 98B[-]) to gnd. At connector (137) measure resistance to gnd. at terminal B (cir. 98C[-]). With connector (252) terminal 8 (cir. 98B[-]) still jumpered to gnd., at connector (421) measure resistance to gnd. at circuit 47/48(-). At connector (252) use test lead to jumper terminal 27 (cir. 98[+]) to gnd. At connector (137) measure resistance terminal A (cir. 98A[+]) to ground. With connector (252) terminal 27 (cir. 98[+]) still jumpered to gnd., at connector (421) measure resistance to gnd. at circuit 47/48(+). The data link circuits between ECM connector (252), diagnostic connector (137) and speedometer/ tachometer connector (421) test good. TEST POINTS (137) , 98C(-) to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 98B(-) or 98C(-) between connectors (252) and (137), then repair. Locate open or poor connection in circuit 47/48(-) between connectors (515) and (421), then repair. Locate open or poor connection in circuit 98(+)/(98A+) between connectors (252) and (137), then repair.

6.

Off

(421), 47/ 48(-) to gnd.

<5 ohms.

Go to next step.

7.

Off

(137), 98A(+) to gnd.

<5 ohms.

Go to next step.

8.

Off

(421), 47/ 48(+) to gnd.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 47/48(+) between connectors (514) and (421), then repair.

9.

Off

3.14. DIAGNOSTIC SWITCHES


The diagnostic On/Off and Idle/Diagnostic switches can be checked with CompulinkTM EZ-Tech or Pro Link 9000 in the switch monitoring mode. If the switches do not operate properly, perform the following test.

s08210

296

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Testing Diagnostic On/Off Switch and Circuit Table 90 STEP 1. Testing Diagnostic On/Off Switch and Circuit KEY Off ACTION Remove connector (241) from On/Off switch. With switch in on position, measure resistance between terminals 5 and 6. With switch in off position, measure resistance between terminals 5 and 6. To test the LED in the switch, connect B+ test lead to terminal 7 and connect terminal 8 to gnd. Does LED illuminate? Remove ECM connector (252) from the ECM. Refer to Inspecting International Engine harness ECM Connector (252) and inspect connector. ECM harness connector and ECM pins OK? TEST POINTS Across terminals 5 and 6. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

Across terminals 5 and 6.

>100K ohms.

Go to next step. Go to next step.

Replace the switch.

3.

Off

Replace the switch.

4.

Off

Go to next step.

Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to gnd. in circuit 97AM, then repair. Locate short to ground in circuit 97-G or 97-GA, then repair. Locate short between circuits where resistance between terminals is less than 100K ohms, then repair.

5.

Off

Disconnect connector (251) measure resistance from terminal V (cir. 97AM) to gnd. At connector (252) measure resistance from terminal 10 (cir. 97-G) to ground. With all CELECT switches in off or neutral position, service brakes set using trailer hand control valve, and clutch switch disconnected, measure resistance between terminal V (cir. 97AM) and all other terminals in (251).

(251), 97AM to gnd. (252), 97-G to gnd. (252), 97AM to all other circuits.

>100K ohms.

Go to next step. Go to next step. Go to next step.

6.

Off

>100K ohms.

7.

Off

>100K ohms.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

297

Table 90 STEP 8.

Testing Diagnostic On/Off Switch and Circuit (cont.) KEY Off ACTION At connector (251), use test lead and jumper terminal V (cir. 97AM) to gnd. At connector (241) measure resistance to gnd. at circuit 97AM. At connector (252), use test lead and jumper terminal 10 (cir. 97-G) to gnd. At connector (241) measure resistance to gnd. at circuit 97-GE. The diagnostic On/Off switch and circuits check good. TEST POINTS (251), 97AM to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97AM between connectors (241) and (251), then repair. Locate open or poor connection in circuit 97-GE, 97-GA or 97-G between connectors (241) and (252), then repair.

9.

Off

(241), 97-GE to gnd.

<5 ohms.

Go to next step.

10.

Off

Testing Idle/Diagnostic Switch (243) and Circuits Table 91 STEP 1. Testing Idle/Diagnostic Switch (243) and Circuits KEY Off ACTION Remove connector (243) from idle/ diagnostic switch and test the switch. With switch in INC position measure resistance between terminals 2 and 3. With switch in neutral position measure resistance between terminals 1, 2 and 3. With switch in DEC position measure resistance between terminals 1 and 2. To test the LED in the switch, connect B+ test lead to terminal 7 and connect terminal 8 to gnd. Does LED illuminate? TEST POINTS Across switch term. 2 and 3. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

Across switch term. 1, 2 and 3. Across sw. term 1 and 2.

> 100K ohms.

Go to next step. Go to next step. Go to next step.

Replace the switch.

3.

Off

<5 ohms.

Replace the switch.

4.

Off

Replace the switch.

s08210

298

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 91 STEP 5.

Testing Idle/Diagnostic Switch (243) and Circuits (cont.) KEY Off ACTION Disconnect ECM connector (252) from the ECM and inspect. Refer to Inspecting International Engine Harness ECM Connector (252). ECM harness connector or ECM pins OK? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to gnd. in circuit where terminal resistance is less than 100K ohms, then repair. Locate short circuit between any circuit where resistance between terminals is less than 100K ohms, then repair. Locate short to unwanted voltage source, then repair. Locate open or poor connection in circuit 97AV between connectors (243) and (252), then repair. Locate open or poor connection in circuit 97AU between connectors (243) and (252), then repair.

6.

Off

At connector (252) use test leads and measure resistance to gnd. at terminals 10, 14, and 23 (circuits 97-G, 97AV and 97AU). At connector (252) measure resistance between terminals 14 and 23 (cir. 97AV and 97AU) and all other terminals in connector. At connector (252) measure voltage to gnd. at terminals 14 and 23 (circuits 97AV and 97AU). At connector (252) use test lead to jumper terminal 14 (circuit 97AV) to gnd. At connector (243) measure resistance to gnd. at circuit 97AV. At connector (252) use test lead to jumper terminal 23 (cir. 97AU) to gnd. At connector (243) measure resistance to gnd. at circuit 97AU.

(252), 97-G, 97AV and 97AU to gnd.

>100K ohms.

Go to next step.

7.

Off

(252), 97AV and 97AU to all other circuits.

>100K ohms.

Go to next step.

8.

On

(252), 97AV and 97AU to gnd. (243), 97AV to gnd.

<1.5 volts.

Go to next step. Go to next step.

9.

Off

<5 ohms.

10.

Off

(243), 97AU to gnd.

<5 ohms.

Go to next step.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

299

Table 91 STEP 11.

Testing Idle/Diagnostic Switch (243) and Circuits (cont.) KEY Off ACTION At connector (252) use test lead to jumper terminal 10 (cir. 97-G) to gnd. At connector (243) measure resistance to gnd. at circuit 97-GD. The idle/diagnostic switch and circuits check good. TEST POINTS (243), 97-GD to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97-GD, 97-GA, or 97-G between connectors (243) and (252), then repair.

12.

Off

3.15. CRUISE CONTROL


When monitoring switches with a Electronic Service Tool, the cruise On/Off switch will indicate On or Off. The Set/Resume switch will indicate either Set or Res, depending on the switch position. If the switch is not operable, the screen will be blank. Testing Cruise Control On/Off Switch and Circuits

CAUTION When testing at ECM connector (252), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 92 STEP 1.

Testing Cruise Control On/Off Switch and Circuits KEY Off ACTION Remove connector (435) from cruise On/Off switch. With switch in on position, measure resistance between terminals 5 and 6. With switch in off position, measure resistance between terminals 5 and 6. To test the LED in the switch, connect B+ test lead to terminal 7 and connect terminal 8 to gnd. Does LED illuminate? TEST POINTS Across terminals 5 and 6. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

Across terminals 5 and 6.

> 100K ohms.

Go to next step. Go to next step.

Replace the switch.

3.

Off

Replace the switch.

s08210

300

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 92 STEP 4.

Testing Cruise Control On/Off Switch and Circuits (cont.) KEY Off ACTION Remove ECM connector (252) from the ECM and inspect (refer to Inspecting International Engine Harness ECM Connector (252), ECM harness connector and ECM pins OK? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to gnd. in circuit with less than 100K ohms, then repair. Locate short between circuit 97AE and any circuit where resistance between terminals is less than 100K ohms, then repair. Locate short between circuit 97AE and unwanted voltage source, then repair. Locate open or poor connection in circuit 97AE between connectors (252) and (435), then repair. Locate open or poor connection in circuit 97-GC, 97-GA or 97-G, then repair.

5.

Off

At ECM connector (252) use test leads and measure resistance to gnd. at terminals 2 and 10 (circuits [97AE and 97-G]). At connector (252) measure resistance between terminal 2 and all other terminals in connector.

(252), 97AE and 97-G to gnd. (252), 2 to all other terminals.

>100K ohms.

Go to next step.

6.

Off

>100K ohms.

Go to next step.

7.

On

At connector (252) measure voltage from terminal 2 (circuit 97AE) to ground. At connector (252) use test lead to jumper terminal 2 (circuit 97AE) to gnd. At connector (435) measure resistance to gnd. at circuit 97AE. At connector (252) use test lead to jumper terminal 10 (circuit 97-G) to gnd. At connector (435) measure resistance to gnd. at circuit 97-GC. The cruise on/off switch and circuits check good.

(252), 97AE to gnd. (435), 97AE to gnd.

<1.5 volts.

Go to next step. Go to next step.

8.

Off

<5 ohms.

9.

Off

(435), 97-GC to gnd.

<5 ohms.

Go to next step.

10.

Off

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

301

Testing Cruise Set/Resume Switch and Circuits

CAUTION When testing at ECM connector (252), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 93 STEP 1.

Testing Cruise Set/Resume Switch and Circuits KEY Off ACTION Remove connector (436) from cruise set/resume switch. With switch in set position, measure resistance between terminals 2 and 3. With switch in neutral position, measure resistance between terminals 1, 2 and 3. With switch in resume position, measure resistance between terminals 1 and 2. To test the LED in the switch, connect B+ test lead to terminal 7 and connect terminal 8 to gnd. Does LED illuminate? Remove ECM connector (252) from the ECM and inspect. Refer to Inspecting International Engine Harness ECM Connector (252). ECM harness connector and ECM pins OK? TEST POINTS Between switch term. 2 and 3. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

Between sw. term. 1, 2 and 3.

>100K ohms.

Go to next step. Go to next step. Go to next step.

Replace the switch.

3.

Off

Between sw. <5 term 1 and 2. ohms.

Replace the switch.

4.

Off

Replace the switch.

5.

Off

Go to next step.

Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to gnd. in circuit with less than 100K ohms, then repair.

6.

Off

At ECM connector (252) use test leads and measure resistance to gnd. at terminals 12, 22 and 10 (cir. 97AB, 97AA and 97-G).

(252), 97AB, 97AA and 97-G to gnd.

>100K ohms.

Go to next step.

s08210

302

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 93 STEP 7.

Testing Cruise Set/Resume Switch and Circuits (cont.) KEY Off ACTION At connector (252) measure resistance between terminal 12 and 22 (circuits 97AB and 97AA), and all other terminals in the connector. At connector (252) measure voltage to gnd. at terminals 12 and 22 (circuits 97AB and 97AA). At connector (252) use test lead to jumper terminal 12 (cir. 97AB) to gnd. At connector (436) measure resistance to gnd. at circuit 97AB. At connector (252) use test lead to jumper terminal 10 (cir. 97-G) to gnd. At connector (436) measure resistance to gnd. at circuit 97-GB. At connector (252) use test lead to jumper terminal 22 (cir. 97AA) to gnd. At connector (436) measure resistance to gnd. at circuit 97AA. The cruise set/resume switch and circuits check good. TEST POINTS (252), between 97AB and 97AA, and all others. (252), 97AB and 97AA to gnd. (436), 97AB to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short between any circuits where resistance between terminals is less than 100K ohms, then repair. Locate short to unwanted voltage source in circuit 97AA or 97AB, then repair. Locate open or poor connection in circuit 97AB between connectors (252) and (436), then repair. Locate open or poor connection in circuits 97-GB, 97-GA or 97-G, then repair.

8.

On

<1.5 volts.

Go to next step. Go to next step.

9.

Off

<5 ohms.

10.

Off

(436), 97-GB to gnd.

<5 ohms.

Go to next step.

11.

Off

(436) , 97AA to gnd.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 97AA between connectors (252) and (436), then repair.

12.

Off

3.16. VEHICLE SPEED SENSOR


When monitoring engine functions with an EST, if the vehicle is moving the miles-per-hour will display as MPH=XXX (actual vehicle speed if operating properly). To test the sensor and circuits to the ECM, use the following test charts. Inspecting and Adjusting the Vehicle Speed Sensor (VSS) 1. Disconnect engine harness connector (250) from the sensor. Loosen the locknut and remove the sensor. The harness connector and sensor should be free of damage or corrosion. Remove any metal shavings or debris from the sensor. 2. To install the adjustable sensor, turn in until the sensor contacts the transmission speedometer gear, then back out one full turn. Tighten locknut to 15 ft-lbs. (20.3 Nm). This assures that the sensor is adjusted properly for the next test.
s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

303

Testing Vehicle Speed Sensor Construct test leads using terminals (International Part No. 1680205C1), short length of 16 gauge wire and alligator clips.

WARNING A jack must never be used alone to support vehicle. The jack may lower and serious injury could result. Always support vehicle with oor jacks. Always block wheels to prevent vehicle from moving.

WARNING EXTREME CAUTION should be used to prevent personal injury resulting from contact with rotating vehicle wheels when connecting test leads.

Table 94 STEP 1.

Testing Vehicle Speed Sensor KEY Off ACTION Inspect VSS for damage and proper adjustment before performing this test. Refer to Inspecting and Adjusting the Vehicle Speed Sensor (VSS) above. Disconnect engine harness (250) from VSS and use test leads to measure resistance between terminal 1 and 2 of sensor connector. VSS, term. 1 to 2. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

2.

Off

600 Go to next to 800 step. ohms for adjustable sensor. 1500 to 3500 for non-adjustable sensor.

Replace the vehicle speed sensor (VSS).

3.

Off

Measure resistance to gnd. at both sensor terminals. Block front wheels and place rear axles on oor stands.

VSS, term. 1 and 2 to gnd.

>100K ohms.

Go to next step.

Replace the vehicle speed sensor (VSS).

4.

Off

Go to next step.

s08210

304

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Table 94 STEP 5.

Testing Vehicle Speed Sensor (cont.) KEY Off ACTION Use AC voltmeter with sufcient length leads to avoid personal contact with rotating vehicle wheels during test. Connect meter leads to test leads. Run engine at idle speed, with transmission in high gear. Measure voltage across the two sensor terminals. VSS, across terminals. >2.0 volts AC. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

6.

Off

VSS checks good.

Replace the VSS (refer to Inspecting And Adjusting the Vehicle Speed Sensor above). NOTE: Improper sensor adjustment will cause low, erratic or no output.

Testing Vehicle Speed Sensor Circuits To ECM To check circuits between the ECM and the speedometer/tachometer unit, refer to ATA Data Link Connector (137) and Speedometer/Tachometer Input Circuits.

CAUTION When testing at ECM connector (252), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 95 Testing Vehicle Speed Sensor Circuits To ECM STEP 1. KEY Off ACTION Remove connector (250) from vehicle speed sensor. Remove ECM connector (252) from the ECM and inspect (refer to Inspecting International Engine Harness ECM Connector (252). ECM harness connector and ECM pins OK? At connector (252), use test leads and measure resistance to gnd. at terminals 3 and 7 (cir. 97AJ and 97AK). (252), 97AJ and 97AK to gnd. >100K ohms. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to gnd. in circuit with less than 100K ohms, then repair.

2.

Off

Go to next step.

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

305

Table 95 STEP 3.

Testing Vehicle Speed Sensor Circuits To ECM (cont.) KEY Off ACTION At connector (252), measure resistance between terminals 3 and 7 (cir. 97AJ and 97AK), and all other terminals in connector. At connector (252), measure voltage at terminals 3 and 7 (circuits 97AJ and 97AK) to gnd. TEST POINTS (252), 97AJ and 97AK and all others. SPEC. >100K ohms YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short circuit between circuits where resistance between terminals is less than 100K ohms, then repair. Locate short to unwanted voltage source in circuit where voltage at terminal is more than 1.5 volts, then repair. Locate open or poor connection in circuit 97AJ between connectors (252) and (250), then repair. Locate open or poor connection in circuit 97AK between connectors (252) and (250), then repair.

4.

On

(252), 97AJ and 97AK to gnd.

<1.5 volts.

Go to next step.

5.

Off

At connector (252) use test leads and jumper terminal 3 (circuit 97AJ) to gnd. At connector (250) measure resistance to gnd. at circuit 97AJ. At connector (252) use test leads and jumper terminal 7 (circuit 97AK) to gnd. At connector (250) measure resistance to gnd. at circuit 97AK. The vehicle speed sensor circuits between the sensor and ECM check good.

(250), 97AJ to gnd.

<5 ohms.

Go to next step.

6.

Off

(250), 97AK to gnd.

<5 ohms.

Go to next step.

7.

Off

4. COMPONENT LOCATIONS
B1 Battery Stud.. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . . . . . Power Distribution Panel (1) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Left Side of Engine Cowl (2) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Right Side of Engine Cowl, Above Connector 3 (3) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Right Side of Engine Cowl, Below Connector 2 (72) Ether Start Connector. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Front End Harness, At Lower Left of Radiator (94) Back-up Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Transmission (137) 6-Way Data Link Connector. . . . . . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (141) Service Brake Switch/Cruise Switch. . . . . . . . .. . . . . . Dash Panel, Left Side, Engine Side (216) ECM Power Connector. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Start Motor (227) Fan Solenoid.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . . . . . At Front of Engine (228) Refrigerant Pressure Switch. . . . . . . . . . . . . . . . . .. . . . . . On A/C Compressor (229) Engine Oil Temp Sender. .. . .. .. . .. . .. .. . .. . .. .. . . . . . Left Side of Engine (230) Cab Overlay to Elect. Eng. Harn.. . . . . . . . . . . .. . . . . . Right Instrument Panel (235) Transmission Oil Temp (Inline). . .. . . . .. . . .. . . .. . . . . . On Front of Transmission (249) Low Coolant Level Switch. . . . . . . . . . . . . . . . . . . . .. . . . . . To Engine Harness

s08210

306

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

(250) Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Transmission (251) CELECT 9-Way ECM Connector. . . . . . . . . . . . .. . . . . . At Engine Harness near ECM (252) Electronic Control Module ECM. . . . . . . . . . . . . .. . . . . . At ECM (267) Accelerator Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . To Cab Overlay (294) Clutch Switch Connector. . . . . . . . . . . . . . . . . . . . . .. . . . . . Near Clutch Switch (403) J1922 Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Dash Panel Right Side (420) Right Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Gauge Cluster (421) Speedo./Tach. Module. . . .. . . .. . .. . . .. . . .. . . .. .. . . . . . Behind Speedo./Tach. Gauge (422) Speedo./Tach. Module. . . .. . . .. . .. . . .. . . .. . . .. .. . . . . . Behind Speedo./Tach. Gauge (423) Left Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Left Gauge Cluster (424) Left Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Left Gauge Cluster (514) Data Link - Positive. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel/Behind Cluster (515) Data Link - Negative. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel/Behind Cluster

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

307

Figure 101

Engine Wiring, Cab

s08210

308

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

1. DASH PANEL (VIEWED FROM INSIDE ENGINE COMPARTMENT) 2. (141) BRAKE SWITCH 3. (640) STOP LIGHT SWITCH 4. (190) ELECTRONIC ENGINE CONNECTOR 5. RIGHT HAND DASH PANEL GROUND STUD 6. (3) ENGINE CONNECTOR 7. (2) CHASSIS HARNESS CONNECTOR 8. POWER DISTRIBUTION PANEL 9. SWITCHES 10. RIGHT GAUGE CLUSTER 11. SPEEDOMETER / TACHOMETER CLUSTER 12. LEFT GAUGE CLUSTER 13. (514) DATA LINK CONNECTOR 14. (515) DATA LINK CONNECTOR 15. (137) DATA LINK 16. CLUTCH SWITCH 17. FRONT END HARNESS CONNECTOR 18. THROTTLE PEDAL 19. (294) CLUTCH SWITCH CONNECTOR 20. (267) THROTTLE PEDAL CONNECTOR

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

309

Figure 102

Engine Wiring, Dash Panel

s08210

310

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

1. (190) ELECTRONIC ENGINE CONNECTOR 2. RH DASH PANEL GROUND STUD 3. (2) CAB/ENGINE HARNESS CONNECTOR 4. MEGAFUSE 5. START MAGNETIC SWITCH 6. CIRCUIT 14A TO (B1) BATTERY STUD 7. CIRCUIT 17C 8. CIRCUIT 17B 9. CIRCUIT 14 10. (249) LOW COOLANT SENDER 11. TO ENGINE HARNESS

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

311

Figure 103

Engine Wiring 1. STARTER MOTOR 2. CIRCUIT 11-GA 3. ECM 4. CIRCUIT 11-GS 5. ENGINE GROUND STUD 6. (411) J1922 DATA LINK 7. CIRCUIT 77C TO A/C COMPRESSOR CLUTCH 8. (228) A/C PRESSURE SWITCH CIRCUITS 23A AND 23-GB 9. TO TRANSMISSION 10. CIRCUIT 21A THERMOSTATIC SWITCH CONNECTOR

s08210

312

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Figure 104 Engine Wiring 1. 2. 3. 4. ALTERNATOR TO ENGINE WIRING AT DASH (9400 & 9900) TO ENGINE WIRING AT DASH (9100 & 9200) TO TRANSMISSION

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

313

Figure 105

Engine Wiring, Transmission Effects 1. 2. 3. 4. (250) VEHICLE SPEED SENSOR TO ENGINE WIRING (235) TRANSMISSION OIL TEMPERATURE CONNECTOR (94) BACK-UP LIGHT SWITCH

s08210

314

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

Figure 106

Engine Wiring, Starter Motor 1. 2. 3. 4. 5. 6. 7. 8. CIRCUIT 11-GL CIRCUIT 11-GS ENGINE GROUND CIRCUIT 97-G ENGINE HARNESS CIRCUIT 97 & 97A FUSIBLE LINK CIRCUIT 14 CIRCUIT 17C

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

315

Figure 107

Engine Wiring, Electronic Control Module

s08210

316

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

1. 2. 3. 4. 5. 6. 7. 8. 9.

CUMMINS ENGINE HARNESS (251) INTERNATIONAL ENGINE HARNESS ECM CONNNECTOR (251) INTERNATIONAL 21-WAY CONNECTOR CIRCUIT 11-GS ELECTRONIC CONTROL CONNECTOR (252) ECM CONNECTOR INLINE FUSES CIRCUIT 97 CIRCUIT 97A

s08210

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

317

Figure 108

Engine Wiring, Alternator Effects (N14) 1. 2. 3. 4. 5. 6. 7. 8. 9. CIRCUIT 11-GL ENGINE HARNESS CIRCUIT 2 CIRCUIT 11-GS ENGINE HARNESS CIRCUIT 2 ENGINE HARNESS CIRCUIT 11-GA CIRCUIT 2

s08210

318

8 CUMMINS N14 ELECTRONIC ENGINE SYSTEM

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

319

Table of Contents

1. DESCRIPTION. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .321 2. OPERATION.. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .322 2.1. ECM POWER. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .322 2.2. ATA DATA LINK CONNECTOR. . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .322 2.3. DIAGNOSTIC ON/OFF SWITCH. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .323 2.4. IDLE/DIAGNOSTIC SWITCH. .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .323 2.5. ELECTRONIC ACCELERATOR PEDAL ASSEMBLY. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .323 2.6. COOLANT LEVEL SWITCH.. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .324 2.7. CRUISE CONTROL. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .324 2.8. BRAKE SWITCH . . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .325 2.9. CLUTCH SWITCH.. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .325 2.10. VEHICLE SPEED SENSOR. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .326 2.11. ENGINE BRAKE SWITCHES. . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .326 2.12. GAUGES AND WARNING LIGHTS. . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .326 2.13. J1939 DATA LINK. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .326 3. TROUBLESHOOTING. .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .326 3.1. ONBOARD DIAGNOSTICS WITH ENGINE RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .327 3.2. PERFORMING A DIAGNOSTIC CHECK WITH THE ENGINE OFF. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .328 3.3. CUMMINS ELECTRONIC SERVICE TOOL.. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .329 3.4. EZ-TECH OR PRO-LINK ELECTRONIC SERVICE TOOL (EST). .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .329 3.5. RELAYS.. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .329 3.6. TESTING RELAY. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .329 3.7. ACCELERATOR PEDAL TPS/IVS.. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .330 Testing Throttle Position Sensor (TPS). . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .330 Testing Idle Validation Switch (IVS).. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .331 Testing Accelerator Pedal (TPS/IVS) System for Short or Open Circuits. . . . . . . . . . . . . .332 Testing TPS/IVS Circuits for Continuity. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .333 Accelerator/ECM Calibration.. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .335 3.8. LOW COOLANT SWITCH. .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .335 Testing Low Coolant Level Switch And Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .335 3.9. POWER SUPPLY CIRCUITS TO ECM.. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .336 Testing Unswitched Battery Power Circuits And ECM Ground Circuit. . . . . . . . . . . . . . . . . . .336 Testing Switched Ignition Power To ECM . .. . .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .337 3.10. SERVICE BRAKE AND CLUTCH SWITCHES. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .338 Testing Clutch Switch.. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .338 Testing Clutch Switch Circuits for "Open and Short" Condition. . . .. . . . . . . .. . . . . . . .. . . . . . .338 Testing Clutch Switch Circuits For Continuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340 Testing Service Brake Switch (141). . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. .340 Testing Service Brake Switch Circuits for "Open and Short" Condition.. .. . .. .. . .. .. . .. .341 Testing Service Brake Switch Circuits for Continuity. .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .342 3.11. ENGINE BRAKE.. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .343 Testing Engine Brake Components And Circuits. .. . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . .343 Testing Engine Brake Switches. . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .344 3.12. ATA DATA LINK CONNECTOR (137) AND SPEEDOMETER/TACHOMETER INPUT CIRCUITS. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .344

s08210

320

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Testing Diagnostic Connector Power and Ground Circuits. . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . .345 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit. . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . .. . . . . . .345 3.13. DIAGNOSTIC ON/OFF SWITCH. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . .347 Testing Diagnostic On/Off Switch And Circuit.. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. ..347 3.14. CRUISE CONTROL. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .349 Testing Cruise Control On/Off Switch and Circuits. .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ..349 Testing Cruise Set/Resume Switch and Circuits. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .350 3.15. VEHICLE SPEED SENSOR.. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..352 Inspecting And Adjusting the Vehicle Speed Sensor (VSS). .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..352 Testing Vehicle Speed Sensor. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . ..352 Testing Vehicle Speed Sensor Circuits To ECM. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. .354 4. COMPONENT LOCATIONS. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..355

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

321

1. DESCRIPTION
This chapter covers International installed components and circuits that directly interact with the Cummins ISM and AHD (AHD is synonymous with Signature Series) engines. This chapter provides: Operation descriptions of International installed components and circuits which work with the Cummins engine controls. Troubleshooting charts for those circuits and components installed by International. Locations for International installed circuits.

Refer to the Cummins Engine Manual furnished with the vehicle for other information. The Cummins ISM and AHD engines use the CM570 engine controller. The controller provides many engine/vehicle functions including: Cruise/PTO Controls Tachometer/Speedometer Input To Gauges Idle Shutdown Adjustable Low Idle Speed (In-Cab) Engine Cooling Fan Control Self Diagnostics Engine Protection System Engine Brake Control J1939 Datalink (Used for Diagnostics and to Interface With Transmission and ABS).

Refer to the Cummins Engine Manual furnished with the vehicle for additional feature information. Since each engine control system is electronically programmable to individual owner specications, the operating parameters will vary from vehicle to vehicle. These parameters include: maximum cruise speed, shift schedules, governor type (automotive type or variable speed), idle RPM, full engine shutdown as part of the engine protection system and many others. The electronic control module (ECM) is the control center of the system. The ECM receives input from Cummins and International sensors and switches, processes the information, then uses electrical signals to control engine and vehicle functions. The ECM receives inputs from International installed components including: Vehicle Speed Sensor (VSS) Throttle Position Sensor (TPS) Idle Validation Switch (IVS) Service Brake Switch Clutch Switch Low Coolant Level Switch ABS/Traction Control Controller
s08210

322

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Engine Fan Operation

The ECM receives information from the sensors and switches and sends signals to the injectors, fuel shut off valve and engine brake relay.

2. OPERATION
Refer to the Cummins AHD and ISM ENGINE CONTROLS circuit diagrams in CTS-5298 or S08225. The ECM is connected to the International electrical system at two points A. International engine harness 50way ECM connector (1091) connects to ECM port C-1. This connector links several International sensors, switched power, unswitched power ground, switches, diagnostic connector to the ECM and the J1939 data link. The J1939 data link will interface with the transmission and ABS as required. B. International 31way connector (1093) connects to the Cummins sensor harness. This connector links the vehicle speed sensor, low coolant switch, air conditioner power switch and engine fan controls to the ECM.

2.1. ECM POWER


Power is supplied at all times to the ECM directly from the battery. Circuits 14A and 14B run from the positive battery post to 15 amp fuses. Circuits 14C and 14D run from the fuses to connector (675), then to ECM power connector (1094). Circuits 14C and 14D are split into circuits 14CJ, 14CK, 14CH, 14CG, and 14CF to 50way ECM connector (1091). The ECM is grounded from the battery on circuit 11G which is split into circuits 11GCF, 11GCB, 11GCK, 11GCJ, and 11GCH for input to 50way ECM connector (1091). Turning the key switch to the ignition or start position applies power to circuit 13Z, 5A fuse F6D and circuit 13D to the 50way ECM connector (1091).

2.2. ATA DATA LINK CONNECTOR


The six pin ATA data link connector (137) allows an electronic service tool (EST) to communicate with the ECM. The data link carries serial data transmissions between the ECM and the electronic service tool and between the ECM and the speedo/tachometer cluster. Thus, the ECM provides vehicle and engine information to the speedo/tachometer and the EST. The ATA data link connector (137), which is located on the left instrument panel, has circuits in four of the six cavities. The data link circuits are a twisted wire pair because twisting the wires helps shield them from interference. The circuits are as follows: Circuit 98A(+) is the positive data link connection and it is fed by the positive data link connector (514), the jumper bus bar, circuit 98(+), connector (190), and circuit 98(+) coming from the ECM connector (1091). Circuit 98C(-) is the negative data link connection and it is fed by the negative data link connector (515), the jumper bus bar, circuit 98B(-), connector (190) and circuit 98B(-) coming from the ECM connector (1091). Circuit 97DL is a 12 volt feed and is fed from the battery adapter (498), circuit 14BK and 20A fuse F5D. Thus it provides power for the electronic service tool.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

323

Circuit 11GR, 11GT is connected to the panel lights ground adapter (506) and provides a ground for the electronic service tool.

2.3. DIAGNOSTIC ON/OFF SWITCH


A lighted diagnostic on/off switch is provided for on-board diagnostics. The switch is connected to the ECM common/ground connection by way of ECM connector (1091), circuits 97GA, connector (190), and circuits 97GA and 97GE. Moving the switch to the on position, closing the switch, applies the ground to circuit 97AM, connector (190) and circuit 97AM to the Cummins engine connector (1091). This tells the ECM that the diagnostic on/off switch has been turned on. Thus, the ECM will switch modes to display fault codes or the absence of codes by ashing the engine warning light and the stop engine light.

2.4. IDLE/DIAGNOSTIC SWITCH


The lighted two-position momentary idle/diagnostic switch is a dual function switch. The switch adjusts the low engine idle speed and is also used during on-board diagnostics (when the diagnostic switch is in the on position) to move through the diagnostic fault code list. The engine idle speed can be adjusted by the switch in increments of 25 RPM by toggling the switch. Maximum idle speed is 800 RPM and minimum idle speed is 550 RPM. When the idle has been changed and the key turned off, the new setting is saved in memory. This feature is owner selected and can be turned off with an electronic service tool. The switch is connected to the ECM common/ground connection by way of ECM connector (252), circuit 97G and 97GA, connector (190) and circuits 97GA and 97GD. Momentarily placing the switch in the increment position applies ground to circuit 97AV, connector (190) and circuit 97AV to the ECM (252). This causes the engine idle RPM to increase 25 RPM. Momentarily placing the switch in the decrement position applies ground to circuit 97AU, connector (190) and circuit 97AU to the ECM (252). This causes the engine idle RPM to decrease 25 RPM.

2.5. ELECTRONIC ACCELERATOR PEDAL ASSEMBLY


The CM570 ECM utilizes an electronic accelerator pedal assembly that includes an integrated throttle position sensor (TPS) and idle validation switch (IVS). The accelerator pedal assembly is serviceable, to the extent that the IVS switch is replaceable without replacing the whole assembly. The TPS is attached to the accelerator pedal and acts like a potentiometer. Movement of the pedal results in a variable signal being sent to the ECM that is proportional to pedal position. A 5 volt signal from the ECM connector (1091) is applied to circuit 99A, connector (190), circuit 99A and the TPS/IVS (267). The variable wiper signal (varies with pedal position) from TPS/IVS (267) is returned to the ECM over circuit 99, connector (190), circuit 99 and ECM connector (1091). This variable signal tells the ECM the position of the accelerator pedal. The TPS (267) is grounded through circuit 99G, connector (190) and circuit 99G to the ECM (1091). NOTE Any time the accelerator pedal sensor (TPS) is disconnected from the ECM with the key switch on, the TPS and ECM must be recalibrated. The IVS is used to indicate when accelerator pedal is in the low idle position and when the pedal is not in the low idle position. A ground path from the ECM connector (1091), circuit 97GA, connector (190), circuit 99GA is applied to the TPS/IVS (267).

s08210

324

9 CUMMINS ISM AND AHD ENGINE SYSTEM

When the accelerator is in the low idle position, the IVS (267) applies a ground signal to circuit 99B, connector (190) and circuit 99B to the ECM (1091). When the accelerator is not in the idle position, the IVS (267) applies a ground signal to circuit 99C, connector (190) and circuit 99C to the ECM (1091). The ECM analyzes the signals received from the TPS and IVS to make certain that the signals fall within certain parameters. For example: if the IVS signal indicates that the accelerator pedal is in the idle position, the ECM expects to see a TPS signal that indicates that no throttle is applied. If it does not see a logical response from both, a fault code may be logged. The ECM and accelerator pedal must be calibrated to one another for proper engine response. Therefore, the ECM and accelerator pedal must be calibrated when the accelerator pedal is initially installed, when an accelerator pedal is replaced, when a new calibration is downloaded to the ECM, or when the accelerator pedal wiring is disconnected at the pedal, the cab oor, or the ECM connector. To recalibrate the ECM and the accelerator pedal, move the key switch to ignition position, slowly move the accelerator pedal from idle position to fully depressed position and then release. Repeat this cycle two more times to assure proper calibration.

2.6. COOLANT LEVEL SWITCH


The coolant level switch is a uid level actuated switch that sends two signals to the ECM, thus providing a warning when coolant is being lost. It is mounted in the coolant surge tank. The coolant level switch is an electronic switch that operates on the electrostatic or capacitance principle and cannot be tested with a multimeter. The probe extends into the coolant and produces a change in capacitance when coolant displaces air immediately surrounding the probe. This change is converted in the switch to an on/off solid state switch closure indicating the absence or presence of coolant. The switch is electrically insulated providing a slick, non-fouling surface as well as good electrical characteristics to prevent current ow into the coolant. The low coolant level switch connects to the engine harness at connector (249). Four circuits from connector (249) connect the low coolant switch to the ECM through the 31way ECM connector (1093). The coolant level switch (249) receives a 5 volt signal on circuit 34B(5V) from the ECM (1093). When the coolant level is above the probe, the switch sends a high signal (3.5 volts minimum) on circuit 34A and a low signal (0.5 volt maximum) on circuit 34 to the ECM (1093). When the coolant level is below the probe, the switch sends a low signal (0.5 volt maximum) on circuit 34A and a high signal (3.5 volts minimum) on circuit 34 to ECM (251). The low coolant level switch is grounded through circuit 34G to ECM (1093). NOTE The low coolant level switch cannot be tested with a multimeter in the ohmmeter mode. This is because the switch is an electronic switch and not a mechanical switch.

2.7. CRUISE CONTROL


The cruise control system has three modes of operation: off, standby and active. The off position of the on/off switch turns cruise control off. The standby mode occurs when the driver switches the cruise control on/off switch to the on position. The driver can then achieve the active mode by toggling the set/resume switch after reaching the desired road speed. Once the system is active, the driver can accelerate beyond the set speed by depressing the accelerator pedal. When the pedal is released, cruise control is reactivated when the vehicle speed reaches the previously set speed. Cruise is deactivated, and returns to the standby mode in several ways: the brake or clutch pedal is depressed, or the vehicle speed (mph) drops below 30 mph.
s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

325

The resume switch can be used to reactivate cruise at the previous set speed, or the set switch can be used to establish a new set speed. While in the active mode, the coast feature is used to decrease vehicle speed and establish a new lower set speed. By holding select switch in the coast position vehicle speed decreases until the switch is released; the speed at release becomes the new set speed. While in the active mode, the accelerate feature is used to increase the vehicle speed and establish a new higher speed. By holding the select switch in the accel. position, vehicle speed increases until the switch is released; the speed at release becomes the new set speed. The cruise control switches are used as PTO or idle adjustment controls when the vehicle road speed is not present (this is a customer selected parameter). The cruise set/resume switch is also used during on-board diagnostics (when the diagnostic switch is in the on position) to move through the diagnostic fault code list. Refer to the operators manual furnished with the vehicle for specic cruise control operating instructions. When the vehicle is not moving and the cruise on/off switch is off, the engine idle speed can be adjusted by the set/resume switch in increments of 25 RPM by toggling the switch. Maximum idle speed is 800 RPM and minimum idle speed is 550 RPM. When the vehicle is not moving and the cruise on/off switch is on, the PTO speed can be adjusted with the set/resume switch. The lighted cruise control on/off switch (435) receives a ground signal on circuits 97GC, 97GA, connector (190), on circuit 97GA from (1091). In the on position, a ground signal is sent from the switch on circuit 97AE, connector (190) and circuit 97AE to ECM connector (1091) terminal 23. This indicates to the ECM that the cruise control switch is in the on position. In the off position, circuit 97AE returns to its 12 volt value, indicating to the ECM that the switch is off. The lighted cruise set/resume switch is a momentary switch. This switch receives a ground signal on circuits 97GB, connector (190) on circuit 97GA, from (1091). The cruise selector switch sends a ground signal from the switch on circuit 97AB, connector (190) and circuit 97AB to the ECM connector (1091) terminal 14 while in the set/accel. position. In the resume/coast position, the switch sends a ground signal by way of circuit 97AA, connector (190) and circuit 97AA to the ECM connector (1091) terminal 24.

2.8. BRAKE SWITCH


The brake switch (141) receives a ground signal on circuit 97GB, through connector (190) on circuit 97GA from (1091). While the brake pedal is released, the switch is closed supplying a ground on circuit 97AL through connector (190) to ECM connector (1091). When the brake is applied the ground will be removed signaling the ECM that the brake has been applied.

2.9. CLUTCH SWITCH


The clutch switch (294) is a N.O. momentary switch, and its contacts are held closed when the clutch pedal is released. The switch is provided a ground path over circuits 97GH, 97GH, through connector (190) on circuit 97GA from (1091). The clutch switch (294) sends a ground signal by way of circuit 97AH, connector (190) and circuit 97AH to the ECM connector (1091) terminal 4 while the clutch pedal is released.

s08210

326

9 CUMMINS ISM AND AHD ENGINE SYSTEM

2.10. VEHICLE SPEED SENSOR


The vehicle speed sensor (1099) feeds a VSS signal to the ECM (1091) by way of circuits 97A and 97AK through connector (190). Two types of sensors are available. The threaded (adjustable) sensor ids used in most transmissions. A new push-in (non-adjustable) sensor is used on some transmissions.

2.11. ENGINE BRAKE SWITCHES


The lighted engine brake on/off switch (434) receives a ground signal on circuits 24G, through connector (190) on circuit 97GA from (1091). In the on position, a ground signal is sent from the switch on circuit 24AD to engine brake selector switch (433). When lighted switch (433) is placed in the rst position, a ground is applied to circuit 24AE, connector (190), and circuit 24AE to the ECM (1091). This tells the ECM to enable the brake solenoid for the front three cylinders on the ISM engine and enables the solenoids for two cylinders on the AHD engine when braking is called for. When switch (433) is placed in the second position, a ground is applied to circuit 24AF (and 14AP with the AHD), through connector (190) to ECM (1091). This tells the ECM to enable the brake solenoid for the rear three cylinders on the ISM engine and enables the solenoids for four cylinders on the AHD engine when braking is called for. When switch (433) is placed in the third position, a ground is placed on circuit 24E. Ground is also placed on circuit 24AF (and 24AP with the AHD), through connector (190) to the ECM (1091). This tells the ECM to enable the brake solenoids for all cylinders on the ISM engine and the AHD engine when braking is called for.

2.12. GAUGES AND WARNING LIGHTS


Refer to separate gauge and warning lights sections in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual for information on speedometer, tachometer, gauges, and warning lights.

2.13. J1939 DATA LINK


The CM570 ECM uses a J1939 data link to communicate with the antilock brake system and some types of transmission. A. Circuit 98YL(+) is the positive data link connection. It originates from ECM connector (1091), terminal 46. The circuit is connected to J1939 terminating resistor connector (1098), terminal A, J1939 backbone connector (1097), terminal A, and J1939 cap diagnostic connector (1095), terminal A. B. Circuit 98GN(-) is the negative data link connection. It originates from ECM connector (1091), terminal 37. The circuit is connected to J1939 terminating resistor connector (1098), terminal C, J1939 backbone connector (1097), terminal C, and J1939 cap diagnostic connector (1095), terminal B. C. Circuit 98SHD is the data link shield connection. It originates from ECM connector (1091), terminal 36. The circuit is connected to J1939 terminating resistor connector (1098), terminal B, J1939 backbone connector (1097), terminal B, and J1939 cap diagnostic connector (1095), terminal C.

3. TROUBLESHOOTING
Refer to the Cummins AHD and ISM ENGINE CONTROLS circuit diagrams in CTS-5298 or S08225.
s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

327

This section includes troubleshooting charts for International installed circuits and components that are part of the CM570 Electronic Control system. To begin the troubleshooting process, refer to the appropriate Cummins manual and follow their directions. If the Cummins diagnostics (fault codes) indicate that the suspect circuits are International circuits or components, then use the charts in this section. Refer to the CTS-5298 or S08225 Circuit Diagram Book. The EZ-Tech or PRO-LINK 9000 EST can also be used to determine if the International switches and components are working properly. If they are not, use a Fluke digital multimeter (DMM) to troubleshoot the circuits. If the Cummins diagnostic (fault codes) or the EZ-Tech or the PRO-LINK indicate a problem with International installed circuits, the diagnostic tables in this chapter provide step-by-step test procedures. 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 laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual. D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit, by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid.

3.1. ONBOARD DIAGNOSTICS WITH ENGINE RUNNING


All CM570 vehicles have a yellow Engine Warning light and a red Engine Stop light located in the instrument cluster. Every time the key is turned to the ignition position, the lights come on for several seconds as a system self-test and then turn off. If the warning lights remain on, it is an indication that the ECM has detected a problem. The CM570 system can show and record certain problems. The problems are shown as fault codes. The fault codes are recorded in the ECM. If a fault is detected (becomes active) during vehicle operation, the driver is alerted by the illumination of either the yellow Engine Warning Light or the red Stop Engine Light. The yellow Service/Check Engine Light may also be illuminated. The yellow Engine Warning light turns on to warn the driver of an active component or system fault that should be serviced as soon as possible to solve the problem, but the situation is not considered an emergency. The red Stop Engine light turns on to warn the driver that there is a major system problem and the vehicle should be stopped and engine shut down as soon as is safely possible.

s08210

328

9 CUMMINS ISM AND AHD ENGINE SYSTEM

The yellow Service/Check Engine Light (engine protection system) turns on to warn the driver that: A. Coolant temperature is out of range. B. Oil temperature is out of range. C. Oil pressure is out of range. D. Intake manifold temperature is out of range. E. Engine coolant level is below the acceptable level.

3.2. PERFORMING A DIAGNOSTIC CHECK WITH THE ENGINE OFF


A diagnostic check may be performed using the Diagnostic On/Off switch and Cruise Set/Resume. Any error codes will be ashed through the red Engine Stop Light and yellow Engine Warning Light. If no errors are found, both lights will stay on while the diagnostics switch is on. Consult the Cummins Operation and Maintenance Manual furnished with the vehicle for exact procedures and fault code information. To determine the fault codes use the following procedure: 1. Begin the procedure with the engine off. 2. Place the switch key in the off position. 3. Turn the diagnostic On/Off switch to the on position. 4. Turn the key switch to run position (not crank). NOTE Cummins CM570 engine diagnostics must be run with the engine NOT RUNNING. If BOTH Yellow Engine Warning andRed Engine Stop lights come ON and stay ON, it is an indication that no engine faults are present. If BOTH the yellow Engine Warning and red Engine Stop lights come on momentarily and then go out, it is an indication that engine faults are present. If BOTH the yellow Engine Warning and red Engine Stop lights come on and stay on, it is an indication that no engine faults are present. 5. Yellow Engine Warning light will ash once. 6. There will be a one to two second pause. 7. Red Engine Stop will ash code with one or two seconds between digits. 8. Yellow Engine Warning light will ash indicating the end of that fault code, and then start over and repeat the same fault code. 9. To go to the second fault code, move the Set/Resume switch to the Inc. position and then release it. The process will then repeat itself as indicated in steps 5 through 8. 10. To move back to the last or previous fault code, move the Set/Resume switch to the Dec position and then release it. The process will then repeat itself as indicated in steps 5 through 8.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

329

11. To stop the diagnostics procedure, correct the faults or move the diagnostic On/Off switch to the off, and turn the vehicle key switch to the off position.

3.3. CUMMINS ELECTRONIC SERVICE TOOL


CM570 vehicles have a data link connected to the ATA date link connector (137). The Cummins electronic service tool can be connected to program owner-specied information into the engine, monitor the system, and aid in troubleshooting the engine. Consult the Cummins ISM or AHD Troubleshooting and Repair Manuals. The Cummins electronic service tool may be available at the nearest Cummins Authorized Service Center.

3.4. EZ-TECH OR PRO-LINK ELECTRONIC SERVICE TOOL (EST)


The EZ-Tech or Pro-Link 9000 EST with the appropriate software program can also be used with the Navistar data link to read active and inactive fault codes through the data link. The use of the EST or specic codes are not discussed in this manual as the information is part of the EZ-Tech or Pro-Link 9000 documentation. The EZ-Tech or Pro-Link 9000 can also be used to monitor operation of various switches and controls and perform other diagnostic tasks. The specic capabilities and operating instructions are included in the EZ-Tech or Pro-Link 9000 documentation.

3.5. 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 in the vehicle. These relays must be replaced with the correct International part. Relays used in exposed areas such as the engine compartment are sealed relays and are a different part number than those in the cab. The part number is embossed on the relay. There is also a circuit diagram of the relay located on the relay body. The terminals are numbered on the relay in the same manner as in the circuit diagrams. To test the relay, refer toTesting Relay below.

3.6. TESTING RELAY


Table 96 STEP 1. Testing Relay KEY Off ACTION With relay removed, measure resistance between terminals 30 and 87. Measure resistance between terminals 30 and 87A. TEST POINTS Relay, 30 to 87. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the relay.

2.

Off

Relay, 30 to 87A.

<2 ohms.

Go to next step.

Replace the relay.

s08210

330

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 96 3.

Testing Relay (cont.) Off Connect 12V lead to terminal 85 and ground lead to terminal 86. Does relay energize with audible click? With relay energized (step 3), measure resistance between terminals 30 and 87. Energized <2 ohms. Relay, 30 to 87. Go to next step. Replace the relay.

4.

Off

Relay tests good.

Replace the relay.

3.7. ACCELERATOR PEDAL TPS/IVS


The following four tests check the accelerator position sensor (TPS), the idle validation switch (IVS) and the related International cab and engine harness circuits connected to the ECM. NOTE The following four tests must be performed in sequence. The tests should be performed if a Cummins fault code indicates a problem in the circuits or if the Compulink, EZ-Tech or Pro-Link 9000 EST indicates that the TPS/IVS is not working properly while monitoring switches. If CompulinkTM detects a fault with the IVS circuits while monitoring switches, the display would show Idle Validation Switch = Fault. If a fault is present while monitoring Percent Of Throttle, the percent displayed does not indicate actual throttle position. NOTE The following two tests, Testing Throttle Position Sensor (TPS) and Testing Idle Validation Switch (IVS), check operation of the TPS and IVS, but do not check the timing between the two functions. Testing Throttle Position Sensor (TPS) This test checks the TPS circuits in the accelerator pedal assembly. This test will help identify if the resistances are within specications and if there are any opens or shorts in the TPS, but will not verify the correct switching of the IVS and TPS. Table 97 STEP 1. Testing Throttle Position Sensor (TPS) KEY Off ACTION Disconnect accelerator pedal from cab harness at connector (267). At pedal side of (267) measure resistance between terminals A and C with the pedal in the idle position, then with the pedal fully depressed. With the pedal in the idle position, at pedal, measure resistance between terminals B and C. TEST POINTS TPS, A to C. SPEC. 2000 to 3000 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibration).

2.

Off

TPS B to C.

1500 to 3000 ohms.

Go to next step.

Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibration).

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

331

Table 97 3.

Testing Throttle Position Sensor (TPS) (cont.) Off With the pedal in the full throttle position, at pedal, measure resistance between terminals B and C. Is reading 1000 ohms less than reading at idle position and between 250 and 1500 ohms? At the accelerator pedal, measure resistance between gnd. (metal part of pedal) and terminals A, B, C, D, and E. The TPS sensor checks good. Proceed to Testing Idle Validation Switch (IVS) which checks the idle validation portion of the accelerator pedal. TPS, B to C. 250 to 1500 ohms, and idle position reading -1000 ohms. Go to next step. Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibration).

4.

Off

TPS, A, B, C, D, and E to gnd.

>100K ohms.

Go to next step.

Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibration).

5.

Off

Testing Idle Validation Switch (IVS) Perform Testing Throttle Position Sensor (TPS) before performing this test. Table 98 STEP 1. Testing Idle Validation Switch (IVS) KEY Off ACTION Disconnect accelerator pedal from cab harness at connector (267). At pedal side of (267) measure resistance between terminals F and E with pedal in idle position. Is it <125 ohms? Pedal measure resistance between terminals F and E while slowly depressing the pedal (idle to full throttle). After approximately 10 degrees of travel, is the resistance 100K ohms or more? At pedal measure resistance between terminals F and D while the pedal is at idle position. TEST POINTS TPS/ IVS, F to E. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibrations).

2.

Off

TPS/ IVS, F to E.

>100K ohms.

Go to next step.

Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibrations).

3.

Off

TPS/ IVS, F to D.

>100K ohms.

Go to next step.

Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibrations).

s08210

332

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 98 STEP 4.

Testing Idle Validation Switch (IVS) (cont.) KEY Off ACTION At pedal measure resistance between terminals F and D while slowly depressing the pedal (idle to full throttle). After approximately 10 degrees of travel the resistance should be less than 125 ohms. At pedal measure resistance between metal part of accelerator pedal and terminals D, E and F. The TPS/IVS pedal assembly checks good. Note that this test is not able to check the timing between TPS and IVS functions. TEST POINTS TPS/ IVS F to D. SPEC. <125 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibrations).

5.

Off

TPS/ IVS, metal to D, E, and F.

>100K ohms.

Go to next step.

Replace the TPS/IVS switch, then recalibrate (refer to Accelerator/ ECM Calibrations).

6.

Off

Testing Accelerator Pedal (TPS/IVS) System for Short or Open Circuits This test checks the cab and engine harness TPS/IVS circuits for opens, shorts to ground, shorts to hot circuits and shorts to other circuits in the harness. Perform the preceding test before performing this test. Table 99 STEP 1. Testing Accelerator Pedal (TPS/IVS) System for Short or Open Circuits KEY Off ACTION With (267) disconnected, disconnect connector (1091) from ECM and inspect ECM connector. Connector and ECM pins OK? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate the ECM to TPS/IVS.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

333

Table 99 Testing Accelerator Pedal (TPS/IVS) System for Short or Open Circuits (cont.) 2. Off At connector (1091) use test leads and measure resistance to gnd. at terminals 3, 13, 49, 47, 48 and 10 (circuits 99B, 99C, 97-GA, 99, 99A and 99-G). Do not use probes or leads other than Cummins P/N 3822758 or the connector could be damaged. At connector (1091) use test leads and measure resistance between terminals 3, 13, 49, 47, 48 and 10 (circuits 99B, 99C, 97-GA, 99, 99A and 99-G) and all other terminals in (1091). At connector (1091) use test leads and measure voltage to gnd. at terminals 3, 13, 49, 47, 48 and 10 (circuits 98B, 99C, 97-GA, 99, 99A and 99-G). (1091), 99B, 99C, 97-GA, 99, 99A and 99G to gnd. >100K ohms. Go to next step. Locate short to ground in circuit where terminal resistance is less than 100K ohms, then repair.

3.

Off

(1091), between 99B, 99C, 97-GA, 99, 99A, and 99-G and all other circuits. (252), 99B, 99C, 97-GA, 99, 99A and 99-G to gnd.

>100K ohms.

Go to next step.

Locate short between any circuits where resistance between terminals is less than 100K ohms, then repair.

4.

On

<1.5 volts.

Go to Testing TPS/IVS Circuits for Continuity.

Locate short to unwanted voltage source in any circuit where more than 1.5 volts is present, then repair. Go to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal.

Testing TPS/IVS Circuits for Continuity This test checks the individual TPS and IVS circuits (cab and engine harness) for correct resistance while disconnected from the accelerator pedal assembly and ECM. Perform the preceding three tests before performing this test. Table 100 STEP 1. Testing TPS/IVS Circuits for Continuity KEY Off ACTION At ECM connector (1091) use test lead to jumper terminal 47 to 48 (circuit 99 to 99A). At connector (267) measure resistance between terminals B and C (cir. 99 to 99A). Do not use probes or leads other than Cummins TEST POINTS (267), 99 to 99A SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of out-ofspecication resistance in either circuit 99 or 99A(5V), then repair. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal.

s08210

334

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 100

Testing TPS/IVS Circuits for Continuity (cont.) P/N 3822758 or the ECM connector could be damaged.

2.

Off

(267), At connector (1092) 99-G to use test lead to jumper terminal 497to 49 (cir. 99 99. to 99-G). At connector (267) measure resistance between terminals A and B (cir. 99-G to 99). (267), 99 At connector (1091) to 99C. use test lead to jumper terminal 47 to 3 (cir. 99 to 99C). At connector (267) measure resistance between terminals B and D (cir. 99 to 99C). (267), 99 At connector (1091) to 99B. use test lead to jumper terminal 47 to 13 (cir. 99 to 99B). At connector (267) measure resistance between terminals B and E (cir. 99 to 99B). (267), 99 At connector (1091) to 99-GA. use test lead to jumper terminal 47 to 10 (cir. 99 to 97-G). At connector (267) measure resistance between terminals B and F (cir. 99 to 99-GA). If the preceding four tests have been performed and defects were not noted, the TPS and IVS circuits check good. If the problem is still present, replace the accelerator pedal. If this does not correct the problem, have Cummins dealer diagnose the ECM operation.

< 5 ohms.

Go to next step.

Locate cause of out-of- specication resistance in circuit 99-G, then repair. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate cause of out-of- specication resistance in circuit 99C, then repair. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate cause of out-of-specication resistance in circuit 99B, then repair. Refer to Accelerator/ ECM Recalibration to recalibrate ECM/ accelerator pedal. Locate cause of out-of-specication resistance in circuit 99B, then repair. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal.

3.

Off

< 5 ohms.

Go to next step.

4.

Off

< 5 ohms.

Go to next step.

5.

Off

< 5 ohms.

Go to next step.

6.

Off

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

335

Accelerator/ECM Calibration The electronic accelerator pedal assembly and the ECM must be calibrated when: A. The pedal assembly is initially installed. B. The pedal assembly or sensor is replaced. C. The accelerator pedal is disconnected (at any point in the circuitry) and the key switch is placed in the ON position. To recalibrate the accelerator pedal and ECM: A. The vehicle key must be in the on position. B. Depress the accelerator pedal slowly through the complete range of movement, then release. Slowly depress and release, three times in this manner. This completes the calibration process.

3.8. LOW COOLANT SWITCH


First check for proper coolant levels. If coolant levels are not low, this test would be performed if Cummins diagnostic codes were logged indicating a low coolant condition or other circuit fault. This test procedure requires a VOM to check the International harness for opens, shorts to ground, or shorts to other circuits in the International harness. The low coolant sensor has complex circuits and a VOM should not be used to test the sensor as it may damage the circuits. Testing Low Coolant Level Switch And Circuits Table 101 Testing Low Coolant Level Switch And Circuits STEP 1. KEY Off ACTION Disconnect 31-way connector (1093) from Cummins connector. Disconnect (249) from low coolant switch. At connector (1093) measure resistance between terminals 7, 19, 5 and 8 (circuits 34B[5V], 34-G, 34A and 34) and all other terminals in (1093). At (1093) measure resistance to gnd. at terminals 7, 19, 5 and 8 (circuits 34B[5V], 34-G, 34A and 34). At (1093) measure voltage to gnd. at terminals 7, 19, 5 and 8 (circuits 34B[5V], 34-G, 34A and 34). TEST POINTS (1093), between 34B(5V), 34-G, 34A and 34 and all other circuits. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short between any circuits where resistance between terminals is less than 100K ohms, then repair.

2.

Off

(1093), 34B(5V), 34-G, 34A and 34 to gnd. (1093), 34B (5V), 34-G, 34A and 34 to gnd.

>100K ohms.

Go to next step.

Locate short to gnd. in any circuit(s) where resistance is less than 100K ohms, then repair. Locate short to unwanted voltage source in any circuit(s) where voltage is more than 1.5V, then repair.

3.

On

<1.5 volts.

Go to next step.

s08210

336

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 101 Testing Low Coolant Level Switch And Circuits (cont.) 4. Off Measure resistance of circuits 34, 34A, 34-G and 34B(5V) between connectors (249) and (1093). The low coolant switch circuits check good. If problem is still present, replace low coolant switch. If problem persists, have Cummins dealer diagnose ECM operation. 34, 34A, 34-G, and 34B(5V) between (249) and (1093). <5 ohms. Go to next step. Locate open or poor connection in circuit(s), if resistance is more than 5 ohms, then repair.

5.

Off

3.9. POWER SUPPLY CIRCUITS TO ECM


This test checks the unswitched battery power feed to the ECM and the ECM ground circuit that is part of the Battery Feed Harness. Check the two 15A Cummins fuses before performing this test. NOTE Batteries must be fully charged before performing this test. Testing Unswitched Battery Power Circuits And ECM Ground Circuit Table 102 STEP 1. Testing Unswitched Battery Power Circuits And ECM Ground Circuit KEY Off ACTION Check ECM power harness connector at starter circuits 14A, 1B and 11-G and at connector (675) and (1094) for clean, tight connections. Check the two 15 amp fuses located in the engine harness for open condition. Disconnect ECM power connector (1094) from Cummins engine harness. Measure voltage to gnd. at circuits 14C and 14D. Battery voltage present? ECM fuses. TEST POINTS SPEC. Good con- nection. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Correct poor connections.

2.

Off

<5 ohms.

Go to next step. Go to next step.

Locate cause of overload condition, then correct. Replace with correct rated fuse. Locate cause of low or no voltage in circuit 14C or 14D from batteries, then repair.

3.

Off

(1094), 4C and 14D to gnd.

12 1.5 volts.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

337

Table 102 STEP 4.

Testing Unswitched Battery Power Circuits And ECM Ground Circuit (cont.) KEY Off ACTION At connector (1094) measure voltage between circuits 14C and 11-G. Battery voltage present? At connector (1094) measure voltage between circuits 14C and 11-G while cranking engine. Unswitched battery power circuits and ECM gnd. circuit at connector (1094) checks good. TEST POINTS (1094), 14C to 11-G. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or high resistance in circuit 11-G between (1094) and batteries, then repair. Locate cause of excess voltage drop in cranking circuit, then repair.

5.

On

(1094), 14C to 11-G while cranking.

>7 volts.

Go to next step.

6.

Off

Testing Switched Ignition Power To ECM Table 103 STEP 1. Testing Switched Ignition Power To ECM KEY Off ACTION Check 5A fuse F6-D for open condition. TEST POINTS F6-D SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace fuse. Locate cause of no or low voltage in 13Z from key switch. Locate open in circuit 13D between fuse and connector (1091) and repair.

2.

On

Measure voltage to ground at input circuit (13Z to F6-D fuse).

13Z to gnd.

12 1.5 volts. 12 1.5 volts.

Go to next step. Go to next step.

3.

Off/On Disconnect engine harness 50-pin ECM connector (1091) from Cummins harness. Turn key on, measure voltage to gnd. at connector (1091) terminal 38 (circuit 13D). Off Measure voltage between terminal 38 (circuit 13D and each terminal 29, 30, 50, 40 and 39) (circuits 11-GCF, 11-GCB, 11-GCK, 11-GCJ and 11-GCH).

(1091), 38 to gnd.

4.

(1091), 38 to each terminal (29, 30, 50, 40 and 39).

12 1.5 volts.

Switched ignition voltage circuit to ECM checks good.

Locate open in circuit between engine ground and connector (1091), then repair.

s08210

338

9 CUMMINS ISM AND AHD ENGINE SYSTEM

3.10. SERVICE BRAKE AND CLUTCH SWITCHES


This test would be performed if the Electronic Service Tool (EST) displayed an incorrect switch position or Cummins diagnostic codes indicate a problem may be present. Testing Clutch Switch Table 104 STEP 1. Testing Clutch Switch KEY Off ACTION Disconnect clutch switch connector (294) from cab harness. With clutch pedal released, measure resistance between the pigtail terminals. With clutch pedal depressed to the bottom of the free travel position (approx. 1.7 inches or 43 mm from pedal stop plate), the u-bolt plate should touch the switch actuator arm. When the clutch pedal returns to the stop, the switch should actuate (to closed position) with an audible click. Is clutch switch adjusted properly? Depress clutch pedal and measure resistance between clutch switch pigtail connector (294) terminals. Clutch switch across pigtail terminals (294). >100K ohms. TEST POINTS Clutch switch across pigtail terminals (294). SPEC. <2 ohm. YES-IN SPEC. Go to Step 3. NO-OUT OF SPEC. Check switch adjustment. Go to next step.

2.

Off

Replace and adjust clutch switch. Go to Step 1.

Adjust clutch switch. Go to Step 1.

3.

Off

Go to next step.

If switch is not properly adjusted, adjust and retest. If switch was properly adjusted, replace the switch. Replace the clutch switch, then adjust.

4.

Off

Check clutch switch for short to gnd. With switch disconnected, measure resistance to gnd. at each switch terminal.

>100K Clutch switch each ohms. pigtail to gnd.

Clutch switch checks good. Perform Testing Clutch Switch Circuits for "Open and Short" Condition.

Testing Clutch Switch Circuits for "Open and Short" Condition Perform Testing Clutch Switch before performing this test.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

339

CAUTION When testing at ECM connector (1091), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 105 Testing Clutch Switch Circuits for "Open And Short" Condition STEP 1. KEY Off ACTION With clutch switch disconnected, remove ECM connector (1091) from the ECM. ECM harness connector or ECM pins OK? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace damaged harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to gnd. in circuit where resistance at terminal was less than 100K ohms, then repair.

2.

Off

Set service brake using trailer hand valve. Disconnect clutch switch (294). Use test leads and measure resistance to ground at connector (1091) terminal 2 and 10 cir. 97AH and 97-GA). Use test leads and measure resistance between terminals 2 and 10 (cir. 97AH and 97-GA) and all other terminals in connector (1091). At connector (1091), use test leads and measure voltage to gnd. at terminals 2 and 10 (cir. 97AH and 97-GA).

(1091), 97AH and 97-GA to gnd.

>100K ohms.

Go to next step.

3.

Off

(1091), 97AH and 97-GA and all other circuits. (1091), 97AH and 97-GA to gnd.

>100K ohms.

Go to next step.

Locate short between circuits, then repair.

4.

On

<1.5 volts.

The clutch switch circuits are free of short circuits. Perform Testing Clutch Switch Circuits for Continuity.

Locate short to unwanted voltage source in circuit with more than 1.5 volts, then repair.

s08210

340

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Testing Clutch Switch Circuits For Continuity

CAUTION When testing at ECM connector (1091), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 106 STEP 1.

Testing Clutch Switch Circuits For Continuity KEY Off ACTION TEST POINTS SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97AH between connectors (1091) and (294), then repair. Locate open or poor connection in circuit 97-GH or 97-GA between connectors (1091) and (294), then repair.

At ECM connector (1091) (294) 97AH to use test lead to jumper gnd. terminal 2 (cir. 97AH) to gnd. At clutch switch connector (294) measure resistance of 97AH to gnd. At ECM connector (1091) use test lead to jumper terminal 2 to 10 (cir. 97AH to 97-GA). At clutch switch connector (294) measure resistance between circuits 97AH and 97-GH. The clutch switch circuits and switch check good. (294), 97AH to 97-GH.

2.

Off

<5 ohms.

Go to next step.

3.

Off

Testing Service Brake Switch (141) Table 107 Testing Service Brake Switch (141) STEP 1. KEY Off ACTION Remove connector (141) from brake switch. With brakes released, measure resistance across switch terminals. Switch should be closed. TEST POINTS Brake pressure switch across terminals. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the brake switch.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

341

Table 107 STEP 2.

Testing Service Brake Switch (141) (cont.) KEY Off ACTION Apply service brakes and measure resistance across the brake pressure switch. Switch should be open. NOTE: Sufcient air pressure must be present to apply service brakes for this test step. Measure resistance to gnd. at both brake switch terminals with service brakes applied, and with brakes released. Both should be isolated from ground at all times. TEST POINTS Brake pressure switch across terminals. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the brake switch.

3.

Off

Brake pressure switch both terminals to gnd.

>100K ohms.

Reconnect (141) to brake switch. Perform Testing Service Brake Switch Circuits for "Open and Short" Condition.

Replace the brake switch.

Testing Service Brake Switch Circuits for "Open and Short" Condition Perform Testing Service Brake Switch (141) before performing this test.

CAUTION When testing at ECM connector (1091), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 108 STEP 1.

Testing Service Brake Switch Circuits for "Open and Short" Condition KEY Off ACTION With connector (141) disconnected from brake switch. Remove connector (1091) from the ECM. ECM connector and ECM pins OK? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness connector terminals if damaged. If ECM pins damaged, have Cummins dealer replace ECM.

s08210

342

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 108 Testing Service Brake Switch Circuits for "Open and Short" Condition (cont.) STEP 2. KEY Off ACTION Disconnect clutch switch. Use test leads and measure resistance to ground at connector (1091) terminals 1 and 10 (circuits 97AL and 97-GA). Use test leads and measure resistance between terminal 1 and 10 (cir. 97AL and 97-G) and all other terminals in connector (1091). At connector (1091), use test leads and measure voltage to gnd. at terminals 1 and 10 (circuits 97AL and 97-GA). TEST POINTS (1091), 97AL and 97-GA to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to gnd. in circuit where resistance at terminal was less than 100K ohms, then repair.

3.

Off

(1091), 97AL to 97-G A and all other circuits. (1091), 97AL and 97-GA to gnd.

>100K ohms.

Go to next step.

Locate short between any circuit where resistance between terminals is less than 100K ohms, then repair. Locate short to unwanted voltage source in circuit with more than 1.5 volts, then repair.

4.

On

<1.5 volts.

The brake switch circuits are free of short circuits. Perform Testing Service Brake Switch Circuits for Continuity.

Testing Service Brake Switch Circuits for Continuity

CAUTION When testing at ECM connector (1091), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 109 Testing Service Brake Switch Circuits for Continuity STEP 1. KEY Off ACTION At ECM connector (1091) use test lead to jumper terminal 1 (cir. 97AL) to gnd. At brake switch connector (141) measure resistance to gnd at circuit 97AL. TEST POINTS (141), 97AL to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97AL between connectors (1091) and (141), then repair.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

343

Table 109 STEP 2.

Testing Service Brake Switch Circuits for Continuity (cont.) KEY Off ACTION At ECM connector (1091) use test lead to jumper terminal 1 to terminal 10 (cir. 97AL to 97-GA). At brake switch connector (141) measure resistance between circuits 97AL and 97-GF. The service brake switch circuits and switch check good. TEST POINTS (141), 97AL to 97-GF. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97-GF or 97-GA between connectors (1091) and (141), then repair.

3.

Off

3.11. ENGINE BRAKE


In the event the engine brake fails to operate, the following chart provides a systematic series of steps to check the switches, circuits that are installed by International. Testing Engine Brake Components And Circuits Table 110 STEP 1. Testing Engine Brake Components And Circuits KEY Off ACTION Remove engine brake on/off switch from connector (434). Measure resistance to gnd. at connector (434), circuit 24-G. With on/off switch removed, refer to Testing Engine Brake Switches and use ohmmeter to check switch. Switch good? Remove connector (433) from selector switch. Measure resistance of circuit 24AD between connectors (434) and (433). Refer to Testing Engine Brake Switches and test the selector switch. Switch good? 24AD between (434) and (433). <5 ohms. TEST POINTS (434), 24-G to gnd. SPEC. <1 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 24-G or 97-GA, then repair.

2.

Off

Go to next step.

Replace the switch.

3.

Off

Go to next step.

Locate open or poor connection in circuit 24AD between connectors (434) and (433), then repair. Replace the switch.

4.

Off

Go to next step.

s08210

344

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 110 STEP 5.

Testing Engine Brake Components And Circuits (cont.) KEY Off ACTION Re-install conn. (434) to engine brake on/off switch and place in on position. Re-install conn. (433) to engine brake switch and place in position 3. Disconnect 50-way conn. (1091) from engine harness. At connector (1091) measure resistance from pin 22, 31 and 32 to ground (circuit 24AE, 24AF and 24AP to ground). (1091), 24AE, 24AF and 24AP to gnd. <1 ohms. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

6.

On

Go to next step.

Locate open or poor connection in circuit 24AE, 24AF or 24AP between connectors (433) and (1091), then repair.

Testing Engine Brake Switches 1. Testing Engine Brake On/Off Switch a. With switch in on position, resistance between terminals 5 & 6 and between 2 & 3 should be less than 5 ohms. b. With switch in off position, resistance should be 100K ohms or more. c. To test the LED in the switch, connect B+ test lead to terminal 7 and ground terminal 8. LEDs should illuminate.

2. Testing Engine Brake Selector Switch With M11 Engine. a. With switch in 3 position, resistance between terminals 2 and 3 and 6 should be less than 5 ohms. b. With switch in 1 position, resistance between terminals 2 and 3 should be less than 5 ohms. c. With switch in 2 position, resistance between terminals 2 and 6 should be less then 5 ohms.

d. To test the LED in the switch, connect B+ test lead to terminal 7 and ground terminal 8. LEDs should illuminate.

3.12. ATA DATA LINK CONNECTOR (137) AND SPEEDOMETER/TACHOMETER INPUT CIRCUITS
This series of tests provide charts for testing: (1) The Data Link circuits between the ECM and ATA Data Link connector (137) and the speedometer/tachometer connector (421). (2) The power and ground circuits to the ATA Data Link connector (137).

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

345

Testing Diagnostic Connector Power and Ground Circuits Table 111 STEP 1. Testing Diagnostic Connector Power and Ground Circuits KEY Off ACTION Remove and check 20A fuse F5-D for open condition. Re-install fuse. At connector (137) measure voltage at terminal C (circuit 97DL) to ground. At connector (137) measure voltage between terminals C and E (circuits 97DA and 11-GR). TEST POINTS F5-D. SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then repair. Replace 20A fuse. Locate cause of no or low voltage in circuit 97DL from fuse F9-C, then repair. Locate open or poor connection in circuit 11-GR between connector (137) and G1 ground adapter (453), then repair.

2.

On

(137), 97DL to gnd. (137), 97DL to 11-GR.

12 1.5 volts.

Go to next step.

3.

On

12 1.5 volts.

Go to next step.

4.

On

The power and gnd. circuits to the ATA data link connector (137) check good.

Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit

CAUTION When testing at ECM connector (1091), do not use probes or leads other than Cummins test lead , Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 112 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit STEP 1. KEY Off ACTION Disconnect ECM conn. (1091) from the ECM. Inspect conn. ECM harness connector OK? TEST POINTS SPEC. Harness conn. OK. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness conn. terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal.

s08210

346

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 112 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit (cont.) STEP 2. KEY Off ACTION Disconnect connector (421) from speedometer/ tachometer unit and if additional devices have been connected to (514) and (515) data link connectors, they must be disconnected. At connector (1091), using test leads, measure resistance to gnd. at terminals 26 and 27 (circuit 98B[+] and 98[-]). At connector (1091) use test leads and measure resistance between terminal 26 and terminal 27 (circuits 98B[+] and 98[-]) and all other terminals in connector. At connector (1091) use test leads and measure voltage to gnd. at terminals 26 and 27 (circuits 98B[+] and 98[-]). TEST POINTS (1091), 98B(-) and 98(+) to gnd. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short circuit to gnd in circuit where resistance is less than 100K ohms, then repair.

3.

On

(1091), 98B(-) and 98(+) and all other circuits in conn. (1091), 98b(-) and 98(+) to gnd.

>100K ohms.

Go to next step.

Locate short between circuits where resistance between terminals is less than 100K ohms, then repair. Locate short to unwanted voltage source in circuit where more than 1.5 volts is present at terminal, then repair. Locate open or poor connection in circuit 98B(-)/98C(-) between connectors (1091) and (137), then repair. Locate open or poor connection in circuit 47/48(-) between connectors (515) and (421), then repair.

4.

On

<1.5 volts.

Go to next step.

5.

Off

(137), At connector (1091) use test lead to jumper terminal 98C(-) to 27 (cir. 98B[-]) to gnd. At gnd. connector (137) measure resistance to gnd. at terminal B (cir. 98C[-]). With connector (1091) terminal 27 (circuit 98B[-]) still jumpered to ground, at speedometer/ tachometer connector (421) measure resistance to gnd. at circuit 47/48(-). (421) 47/ 48(-) to gnd.

<5 ohms.

Go to next step.

6.

Off

<5 ohms.

Go to next step.

7.

Off

(137), At connector (1091) use test lead to jumper terminal 98A(+) to gnd. 27 (cir. 98[+]) to gnd. At connector (137) measure resistance terminal A (circuit 98A[+]) to gnd.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 98(+)/98(+) between connectors (1091) and (137), then repair.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

347

Table 112 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit (cont.) STEP 8. KEY Off ACTION With connector (1091) terminal 27 (cir. 98[+]) still jumpered to ground, at connector (421) measure resistance to gnd. at circuit 47/48(+). The data link circuits between ECM connector (1091), diagnostic connector (137) and speedometer/ tachometer connector (421) test good. TEST POINTS (421), 47/ 48(+) to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 47/48(+) between connectors (514) and (421), then repair.

9.

Off

3.13. DIAGNOSTIC ON/OFF SWITCH


The diagnostic On/Off switch can be checked with CompulinkTM, EZ-Tech or Pro-Link 9000 in the switch monitoring mode. If the switches do not operate properly, perform the following test. Testing Diagnostic On/Off Switch And Circuit Table 113 STEP 1. Testing Diagnostic On/Off Switch And Circuit KEY Off ACTION Remove connector (241) from on/off switch. With switch in on position, measure resistance between terminals 5 and 6. With switch in position, measure resistance between terminals 5 and 6. To test the LED in the switch, connect B+ test lead to terminal 7 and connect terminal 8 to gnd. Does LED illuminate? TEST POINTS Across switch terminals 5 and 6. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

Across switch terminals 5 and 6.

>100K ohms.

Go to next step. Go to next step.

Replace the switch.

3.

Off

Replace the switch.

s08210

348

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 113 STEP 4.

Testing Diagnostic On/Off Switch And Circuit (cont.) KEY Off ACTION Remove ECM connector (1091) from the ECM. Inspect connector. ECM harness connector and ECM pins? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to ground in circuit 97AM, then repair.

5.

Off

Disconnect connector (1091) measure resistance to gnd. at terminal 44 (cir. 97AM) to ground. At connector (1091) measure resistance from terminal 10 (cir. 97-GA) to gnd. Set service brakes using trailer hand control valve, with clutch switch disconnected, measure resistance between terminal 44 (cir. 97AM) and all other terminals in (1091). At connector (1091), use test lead to jumper terminal 44 (cir. 97AM) to gnd. At connector (241) measure resistance to ground at circuit 97AM. At connector (1091), use test lead and jumper terminal 10 (cir. 97-G) to gnd. At connector (241) measure resistance to gnd. at circuit 97-GE. The diagnostic on/off switch and circuits check good.

>100K (1093), 97AM to gnd. ohms.

Go to next step.

6.

Off

(1091), 97-GA to gnd. (1091), 97AM to all other circuits.

>100K ohms.

Go to next step. Go to next step.

Locate short to ground in circuit 97-GA, then repair. Locate short between circuits where resistance between terminals is less than 100K ohms, then repair.

7.

Off

>100K ohms.

8.

Off

(241), 97AM to gnd.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 97AM between connectors (241) and (1091), then repair. Locate open or poor connection in circuit 97-GE, 97-GA or 97-G between connectors (241) and (1091), then repair.

9.

Off

(241), 97-GE to gnd.

<5 ohms.

Go to next step.

9.

Off

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

349

3.14. CRUISE CONTROL


When monitoring switches with a Electronic Service Tool, the cruise On/Off switch will indicate on or off. The Set/Resume switch will indicate either Set or Res, depending on the switch position. If the switch is not operable, the screen will be blank. Testing Cruise Control On/Off Switch and Circuits

CAUTION When testing at ECM connector (1091), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 114 STEP 1.

Testing Cruise Control On/Off Switch and Circuits KEY Off ACTION Remove connector (435) from cruise On/Off switch. With switch in on position, measure resistance between terminals 5 and 6. With switch in off position, measure resistance between terminals 5 and 6. To test the LED in the switch, connect B+ test lead to terminal 7 and connect terminal 8 to gnd. Does LED illuminate? Remove ECM connector (1091) from the ECM and inspect. ECM harness connector and ECM pins OK? TEST POINTS Across terminals 5 and 6. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

2.

Off

Across terminals 5 and 6.

> 100K ohms.

Go to next step. Go to next step.

Replace the switch.

3.

Off

Replace the switch.

4.

Off

Go to next step.

Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to gnd. in circuit with less than 100K ohms, then repair.

5.

Off

At ECM connector (1091) use test leads and measure resistance to gnd. at terminals 23 and 10 (cir. 97AE and 97-G).

(1091), 97AE and 97-G to gnd.

>100K ohms.

Go to next step.

s08210

350

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 114 STEP 6.

Testing Cruise Control On/Off Switch and Circuits (cont.) KEY Off ACTION At connector (1091) measure resistance between terminal 23 and all other terminals in connector. TEST POINTS (1091), 23 to all other terminals. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short between circuit 97AE and any circuit where resistance between terminals is less than 100K ohms, then repair. Locate short between circuit 97AE and unwanted voltage source, then repair. Locate open or poor connection in circuit 97AE between connectors (1091) and (435), then repair. Locate open or poor connection in circuit 97-GC, 97-GA or 97-G, then repair.

7.

On

At connector (1091) measure voltage from terminal 23 (circuit 97AE) to ground.

(1091), 97AE to gnd.

<1.5 volts.

Go to next step. Go to next step.

8.

Off

(435), At connector (1091) use test lead to jumper terminal 97AE to gnd. 23 (cir. 97AE) to gnd. At connector (435) measure resistance to gnd. at circuit 97AE. Measure the resistance between connector (1091), terminal 10 (cir. 97-G) and connector (435), cir. 97-GC. The cruise On/Off switch and circuits check good. Between (1091), terminal 10 and (435), 97-GC.

<5 ohms.

9.

Off

<5 ohms.

Go to next step.

10.

Off

Testing Cruise Set/Resume Switch and Circuits

CAUTION When testing at ECM connector (1091), do not use probes or leads other than Cummins test leads, Part No. 3822758. The connector will be damaged. The leads must t snug without expanding the connector terminal.

Table 115 Testing Cruise Set/Resume Switch and Circuits STEP 1. KEY Off ACTION Remove connector (436) from cruise set/resume switch. With switch in set position, measure resistance between terminals 2 and 3. TEST POINTS Between switch term. 2 and 3. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the switch.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

351

Table 115 Testing Cruise Set/Resume Switch and Circuits (cont.) STEP 2. KEY Off ACTION With switch in neutral position, measure resistance between terminals 1, 2 and 3. With switch in resume position, measure resistance between terminals 1 and 2. To test the LED in the switch, connect B+ test lead to terminal 7 and connect terminal 8 to gnd. Does LED illuminate? Remove ECM connector (1091) from the ECM and inspect. ECM harness connector and ECM pins OK? ECM harness conn. and ECM pins OK. TEST POINTS Between switch term. 1, 2 and 3. Between switch term. 1 and 2. SPEC. >100K ohms. YES-IN SPEC. Go to next step. Go to next step. Go to next step. NO-OUT OF SPEC. Replace the switch.

3.

Off

<5 ohms.

Replace the switch.

4.

Off

Replace the switch.

5.

Off

Go to next step.

Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to gnd. in circuit with less than 100K ohms, then repair.

6.

Off

At ECM connector (1091) use test leads and measure resistance to ground at terminals 24 and 14 (cir. 97AB and 97AA). At connector (1091) measure resistance between terminal 24 and 14 (cir. 97AB and 97AA), and all other terminals in the connector. At connector (1091) measure voltage to ground at terminals 24 and 14 (cir. 97AB and 97AA).

(1091), 97AB to 97AA to gnd.

>100K ohms.

Go to next step.

7.

Off

(1091) between 97AB and 97AA, and all others. (1091), 97AB and 97AA to gnd.

>100K ohms.

Go to next step.

Locate short between any circuits where resistance between terminals is less than 100K ohms, then repair. Locate short to unwanted voltage source in circuit 97AA or 97AB, then repair.

8.

On

<1.5 volts.

Go to next step.

s08210

352

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Table 115 STEP 9.

Testing Cruise Set/Resume Switch and Circuits (cont.) KEY Off ACTION At connector (1091) use test lead to jumper terminal 24 (cir. 97AB) to gnd. At connector (436) measure resistance to ground at circuit 97AB. Measure the resistance between connector (1091), terminal 10 (cir. 97-G) and connector (436), circuit 97-GB). At connector (1091) use test lead to jumper terminal 24 (cir. 97AA) to gnd. At connector (436) measure resistance to ground at circuit 97AA. The cruise set/resume switch and circuits check good. TEST POINTS (436), 97AB to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97AB between connectors (1091) and (436), then repair. Locate open or poor connection in circuit 97-GC, 97-GA or 97-G, then repair. Locate open or poor connection in circuit 97AA between connectors (1091) and (436), then repair.

10.

Off

Between (1091), term. 10 and (436), 97-GB. (436) circuit 97AA to gnd.

<5 ohms.

Go to next step.

10.

Off

<5 ohms.

Go to next step.

11.

Off

3.15. VEHICLE SPEED SENSOR


When monitoring engine functions with an EST, if the vehicle is moving the miles-per-hour will display as MPH=XXX (actual vehicle speed if operating properly). To test the sensor and circuits to the ECM, use the following charts. Inspecting And Adjusting the Vehicle Speed Sensor (VSS) 1. Disconnect engine harness connector (1099) from the sensor. Loosen the locknut and remove the sensor. The harness connector and sensor should be free of damage or corrosion. Remove any metal shavings or debris from the sensor. 2. To install the adjustable sensor, turn in until the sensor contacts the transmission speedometer gear, then back out one full turn. Tighten lock nut to 15 ft-lbs. (20.3 Nm). This assures that the sensor is adjusted properly for the next test. Testing Vehicle Speed Sensor Construct test leads using terminals (International Part No. 1680205C1), short length of 16 gauge wire and alligator clips.

WARNING A jack must never be used alone to support vehicle. The jack may lower and serious injury could result. Always support vehicle with oor jacks. Always block wheels to prevent vehicle from moving.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

353

WARNING EXTREME CAUTION should be used to prevent personal injury resulting from contact with rotating vehicle wheels when connecting test leads.

Table 116 STEP 1.

Testing Vehicle Speed Sensor KEY Off ACTION Inspect VSS for damage and proper adjustment before performing this test. Refer to Inspecting and Adjusting the Vehicle Speed Sensor (VSS) above. Disconnect engine harness (1099) from VSS and use test leads to measure resistance between terminal 1 and 2 of sensor connector. VSS, terminal 1 to 2. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

2.

Off

600 to Go to 800 ohms next with the step. adjustable sensor. 1500 to 3500 ohms with the push-in sensor.

Replace the vehicle speed sensor (VSS).

3.

Off

Measure resistance to gnd. at both sensor terminals. Block front wheels and place rear axles on oor stands. Use AC voltmeter with sufcient length leads to avoid personal contact with rotating vehicle wheels during test. Connect meter leads to test leads. Run engine at idle speed, with transmission in high gear. Measure voltage across the two sensor terminals.

VSS, term. 1 and 2 to gnd.

>100K ohms.

Go to next step. Go to next step. Go to next step.

Replace the vehicle speed sensor (VSS).

4.

Off

5.

Off

6.

Off

VSS, across terminals.

>2.0 volts AC

VSS checks good.

Replace the VSS (refer to Inspecting And Adjusting The Vehicle Speed Sensor above). Note: Improper sensor adjustment will cause low, erratic or no output.

s08210

354

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Testing Vehicle Speed Sensor Circuits To ECM To check circuits between the ECM and the speedometer/tachometer unit, refer toATA Data Link Connector (137) and Speedometer/Tachometer Input Circuits. Table 117 Testing Vehicle Speed Sensor Circuits To ECM STEP 1. KEY Off ACTION Remove connector (1099) from vehicle speed sensor. Remove ECM connector (1093) from the ECM and inspect. ECM harness connector and ECM pins OK? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace harness connector terminals if damaged. If ECM pins are damaged, have Cummins dealer replace ECM. Refer to Accelerator/ ECM Calibration to recalibrate ECM/ accelerator pedal. Locate short to gnd. in circuit with less than 100K ohms, then repair. Locate short circuit between circuits where resistance between terminals is less than 100K ohms, then repair. Locate short to unwanted voltage source in circuit where voltage at terminal is more than 1.5 volts, then repair. Locate open or poor connection in circuit 97AJ between connectors (1093) and (1099), then repair.

2.

Off

At connector (1093), use test leads and measure resistance to gnd. at terminals 21 and 22 (cir. 97AJ and 97AK). At connector (1093), measure resistance between terminals 21 and 22 (cir. 97AJ and 97AK) and all other terminals in connector. At connector (1093), measure voltage at terminals 21 and 22 (cir 97AJ and 97AK) to ground. At connector (1093) use test leads and jumper terminal 21 (cir. 97AJ) to gnd. At connector (1099) measure resistance to gnd. at circuit 97AJ.

(1093), 97AJ and 97AK to gnd. (1093), 97AJ and 97AK and all others.

>100K ohms.

Go to next step.

3.

Off

>100K ohms.

Go to next step.

4.

On

(1093), 97AJ and 97AK to gnd.

<1.5 volts.

Go to next step.

5.

Off

(1099), 97AJ to gnd.

<5 ohms.

Go to next step.

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

355

Table 117 Testing Vehicle Speed Sensor Circuits To ECM (cont.) STEP 6. KEY Off ACTION At connector (1093) use test leads and jumper terminal 22 (cir. 97AK) to gnd. At connector (1099) measure resistance to gnd. at circuit 97AK. The vehicle speed sensor circuits between the sensor and ECM check good. TEST POINTS (1099), 97AK to gnd. SPEC. <5 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97AK between connectors (1093) and (1099), then repair.

7.

Off

4. COMPONENT LOCATIONS
B1 Battery Stud.. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . . . . . Power Distribution Panel (1) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Left Side of Engine Cowl (2) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Right Side of Engine Cowl, Above Connector 3 (3) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Right Side of Engine Cowl, Below Connector 2 (72) Ether Start Connector. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Front End Harness, At Lower Left of Radiator (94) Back-up Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Transmission (137) 6-Way Data Link Connector. . . . . . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (141) Service Brake Switch/Cruise Switch. . . . . . . . .. . . . . . Dash Panel, Left Side, Engine Side (190) Cab Overlay to Elect. Eng. Harn.. . . . . . . . . . . .. . . . . . Right Instrument Panel (227) Fan Solenoid . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . At Front of Engine (228) Refrigerant Pressure Switch . . .. . .. . .. . .. . .. . .. . . . . . On A/C Compressor (229) Engine Oil Temp. Sender. .. . .. . .. . .. . .. . .. . .. .. . . . . . Left Side of Engine (235) Transmission Oil Temp. (Inline). . . .. . . . . .. . . . .. . . . . . On Front of Transmission (249) Low Coolant Level Switch. . . . . . . . . . . . . . . . . . . . .. . . . . . To Engine Harness (267) Accelerator Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . To Cab Overlay (294) Clutch Switch Connector. . . . . . . . . . . . . . . . . . . . . .. . . . . . Near Clutch Switch (420) Right Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Gauge Cluster (421) Speedo./Tach. Module. .. . . .. . . .. . . .. . . .. . . .. . .. . . . . . Behind Speedo./Tach. Gauge (422) Speedo./Tach. Module. .. . . .. . . .. . . .. . . .. . . .. . .. . . . . . Behind Speedo./Tach. Gauge (423) Left Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Left Gauge Cluster (424) Left Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Left Gauge Cluster (514) Data Link Positive. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . . . . Behind Instrument Panel/Behind Cluster (515) Data Link Negative. .. .. . .. .. .. .. .. . .. .. .. .. .. . . . . . Behind Instrument Panel/Behind Cluster (1091) Electronic Control Module ECM. . . . . . . . . . . . .. . . . . . At ECM (1093) ECM Interface Connector. . . . . . . . . . . . . . . . . . . .. . . . . . At Engine Harness near ECM (1094) ECM Power Connector. . . . . .. . . . . .. . . . . .. . . . .. . . . . . At Engine Harness near ECM (1099) Vehicle Speed Sensor. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . On Transmission

s08210

356

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Figure 109

Engine Wiring, Cab

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

357

1. DASH PANEL (VIEWED FROM INSIDE ENGINE COMPARTMENT) 2. (141) BRAKE SWITCH 3. (640) STOP LIGHT SWITCH 4. (190) ELECTRONIC ENGINE CONNECTOR 5. RIGHT HAND DASH PANEL GROUND STUD 6. (3) ENGINE CONNECTOR 7. (2) CHASSIS HARNESS CONNECTOR 8. POWER DISTRIBUTION PANEL 9. SWITCHES 10. RIGHT GAUGE CLUSTER 11. SPEEDOMETER / TACHOMETER CLUSTER 12. LEFT GAUGE CLUSTER 13. (514) DATA LINK CONNECTOR 14. (515) DATA LINK CONNECTOR 15. (137) DATA LINK 16. CLUTCH SWITCH 17. FRONT END HARNESS CONNECTOR 18. THROTTLE PEDAL 19. (294) CLUTCH SWITCH CONNECTOR 20. (267) THROTTLE PEDAL CONNECTOR

s08210

358

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Figure 110

Engine Wiring, Dash Panel 1. (190) ELECTRONIC ENGINE CONNECTOR 2. RH DASH PANEL GROUND STUD 3. (2) CAB/ENGINE HARNESS CONNECTOR 4. MEGAFUSE 5. START MAGNETIC SWITCH 6. CIRCUIT 14A TO (B1) BATTERY STUD 7. CIRCUIT 17C 8. CIRCUIT 17B 9. CIRCUIT 14 10. (249) LOW COOLANT SENDER 11. TO ENGINE HARNESS

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

359

Figure 111 Engine Wiring, Cummins ISM

s08210

360

9 CUMMINS ISM AND AHD ENGINE SYSTEM

1. (228) A/C PRESSURE SWITCH CIRCUITS 23C AND 23GB 2.(1091) 50WAY OEM ECM CONNECTOR 3. (1093) 31WAY INTERFACE CONNECTOR 4. TO ENGINE WIRING AT DASH PANEL 5. TRANSMISSION TEMPERATURE SENSOR 6. TO TRANSMISSION 7. STARTER 8. FRAME GROUND 9. ENGINE GROUND 10. (1094) ECM POWER CONNECTOR 11. CONTROL DATA LINK CONNECTOR

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

361

Figure 112

Engine Wiring, Cummins ISM 1. 2. 3. 4. (228) A/C PRESSURE SWITCH CIRCUITS 23C AND 23GB ETHER START CONNECTOR ENGINE OIL TEMPERATURE CONNECTOR TO ENGINE WIRING AT DASH PANEL

s08210

362

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Figure 113 Engine Wiring Cummins Signature Series 1. (228) A/C PRESSURE SWITCH CIRCUITS 23C AND 23GB 2. (1091) 50WAY OEM ECM CONNECTOR 3. (1093) 31WAY INTERFACE CONNECTOR 4. J1939 SERVICE CONNECTOR 5. TO ENGINE WIRING AT DASH PANEL 6. ETHER START CONNECTOR 7. OIL TEMPERATURE GAUGE CIRCUITS 30B AND 30GB 8. (1097) SAE J1939 DATA LINK CONNECTOR USED WITH ABS/TRACTION CONTROL 9. ENGINE GROUND STUD 10. (1094) ECM POWER CONNECTOR 11. FRAME GROUND 12. J1939 TERMINATING RESISTOR

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

363

Figure 114

Engine Wiring Cummins Signature Series 1. 2. 3. 4. 5. (228) A/C PRESSURE SWITCH CIRCUITS 23C AND 23GB AC COMPRESSOR CLUTCH CONNECTOR OIL TEMPERATURE SENDER CONNECTOR TO ENGINE WIRING AT DASH PANEL TO TRANSMISSION

s08210

364

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Figure 115

Engine Wiring, Transmission Effects 1. ENGINE HARNESS 2. (94) BACK-UP LIGHT SWITCH CONNECTOR 3. (250) VEHICLE SPEED SENSOR

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

365

Figure 116

Engine Wiring, Starter Motor 1. CIRCUIT 17C 2. CIRCUIT 14 3. CIRCUIT 11-GS


s08210

366

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Figure 117

Engine Wiring, ECM Cummins ISM 1. ECM GROUND CONNECTION 2. (1091) 50WAY CONNECTOR 3. (1093) 31WAY CONNECTOR

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

367

Figure 118

Engine Wiring, ECM Cummins Signature Series 1. ECM GROUND CONNECTION 2. (1091) 50WAY CONNECTOR 3. (1093) 31WAY CONNECTOR
s08210

368

9 CUMMINS ISM AND AHD ENGINE SYSTEM

Figure 119

Engine Wiring, Alternator Effects ISM 1. CIRCUIT 2-G 2. CIRCUITS 2 AND 14 3. ENGINE HARNESS

s08210

9 CUMMINS ISM AND AHD ENGINE SYSTEM

369

Figure 120

Engine Wiring, Alternator Effects Signature Series 1. 2. 3. 4. CIRCUIT 2 CIRCUIT 14 CIRCUIT 2-G ENGINE HARNESS

s08210

370

9 CUMMINS ISM AND AHD ENGINE SYSTEM

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

371

Table of Contents

1. DESCRIPTION. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .373 2. OPERATION.. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .373 2.1. CEC POWER AND GROUND. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .374 2.2. ACCELERATOR POSITION SENSOR (APS) AND IDLE VALIDATION SWITCH (IVS).. .. .. .. .374 2.3. BAROMETRIC AIR PRESSURE (BAP) SENSOR. . . . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .375 2.4. AIR TEMPERATURE SENSOR (ATS). .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .375 2.5. ATA DATA LINK CONNECTOR. . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .375 2.6. DIAGNOSTIC ON/OFF SWITCH. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .376 2.7. CRUISE CONTROL/PTO SYSTEM. .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .376 2.8. CLUTCH SWITCH.. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . .376 2.9. COOLANT LEVEL PROBE. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .377 2.10. VEHICLE SPEED SENSOR (VSS). .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .377 2.11. SERVICE BRAKE SWITCH. .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .377 2.12. ANTILOCK BRAKE INTERFACE. . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .377 2.13. ENGINE BRAKE. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .377 3. TROUBLESHOOTING. .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .378 3.1. DETERMINING FAULT CODES.. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .378 Reading Flash Codes. . . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .379 3.2. IMPORTANT STEPS BEFORE TESTING. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .379 3.3. INSPECTING ELECTRICAL CONNECTORS. . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .380 Visual Inspection. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .380 Performing Electrical Tests at CEC Module Connector (379). . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .380 Replacing International Components. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .380 3.4. TESTING HELLA RELAY. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .381 3.5. CEC POWER AND GROUND SYSTEM CIRCUITRY.. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .381 3.6. ACCELERATOR (APS/IVS), BAROMETRIC AIR PRESSURE (BAP) AND AMBIENT AIR TEMPERATURE SENSOR SYSTEMS (ATS). . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .384 3.7. DIAGNOSTIC CONNECTOR (137) AND DATA LINK CIRCUITS. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .386 Testing Diagnostic Connector Power and Ground Circuits. . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .386 3.8. TESTING DIAGNOSTIC CONNECTOR AND SPEEDOMETER/TACHOMETER POSITIVE AND NEGATIVE DATA LINK CIRCUITS. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .387 3.9. VEHICLE SPEED SIGNAL.. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .388 Testing Vehicle Speed Sensor (303). .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .389 Testing Vehicle Speed Sensor To ECM Circuits. .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .390 3.10. CRUISE AND PTO CONTROLS.. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .391 Testing Cruise On/Off Switch and Circuits. . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .391 Testing Cruise Set/Resume Switch and Circuits. . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .391 3.11. CLUTCH SWITCH (294). . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .392 Testing Clutch Switch and Circuits.. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .392 Adjusting Clutch Switch.. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .393 3.12. SERVICE BRAKE SWITCH (141). . . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .393 Testing Service Brake Switch and Circuits. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .393 3.13. TESTING LOW COOLANT SENSOR AND CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394 3.14. ENGINE BRAKE CONTROLS. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . .395 Testing Engine Brake Switches and Circuits. . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .395

s08210

372

10 INTERNATIONAL 530E I6 HEUI ENGINES

4. COMPONENT LOCATIONS. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..397

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

373

1. DESCRIPTION
Refer to Diagnostic Manual EGES-175 for detailed information. The Diamond Logic CEC is standard on International engines and provides many engine/vehicle functions including: A. Cruise/PTO Controls B. Engine Diagnostics C. Engine Protection System D. Engine Cooling System E. Exhaust Brake Control F. Speedometer/Tachometer Input Signals

G. ABS/Traction Control Interface. Refer to the International manual furnished with the vehicle for additional feature information. Since each CEC is electronically programmable to individual owner specications, the operating parameters will vary from vehicle to vehicle. The CEC receives inputs from the following International components: A. Vehicle Speed Sensor (VSS) B. Accel. Position Sensor (APS) C. Idle Validation Switch (IVS) D. Service Brake Switch E. Park Brake Switch F. Clutch Switch

G. Low Coolant Level Sensor H. Cab Switches The CEC receives inputs from sensors and switches, then outputs signals to the injectors, exhaust brake solenoid, and other system components. For information on remote PTO control for body builder applications, refer to Miscellaneous Information in CT-471 Body Builder Book.

2. OPERATION
Refer to the circuit diagram I6 HEUI-ENGINE CONTROLS in CTS-5298 or S08225. The CEC is connected to the International electrical system at CEC module connector (379).

s08210

374

10 INTERNATIONAL 530E I6 HEUI ENGINES

2.1. CEC POWER AND GROUND


The CEC receives 12 volt operating power, with the key switch in the ignition position, from the CEC power relay. The circuitry is protected by a 40 amp fuse that is part of the battery cable assembly. The control module ground is to the negative post of the batteries. Power is supplied from the batteries to circuit 14A, a 40A power relay fuse, circuit 14B, positive battery connector, circuit 14B, power connector (490), and circuit 14B to the Electronic Control Module (CEC) power relay (396) contacts. Power is also supplied from the (B1) battery feed stud to circuit 14BB, fuse F10B, circuit 97DCT, circuit 97CT, bulkhead connector (190), and circuit 97CT to the Module power relay coil. From the relay, power is applied to circuit 97AH and pin 25 of the CEC (379). When key switch (24) is moved to the ignition position, power is supplied to circuit 13AA, fuse F10C, circuit 97DS, circuit 97CR, bulkhead connector (190), and circuit 97CR to pin 24 of the CEC (379). This signals the CEC that the ignition switch is on and causes the CEC to internally switch pin 25 to ground. This completes the circuit for the Module power relay (396) and energizes the relay. With the relay energized, power is applied through the relay contacts to circuit 97CM and a splice. From the splice power is applied to the CEC pins 21, 22, and 41 on circuits 97CL, 97CK, and 97AL respectively. Grounds for the CEC pins 1, 2, 23, and 42 are through circuits 11GW, 11GX, 11GY, and 11GZ respectively, to a splice. From the splice, ground is through circuit 11G, the battery harness connector (490), circuit 11G, negative battery connector (665) and circuit 11G to the negative battery terminal.

2.2. ACCELERATOR POSITION SENSOR (APS) AND IDLE VALIDATION SWITCH (IVS)
The Accelerator Pedal Position Sensor (APS) is a potentiometer type sensor which, when supplied with a 5 volt reference signal from the Electronic Control Module (CEC), provides a linear analog voltage signal that indicates the drivers demand for power. The APS signal is used in calculating desired fuel quantity and injector timing. The Idle Validation Switch (IVS) is a 1/12 volt switch that provides the CEC with a redundant signal to verify when the pedal is in the idle position. These two functions are integrated into one component mounted on the accelerator pedal. The pedal assembly is serviceable to the extent that the APS/IVS can be replaced without replacing the complete pedal. The engine Electronic Control Module (CEC) determines the position of the accelerator pedal by processing the input signals from the Accelerator Position Sensor (APS) and Idle Validation Switch (IVS). The CEC sends a regulated 5 volt signal through the black CEC module connector (379), circuit 97U, engine connector (190), circuit 97U to a splice, and circuit 99C to the APS/IVS (267). The APS then returns a variable voltage signal (depending on pedal position) from connector (267), circuit 99A, connector (190) and circuit 99B to CEC module connector (379). The APS is grounded through circuit 99B/97W, connector (190), and circuit 97W/97BW to CEC (379). The CEC learns the lowest and highest pedal positions by reading and storing the minimum and the maximum voltage levels from the APS. In this manner the CEC auto-calibrates the system to allow maximum pedal sensitivity. The CEC auto-calibrates as the key is on, but when the key is turned off, these values are lost. When the key is turned on again, this process starts over. When the pedal is disconnected (or a new one is installed), the pedal does not need to be calibrated, as the calibration happens when the key is turned on.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

375

The Idle Validation Switch (IVS) (267) receives 12 volt ignition voltage from ignition adapter (494) circuits 13BBB, fuse F10A, circuit 47A and circuit 99E. When the pedal is not in the idle position (throttle applied), the IVS sends this 12 volt signal to the CEC over circuit 99D, clutch switch (294), connector (190), and circuit 99D to the CEC (379). The CEC (379) compares the inputs it receives on circuit 99B and circuit 97A from the APS/IVS to verify when the pedal is in the idle position. If the APS signal from circuit 99B indicates throttle is being applied, then the CEC expects to see 12 volts at IVS circuit 97A. If the APS signal, circuit 99B, indicates throttle is not applied, then the CEC expects to see 0 volts at the IVS circuit 97A. The timing process is critical between the APS and the IVS sensors. For this reason, it is very difcult to determine if the APS/IVS assembly is working properly using a volt-ohmmeter.

2.3. BAROMETRIC AIR PRESSURE (BAP) SENSOR


The Barometric Air Pressure sensor (BAP) is a variable capacitance sensor which produces a linear analog voltage signal that varies with altitude. The BAP signal is used by the CEC to adjust timing and fuel quantity, to optimize engine operation and control smoke throughout all altitude conditions. The CEC (379) sends a regulated 5 volt signal from CEC (379) on circuit 97U, through the black CEC module connector (379), circuit 97U, engine connector (190), circuit 97U to a splice, and circuit 97BL to BAP sensor (1160). The BAP sensor (1160) returns a variable voltage signal (represents atmospheric pressure) on circuit 97CD, connector (190) and circuit 97CD to the CEC (379). The BAP sensor (1160) is grounded by circuit 97Z/97W, connector (190), circuit 97BW to the CEC (379) signal ground.

2.4. AIR TEMPERATURE SENSOR (ATS)


The ambient Air Temperature Sensor (ATS) is a thermistor type sensor that has a variable resistance which changes when exposed to different temperatures. The CEC measures the signal from the sensor and uses the data to adjust timing and fuel rate to limit smoke emissions in cold weather starting. The CEC module connector (379) sends a regulated 5 volt reference signal through circuit 97AX to the Air Temperature Sensor (463). As the temperature changes, the sensor changes resistance and provides the CEC with an air temperature signal voltage. The sensor is grounded through circuit 97BU/97BW to the CEC signal ground.

2.5. ATA DATA LINK CONNECTOR


The six pin ATA data link connector (37) allows an electronic service tool (EST) to communicate with the ECM. The data link carries serial data transmissions between the ECM and the electronic service tool, and between the ECM and the speedo/tachometer cluster. Thus, the ECM provides vehicle and engine information to the speedo/tachometer, and the EST. The ATA data link connector (137), which is located on the left instrument panel, has circuits in four of the six cavities. The data link circuits are a twisted wire pair because twisting the wires helps shield them from interference. The circuits are as follows: A. Circuit 98X(+) is the positive data link connection, and it is fed by the positive data link connector (514), circuit 98(+), connector (190), and circuit 98(+) coming from the CEC module connector (379).

s08210

376

10 INTERNATIONAL 530E I6 HEUI ENGINES

B. Circuit 98B(-) is the negative data link connection, and it is fed by the negative data link connector (515), circuit 98C(-), connector (190), and circuit 98C(-) coming from the ECM CEC module connector (379). C. Circuit 97DL is a 12 volt feed and is fed from the battery adapter (497), circuit 14DLF, and 5A fuse F10D. Thus, it provides power for the electronic service tool. D. Circuit 11GR is connected to ground adapter (453), and provides a ground for the electronic service tool.

2.6. DIAGNOSTIC ON/OFF SWITCH


A lighted diagnostic on/off switch is provided for on-board diagnostics. The switch is connector to ground adapter (453). Moving the switch to the on position, closing the switch, applies the ground to circuit 98, connector (190), and circuit 98 to the CEC module connector (379). This tells the ECM that the diagnostic on/off switch has been turned on. Thus, the ECM will switch modes to display fault codes or the absence of codes by ashing the engine warning light and the stop engine light.

2.7. CRUISE CONTROL/PTO SYSTEM


The Cruise/PTO system feature controls engine and vehicle speed using automotive style set/coast, resume/accel., on/off switches and is controlled by the CEC. Speed control is disabled when the off switch is depressed, the brake is applied, the clutch pedal is depressed or an automatic transmission is placed in neutral. The cruise control switches and circuitry are also used for in-cab control of preset, variable, and mobile PTO operation applications and required programming of the engine CEC. Power is supplied to the lighted cruise control on/off switch (391) through I1 ignition adapter, circuit 13AA, fuse F-10C, circuit 97DS and circuit 97AD. When the on/off switch is in the on position, power is supplied through circuit 97CF, circuit 97CF, dash connector (190) and circuit 97CF to CEC (379). This enables the cruise control. The lighted cruise set/resume (436) is a momentary switch. This switch receives 12 volts on circuits 97CA and 97CF from the cruise on/off switch (435) when it is in the on position. The cruise selector switch sends 12 volts from the switch on circuit 97DJ, connector (190), and circuit 97DJ to CEC module connector (379) terminal 32 while in the set position. In the resume position, the switch sends 12 volts by way of circuit 97DK, connector (190), and circuit 97DK to the ECM CEC module connector (379) terminal 22. If the cruise control speed has not been engaged, momentarily depressing the switch causes the CEC to resume the last engine RPM setting. If the cruise control is already engaged, momentarily depressing the resume/accel portion of the switch will cause the engine RPM and speed to increase in small incremental amounts until the desired speed is reached. For information on remote PTO control for body builder applications, refer to Miscellaneous Information in CT-471 Body Builder Book.

2.8. CLUTCH SWITCH


The clutch pedal switch supplies the Driveline Disengaged Signal (DDS) to the CEC and the service brake switches supply a Brake Normally Open (BNO) and Brake Normally Closed (BNC) signal to the CEC. These signals indicate pedal positions and are used by the CEC in operating the Cruise/PTO control system. The clutch switch (294) is a normally open (N.O.) switch that is adjusted so that its contacts are closed when the clutch pedal is in the released position. Depressing the clutch pedal causes the switch contacts to open.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

377

Twelve (12) volts is supplied to connector (294) terminal B from I1 ign. adapter (494) through circuit 13BBB, fuse F-10A, circuit 47A and circuit 97. When the switch is closed 12 volts is applied on circuit 97A through connector (190) to CEC (379).

2.9. COOLANT LEVEL PROBE


The low coolant level probe is connected through connector (400A) and circuit 34B to CEC module connector (379). A signal from the ECM is sent to the probe on this circuit. The other side of the probe is connected to chassis ground. When coolant level is below the probe, the circuit resistance changes, indicating to the ECM that the coolant level is below the critical level.

2.10. VEHICLE SPEED SENSOR (VSS)


The Vehicle Speed Sensor (VSS) provides vehicle speed and engine RPM signals to the CEC. This information is also used by the CEC to control the Cruise/PTO system. Two types of sensors are available. The threaded (adjustable) sensor is used on most transmissions. A new push-in style sensor (nonadjustable) is used on some transmissions.

2.11. SERVICE BRAKE SWITCH


The service brake switch (141) is a normally closed (N.C.) air operated switch. Its contacts are closed when the brakes are not applied, and its contacts open up when the brakes are applied. One terminal of the service brake switch (141) is connected to circuit 97NM, connector (190), circuit 97NM and the ECM (379). The other terminal of the switch is connected to 12 volts by way of circuits 97AL and 97DT to fuse F-10B.

2.12. ANTILOCK BRAKE INTERFACE


If the vehicle is equipped with antilock brakes, information is shared with the ABS controller module over the ATA data link. Circuits 98K(-) and 97J(+) from the ABS controller connector to connector (282) and terminate at data link neg. (515) and data link pos. (514). With the cruise control on/off switch in the on position, power is also applied from the switch to the cruise set/resume switch (392) through circuit 97CA. Momentarily depressing the set portion of this switch supplies a 12 volt signal to the CEC through circuit 97DA, dash connector (190), and circuit 97DH/7DJ. This engages the cruise control and causes the CEC to maintain the current engine RPM. If the cruise control speed is already set, depressing the switch in the set position causes the engine RPM to decrease until the switch is released. With the cruise control on/off switch (391) in the on position, depressing the resume/accel portion of the set/resume switch (392) supplies a 12 volt signal to the CEC through circuit 97DE, dash connector (190) and circuit 97DE/97DK. If the cruise control speed has not been engaged, momentarily depressing the switch causes the CEC to resume the last engine RPM setting. If the cruise control is already engaged, momentarily depressing the resume/accel portion of the switch will cause the engine RPM and speed to increase in small incremental amounts until the desired speed is reached. The cruise control switches and circuitry are also used for in-cab control of preset, variable, and mobile PTO operation applications and required programming of the engine CEC.

2.13. ENGINE BRAKE


On vehicles equipped with compression braking, switch (434) will turn the engine brake on or off. Switch (433) will determine how many cylinders are used for braking by putting resistances from the resistor printed circuit

s08210

378

10 INTERNATIONAL 530E I6 HEUI ENGINES

board (390) in parallel. The CEC senses the voltage drop, across the parallel resistance, through (390) and will control the engine accordingly. The engine brake relay (286) disables engine braking when the ABS is active. When engine brake on/off switch (434) is on and the engine brake relay is not energized, a ground is sent from G1 ground adapter (453) on circuit 24GA, 24AN and 24AT to terminals 2 and 5 of engine brake on/off switch (434). When engine brake select switch (434) is on, ground will be available at terminals 3 and 6 of the switch. 5 volts from CEC connector (379) will be applied to resistor printed circuit board (390), terminal F. This voltage will drop across a 2.2K ohm resistor (which may be selected in parallel with other resistors). When engine brake select switch (433) is in the 1 position, only the 2.2k ohm resistor connected to terminal D in the printed circuit board (390) will affect the voltage drop in the circuit. This will signal the CEC to select compression braking on two cylinders of the engine. When engine brake select switch (433) is in the 2 position, ground from (434) is supplied from terminal 3, on circuit 24AD, to resistor printed circuit board (390) terminal C. 5 volts from CEC connector (379) will be applied to resistor printed circuit board (390). The voltage drop across the parallel resistance between the 2.2K ohm and the 680 ohm resistor of printed circuit board (390) will signal the CEC to engage compression braking on four cylinders of the engine. When engine brake select switch (433) is in the 3 position, ground from (434) is supplied from terminal 3, on circuit 24AD, through switch (433), contacts 6, 2 & 3 to resistor printed circuit board (390) terminals B and C. 5 volts from CEC connector (379) will be applied to resistor printed circuit board (390). The voltage drop across the parallel resistance between the 2.2K ohm, the 680 ohm and the 121 ohm resistor of printed circuit board (390) will signal the CEC to engage compression braking on all six cylinders of the engine.

3. TROUBLESHOOTING
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. Check any light or indicator lamp laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. C. Inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual. D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit, by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not covered in detail. It is assumed that the technician knows to check for a malfunctioning switch, relay, or solenoid.

3.1. DETERMINING FAULT CODES


Refer to Engine/Vehicle Manual EGES-175 for detailed directions on reading fault codes.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

379

The EZ-Tech or PRO-LINK 9000 electronic service tools (EST) can be used to identify logged fault codes. Refer to the EST manual for operating instructions. The Serv/Check Engine and Warn Engine lights can be used to read fault codes by following the procedure following. Reading Flash Codes KEY ON ENGINE OFF PROCEDURE NOTE All International ash codes are three digit numbers. 1. Hold in the diagnostic on/off button and turn the key to the on position. Release the diagnostic button. Do not start the vehicle. 2. The Serv/Check Engine light will FLASH one time. This indicates the beginning of active fault codes. 3. The Warn Engine light will FLASH repeatedly signalling the active fault codes. The number of ashes should be counted in sequence. 4. At the end of each digit of the code there will be a short pause. 5. After each active code is displayed the Serv/Check Engine light will FLASH once to indicate the next code. 6. Once all active codes have been displayed, the Serv/Check Engine light will FLASH twice to indicate the beginning of the inactive codes. 7. Inactive codes will be displayed in the same manner as active codes. 8. Once the inactive codes have been displayed, the Serv/Check Engine light will FLASH three times to indicate that all stored codes have been displayed. Refer to the directions in Engine/Vehicle Manual EGES-175. If the diagnostics indicate that a circuit external to the engine is suspect, use the diagnostic tables included in this section for a step-by-step procedure. Refer to the appropriate circuit diagram for International I6 HEUI ENGINES in CTS-5298 or S08225.

3.2. IMPORTANT STEPS BEFORE TESTING


1. Gather information by talking to the driver 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 problem. Is the complaint due to misunderstood customer selected parameters? Use an EST to review customer selected parameters. 3. Check for and record any logged fault codes.

s08210

380

10 INTERNATIONAL 530E I6 HEUI ENGINES

a. Do the logged codes correlate to probable causes? 4. Were the codes logged about the same time as the symptoms appeared? Were the codes logged repeatedly? 5. Are the logged codes related to other symptoms? Do they have a common cause? 6. Avoid preconceived ideas! Eliminate any non-electrical causes for the problem rst (contaminated fuel, clogged air lters, etc.).

3.3. INSPECTING ELECTRICAL CONNECTORS


Visual Inspection The troubleshooting guide requires checking specic connectors. Use the following steps to determine if the connector is causing the problem. If a defective condition is found, make the necessary corrections and continue the process. 1. Check the connector lock mechanism or retaining screw. Make sure the connector is capable of properly locking the connector together. 2. Perform a 10 pound pull-test on each terminal/wire in the connector. Each terminal/wire assembly should easily withstand 10 pounds of pull and remain in the connector. This test determines (A) if the wire is properly in the terminal and (B) if the terminal is properly inserted into the connector. Correct any defects noted. 3. Visually inspect wiring. Inspect for worn or damaged wires. Check for pinched or damaged harness. 4. Visually inspect connectors. Verify that pins and sockets are free of corrosion, dirt or any other contaminants, and damage. Verify correct alignment and location of terminals in the connector. 5. Check individual pins and sockets. This is especially important with an intermittent symptom. Using a new pin, insert the pin into each socket, one at a time, checking for a good grip on the pin by the socket. Repeat for each pin on the mating side of the connector, using a new female terminal for the test. 6. Inspect Engine Ground Stud. Inspect this ground and other related grounds for clean, tight connections that are free of corrosion and/or other defective conditions. Performing Electrical Tests at CEC Module Connector (379) CEC module connector (379) mates with the black ECM connector. This is a 60pin connector, with the International side having female terminals (sockets) and the ECM side having pins. NOTE No tests in this manual require testing into the black ECM connector. When testing the chassis side of CEC module connector (379), never insert meter probes into the sockets, as the probes will damage the sockets.Always use breakout box (ZTSE-4445) as described in International Engine/Vehicle Manual EGES-175. Replacing International Components When replacing electrical switches, connectors (including pins and sockets), relays or other components, use only approved International replacement parts. Many of the switches have gold or silver plated contacts and

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

381

some of the connectors have gold plated terminals. By using correct replacement parts, you maintain the design integrity of the system. All of the relays and other solenoids installed by International are suppressed to prevent voltage spikes from damaging electrical components. Again, use only International replacements for these components.

3.4. TESTING HELLA RELAY


International circuits use suppressed Hella 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 in the vehicle. These relays must be replaced by 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 Test Procedure 1. With relay removed, measure resistance between terminals 30 and 87A. If resistance is less than 5 ohms, go to step 2; otherwise replace the relay. 2. Measure resistance between terminals 30 and 87. If resistance is 100K ohms or more, go to step 3; otherwise replace the relay. 3. Using 12V battery source and test leads, connect (+) lead to terminal 85 and (-) lead to terminal 86. If relay energizes with an audible click sound, go to step 4; otherwise replace the relay. 4. While relay is energized, measure resistance between terminals 30 and 87. If resistance is less than 5 ohms, go to step 5; otherwise replace the relay. 5. While relay is energized, measure resistance between terminals 30 and 87A. If resistance is 100K or more, the relay is good; otherwise replace relay.

3.5. CEC POWER AND GROUND SYSTEM CIRCUITRY


Table 118 STEP 1. CEC Power and Ground System Circuitry KEY Off/ On ACTION Disconnect black CEC module connector (379). Turn key on and at cavity 24, measure voltage from circuit 97CR to ground. Remove fuse F10-C and check for open condition. TEST POINTS (379), cavity 24, 97CR to gnd. SPEC. 12 1.5 volts. YES-IN SPEC. Go to Step 6. NO-OUT OF SPEC. Go to next step.

2.

Off

F10-C

<1 ohm.

Go to next step. Go to next step.

Locate cause of overload condition, then repair. Replace fuse. Locate cause of low or no voltage in circuit 13AA, then repair.

3.

On

At F10-C fuse cavity A, check voltage from circuit 13AA to ground. Re-install fuse.

F10-C, cavity A, 13AA to ground.

12 1.5 volts.

s08210

382

10 INTERNATIONAL 530E I6 HEUI ENGINES

Table 118 STEP 4.

CEC Power and Ground System Circuitry (cont.) KEY Off/ On ACTION Disconnect bulkhead connector (190). Turn key on and at cavity V, measure voltage from circuit 97CR to ground. Locate cause of low or no voltage in circuit 97CR between (190) and CEC connector (379). Reconnect connectors. Remove CEC power relay (396). At socket cavity 1/E, measure voltage from circuit 14B to ground. Remove 40A power module fuse holder from between circuits 14A and 14B, and check for open condition. At fuse holder, measure voltage from circuit 14A to ground. Re-install fuse. Disconnect battery/engine harness connector (490). At circuit 14B, check voltage to ground. Locate cause of low or no voltage in circuit 14B between (490) and CEC power relay (396), then repair. Reconnect connectors. At relay (396) socket cavity A/5, measure voltage from circuit 97CT to ground. Remove fuse F10B and check for open condition. (396), cavity A/5, 97CT to ground. F10B (396), cavity 1/E, 14B to ground. TEST POINTS (190), cavity V, 97CR to ground. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of low or no voltage in circuit 97CR, then repair.

5.

Off

If condition persists, go to next step. 12 1.5 volts. Go to Go to next step. Step 11.

6.

Off

7.

Off

Fuse holder, 40A fuse.

<1 ohm.

Go to next step.

Locate cause of overload condition, then repair. Replace fuse. Locate cause of low or no voltage in circuit 14A, then repair. Locate cause of low or no voltage in circuit 14B, then repair.

8.

Off

Fuse holder, 14A to ground. (490), 14B to ground.

12 1.5 volts.

Go to next step. Go to next step.

9.

Off

12 1.5 volts.

10.

Off

If condition persists, go to next step. 12 1.5 volts. Go to Step 16. Go to next step. Go to next step.

11.

Off

12.

Off

<1 ohm.

Locate cause of overload condition, then repair. Replace fuse.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

383

Table 118 STEP 13.

CEC Power and Ground System Circuitry (cont.) KEY Off ACTION At F10B fuse cavity A, measure voltage from circuit 14B, to ground. Re-install fuse. Disconnect bulkhead connector (190). Turn key on and at cavity F, measure voltage from circuit 97CT to ground. Locate cause of low or no voltage in circuit 97CT between (190) and CEC power relay (396), then repair. Bench test CEC power relay (396). Refer to Testing Hella Relay. Measure resistance of circuit 97AH between relay (396), socket cavity B/2, and CEC module connector (379), cavity 25. Measure resistance of circuits between relay (396), socket cavity C/4 and CEC module connector (379), cavity 21, 22, and 41. At CEC module connector (379), measure resistance of circuits at cavities 1, 2, 23, and 42 to ground. Disconnect battery harness connector (490). At cavity B, measure existence of circuit 11-G to ground. Relay (396) Relay tests good. <1 ohm. Go to next step. Go to next step. Replace CEC power relay. Locate open or poor connection in circuit 97AH, then repair. TEST POINTS F10B, cavity A, 14B to ground. (190), cavity F, 97CT to ground. SPEC. 12 1.5 volts. YES-IN SPEC. Go to next step. Go to next step. NO-OUT OF SPEC. Locate cause of low or no voltage in circuit 14B, then repair. Locate cause of low or no voltage in circuit 97CT, then repair.

14.

Off/ On

12 1.5 volts.

15.

Off

16.

Off

17.

On

(396), cavity B/2 ,to (379), cavity 25.

18.

Off

(396), cavity C/4, to (379), cavity 21, 22, 41.

<1 ohm.

Go to next step.

Locate open or poor connection in circuits 97CM/97CL, 97CM/97CK, or 97CM/97AL, then repair. Go to next step.

19.

Off

(379), cavity 1, 2, 23, & 42 to ground.

<5 ohms.

Go to Step 22.

20.

Off

(490), cavity B, 11-G to ground.

<1 ohm.

Go to next step.

Locate open or poor connection in circuit 11-G to negative battery terminal, then repair.

s08210

384

10 INTERNATIONAL 530E I6 HEUI ENGINES

Table 118 STEP 21.

CEC Power and Ground System Circuitry (cont.) KEY Off ACTION Locate open or poor connection in circuits 11-G/11-GX, 11-G/11-GW, 11-G/11-GY, or 11-G/11-GZ, then repair. Go to next step. Reconnect connectors. Power and ground system circuits check good. TEST POINTS SPEC. YES-IN SPEC. NO-OUT OF SPEC.

22.

Off

3.6. ACCELERATOR (APS/IVS), BAROMETRIC AIR PRESSURE (BAP) AND AMBIENT AIR TEMPERATURE SENSOR SYSTEMS (ATS)
Table 119 Accelerator (APS/IVS), Barometric Air Pressure (BAP) and Ambient Air Temperature Sensor Systems (ATS) STEP 1. KEY Off ACTION Is a fault code present for APS/IVS sensor/switch? Remove and check fuse F10A for open condition. F10A <1 ohm. TEST POINTS SPEC. YES-IN SPEC. Go to next step. Go to next step. Go to next page. NO-OUT OF SPEC. Go to Step 10.

2.

Off

Locate cause of overload condition, then repair. Replace fuse. Locate cause of low or no voltage in circuits 13BB or I1 Ignition Adapter (494), then repair. Locate cause of low or no voltage in circuit 99E, then repair. Locate open or poor connection in circuit 99B or bulkhead connector (190), then repair.

3.

On

At fuse F10A, measure voltage from cavity A, circuit 13BB to ground. Re-install fuse. Disconnect APS/IVS connector (267) and at cavity F, measure voltage from circuit 99E to ground. At (267), install jumper from cavity A, circuit 99A to ground. Disconnect CEC connector (379). At cavity 8, measure resistance from cir. 99B to ground.

F10A, cavity A, 13BB to ground.

12 1.5 volts.

4.

On

(267) cavity F, 99E to ground. (379), cavity 8, 99B to ground.

12 1.5 volts.

Go to next step. Go to next step.

5.

Off

<1 ohm.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

385

Table 119 Accelerator (APS/IVS), Barometric Air Pressure (BAP) and Ambient Air Temperature Sensor Systems (ATS) (cont.) STEP 6. KEY Off ACTION At (267), move jumper to cavity B, circuit 99B and ground. At (379) cavity 11, measure resistance of cir. 97BW to ground. At (267), move jumper to cavity C, cir. 99C and ground. At (379) cavity 3, measure resistance of circuit 97U to ground. At (267), move jumper to cavity D, circuit 99D and ground. At (379) cavity 27, measure resistance of circuit 99D to ground. Remove jumper and reconnect connectors. APS/IVS circuits check good? Is problem corrected? Is a fault code present for BAP sensor? Disconnect BAP sensor connector (1160). Install jumper wire from cavity 1, cir. 97Z to ground. Disconnect CEC module connector (379). At cavity 11, measure resistance of cir. 97BW to ground. At (1160), move jumper wire to cavity 2, circuit 97BL and ground. At (379) cavity 3, measure resistance of circuit 97U to ground. At (1160), move jumper wire to cavity 3, circuit 97D and ground. At (379) cavity 29, measure resistance of circuit 97CD to ground. (379), cavity 11, 97BW to ground. <1 ohm. TEST POINTS (379), cavity 11, 97BW to ground. SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 97BW/97W, bulkhead connector (190), or cir. 97W/99B, then repair. Locate open or poor connection in circuit 97U, bulkhead connector (90), or cir. 97U/99C, then repair. Locate open or poor connection in circuit 99D, or bulkhead connector (190), then repair. Replace APS/IVS. If problem persists, refer to Engine Diagnostic Manuals. Go to Step 15.

7.

Off

(379), cavity 3, 97U to ground.

<1 ohm.

Go to next step.

8.

Off

(379), cavity 27, 99D to ground.

<1 ohm.

Go to next step.

9.

Off

End test.

10.

Off

Go to next step. Go to next step.

11.

Off

Locate open or poor connection in circuit 97Z/97W, bulkhead connector (190), or circuit 97W/97BW, then repair.

12.

Off

(379), cavity 3, 97U to ground.

<1 ohm

Go to next step.

Locate open or poor connection in circuit 97U, bulkhead connector (190), or circuit 97U/97Bl, then repair. Locate open or poor connection in circuit 97CD or bulkhead connector (190), then repair.

13.

Off

(379), cavity 29, 97CD to ground.

<1 ohm.

Go to next step.

s08210

386

10 INTERNATIONAL 530E I6 HEUI ENGINES

Table 119 Accelerator (APS/IVS), Barometric Air Pressure (BAP) and Ambient Air Temperature Sensor Systems (ATS) (cont.) STEP 14. KEY Off ACTION Remove jumper and reconnect connectors. BAP system circuits check good? Is problem corrected? Is a fault code present for the ATS system? Disconnect ATS connector (463). Install jumper wire from cavity B, circuit 97AX to ground. Disconnect CEC module connector (379). At cavity 12, measure resistance from circuit 97AX to ground. At (463), move jumper to cavity A, circuit 97BU and ground. At (379), cavity 11, measure resistance of circuit 97BW to ground. Remove jumper and reconnect connectors. ATS system circuits check good? Is problem corrected? (379), cavity 12, 97AX to ground. <1 ohm. TEST POINTS SPEC. YES-IN SPEC. End test. NO-OUT OF SPEC. Replace BAP sensor. If problem persists, refer to Engine Diagnostic Manuals. End test.

15.

Off

Go to next step. Go to next step.

16.

Off

Locate open or poor connection in circuit 97AX, then repair.

17.

Off

(379), cavity 11, 97BW to ground.

<1 ohm.

Go to next step.

Locate open or poor connection in circuit 97BW/7BU, then repair. Replace ATS. If problem persists, refer to Engine Diagnostic Manuals.

18.

Off

End test.

3.7. DIAGNOSTIC CONNECTOR (137) AND DATA LINK CIRCUITS


Testing Diagnostic Connector Power and Ground Circuits Table 120 STEP 1. Testing Diagnostic Connector Power and Ground Circuits KEY Off ACTION Remove and check 5A fuse F10D for open condition. Is fuse open? TEST POINTS F10D SPEC. <1 ohm. YES - IN SPEC. Go to next step. NO - OUT OF SPEC. Locate cause of overload condition, then repair. Replace the fuse.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

387

Table 120 Testing Diagnostic Connector Power and Ground Circuits (cont.) STEP 2. KEY On ACTION Re-install fuse F10D. At connector (137), measure voltage from circuit 97DL to ground. At connector (137), measure voltage between circuit 97DL and circuit 11-GR. TEST POINTS (137), 97DL to ground. SPEC. 12 1.5 volts. YES - IN SPEC. Go to next step. NO - OUT OF SPEC. Locate cause of no or low voltage in circuit 97DL, then repair. Locate open or poor connection in circuit 11-GR or ground adapter (43), then repair.

3.

On

(137) between 97DL and 11-GR.

12 1.5 volts.

Power and gnd. circuits to diagnostic conn. (137) check good.

3.8. TESTING DIAGNOSTIC CONNECTOR AND SPEEDOMETER/TACHOMETER POSITIVE AND NEGATIVE DATA LINK CIRCUITS
NOTE A multimeter cannot be used to measure the voltage of the signal on these circuits. Table 121 Testing Diagnostic Connector and Speedometer/Tachometer Positive and Negative Data Link Circuits STEP 1, KEY Off ACTION Disconnect CEC module connector (379) from ECM and (421) from speedometer unit. If other devices are connected at data link connectors (514) and (515), disconnect them. At connector (137) measure resistance from terminal A, circuit 98(+) to ground. At connector (137) measure resistance from terminal B, circuit 98B(-) to ground. At connector (137), measure resistance between terminal A, circuit 98(+) and terminal B, circuit 98B(-). TEST POINTS (137), 98(+) to ground. SPEC. >100K ohms. YES - IN SPEC. Go to next step. NO - OUT OF SPEC. Locate short to ground, then repair.

2.

Off

(137), 98B(-) to ground. (137) between 98(+) and 98B(-).

>100K ohms

Go to next step.

Locate short to ground, then repair.

3.

Off

>100K ohms.

Go to next step.

Locate short circuit between circuits connected to terminal A 98(+), 47/48(+) and terminal B 98B(-), 47/48(-), then repair.

s08210

388

10 INTERNATIONAL 530E I6 HEUI ENGINES

Table 121 Testing Diagnostic Connector and Speedometer/Tachometer Positive and Negative Data Link Circuits (cont.) STEP 4. KEY Off ACTION At CEC module connector (379), use test lead to jumper terminal 16, circuit 98A(+) to ground. At connector (137) terminal A, circuit 98(+) measure resistance to ground. With jumper still in place at terminal 16, circuit 98A(+), measure resistance to ground at circuit 47/48(+) and connector (421). At CEC module connector (379) use test lead to jumper terminal 16, circuit 98A(+) to terminal 17, circuit 98C(-). At connector (137) measure resistance between terminal A, circuit 98(+) and terminal B, circuit 98B(-). With jumper still in place, at connector (421) measure resistance between 47/48(-) and ground. TEST POINTS (137), 98(+) to ground. SPEC. <5 ohms. YES - IN SPEC. Go to next step. NO - OUT OF SPEC. Locate open or poor connection in circuit 98(+) between connectors (514) and (137) or open or poor connection in circuit 98A(+) between connectors (514) and (379), then repair. Locate open or poor connection in circuit 47/48(+) between connectors (421) and (514), then repair. Locate open or poor connection in circuit 98B(-) between connectors (515) and (137), or open or poor connection in circuit 98C(-) between connectors (515) and (379), then repair.

5.

Off

(421), 47/48(+) to ground.

<5 ohms.

Go to next step.

6.

Off

(137) between 98(+) and 98B(-).

<5 ohms.

Go to next step.

7.

Off

(421), 47/48(-) to ground.

<5 ohms.

Locate open in circuit 47/48(-) between conn. (421) and (515), then repair.

All data link circuits check good.

3.9. VEHICLE SPEED SIGNAL


Adjustable VSS Adjustment: Turn sensor in until it bottoms out, then back off one full turn. Construct test leads using terminals 1680205C1, short length of 16 gauge wire and alligator clips.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

389

WARNING A jack must never be used alone to support vehicle. The jack may lower and serious injury could result. Always support vehicle with oor jacks. Always block wheels to prevent vehicle from moving.

WARNING EXTREME CAUTION should be used to prevent personal injury resulting from contact with rotating vehicle wheels when connecting. Testing Vehicle Speed Sensor (303) Table 122 STEP 1. Testing Vehicle Speed Sensor (303) KEY Off ACTION Inspect VSS for damage and proper adjustment before performing this test. Disconnect engine harness connector (303) from VSS and use test leads to measure resistance between terminal A and B of the sensor. VSS, A to B. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

2.

Off

600 Go to next to 800 step. ohms for adjustable sensor. 1500 to 3500 ohms for push- in sensor. >100K ohms. Go to next step. Go to next step.

Replace the vehicle speed sensor (VSS).

3.

Off

Measure resistance to ground at both terminals (A and B) of the sensor. VSS sensor output test: This test checks for proper AC voltage output signal from the VSS sensor. Improper sensor adjustment will cause low, erratic or no output. Block front wheels and place rear axles on oor stands.

VSS, A and B to ground.

Replace the vehicle speed sensor (VSS).

4.

Off

5.

Off

Go to next step.

s08210

390

10 INTERNATIONAL 530E I6 HEUI ENGINES

Table 122 STEP 6.

Testing Vehicle Speed Sensor (303) (cont.) KEY Off ACTION Use AC voltmeter with sufcient length leads to avoid personal contact with rotating vehicle wheels during test. Connect meter leads to sensor test leads. Run engine at idle speed with transmission in high gear. Measure voltage across the two sensor terminals. VSS, A to B. >2.0 volts AC. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

7.

On

The vehicle speed sensor checks good.

If sensor was properly adjusted, replace the sensor.

Testing Vehicle Speed Sensor To ECM Circuits Table 123 STEP 1. Testing Vehicle Speed Sensor To ECM Circuits KEY Off ACTION Disconnect connector (303) from VSS and (379) from the ECM. At connector (303) measure resistance to ground at both terminals. At (303) measure resistance between terminals. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate short to ground in circuit (47A or 47), then repair.

(303), both >100K terminals to ohms. ground.

2.

Off

(303), between terminals.

>100K ohms.

Go to next step.

Locate short circuit between circuits 47 and 47A, between connectors (303) and (379), then repair. Locate open or poor connection in circuit 47A, then repair.

3.

Off

At CEC module connector (379) use test lead to jumper terminal 40 to ground. At connector (303) measure resistance to ground, at circuit 47A. At CEC module connector (379) use test lead to jumper terminal 39 to ground. At connector (303) measure resistance to ground at circuit 47.

(303), 47A to ground.

<5 ohms.

Go to next step.

4.

Off

(303), 47 to ground.

<5 ohms.

Vehicle speed circuits and VSS check good.

Locate open or poor connection in circuit 47, then repair.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

391

3.10. CRUISE AND PTO CONTROLS


The EZ-Tech or Pro-Link Electronic Service Tool (EST) can be used to monitor system parameters relating to Cruise Control operation. Use the EST to monitor operation of system switches, including the Cruise On/Off, Set/Resume, service brake and clutch switch. Testing Cruise On/Off Switch and Circuits Table 124 Testing Vehicle Speed Sensor To ECM Circuits STEP 1. KEY Off ACTION Disconnect connector (435) from cruise on/off switch. With switch in the on position measure resistance between terminals 5 and 6. Disconnect CEC connector (379) from ECM. Measure the resistance between connector (435), terminal 6 (circuit 97AD) and (379) terminal 24 (circuit [97CR]). Measure the resistance between connector (435), terminal 5 (circuit 97AE) and (379) terminal 35 (circuit [97CF]). TEST POINTS Across cruise on/off switch. SPEC. <2 ohms. YES-IN SPEC. Go to next step NO-OUT OF SPEC. Replace the switch.

2.

Off

(435), 97AD to (379), 97CR.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 97AD or 97CR between connector (435) and (379), then repair. Locate open or poor connection in circuit 97AE or 97CF between connectors (435) and (379), then repair.

3.

Off

(435) 97AE to (379), 97.

<5 ohms.

Cruise on/off switch and circuits to (379) check good.

Testing Cruise Set/Resume Switch and Circuits Table 125 Testing Cruise Set/Resume Switch and Circuits STEP 1. KEY Off ACTION Remove connector (436) from cruise set/resume switch. With switch in neutral position, measure resistance between switch terminal 2 and terminals 1 and 3. With switch in resume position, measure resistance between switch terminals 1 and 2. TEST POINTS Set/ resume switch, 2 to 1 and 2 to 3. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace set/ resume switch.

2.

Off

Set/ resume switch, 1 to 2.

<2 ohms.

Go to next step.

Replace set/ resume switch.

s08210

392

10 INTERNATIONAL 530E I6 HEUI ENGINES

Table 125 Testing Cruise Set/Resume Switch and Circuits (cont.) STEP 3. KEY Off ACTION With switch in set position, measure resistance between switch terminals 2 and 3. Disconnect CEC connector (379) from ECM. Measure the resistance between connector (436) terminal 2 (circuit 97GB) and (379) terminal 35 (circuit 97CF. Measure the resistance between connector (436) terminal 3 and (379) terminal 32. TEST POINTS Set/ resume switch, 2 to 3. (436) circuit 97GB and (379) circuit 97CF. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace set/ resume switch.

4.

Off

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 97GB or 97CF, then repair.

5.

Off

(436), terminal 3 and (379) terminal 32.

<5 ohms.

Go to next step.

Locate open or poor connection in circuit 97DJ between connectors (436) and (379), then repair. Locate open or poor connection in circuit 97DK between connectors (436) and (379), then repair.

6.

Off

Measure the resistance between connector (436) terminal 1 and (379) terminal 31.

(436) terminal 1 and (379) terminal 31.

<5 ohms.

The set/ resume switch and circuits test good.

3.11. CLUTCH SWITCH (294)


Testing Clutch Switch and Circuits NOTE If the vehicle is equipped with an Allison transmission, this switch is replaced with a jumper connection. Table 126 Testing Clutch Switch and Circuits STEP 1. KEY Off ACTION At (294) disconnect clutch switch lead from cab harness. With clutch pedal released, measure resistance across clutch switch pigtail connector (A to B). Switch should read closed. TEST POINTS Clutch switch, A to B. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. If switch is not adjusted properly, adjust and retest. (Refer to Adjusting Clutch Switch.) If switch is adjusted properly replace the switch.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

393

Table 126 STEP 2.

Testing Clutch Switch and Circuits (cont.) KEY Off ACTION Depress clutch pedal while measuring resistance across clutch switch pigtail (294) terminal A to B. TEST POINTS Clutch switch, A to B. SPEC. >100K ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. If switch is not adjusted properly, adjust and retest (refer to Adjusting Clutch Switch). If switch is adjusted properly, replace the switch. Locate cause of no or low voltage in circuit 97 or 97AK, then repair. Locate open in circuit 97A, then repair.

3.

On

With ignition on measure the voltage between clutch switch (294), circuit 97 to ground. Disconnect CEC module connector (379) from ECM. Measure resistance between clutch switch (294) terminal A (circuit 97A) and (379) terminal 26. Measure resistance from clutch switch (294) terminal A (circuit 97A) to ground.

(294), circuit 97 to ground. (294), 97AH to ground.

12 1.5 volts.

Go to next step.

4.

Off

<5 ohms.

Go to next step.

5.

Off

(294), 97A to ground.

>100K ohms

The clutch switch circuits check good.

Locate short in circuit 97A, then repair.

Adjusting Clutch Switch The clutch switch should be mounted so that the switch actuator makes contact with the clutch pedal arm when the arm is depressed 0.5 inch at the point of actuator contact. The bracket can be bent forward or backward for adjustment. An audible click (switch closing) should be heard when the pedal is released.

3.12. SERVICE BRAKE SWITCH (141)


Testing Service Brake Switch and Circuits Table 127 STEP 1. Testing Service Brake Switch and Circuits KEY Off ACTION Remove connector (141) from service brake switch. With brakes released, measure resistance to ground at each switch terminal (not the harness connector side). TEST POINTS Brake switch to ground at each terminal. SPEC. >100K volts. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the brake switch.

s08210

394

10 INTERNATIONAL 530E I6 HEUI ENGINES

Table 127 STEP 2.

Testing Service Brake Switch and Circuits (cont.) KEY Off ACTION With (141) removed from service brake switch, and service brakes released, measure resistance across switch terminals. With vehicle air pressure >80 PSI, apply service brakes while measuring resistance across the brake switch terminals. Disconnect CEC module connector (379) from ECM and do not reconnect (141) to switch. Use test lead to jumper CEC module connector (279) terminal 44 (circuit 97M) to ground. At brake switch (141), measure resistance to ground at circuit 97NM. Measure resistance between brake switch (141) terminal C (circuits 97NM and ground. Measure resistance between CEC module connector (379) terminal 44 and 43. Measure the voltage between brake switch (141) terminal D (circuit 97AL) and ground. TEST POINTS Across switch terminals. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace the brake switch.

3.

Off

Across switch terminals.

>100K volts.

Go to next step.

Replace the brake switch.

4.

Off

(141), 97AL to ground.

<5 ohms.

Go to next step.

Locate open or poor connection condition in circuit 97NM between connectors (141) and (379), then repair.

5.

Off

(141), 97NM to ground. (379) terminal 44 and 43.

>100K ohms.

Go to next step.

Locate short circuit between circuit 97NM and ground, then repair. Locate open in circuit 97M or 97N between (379) terminals 44 and 43. Locate cause of no or low voltage in circuit 97AL, then repair.

6.

Off

<5 ohms.

Go to next step.

7.

Off

(141), 97AL to ground.

12 1.5 volts.

The brake switch and circuits check good.

3.13. TESTING LOW COOLANT SENSOR AND CIRCUITS


Table 128 STEP 1. Testing Service Brake Switch and Circuits KEY Off ACTION Disconnect (400) from the surge tank. Drain the coolant from the reservoir and remove the sensor. Measure resistance between sensor TEST POINTS Sensor terminal A and the probe tip. SPEC. <1 ohm. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace open sensor.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

395

Table 128 Testing Service Brake Switch and Circuits (cont.) STEP KEY ACTION terminal A and the probe tip. 2. Off Measure resistance between sensor terminal B and the probe tip. Disconnect CEC connector. (379) from the ECM. Measure the resistance from (379) terminal 10 (circuit 34B) to ground. At (400-A) place a jumper between circuit 34B and ground. Measure resistance from (379) terminal 10 (circuit 34B) to ground. Sensor terminal B and the probe tip. (379) circuit 34B to ground. >100 K ohms. Go to next step. Replace shorted sensor. TEST POINTS SPEC. YES-IN SPEC. NO-OUT OF SPEC.

3.

Off

>100K ohms.

Go to next step.

Locate short in circuit 34B, then repair.

4.

Off

(379) terminal 10 (circuit 34B) to ground.

<5 ohms.

Sensor and low coolant circuits check good.

Locate open in circuit 34B, then repair.

3.14. ENGINE BRAKE CONTROLS


Testing Engine Brake Switches and Circuits Table 129 Testing Engine Brake Switches and Circuits STEP 1. KEY Off ACTION Remove engine brake relay (286). At relay socket, measure resistance from circuit 24-GA to ground. Turn ignition on. At relay socket, measure voltage between circuit 24AS and ground. Bench check the engine brake relay (286). Refer to Testing Hella Relay. TEST POINTS Circuit 24-GA to ground. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit 24-GA to ground.

2.

On

Circuit 24AS and ground.

12 1.5 volts

Go to next step.

Locate cause of incorrect voltage on circuit 24AS. Replace engine brake relay.

3.

Off

Relay checks good.

Re- install relay. Go to next step.

s08210

396

10 INTERNATIONAL 530E I6 HEUI ENGINES

Table 129 STEP 4.

Testing Engine Brake Switches and Circuits (cont.) KEY Off ACTION Remove connector (434) from on/off switch. Use ohmmeter to test the switch. In the on position, continuity should be present between terminals 5 and 6, as well as 2 and 3. Use ohmmeter to test the switch. In the off position, no continuity should be present between terminals 5 and 6 or 2 and 3. At (434), measure resistance between terminal 2 and 5 to ground. Remove connector (433) from engine brake select switch. Use ohmmeter to test the switch. In the 3 position, continuity should be present between terminals 2, 6, and 3. Use ohmmeter to test the switch. In the 1 position, continuity should be present between terminals 2 and 3. Use ohmmeter to test the switch. In the 2 position, continuity should be present between terminals 2 and 6. Place engine brake on/off switch (434) to the on position. Measure the resistance from (433), circuit 24AD to ground. TEST POINTS Engine brake switch 5 to 6, as well as 2 and 3. SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Replace engine brake on/off switch.

5.

Off

Engine brake switch 5 to 6 as well as 2 and 3. (434), terminal 2 and 5 to ground. Engine brake select switch terminals 2, 5, 6, and 3. Engine brake select switch terminals 2 and 3. Engine brake select switch terminals 2 and 6. (433), circuit 24AD to ground.

>100K ohms.

Go to next step.

Replace engine brake on/off switch.

6.

Off

<5 ohms.

Re-install (434). Go to next step.

Locate open or poor connection in circuit(s) 24AN, 24AT, or 24A, then repair. Replace engine brake select switch.

7.

Off

<2 ohms.

Go to next step.

8.

Off

<2 ohms.

Go to next step.

Replace engine brake select switch.

9.

Off

<2 ohms.

Go to next step.

Replace engine brake select switch.

10.

Off

<2 ohms.

Re-install (433). Go to next step.

Locate open in circuit 24AD.

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

397

Table 129 STEP 11.

Testing Engine Brake Switches and Circuits (cont.) KEY Off ACTION Remove connector (390). Measure resistance between (390) terminal C and (433) terminal 2. Measure resistance between (390) terminal B and (433) terminal 3. Measure resistance between (390) terminal D and ground. Measure resistance between printed circuit board terminal B and F of the circuit board. Measure resistance between terminal C and F of the circuit board. Measure resistance between terminal D and F of the circuit board. TEST POINTS (390) terminal C and (433) terminal 2. (390) terminal B and (433) terminal 3. (390) terminal D and ground. Terminal B and F of the circuit board Terminal C and F of the circuit board Terminal D and F of the circuit board 24A between (434) and (433). SPEC. <2 ohms. YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open in circuit 24AF.

12.

Off

<2 ohms.

Go to next step.

Locate open in circuit 24AE.

13.

Off

<2 ohms.

Go to next step.

Locate open in circuit 24AM.

14.

Off

122 to 120 ohms. 714 to 646 ohms. 2310 to 2090 ohms.

Go to next step.

Replace resistor printed circuit board. Replace resistor printed circuit board.

15.

Off

Go to next step.

16.

Off

Replace resistor Re-install printed circuit printed board. circuit board. Go to next step. Go to next step. Locate open or poor connection in circuit 24A between connectors (434) and (379), then repair. Locate short in circuit 24A between connectors (434) and (379), then repair.

17.

Off

Disconnect CEC module connector (379) from CEC. Measure resistance of circuit 24 between connectors (390) terminal F and (379) terminal 13. Measure resistance between connectors (379) terminal 13 and ground.

<5 ohms.

18.

Off

(379) circuit 24 to ground.

>100K ohms.

Engine brake circuits check good. Consider replacing the CEC.

4. COMPONENT LOCATIONS
(B1) Battery Stud. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . . Power Distribution Panel (94) Back-Up Light Switch. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . . . . . On Transmission (137) 6Way Data Link Connector. . . . . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (141) Service Brake Switch/Cruise Switch. . . . . . . . .. . . . . . Dash Panel, Left Side, Engine Side
s08210

398

10 INTERNATIONAL 530E I6 HEUI ENGINES

(190) Cab Overlay to Elect. Eng. Harn.. . . . . . . . . . . .. . . . . . Right Instrument Panel (227) Fan Solenoid. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . ... . . . . . At Front of Engine (228) Refrigerant Pressure Switch .. . .. . .. . . .. . .. . ... . . . . . On A/C Compressor (229) Engine Oil Temp. Sender. . .. . .. . .. . .. . .. . .. . ... . . . . . Left Side of Engine (190) Cab Overlay to Elect. Eng. Harn.. . . . . . . . . . . .. . . . . . Right Instrument Panel (235) Transmission Oil Temp (Inline).. . . .. . . . .. . . .. .. . . . . . On Front of Transmission (390) Resistor Printed Circuit Board. . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Taped to Cab Harness (400A) Low Coolant Level Switch. . . . . . . . . . . .. . . . . .. . . . . . To Engine Harness (267) APS/IVS Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Electronic Foot (Gas) Pedal (294) Clutch Switch Connector. . . . . . . . . . . . . . . . . . . . . .. . . . . . Near Clutch Switch (303) Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Transmission (379) CEC Module Connector. . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Engine (396) Module Power Relay On Engine. . .. . . .. . . . .. .. . . . . . On Bracket at Center of Dash, Engine Side (490) ECM Power Conn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Battery Terminal Pigtail (514) Data Link Positive.. . . .. . . .. . . .. . . .. . . .. . . .. .. . . . . . Behind Instrument Panel/Behind Cluster (515) Data Link Negative.. .. .. .. . .. .. .. .. . .. .. .. ... . . . . . Behind Instrument Panel/Behind Cluster (1160) BAP Sensor Connector. .. . .. . . .. . .. . .. . .. . . ... . . . . . Under Dash to Right of Ignition Switch (1161) Ambient Air Temperature Sensor. . . . .. . . . .. .. . . . . . Air Intake Tube

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

399

Figure 121

Engine Wiring, Cab

s08210

400

10 INTERNATIONAL 530E I6 HEUI ENGINES

1. DASH PANEL (VIEWED FROM INSIDE ENGINE COMPARTMENT) 2. (141) BRAKE SWITCH 3. (640) STOP LIGHT SWITCH 4. (190) ELECTRONIC ENGINE CONNECTOR 5. RIGHT HAND DASH PANEL GROUND STUD 6. (3) ENGINE CONNECTOR 7. (2) CHASSIS HARNESS CONNECTOR 8. POWER DISTRIBUTION PANEL 9. SWITCHES 10. RIGHT GAUGE CLUSTER 11. SPEEDOMETER / TACHOMETER CLUSTER 12. LEFT GAUGE CLUSTER 13. (514) DATA LINK CONNECTOR 14. (515) DATA LINK CONNECTOR 15. (137) DATA LINK 16. CLUTCH SWITCH 17. FRONT END HARNESS CONNECTOR 18. THROTTLE PEDAL 19. (294) CLUTCH SWITCH CONNECTOR 20. (267) THROTTLE PEDAL CONNECTOR

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

401

Figure 122

Engine Wiring, Dash Panel 1. (190) ELECTRONIC ENGINE CONNECTOR 2. RH DASH PANEL GROUND STUD 3. (2) CAB/ENGINE HARNESS CONNECTOR 4. MEGAFUSE 5. CIRCUIT 17C 6. CIRCUIT 17B 7. CIRCUIT 14A 8. CIRCUIT 14 9. START MAGNETIC SWITCH 10. CIRCUIT 17D 11. COOLANT LEVEL SENSOR 12. TO ENGINE HARNESS

s08210

402

10 INTERNATIONAL 530E I6 HEUI ENGINES

Figure 123 Engine Wiring 1. 2. 3. 4. 5. 6. 7. 8. 9. TO TRANSMISSION CIRCUIT 14B & 11G GROUND STUD (379) ECM CONNECTOR TO OTHER SIDE OF ENGINE (1075) ENGINE FAN CONTROL CONNECTOR AMBIENT AIR TEMPERATURE CONNECTOR (249) LOW COOLANT SENDER CONNECTOR TO ENGINE WIRING AT DASH PANEL

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

403

Figure 124

Engine Wiring 1. 2. 3. 4. TO OTHER SIDE OF ENGINE CIRCUIT 77C TO COMPRESSOR CLUTCH CIRCUIT 23A AND 23B TO REFRIGERANT PRESSURE SWITCH ALTERNATOR

s08210

404

10 INTERNATIONAL 530E I6 HEUI ENGINES

Figure 125

Engine Wiring, Starter Motor 1. 2. 3. 4. 5. 6. CIRCUIT 14FL CIRCUIT 17C CIRCUIT 11-GU TO ENGINE BLOCK CIRCUIT 11-GA CIRCUIT 11-GL

s08210

10 INTERNATIONAL 530E I6 HEUI ENGINES

405

Figure 126

Engine Wiring, Alternator Effects 1. 2. 3. 4. CIRCUIT 1A ENGINE HARNESS CIRCUIT 11-GL CIRCUIT 2

s08210

406

10 INTERNATIONAL 530E I6 HEUI ENGINES

Figure 127 Engine Wiring, Transmission Effects 1. (94) BACKUP LIGHT SWITCH CONNECTOR 2. TO ENGINE HARNESS

s08210

11 CHASSIS ACCESSORIES

407

Table of Contents

1. DESCRIPTION. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .409 1.1. AIR DRYER. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .409 1.2. TRUCK BODY CONNECTION. . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .409 1.3. TRAILER CONNECTION. . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .409 1.4. FOUR WHEEL TRAILER CONNECTION. .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .409 1.5. TWO SPEED AXLE WIRING. . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .409 2. OPERATION.. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .410 2.1. AIR DRYER. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .410 2.2. TRUCK BODY CONNECTION. . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .410 2.3. TRAILER CONNECTION. . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .410 Red Terminal - Stop Light. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .410 Yellow and Green Terminals - Turn And Hazard Lights. . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .410 Brown Terminal - Tail Light. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .410 Black Terminal - Marker Light . . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . ..411 Blue Terminal - Trailer ABS.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..411 White Terminal - Trailer Socket Ground. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. ..411 2.4. TRAILER CONNECTION FOUR WHEEL TRAILER FRAME MOUNTED. . . . . . . . . . . . . . . . . . . . .411 Red Terminal Stop Light.. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. ..411 Yellow and Green Terminals Turn and Hazard Lights. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .411 Brown Terminal Tail Light. .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .412 Black Terminal Marker Light.. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .412 Blue Terminal Trailer Auxiliary Power. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412 White Terminal Trailer Socket Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412 Two Speed Axle Wiring. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .412 3. TROUBLESHOOTING. .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .412 3.1. AIR DRYER. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .413 3.2. TRUCK BODY CONNECTION. . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .414 Testing Marker Lights Power Feed. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .414 Testing Ground Circuit.. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .415 3.3. TRAILER CONNECTION. . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .416 Testing Stop Light Circuit. . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .416 Testing Turn and Hazard Circuits. .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .417 Testing Tail Light Circuit. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .418 Testing Marker Light Circuit. . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .418 Testing ABS Trailer Circuit. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .419 Testing Trailer Socket Ground Circuit.. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .420 3.4. TWO SPEED AXLE WIRING. . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .421 4. COMPONENT LOCATIONS. .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .422

s08210

408

11 CHASSIS ACCESSORIES

s08210

11 CHASSIS ACCESSORIES

409

1. DESCRIPTION
1.1. AIR DRYER
The air dryer collects and removes moisture and contaminants from the vehicles compressed air system before the moisture reaches the rst air reservoir. The heater and thermoswitch assembly, located in the air dryer, prevents freeze-up in the purge drain valve during cold weather operation.

1.2. TRUCK BODY CONNECTION


The truck body connection provides power and ground paths for the marker lights to be installed along with the body builders body assembly. An additional auxiliary power circuit and switch are also provided for compartment lights etc.

1.3. TRAILER CONNECTION


The 7-way trailer socket (112) connects the tractor and trailer wiring for operation of stop, tail, turn and hazard signal lights, and tail and clearance lights. Additionally, the trailer socket includes a circuit that provides voltage from the (B1) battery stud to power the trailer antilock brake system. The trailer socket terminals are color coded as shown in Trailer Socket Figure.

1.4. FOUR WHEEL TRAILER CONNECTION


The 7way four wheel trailer socket (112) connects the truck and trailer wiring for operation of stop, tail, turn and hazard signal lights and tail and clearance lights. Additionally, the trailer socket includes a circuit that provides voltage from the (B1) battery stud to power the trailer antilock brake system. The trailer socket terminals are color coded as shown in Trailer Socket Figure.

Figure 128

Trailer Socket (112)

1.5. TWO SPEED AXLE WIRING


The two speed axle wiring provides a voltage signal to the speedometer/tachometer module so that the speedometer and tachometer will correctly measure speed and mileage when the rear axle assembly shifts to a different gear ratio.

s08210

410

11 CHASSIS ACCESSORIES

2. OPERATION
2.1. AIR DRYER
Turning the key switch on applies ignition power on circuit 13AH to energize the air dryer control relay (146). With the relay energized, battery voltage on circuit 14AD, fuse F10A and circuit 39A from battery adapter (B1) passes through the relay normally open (N.O.) contacts (30 to 87). It then ows out the relay on circuit 39B, through connector (1), and is applied to the air dryer assemblys electrical pigtail. The air dryer thermocouple closes at less than 50F/10C, applying battery power to the heater element located in the air dryer assembly. The air dryer control relay ground circuit 13-GAD is grounded through ground adapter (455), then through 11-GE to ground stud at left dash panel.

2.2. TRUCK BODY CONNECTION


The truck body junction block, located at the rear of the cab, provides a ground at terminal and a marker light voltage from the marker light relay (463-R8) at terminal 2. Terminal 1 of the truck body junction block is grounded through circuit 11-GM to trailer socket ground inside the cab, 11-GN and 11-GI to ground stud at left dash panel. Turning the headlights to park or on energizes the trailer marker lights relay. This delivers battery power from (B2) stud through circuit 14H, 14E, fuse F3-A, circuit 58D, relay (463-R8), circuit 58R, and 58S to terminal 2 of the truck body junction block.

2.3. TRAILER CONNECTION


Red Terminal - Stop Light When the tractor brakes are applied, the vehicle stop light switch supplies power through circuit 70A/70D to energize the stop light relay (464)/R10. With the stop light relay energized, power from the (B1) battery stud, circuit 14K/14F, fuse F7-D, and circuit 70E is sent through the normally open contacts of stop light relay on circuit 70C, conn. (922), conn. (925), and circuit 70C to trailer socket conn. (112) at the red terminal. Yellow and Green Terminals - Turn And Hazard Lights In the LEFT TURN mode (or hazard switch on), power ows from (B1) battery stud through circuit 14K, 14R, fuse F2-D, circuit 55, asher, circuits 14BK, 55A and 16BK to turn signal switch. From the switch it ows through circuit 56E to energize relay (464)/R11. With the left turn relay energized, power ows from (B1) battery stud through circuits 14K, 14L, fuse F7-B, circuit 56H, through normally open contacts of left turn relay, and circuit 56C conn. (923), conn. (926) and circuit 56D to the trailer socket (112) yellow terminal. In the RIGHT TURN mode (or hazard switch on), power ows from (B1) battery stud through circuits 14K, 14R, fuse F2-D, circuit 55, asher, circuits 14BK, 55A and 16BK to turn signal switch. From the switch it ows through circuit 57E to energize relay (464)/R12. With the right turn relay energized, power ows from (B1) battery stud through circuits 14K, 14L, fuse F7-C, circuit 57H, through normally open contacts of right turn relay, and circuit 57C conn. (923), conn. (926) and circuit 57D to the trailer socket (112), green terminal. Brown Terminal - Tail Light When the headlight and trailer light switches are closed, power ows from (B2) battery stud through circuit 14W, 14B, fuse F8-A, and circuit 50 to headlight switch (465). It then ows out of the switch through circuit 58E, cab and trailer lights switch (466), and circuit 58P to energize tail light relay (464)/R9. When relay energizes, power ows from (B2) battery stud through circuits 14W, 14B, fuse F3-C, and circuit 68 to tail light

s08210

11 CHASSIS ACCESSORIES

411

relay. Power then ows through relay normally open contacts, circuit 68E, circuit 68B, conn. (922), conn. (925), and circuit 68A to the brown terminal of trailer socket (112). NOTE The cab trailer lights switch is a momentarily open interrupt switch. Depressing the switch will interrupt the power to the trailer socket brown terminal. Black Terminal - Marker Light When the headlight and trailer light switches are closed, power ows from (B2) battery stud through circuits 14W, 14B, fuse F3D, and circuit 50 to headlight switch (465). It then ows out of the switch through circuit 58E, cab and trailer lights switch (466), and circuit 58C to energize trailer marker lights relay (463-R8). When the relay energizes, power ows from (B2) battery stud through circuits 14W, 14E, fuse F3-A, circuit 58D, relay (463-R8), circuits 58R, 58S , conn. (923), conn. (926) and circuit 58A to the trailer socket black terminal. Blue Terminal - Trailer ABS With ignition key on power ows from (B1) through circuit 14CP, fuse F10A, circuit 94AH, ABS trailer relay (470), circuit 94AF to the trailer socket (112) blue terminal. White Terminal - Trailer Socket Ground The white terminal of (112) is grounded through circuit 11GAL to sleeper ground, and circuits 11GN and 11GI to ground stud at left dash panel. With Pro Sleeper, the white terminal of (112) is grounded through circuit 11GAL to trailer socket ground inside sleeper, circuit 11GN to the sleeper ground, through circuit 11GAN to the trailer socket ground inside the cab, and circuits 11GN and 11GI to ground stud at left dash panel.

2.4. TRAILER CONNECTION FOUR WHEEL TRAILER FRAME MOUNTED


Red Terminal Stop Light When the tractor brakes are applied, the vehicle stop light switch supplies power through circuit 70A/70D to energize the stop light relay (464)/R10. With the stop light relay energized, power from the (B1) battery stud, circuit 14K/14F, fuse F7D, and circuit 70E is sent through the normally open contacts of stop light relay on circuit 70C, connector (922), conn. (925), conn. (318), conn. (113) and circuit 70C to trailer socket connector (112) at the red terminal. Yellow and Green Terminals Turn and Hazard Lights In the LEFT TURN mode (or hazard switch on), power ows from (B1) battery stud through circuits 14K, 14R, fuse F2D, circuit 55, asher, circuits 14BK, 55A and 16BK to turn signal switch. From the switch it ows through circuit 56E to energize relay (464)/R11. With the left turn relay energized, power ows from (B1) battery stud through circuits 14K, 14L, fuse F7B, circuit 56H, through normally open contacts of left turn relay, circuit 56C, conn. (923), conn. (926), conn. (316), conn. (113) and circuit 56C to the trailer socket (112), yellow terminal. In the RIGHT TURN mode (or hazard switch on), power ows from (B1) battery stud through circuits 14K, 14R, fuse F2D, circuit 55, asher, circuits 14BK, 55A and 16BK to turn signal switch. From the switch it ows through circuit 57E to energize relay (464)/R12. With the right turn relay energized, power ows from (B1) battery stud through circuits 14K, 14L, fuse F7C, circuit 57H, through normally open contacts of right turn relay, circuit 57C, connector (923), conn. (926), conn. (316), conn. (113) and circuit 57C to the trailer socket (112), green terminal.

s08210

412

11 CHASSIS ACCESSORIES

Brown Terminal Tail Light When the headlight and trailer light switches are closed, power ows from (B2) battery stud through circuits 14H, 14D, fuse F8A and circuit 50 to headlight switch (465). It then ows out of the switch through circuit 58E, cab and trailer lights switch (466) and circuit 58P to energize tail light relay (464)/R9. When the relay energizes, power ows from (B2) battery stud through circuit 14W, 14B, fuse F3C and circuit 68 to tail light relay. Power then ows through relay normally open contacts, circuit 68E, circuit 68B, connector (922), conn. (925), conn. (316), conn. (113) and circuit 68B to the brown terminal of trailer socket (112). NOTE The cab trailer lights switch is a momentarily open interrupter switch. Depressing the switch will interrupt the power to the trailer socket brown terminal. Black Terminal Marker Light When the headlight and trailer light switches are closed, power ows from (B2) battery stud through circuits 14W, 14B, fuse F3D and circuit 50 to headlight switch (465). It then ows out of the switch through circuit 58E, cab and trailer marker lights switch (466), and circuit 58C to energize trailer maker lights relay (463R8). When the relay energizes, power ows from (B2) battery stud through circuits 14W, 14E, fuse F3A, circuit 58D, relay (463R8), circuits 58S, connector (923), conn. (926), conn. (316), conn. (113) and circuit 58R to the trailer socket black terminal. Blue Terminal Trailer Auxiliary Power With ignition key on, power ows from (B1) through circuit 14CP, fuse F10A, circuit 94AH, ABS trailer relay (470), circuit 94AF, connector (922), conn. (925), conn. (318), conn. (113) and circuit 94AF to the trailer socket (112) blue terminal. White Terminal Trailer Socket Ground With frame mounted connector for four wheel trailer, the white terminal of (112) is grounded through circuit 11GN to junction block ground. Two Speed Axle Wiring With ignition key on, power ows from (B1) battery stud through circuits 14K, 14R, fuse F2C, circuit 14S, ignition relay (462)/R1, and circuit 13P to ignition adapter 12 (495). Then power ows through circuit 93, two speed axle switch (417), circuits 93A and 93B to the speedometer/tachometer module connector (421). When the axle is shifted into high range, air is supplied to the axle shift circuit opening the two speed axle switch and changing the voltage signal to 0 at the speedometer/tachometer module. Thus speed and mileage are calculated for the different axle ratio.

3. TROUBLESHOOTING
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 laments that are suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks. C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 ELECTRICAL in the CTS-5000 Master Service Manual.

s08210

11 CHASSIS ACCESSORIES

413

D. When the technician determines that a fuse is blown, while checking its condition, he is directed to locate the cause of the overload condition and to repair it. While no further instruction on this procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections of the circuit, by disconnecting connectors, and measure the resistance to ground to nd the circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and repair. E. Diagnostics for circuits that are malfunctioning by sticking in the position are generally not covered in detail. It is assumed that the mechanic knows to check for a malfunctioning switch, relay, or solenoid.

3.1. AIR DRYER


NOTE The thermal switch located in the air dryer should only close when the temperature is less than 50F/10C, causing the air dryer heater to operate. Table 130 Air Dryer STEP 1. KEY Off ACTION Check 15A fuse F10-A for open condition. TEST POINTS F10-A. SPEC. <1 ohm YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then correct. Replace fuse. Locate cause of low or no voltage in circuit 39A/14AD, then repair. Locate cause of low or no voltage in circuit 13AH, then repair. Locate open or poor connection in circuit 13-GAD, then repair. Locate short to ground, then repair. Locate open or poor connection in circuit, then repair.

2.

Off

Remove air dryer relay at connector (146). At (146) and circuit 39A measure voltage to ground. With key on, at (146) and circuit 13AH measure voltage to ground. At (146) measure voltage between circuits 13AH and 13-GAD. At (146) measure resistance from circuit 39B to gnd. Disconnect connector (1) from air dryer pigtail/circuit. Measure resistance of circuit 36B between connectors (1) and (146). Install air dryer relay at (146), and turn key on. Measure voltage at (1)/circuit 39B to gnd.

(146), 39A to gnd.

121.5 volts

Go to next step.

3.

On

(146), 13AH to gnd. (146), 13AH to 13- GAD. (146), 39B to gnd. 36B between (1) and (146).

121.5 volts

Go to next step.

4.

On

121.5 volts >100K ohms. <5 ohms

Go to next step. Go to next step. Go to next step.

5.

Off

6.

Off

7.

Off/ On

39B to gnd.

121.5 volts

Go to next step.

Replace defective air dryer relay.

s08210

414

11 CHASSIS ACCESSORIES

Table 130 Air Dryer (cont.) STEP 8. KEY Off ACTION Disconnect gnd. circuit 39-G (14BN with B.W. AD-9) from air dryer. Measure resistance between gnd. and this circuit. Turn key on and measure voltage between gnd. terminal of air dryer and circuit 39-G (or 14BN). TEST POINTS 39-G/14BN to gnd. SPEC. <5 ohms YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate open or poor connection in circuit, then repair.

9.

On

39-G 14BN to air dryer.

12 1.5 volts.

Air dryer circuits check good.

Service thermal switch/heater assembly of air dryer.

3.2. TRUCK BODY CONNECTION


Testing Marker Lights Power Feed Table 131 Testing Marker Lights Power Feed STEP 1. KEY Off/ On ACTION Remove trailer marker lights relay from connector (463-R8). Turn key on and place headlight switch and cab and trailer lights switch in on position. Measure voltage at circuit 58C to ground. At (463-R8) measure voltage from circuit 58C to 58-GA. Remove fuse F3-A and check for open condition. TEST POINTS (463) /R8, 58C to gnd. SPEC. 121.5 volts YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of no or low voltage in circuit 58C or cab light circuitry, then repair. Refer to Trailer Connectionfor feed circuit troubleshooting. Locate open or poor connection in circuit 58-GA or 11-G, then repair. Locate cause of overload condition, then correct. Replace fuse. Locate cause of low or no voltage, in circuits 14H and 14E, then repair. Locate cause of low or no voltage in circuit 58D, then repair.

2.

On

(463)/R8, 58C to 58-GA. F3-A.

121.5 volts

Go to next step.

3.

Off

<1 ohm

Go to next step.

4.

Off

Re-install fuse F3-A and at the fuse and circuit 14E measure voltage to ground. With trailer marker lights relay still removed, measure voltage from circuit 58D to 58-GA.

F3-A. 14E to gnd.

121.5 volts

Go to next step.

5.

Off

(463)/R8, 58D to 58-GA.

121.5 volts

Go to next step.

s08210

11 CHASSIS ACCESSORIES

415

Table 131 STEP 6.

Testing Marker Lights Power Feed (cont.) KEY Off ACTION Disconnect halves of connector (43), then with a test lead jumper circuit 58D to circuit 58R. Measure voltage to ground at connector (43), circuit 58R. Remove jumper and re-install trailer marker light relay. Then move headlight and cab and trailer lights switch to on position. At connector (43) circuit 58S, measure voltage to ground. Turn headlight switch off, reconnect (43) and turn headlight switch back on. Measure voltage to ground at terminal 2 of truck body junction block. (43), 58S to gnd. Truck body junction block, 2 to gnd. 121.5 volts 121.5 volts (43), 58R to gnd. 121.5 volts TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

7.

Off

Go to next step.

Locate cause of low or no voltage in circuit 58R, then repair.

8.

Off

Go to next step.

9.

Off

Go to next step. Marker light circuit checks good.

Replace faulty trailer marker lights relay. Locate cause of low or no voltage in circuit 58S, then repair.

10.

Off

Testing Ground Circuit Table 132 Testing Ground Circuit STEP 1. KEY Off ACTION Measure resistance from left dash ground stud to terminal 1 of truck body junction block. TEST POINTS Gnd stud to truck body junction block 1. SPEC. <2 ohms YES-IN SPEC. Junction block gnd. circuit checks good. NO-OUT OF SPEC. Locate open or poor connection in circuits 11-GM, 11-GN, and 11-GI, then repair.

s08210

416

11 CHASSIS ACCESSORIES

3.3. TRAILER CONNECTION


Testing Stop Light Circuit Table 133 STEP 1. Testing Stop Light Circuit KEY Off ACTION Remove and check fuse F7-D for open condition. TEST POINTS F7-D. SPEC. <1 ohm YES-IN SPEC. Go to next step. Go to next step. Go to next step. NO-OUT OF SPEC. Locate cause of overload condition, then correct. Replace fuse. Locate cause of low or no voltage in circuits 14F and 14K, then repair. Locate cause of low or no voltage in circuit 70E, then repair.

2.

Off

Re-install fuse F7-D. At fuse F7-D, circuit 14F, measure voltage to ground. Remove stop light relay from connector (464)/R10. At (464)/R10 measure voltage at circuit 70E to ground. At (464)/R10 measure voltage from circuit 70E to 70-G.

F7-D, 14F to gnd.

121.5 volts

3.

Off

(464) /R10, 70E to gnd.

121.5 volts

4.

Off

(464) /R10, 70E to 70-G.

121.5 volts

Go to next step.

Locate open or poor connection in circuit 70-G if left turn indicator functions, or circuit 56-G if turn indicator does not function. Check 57-G/11-G if right turn indicator does not function. Then repair faulty gnd. circuit. Locate cause of overload condition, then correct. Replace fuse. Locate cause of low or no voltage in circuits 14H and 14E, then repair. Locate cause of low or no voltage in circuit 70, then repair. Replace stop light switch.

5.

Off

Remove and check fuse F3-B for open condition.

F3-B.

<1 ohm

Go to next step. Go to next step. Go to next step. Go to next step.

6.

Off

Re-install fuse F3-B. At fuse F3-B, circuit 14E measure voltage to ground. Disconnect stop light switch connector (640). At (640) and circuit 70 measure voltage to gnd. With brake pedal depressed, measure resistance across terminals of stop light switch.

F3-B, 14E to gnd.

121.5 volts

7.

Off

(640), 70 to gnd.

121.5 volts

8.

Off

Stop light switch, across terminals.

<1 ohm

s08210

11 CHASSIS ACCESSORIES

417

Table 133 STEP 9.

Testing Stop Light Circuit (cont.) KEY Off ACTION Reconnect (640) and disconnect (4). With brake pedal depressed, at (4) measure voltage from circuit 70A to ground. Reconnect (4). With brake pedal depressed, at (464)/R10 measure voltage from circuit 70D to ground. At (464)/R10 use test lead to jumper circuit 70E to 70C. With test jumper still in place, measure voltage at trailer socket (112) red terminal/circuit 70C to gnd. Replace defective stop light relay. Stop light circuits check good. (112), 70C to gnd. 121.5 volts TEST POINTS (4), 70A to gnd. SPEC. 121.5 volts YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of low or no voltage in circuit 70A, then repair.

10.

Off

(464)/R10, 70D to gnd.

121.5 volts

Go to next step. Go to next step. Go to next step.

Locate cause of low or no voltage in circuit 70D, then repair.

11.

Off

12.

Off

Locate cause of low or no voltage in circuit 70C, then repair.

13.

Off

Testing Turn and Hazard Circuits Table 134 STEP 1. Testing Turn and Hazard Circuits KEY Off ACTION Proceed with this test only if tractor turn signals, hazard ashers and indicators work properly. Do turn, hazard, and indicator lights of tractor function properly? Remove turn signal asher, and use test lead to jumper between circuits 55 and 55A. With left turn signal switch on, measure voltage at trailer socket (112) yellow terminal/ circuit 56C or 56D to gnd. (112), 56C or 56D to gnd. 121.5 volts TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

2.

Off

Go to next step.

3.

Off

Go to next step.

Locate cause of low or no voltage in circuit 56C or 56D, then repair.

s08210

418

11 CHASSIS ACCESSORIES

Table 134 STEP 4.

Testing Turn and Hazard Circuits (cont.) KEY Off ACTION With right turn signal switch on, measure voltage at trailer socket (112) green terminal/circuit 57C or to 57D to gnd. Test complete; remove test jumper at asher and re-install asher unit. TEST POINTS (112), 57C or 57D to gnd. SPEC. 121.5 volts YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of low or no voltage in circuit 57C or 57D , then repair.

5.

Off

Testing Tail Light Circuit Table 135 STEP 1. Testing Tail Light Circuit KEY Off ACTION Proceed with this test only if tractor tail lights work properly. Do tail lights of tractor function properly? With head light switch on or in parking light mode, and cab and trailer lights switch on, measure voltage at trailer socket (112) brown terminal/circuit 68A or 68B to gnd. Tail lights circuit checks good. Turn off headlight switch. (112), 68A or 68B to gnd. 121.5 volts. TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

2.

Off

Go to next step.

Locate cause of low or no voltage in circuit 68A or 68B, then repair.

3.

Off

Testing Marker Light Circuit Table 136 STEP 1. Testing Marker Light Circuit KEY Off ACTION Proceed with this test only if tractor tail lights work properly. Do tail lights of tractor function properly? TEST POINTS SPEC. YES-IN SPEC. Go to next step. NO-OUT OF SPEC.

s08210

11 CHASSIS ACCESSORIES

419

Table 136 STEP 2.

Testing Marker Light Circuit (cont.) KEY Off ACTION Remove marker lights relay (463-R8). With trailer lights switch on and headlight switch on or in parking light mode, measure voltage at (463-R8) circuit 58C to gnd. Remove and check fuse F3-A. Re-install fuse F3-A. At fuse holder F3-A, measure voltage from circuit 14E to gnd. At (463-R8) measure voltage from circuit 58D to gnd. At (463-R8) measure voltage from circuit 58D to 58-GA. At (463-R8) use test lead to jumper circuit 58D to 58R. Measure voltage at trailer socket (112) black terminal/circuit 58A or 58R to gnd. Replace defective trailer marker lights relay. Marker light circuits check good. (112), 58A or 58R to gnd. 121.5 volts TEST POINTS (463)/R8, 58C to gnd. SPEC. 121.5 volts YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of low or no voltage in circuit 58C, then repair.

3.

Off

F3-A.

<1 ohm

Go to next step. Go to next step. Go to next step. Go to next step. Go to next step. Go to next step.

Locate cause of overload condition, then repair. Locate cause of low or no voltage in circuit 14E, then repair. Locate cause of low or no voltage in circuit 58D, then repair. Locate open or poor connection in circuits 58-GA and 11-G, then repair.

4.

Off

F3-A, 14E to gnd.

121.5 volts

5.

Off

(463)/R8, 58D to gnd. (463)/R8, 58D to 58-GA.

121.5 volts 121.5 volts

6.

Off

7.

Off

8.

Off

Locate cause of low or no voltage in circuit 58A or 58R, then repair.

9.

Off

Testing ABS Trailer Circuit Table 137 Testing ABS Trailer Circuit STEP 1. KEY On ACTION Measure voltage between blue terminal circuit 94AF of trailer socket and ground. TEST POINTS Blue terminal circuit 94AF of trailer SPEC. 12 1.5 volts. YES-IN SPEC. ABS trailer circuits check good. NO-OUT OF SPEC. Go to next step.

s08210

420

11 CHASSIS ACCESSORIES

Table 137 Testing ABS Trailer Circuit (cont.) STEP KEY ACTION TEST POINTS socket & gnd. 2. Off Remove and check fuse F10-A for open condition. F10-A <1 ohm. Go to next step. Locate cause of overload condition and correct. Replace fuse. Locate cause of low or no voltage in circuit 94AH or 14CP, then repair. SPEC. YES-IN SPEC. NO-OUT OF SPEC.

3.

Off/ On

Replace fuse F10-A. Remove ABS trailer relay (470). Turn key on and measure voltage between circuit 94AH and ground. Measure the voltage between circuits 13-GCP and 13CP at connector (470). Remove fuse F-10A and install a jumper between circuits 94AH and 94AF at (470). Install F-10A and measure the voltage between blue terminal, circuit 94AF, of trailer socket and ground. Remove jumper and reinstall relay (470). Measure the voltage between blue terminal, circuit 94AF, of trailer socket and gnd.

(470), 94AH and gnd.

12 1.5 volts.

Go to next step.

4.

On

(470), between 13-GCP and 13CP. Between blue terminal, circuit 94AF, of trailer socket and gnd. Between blue terminal, circuit 94AF, of trailer socket.

12 1.5 volts.

Go to next step.

Locate open in circuit 13-GCP or 13CP, then repair.

5.

Off

12 1.5 volts.

Go to next step.

Locate open in circuit 94AF between (470) and the trailer socket, then repair.

6.

Off

12 1.5 volts.

Trailer ABS circuits check good.

Replace defective relay (470).

Testing Trailer Socket Ground Circuit Table 138 Testing Trailer Socket Ground Circuit STEP 1. KEY Off ACTION With long test leads, measure resistance between left dash panel ground stud and white terminal of trailer socket (112). TEST POINTS (112), white terminal to gnd. stud. SPEC. <1 ohm YES-IN SPEC. Gnd. circuit checks good. NO-OUT OF SPEC. Locate open or poor connection in ground circuit, then repair. NOTE: Refer to circuit diagram book for ground circuits which

s08210

11 CHASSIS ACCESSORIES

421

Table 138 Testing Trailer Socket Ground Circuit (cont.) STEP KEY ACTION TEST POINTS SPEC. YES-IN SPEC. NO-OUT OF SPEC. vary for different sleeper models.

3.4. TWO SPEED AXLE WIRING


Table 139 Two Speed Axle Wiring STEP 1. KEY On ACTION Turn ignition key on. Do the speedo/tacho. needles move? Remove and check fuse F5-C. F5-C. <1 ohm TEST POINTS SPEC. YES-IN SPEC. Go to Step 9. Go to next step. Go to next step. Go to next step. Go to next step. Go to next step. Go to next step. Go to next step. Go to next step. NO-OUT OF SPEC. Go to next step.

2.

Off

Locate cause of overload condition, then repair. Replace fuse. Locate cause of low or no voltage in circuit 14AM, then repair. Locate cause of low or no voltage in circuit 14J or 14G, then repair. Locate cause of overload condition, then repair. Replace fuse. Locate cause of low or no voltage in circuit 13B, then repair. Locate cause of low or no voltage in circuit 13V or 28B, then repair. Locate open or poor connection in ground circuit 11-GL, 11-GQ or 11-GF , then repair. Go to Power Distribution and Ground System Troubleshooting section.

3.

Off

At fuse holder F5-C measure voltage from circuit 14AM to ground. Replace fuse F5-C. At (421) measure voltage from circuit 14G to ground. Remove and check fuse F4-A.

F5-C, 14AM to gnd. (421), 14G to gnd.

121.5 volts 121.5 volts

4.

Off

5.

Off

F4-A.

<1 ohm.

6.

Off

At fuse holder F4-A measure voltage from circuit 13B to ground. Replace fuse F4-A. At (421) measure voltage from circuit 28B to gnd. At (421) measure voltage from circuit 14G to 11-GL.

F4-A, 13B to gnd. (421), 28B to gnd.

121.5 volts 121.5 volts

7.

Off

8.

Off

(421), 14G to 11-GL.

121.5 volts

9.

On

With ignition key on measure voltage from ignition adapter (495) to ground.

(495) to gnd.

121.5 volts

s08210

422

11 CHASSIS ACCESSORIES

Table 139 STEP 10.

Two Speed Axle Wiring (cont.) KEY Off/ On ACTION Disconnect two speed axle switch from connector (417). Turn ignition key on and at (417) measure voltage from circuit 93 to ground. With two speed axle switch in the closed position (air released) measure between terminals. With two speed axle switch in the open position (air applied) measure between terminals. Reconnect two speed axle switch to connector (417). disconnect connector (421). NOTE: This will not cause the digital odometer and hour meters to lose their readings. Turn ignition key on and at (421) circuit 93B, with air released to axle switch, measure voltage to ground. At (421) circuit 93B, with air applied to axle switch, measure voltage to gnd. Two speed axle wiring circuits check good. Refer to GROUP 08 ELECTRICAL Gauges and Warning Lights section in the CTS-5000 Master Service Manual for replacement and programming of the Speedo/Tachometer Module. TEST POINTS (417), 93 to gnd. SPEC. 121.5 volts YES-IN SPEC. Go to next step. NO-OUT OF SPEC. Locate cause of low or no voltage in circuit 93, then repair.

11.

Off

Axle switch, across terminals. Axle switch, across terminals. (421), 93B to gnd.

<1 ohm

Go to next step.

Replace faulty switch.

12.

Off

>100K ohms

Go to next step. Go to next step.

Replace faulty switch.

13.

Off/ On

121.5 volts.

Locate cause of low or no voltage in circuit 93B, then repair.

14.

On

(421), 93B to gnd.

0 volts

Go to next step.

Locate short to voltage source in circuit 93B, then repair.

15.

Off

4. COMPONENT LOCATIONS
J7 Junction Point. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . .. . . . . . In Dash Panel Left Side
s08210

11 CHASSIS ACCESSORIES

423

(1) Dash Panel Connector. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . . . . . Left Side of Engine Cowl (6) Cab/Sleeper Connector.. . .. .. .. . .. .. . .. .. .. . .. .. .. . . . . . Left Back of Cab, B Pillar (43) Truck Body/Trailer Feed. .. .. . .. .. .. . .. .. .. . .. .. .. . . . . . Left Back of Cab, "B" Pillar (112) Trailer Socket W/O Sleeper. . . . . . . . . . . . . . . . . . .. . . . . . Located on Rear of Cab (113) Four Wheel Trailer Junction Block. . . . . . . . . . . .. . . . . . Rear Crossmember (146) Air Dryer Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Power Distribution Panel (316) Four Wheel Trailer (Inline).. . .. . . .. . .. . . .. . .. . .. . . . . . Rear of Cab, Inside (363) AD-9 Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Air Dryer (417) Two Speed Axle Switch.. . .. . .. . .. . .. . .. . .. . .. .. . . . . . Behind Instrument Cluster (421) Speedo./Tach. Gauge Cluster. . . . . . . . . . . . . . . .. . . . . . At Speedo./Tach. Gauge (455) G3 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel (494) I1 Ignition Adapter. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . . . Behind Fuse Panel (497) B1 Battery Adapter. . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . Behind Fuse Panel (499) A1 Accessory Adapter. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Fuse Panel Right Side (503) L1 Panel Light Feed Adapter.. . .. . .. . .. . .. . .. .. . . . . . Behind Lt Instrument Panel (506) L4 Panel Light Grd Adapter. . . . . . . . . . . . . . . . . . .. . . . . . At Right of Instrument Panel (642) Sleeper to Roof Connector with PRO SLEEPER. .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . . At Lower Left Front Corner of Sleeper Box ) (643) Sleeper to Roof Connector with PRO SLEEPER. .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . . At Lower Left Front Corner of Sleeper Box) (922) Trailer Socket #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left Back of Cab, B Pillar (923) Trailer Socket #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left Back of Cab, B Pillar (925) Trailer Socket #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left Back of Cab, B Pillar (926) Trailer Socket #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left Back of Cab, B Pillar (935) Work Light, Trailer. . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . . Left Back of Cab, B Pillar

s08210

424

11 CHASSIS ACCESSORIES

Figure 129 Air Dryer Wiring 1. 2. 3. 4. 5. 6. 7. (1) DASH PANEL CONNECTOR CIRCUIT 39B CIRCUIT 39A FUSE F10-A, 15A B2 BATTERY STUD B1 BATTERY STUD AIR DRYER RELAY (146)

s08210

11 CHASSIS ACCESSORIES

425

Figure 130

Air Dryer Wiring 1. 2. 3. 4. 5. 6. 7. CIRCUITS 14RD & 14BN FRONT END HARNESS TO DASH PANEL CONNECTOR (1) CIRCUIT 39 CIRCUIT 39-G CONNECTOR (363) CIRCUIT 14RD & 14BN BENDIX AD-9 AIR DRYER

s08210

426

11 CHASSIS ACCESSORIES

Figure 131

Trailer Connection N/Sleeper 1. 2. 3. 4. 5. 6. 7. MAIN CAB HARNESS CONNECTOR (922) & (923) TRAILER SOCKET (112) CIRCUIT 11-GN CIRCUIT 11-GAN TRAILER SOCKET GROUND CIRCUIT 11-GN

s08210

11 CHASSIS ACCESSORIES

427

Figure 132

Pro Sleeper Wiring 1. ROOF HARNESS CONNECTOR (643) 2. ROOF HARNESS CONNECTOR (642) 3. SLEEPER CONNECTOR # 1 (906) 4. TRAILER SOCKET CONNECTOR (922) 5. TRAILER SOCKET CONNECTOR (923) 6. WORK LIGHT CONNECTOR #2 (935) 7. SLEEPER CONNECTOR #2 (942) 8. SLEEPER GROUND 9. TRAILER SOCKET CONNECTORS (925) AND (926) 10. TRAILER SOCKET (112)

s08210

428

11 CHASSIS ACCESSORIES

Figure 133

Trailer Connection With Trailer Cable Wired Directly to Cab Harness

s08210

11 CHASSIS ACCESSORIES

429

1. 2. 3. 4. 5. 6. 7.

TRAILER SOCKET GROUND CONNECTOR (5) CIRCUITS 58S AND 68B TO BLACK AND BROWN WIRE CIRCUITS 70 AND 72 TO RED AND BLUE WIRE CIRCUITS 56C AND 57C TO YELLOW AND GREEN WIRE 11GT AND WHITE WIRE 7WAY COILED TRAILER CABLE

Figure 134

Trailer Connection With Four Wheel Trailer N/Sleeper Box 1. 2. 3. 4. 5. 6. TRAILER SOCKET WIRING TRAILER IN-LINE CONNECTOR (316) TRAILER IN-LINE CONNECTOR (318) HARNESS ASSEMBLY CONNECTORS (922) & (923) MAIN CAB HARNESS

s08210

430

11 CHASSIS ACCESSORIES

Figure 135

Trailer Connection With Four Wheel Trailer

s08210

11 CHASSIS ACCESSORIES

431

1. 2. 3. 4. 5. 6.

7-WAY SOCKET HARNESS TRAILER SOCKET WIRING 7-STUD JUNCTION BLOCK BOX (113) 7-WAY SOCKET (112) 7-STUD JUNCTION BLOCK BOX (113) TRAILER SOCKET WIRING

Figure 136

Two Speed Axle Wiring 1. 2. 3. 4. 5. TWO SPEED AXLE SWITCH (417) SPEEDOMETER/TACHOMETER (421) 2 SPEED AXLE WIRING HARNESS CIRCUIT 93 I2 IGNITION ADAPTER (495) CAB MAIN HARNESS

s08210

432

11 CHASSIS ACCESSORIES

s08210

12 LIGHT SYSTEMS

433

Table of Contents

1. DESCRIPTION. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .435 1.1. BACK-UP LIGHTS. .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. .435 1.2. CAB AND TRAILER LIGHTS SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435 1.3. CAB CLEARANCE AND IDENTIFICATION LIGHTS. .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .435 1.4. CAB DOME, READING, AND COURTESY LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435 1.5. DAYTIME RUNNING LIGHTS (DRL) MODULE WIRING-STANDARD USA AND CANADA. . .435 1.6. FOG LIGHTS.. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .435 1.7. HEADLIGHT SWITCH AND DIMMER SWITCH WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435 1.8. HEADLIGHTS .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .435 1.9. PANEL LIGHTS. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .436 1.10. PARK/TURN/MARKER LIGHTS.. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .436 1.11. SPOTLIGHT. .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .436 1.12. STOP, TAIL, TURN AND HAZARD SIGNAL LIGHTS WITH FLASHER. . . . . . . . . . . . . . . . . . . . . . . . .436 1.13. WORK LIGHT WITHOUT SLEEPER.. .. . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .436 1.14. WORK LIGHT WITH PRO SLEEPER. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .436 2. OPERATION.. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .436 2.1. BACK-UP LIGHTS. .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. .436 2.2. CAB AND TRAILER LIGHTS SWITCH AND RELAYS WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436 2.3. CAB CLEARANCE AND IDENTIFICATION LIGHTS. .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .437 2.4. CAB DOME, READING, AND COURTESY LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437 2.5. DAYTIME RUNNING LIGHTS (DRL) MODULE WIRING-STANDARD USA AND CANADA. . .437 2.6. FOG LIGHTS.. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .438 2.7. HEADLIGHT SWITCH AND DIMMER SWITCH WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438 2.8. HEADLIGHTS .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .438 2.9. PANEL LIGHTS. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .439 2.10. PARK/TURN/MARKER LIGHTS . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .439 2.11. SPOTLIGHT. .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .440 2.12. STOP, TAIL, TURN AND HAZARD SIGNAL LIGHTS WITH FLASHER. . . . . . . . . . . . . . . . . . . . . . . . .440 2.13. WORK LIGHT WITHOUT SLEEPER.. .. . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .440 2.14. WORK LIGHT WITH PRO SLEEPER. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .441 3. TROUBLESHOOTING. .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .441 3.1. BACK-UP LIGHTS. .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. .441 3.2. CAB AND TRAILER LIGHTS SWITCH AND RELAYS WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442 3.3. CAB CLEARANCE AND IDENTIFICATION LIGHTS. .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .445 3.4. CAB DOME, READING, AND COURTESY LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447 3.5. DAYTIME RUNNING LIGHTS (DRL) MODULE WIRING- STANDARD USA AND CANADA.. .453 3.6. FOG LIGHT