Sistema Electrico 7400 Internatinal-1

11 LIGHT SYSTEMS 827
Table of Contents
1. BACK-UP LIGHTS. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .831

1.1. CIRCUIT FUNCTIONS. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .831
1.2. DIAGNOSTICS. .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .831
1.3. FAULT DETECTION MANAGEMENT. . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .831
1.4. EXTENDED DESCRIPTION.. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .833
1.5. COMPONENT LOCATIONS.. . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .834
2. ROOF CLEARANCE AND MARKER OR SUNSHADE LIGHTS.. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .838

2.2. DIAGNOSTICS. .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .839
2.3. FAULT DETECTION MANAGEMENT. . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .839
2.4. EXTENDED DESCRIPTION.. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .841
Roof Clearance and Marker Lights. . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .841
Sunshade Lights. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .841
Marker Interrupt. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .841
3. MARKER, PARK AND TAIL LAMPS. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .844

3.2. DIAGNOSTICS. .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .845
Marker, Park and Tail Lights Preliminary Check. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .845
Diagnostic Trouble Codes. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .846
3.3. MARKER, PARK AND TAIL LIGHT INPUTS TO ESC.. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .847
Fault Detection Management. . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .847
Extended Description. . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .849
3.4. MARKER, PARK AND TAIL LIGHT OUTPUTS FROM ESC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .849
4. DOME AND MAP LIGHTS. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .858

4.2. DIAGNOSTICS. .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .859
Dome Light Preliminary Check. .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .860
4.3. DOOR SWITCH INPUTS INTO ESC. .. .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .862
4.4. DOME LIGHT CIRCUITS.. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .864
5. FOG LIGHT SYSTEM. . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .870

5.2. DIAGNOSTICS. .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .870
Fog Light Preliminary Check.. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .871
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828 11 LIGHT SYSTEMS
Diagnostic Trouble Codes.. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. ..872

5.3. FAULT DETECTION MANAGEMENT. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. .873
5.4. EXTENDED DESCRIPTION. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .876
5.5. COMPONENT LOCATIONS. . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. .877
6. HEADLIGHT SYSTEM. .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. .878

6.1. CIRCUIT FUNCTIONS.. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. ..878
6.2. DIAGNOSTICS. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . ..879
Headlight Preliminary Check. . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . .. . . . . .880
6.3. HEADLIGHT CIRCUIT INPUTS TO ESC. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. ..881
Fault Detection Management. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . .881
Extended Description.. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. .884
6.4. HEADLIGHT OUTPUTS FROM ESC. .. . . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .. .885
7. PANEL LIGHTS. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . ..895

7.2. DIAGNOSTICS. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . ..896
Panel Light Preliminary Check. . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . .896
7.3. PANEL LIGHT SWITCH INPUTS TO EGC.. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. ..897
7.4. PANEL LIGHT OUTPUT FROM EGC. . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . .900
8. TRUCK STOP/TURN SIGNAL/HAZARD LIGHT.. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. ..904

8.2. DIAGNOSTICS. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . ..905
Turn/Hazard Signal And Stop Light Preliminary Check. . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. .905
8.3. TURN SIGNAL/ HAZARD SWITCH INPUTS TO ESC.. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. ..909
8.4. HYDRAULIC BRAKE SWITCH INPUTS TO ESC. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. ..912
8.5. AIR BRAKE SWITCH INPUTS TO ESC.. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. ..915
8.6. FRONT TURN SIGNAL/HAZARD AND SEPARATE TURN SIGNAL LIGHT OUTPUTS FROM
ESC. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. ..919
8.7. REAR STOP/TURN SIGNAL/HAZARD LIGHT OUTPUTS FROM ESC. .. . .. . .. .. . .. .. . .. . .. .. . ..924
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9. WORK LIGHTS. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .939

9.2. DIAGNOSTICS. .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .940
Work Light Preliminary Check. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .940
9.3. WORK LIGHT CIRCUIT INPUTS TO ESC. . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . .942
9.4. WORK LIGHT CIRCUIT OUTPUTS FROM ESC.. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .944
10. AUXILIARY HEADLIGHTS.. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .948

10.1. CIRCUIT FUNCTIONS.. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .948
10.2. DIAGNOSTICS. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .949
Auxiliary Headlights Preliminary Check. . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .949
10.3. AUXILIARY HEADLIGHTS CIRCUITS TO ESC. . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . .951
10.4. AUXILIARY HEADLIGHTS CIRCUITS FROM ESC. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .953
10.5. COMPONENT LOCATIONS.. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .959
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1. BACK-UP LIGHTS
1.1. CIRCUIT FUNCTIONS
Figure 410 Back–Up Lights Function Diagram

1. RIGHT BACK–UP LIGHT
2. LEFT BACK–UP LIGHT
3. BACK–UP LIGHT SIGNAL FROM TRANSMISSION CIRCUITS (SEE TRANSMISSION
SECTION)
The vehicle back-up lights come on when the vehicle transmission is shifted into reverse. Depending on the
transmission installed on the vehicle, the lights are controlled by a switch on the transmission or a signal from
the transmission electronic control unit (ECU). Refer to the Back–Up Lights Function Diagram.
This section only covers circuits from the back-up light turn signal splice (4810) to the tail lights. Refer to the
transmission section for information on the circuits from the transmission to the back-up light turn signal splice.
1.2. DIAGNOSTICS
There are no diagnostic trouble codes (DTC’s) associated with the back-up light circuits.
A fault in the back-up light circuits will be apparent when the transmission is shifted into reverse and the lights
don’t come on and back-up lamps are not burned out.
1.3. FAULT DETECTION MANAGEMENT

NOTE – The testing method for troubleshooting the electrical systems portrayed in this manual is a
basic voltage test. An alternative method of checking for voltage drops within a given circuit may be a
quicker method of identifying an exact problem.
Refer to the Back–Up Lights Connector Diagram
Problems in the back-up light circuits can be caused by burned out lamps, a blown fuse, a short, an open, a
faulty relay, a faulty switch on the transmission, or a failed transmission ECU.
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Figure 411 Back–Up Lights Connector Diagram—Always Refer to the Circuit Diagram Book for
Latest Circuit Information.
(71) LEFT TAIL LIGHT CONNECTOR
(72) RIGHT TAIL LIGHT CONNECTOR
(4705) TRANSMISSION/DASH CONNECTOR (TO TRANSMISSION CIRCUITS)
LOCATED IN ENGINE COMPARTMENT BY WIPER MOTOR BRACKET
(4810) BACK–UP LIGHT TURN SIGNAL SPLICE
LOCATED NEAR ENGINE POWER DISTRIBUTION CENTER
(8803) CHASSIS GROUND SPLICE PACK
(9303) STOP TAIL AND TURN CONNECTOR
(9700) CHASSIS DASH INTERCONNECT
(9800) CENTER CHASSIS/REAR CHASSIS CONNECTOR
Table 284 Back–Up Lights Circuit Tests

Stop Tail and Turn connector (9303)
Check with ignition on, transmission in reverse and (9303) disconnected.

Test Points Spec. Comments
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Table 284 Back–Up Lights Circuit Tests (cont.)

With transmission in 12 ± 1.5 volts If voltage is missing, check for blown fuse, short
reverse, (9303) cavity or open in circuits between (9303) cavity A and
A to ground. transmission backup light switch circuits. Perform the
Transmission/Dash Connector (4705) Transmission
Backup light Switch check.
With transmission in 12 ± 1.5 volts If voltage is missing, check for open in ground
reverse, (9303) cavity circuits between (9303) cavity E and Cab ground
A to cavity E. (4006). Perform the Tail Light Connector (72)
Resistance and Voltage checks
With transmission in 0 volts If voltage is present, check for faulty transmission
neutral, (9303) cavity backup circuits. (See transmission section)
A to ground.
Transmission/Dash Connector (4705) Transmission Backup light Switch check Check
with ignition on, transmission in reverse and (9303) connected.
Manual Transmission Backup lights on. If backup lights off, see transmission section
connector (4705), for switch repair.
jumper terminals A to B.
Allison LCT Backup lights on. If backup lights are off, see transmission section
Transmission for switch repair.
connector (4705),
jumper terminals D to H.
Eaton Autoshift Backup lights on. If backup lights are off, see transmission section
Transmission for switch repair.
connector (4705),
jumper terminals
18 to 19.
Allison MD WTEC Backup lights on. If backup lights are off, see transmission section for
Transmission switch repair. Check backup lamp relay (WTEC) (4002)
connector (4705), in the engine compartment power distribution center.
jumper terminal 13
to Ground.
Tail Light Connector (72) Resistance checks Check with (9303) disconnected
Harness connector (72) Resistance should If resistance is incorrect check for shorts to ground
terminal A to ground read >50K ohms. in both tail light assemblies.
Tail Light Connector (72) Voltage checks Check with transmission in reverse and (9303) connected.
Harness connector (72) 12 ± 1.5 volts. If voltage is incorrect check for open circuits
terminal A to ground in tail light assemblies.
Harness connector (72) 12 ± 1.5 volts. If voltage is incorrect check for open in ground
terminal E to terminal A circuits in tail light assemblies.
1.4. EXTENDED DESCRIPTION

Refer to the Back–Up Lights Connector Diagram.
When the transmission is shifted into reverse, transmission circuits will apply battery voltage to backup
lamp/turn signal splice (4810) and the back-up lights.
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Ground for the back-up lights is supplied from ground stud (4006) to stop tail & turn connector (9303) terminal E.
1.5. COMPONENT LOCATIONS
Figure 412 Stop/Turn Signal/Hazard Light Connector Locations (Engine Compartment Looking
Toward Cab)
1. FORWARD CHASSIS CONNECTOR (4301)
2. DASH/CHASSIS CONNECTOR (9700)
3. TRANSMISSION CONNECTOR
4. ENGINE CONNECTOR
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Figure 413 Rear Chassis Wiring Connector Locations

1. HARNESS TO CENTER CHASSIS WIRING
(9100) FUEL LEVEL SENDER CONNECTOR
(9700) REAR CHASSIS CONNECTOR
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Figure 414 Rear Center Chassis Connector Locations

(9800) REAR CENTER CHASSIS CONNECTOR
Figure 415 Stop, Tail and Turn Connector Location

(9303) STOP, TAIL AND TURN CONNECTOR
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Figure 416 (Typical) Rear Signal Light Connector Locations

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2. ROOF CLEARANCE AND MARKER OR SUNSHADE LIGHTS

Figure 417 Roof Clearance and Marker or Sunshade Lights Function Diagram
1. ELECTRICAL SYSTEM CONTROLLER
2. DRIVETRAIN J1939 DATA LINK
3. HEADLIGHT PARK LIGHT SWITCH (MOUNTED ON ELECTRONIC GAUGE CLUSTER)
4. CAB ROOF CLEARANCE AND MARKER OR SUNSHADE LIGHTS
Refer to the Roof Clearance and Marker or Sunshade Lights Function Diagram.
NOTE – The clearance or sunshade lights are connected to the park lamp circuits in the ESC. If clearance
lights and park lamps are inoperative refer to the Marker, Park and Tail lamps section (See MARKER,
PARK AND TAIL LAMPS, page 844) of this manual. If the clearance lights are inoperative but the park
lights are working, proceed with this section.
The standard cab roof clearance and marker lights are part of the basic cab design. If a sunshade is installed,
the 5 lights are located in the sunshade.
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The lights are activated when the headlight switch is in the headlight or park position. The electronic gauge
cluster will send a message to the ESC to command the lights on.
The marker interrupt switch will also affect operation of the marker lights, park lights and clearance lights. The
lights will turn on while the switch is held on, if the lights were previously off. The lights will turn off while the
switch is held on, if the lights were previously on.
The ESC supplies battery voltage to the roof lights, marker and identification lights.
2.2. DIAGNOSTICS
If any of the other park lights are working (only the roof marker lights are inoperative) there will be no diagnostic
trouble codes logged.
A short or open in the roof clearance and marker or sunshade light circuits will be apparent when the park or
headlights are turned on and the clearance, marker and identification lights don’t come on.
The mirror marker lights are also connected to the roof clearance and marker or sunshade light circuits.
An electronic service tool, running the "INTUNE" diagnostic software, can be used to check operation of the
park lights and monitor activation of the park light switch. See the diagnostic software manual for details
on using the software.

Refer to Roof Clearance and Marker or Sunshade Lights.
Problems which affect only the roof clearance or sunshade light circuits can be caused by burned out lamps, a
short, an open, or a problem in the ESC.
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Figure 418 Roof Clearance and Marker or Sunshade Lights — Always Refer to Circuit Diagram
Book for Latest Circuit Information
(520)-(524) SUNSHADE CLEARANCE LIGHT CONNECTORS
(1601) ESC BOOSTER CONNECTOR
(1851) CAB GROUND
(2000) ROOF/INSTRUMENT PANEL CONNECTOR
(2002)-(2006) MARKER AND CLEARANCE LAMP CONNECTORS
(2007) SUNSHADE CONNECTOR
Table 285 Roof Clearance and Marker or Sunshade Lights Circuit Tests
Roof Instrument Panel Connector (2000) Voltage Checks
With (2000) disconnected and park lights on, check instrument panel harness connector
NOTE – Always check connectors for damage and pushed–out terminals. Also check
turn signal assemblies for damage or corrosion.
NOTE – Always use breakout box ZTSE 4477 to take measurements on ESC connectors.
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Table 285 Roof Clearance and Marker or Sunshade Lights Circuit Tests (cont.)
(2000) NOTE – A load device, If voltage is missing, check for open or
Socket 9 to such as a test light, must short in circuit A58L. A short in circuits
ground be used in parallel with A58L or A58S to the mirror lights. Also
voltmeter probes to read insure proper voltage out of ESC.
an accurate voltage.
Refer to ESC Replacement in this manual.
12 ± 1.5 volts (See ESC REPLACEMENT, page 124)
(2000) NOTE – A load device, If voltage is missing, check for open in circuits
Socket 9 to such as a test light, must A63–GA or A11–G to ground.
Socket 2 be used in parallel with
voltmeter probes to read
12 ± 1.5 volts
Roof Connector (2000) Resistance checks.
Pin 9 to >1000 ohms Resistance less than 1000 ohms indicates
ground a short to ground.
Pin 9 to pin 2 < 5 ohms Resistance greater than 5 ohms indicates open
in power circuits or ground circuits to lights.

Refer to Roof Clearance and Marker or Sunshade Lights.
Roof Clearance and Marker Lights
When the ESC is commanded to turn the roof lights on, the ESC will provide 12 volts to the lights from ESC
booster connector (1601) terminal H. The circuit path is from Connector (1601) terminal H through circuit A58L,
through roof/IP connector (2000) terminal 9 through D58H to individual circuits splitting out to the lights.
The ground circuit path is from negative stud (1852) through circuit A11–G, circuit A63–GA, roof connector
(2000) terminal 2 and circuit D58–GC to individual ground circuits splitting out to the lights.
Sunshade Lights
When the ESC is commanded to turn the roof lights on, the ESC will provide 12 volts to the lights from ESC
booster connector (1601) terminal H. The circuit path is from Connector (1601) terminal H through circuit A58L,
through roof/IP connector (2000) terminal 9 through D58H and D58T, through sunshade connector (2007)
terminal A, through circuit 58A to individual circuits splitting out to the lights.
The ground circuit path is from negative stud (1852) through circuit A11–G, circuit A63–GA, roof connector
(2000) terminal 2, through circuit D58–GC and D58–GL, through sunshade connector (2007) terminal B,
through circuit 58–GA to individual ground circuits splitting out to the lights.
Marker Interrupt
When the marker interrupt is held on, the switch pack will send a message via the switch data link to the ESC.
The ESC will command the lights to go and off as required.
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Figure 419 Roof Clearance and Marker Lights

1 CLEARANCE AND MARKER LIGHTS
2. ROOF HARNESS TO ROOF/INSTRUMENT PANEL CONNECTOR (2000)
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Figure 420 Sunshade Lights

1. SUNSHADE CLEARANCE LIGHTS
2. SUNSHADE CONNECTOR (2007)
3. ROOF HARNESS TO ROOF/INSTRUMENT PANEL CONNECTOR (2000)
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3. MARKER, PARK AND TAIL LAMPS

Figure 421 Marker, Park and Tail Lights

1. MARKER, PARK AND TAIL LIGHTS
3. DRIVETRAIN J1939 DATA LINK
4. HEADLIGHT PARK LIGHT SWITCH (PART OF ELECTRONIC GAUGE CLUSTER)
The marker, park and tail lamps are activated when the headlight switch is in the headlight or park position.
The electronic gauge cluster will send a message to the ESC to command the lights on. The ESC supplies
battery voltage for the marker, park and tail lamps.
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The marker interrupt switch will also affect operation of the marker lights and park lights. The lights will turn
on while the switch is held on, if the lights were previously off. The lights will turn off while the switch is
held on, if the lights were previously on.
The roof clearance and marker lights or sunshade lights are directly connected to the park circuits inside the
ESC. The roof or sunshade lights have a separate fuse between their circuits and the ESC. If the clearance
lights are inoperative but the park lights work, refer to the Roof Clearance and Marker or Sunshade Section
(See ROOF CLEARANCE AND MARKER OR SUNSHADE LIGHTS, page 838)
3.2. DIAGNOSTICS
Refer to Marker, Park and Tail Lights.
If the lights stay on when the headlight switch is in the off position, the problem is most likely a defective
headlight switch, switch pack, wiring between the switch pack and the EGC, or a problem in the EGC (the
system is designed to turn the park lights on when there is no input to the EGC from the switch).
Should the lights fail to come on when the headlights are on, the problem could be attributed to open or shorted
output wiring between the ESC and the tail lights, side marker lights and front marker lights lamps. The ESC
has an internal virtual fuse software algorithm to protect output circuits in an over current situation.
A diagnostic trouble code will be logged if there is an over current caused by a short to ground or excessive
load (too many accessories) or an open in the circuits between the ESC and the tail lights, side marker
lights and front marker lights.
If individual lights are inoperative the problem must be attributed to faulty lamps or open wiring to the individual
lamps.
An electronic service tool, running the "INTUNE" diagnostic software, can be used to command the ESC to
turn on the lights and monitor activation of the park light switch. See the diagnostic software manual for
details on using the software.
Marker, Park and Tail Lights Preliminary Check
Table 286 Marker, Park and Tail Lights Preliminary Check

STEP KEY ACTION TEST SPEC. YES - IN NO - OUT OF SPEC.
POINTS SPEC.
1. On Verify marker, park Visually Marker, Go to next Marker, park and tail
and tail lights are check park step. lights are operating.
inoperative. marker, park and tail Problem does not
and tail lights are exist or is intermittent.
lights. inoper- (Check for inactive
ative. diagnostic trouble
codes.)
2. On Determine if any Visually No other Go to next Identify and repair
other features are check features step. condition causing
malfunctioning that for other are several features to be
may have common malfunc- malfunc- inoperative.
circuits. (Example: tioning tioning.
Missing ground features.
common to several
features.)
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Table 286 Marker, Park and Tail Lights Preliminary Check (cont.)
POINTS SPEC.
3. On Are all marker, Visually All lights Go to next Check specific circuits
park and tail lights check if are step. of the inoperative
inoperative? all lights inoper- light(s) for open
are inoperative. circuits.
ative.
4. On Check for marker, Read No light Go to Go to marker, park
park and tail lights display on diagnostic marker, and tail lights circuit
diagnostic trouble odometer. trouble park and outputs from ESC.
codes. (See codes are tail lights (See MARKER, PARK
Diagnostic Trouble active. circuit AND TAIL LIGHT
Codes, page 846) inputs to OUTPUTS FROM
ESC. (See ESC, page 849)
MARKER,
PARK
AND TAIL
LIGHT
INPUTS
TO ESC,
page 847)
Diagnostic Trouble Codes
To display diagnostic trouble codes (DTC’s), set the parking brake and turn the Ignition key “ON”. Then
press the Cruise “ON” switch and the Cruise “Resume” switch simultaneously. If no faults are present, the
cluster odometer will display “NO FAULTS”. If faults are present, the gauge cluster display will show the
number of faults and each diagnostic trouble code for 10 seconds and then automatically scroll to the next
entry and continue to cycle through the faults. To manually cycle through the fault list, press the cluster display
select/reset button. The last character of the diagnostic trouble code will end in “A” for active faults or “P”
for previously active faults. Releasing the parking brake or turning the ignition key off will take the ESC
and the gauge cluster out of the diagnostic mode.
After all repairs have been made, the diagnostic trouble codes may be cleared by putting the key switch in the
accessory position, turning on the left turn signal and pressing the cruise on and set switches simultaneously.
Table 287 Marker, Park and Tail Lights

DIAGNOSTIC TROUBLE CODE FAULT DESCRIPTION
NO DIAGNOSTIC TROUBLE CODE Diagnostic trouble codes are not logged for every possible
fault in the park light circuits.
If the lights stay on when the headlight switch is in the off position, the problem is most likely a defective
headlight switch, switch pack, wiring between the switch pack and the EGC, or a problem in the EGC (The
system is designed to turn the park lights on when there is no input to the EGC from the switch).
Go to marker, park and tail lights circuit inputs to ESC. (See MARKER, PARK AND
TAIL LIGHT INPUTS TO ESC, page 847)
When the park light switch is on and an individual light or several lights, but not all lights, are
inoperative there is probably a failed bulb or an on open circuit to those lights.
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Table 287 Marker, Park and Tail Lights (cont.)

The roof clearance and marker lights or sunshade lights have a separate fuse between their
circuits and the ESC. Refer to the Roof Clearance and Marker or Sunshade section (See ROOF
CLEARANCE AND MARKER OR SUNSHADE LIGHTS, page 838)
611 14 4 1 Marker, park and tail lamps open circuit, 4007 pin H.
This fault is the result of an open in the circuits between the marker, park and tail lamps circuits and the ESC.
Inspect marker park and tail lights (See MARKER, PARK AND TAIL LIGHT OUTPUTS
FROM ESC, page 849) for proper operation
611 14 4 2 Marker, park and tail lamps over current, 4007 pin H.
This fault is the result of a short or overload in the circuits between the marker,
park and tail lamps circuits and the ESC.
Inspect Marker Park And Tail Lights (See MARKER, PARK AND TAIL LIGHT OUTPUTS
611 14 4 3 Marker, park and tail lamps, less than normal low
current but more than open circuit
611 14 4 4 Marker, park and tail lamps, greater than normal high
current and less than fusing current
611 14 4 6 Marker, park and tail lamps has current flow when
output commanded off
3.3. MARKER, PARK AND TAIL LIGHT INPUTS TO ESC

Fault Detection Management
Refer to Park Light EGC and ESC Input Circuits.
A fault in the input circuits will be apparent when the park lights are always on and no active faults are present.
The ESC will not log any faults for park light circuits in the EGC. The park light request from the EGC is
communicated on the 1939 data link. Loss of the drivetrain 1939 data link between the EGC and ESC will
cause several problems to occur simultaneously and the check electrical system lamp will illuminate. Go to
the section on the drivetrain 1939 data link to troubleshoot this condition. Problems in the work light
input circuits can be caused by a short circuit between the 3 switch pack and the EGC, an open circuit between
the 3 switch pack and the EGC, a faulty switch, or a problem in the EGC.
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Figure 422 Park Light EGC and ESC Input Circuits—Always Refer to Circuit Diagram Book for Latest
Circuit Information
A. 3 SWITCH PACK CONNECTOR
B. EGC CIRCUIT BOARD CONNECTOR
(1500) EGC CONNECTOR
LOCATED BEHIND CLUSTER
(1600) ELECTRICAL SYSTEM CONTROLLER CONNECTOR
LOCATED ON CAB SIDE OF ESC
Table 288 EGC, 3 Switch Pack Circuit Tests

There are no diagnostic trouble codes associated with the 3 switch pack in the EGC.
A mechanically defective park light switch could also prevent the park light from operating. Remove
the mechanical portion of the switch and attempt to turn the switch on by pressing the top microswitch.
If the park lights go out, the mechanical switch assembly should be replaced.
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Table 288 EGC, 3 Switch Pack Circuit Tests (cont.)

3 Switch Pack Harness Connector Park Light Voltage Checks
Check with ignition key on and 3 switch pack disconnected.
NOTE – If the EGC and switch are working correctly, disconnecting the 3 switch pack connector
should cause the park lights to come on.
NOTE – Always check connectors for damage and pushed–out terminals.

3 switch pack harness 5 ± .5 volts If voltage is missing, check for open
connector, cavity 8 to ground or shorts in circuits between EGC
connector and switch connector.
Also insure proper voltage out of EGC.

3 switch pack harness 0 volts Ground circuit from EGC
connector, cavity 10 to ground
If voltage is incorrect, check for shorts in
circuits between EGC and switch.

3 switch pack harness 5 ± .5 volts If voltage is incorrect, check for shorts in
connector, cavity 8 to cavity 10. circuits between EGC and switch.
3 Switch Pack Work Light Resistance Check

Check resistance between Approximately 1.5M ohms. If there is no continuity, the switch
pins 10 (negative probe on pin pack needs replaced.
10) and 8 of the switch pack,
when the switch is off.
Extended Description
The park light switch is wired directly to the EGC circuit board. When the park light switch is turned off,
5 volts on pin 8 from the EGC will drop to ground. This will cause the EGC to send a message to the ESC
requesting the light to be turned on.
3.4. MARKER, PARK AND TAIL LIGHT OUTPUTS FROM ESC

NOTE – The virtual fuse in the ESC will trip during a short. To reset the fuse, the key switch must be
cycled.
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Refer to Marker, Park and Tail Lamps.
A fault in the marker, park and tail lights will be apparent when the headlights are turned on and the marker,
park and tail lamps don’t come on. The ESC will also log a diagnostic trouble code (DTC) when there is a short
in any of the marker, park and tail lamp circuits. Problems in the marker, park and tail lamp circuits can be
caused by burned out lamps, a short, an open, or a problem in the ESC.
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Figure 423 Marsker, Park and Tail Lamps — Always Refer to Circuit Diagram Book for Latest Circuit
Information
1. LEFT REAR LIGHT ASSEMBLY
2. RIGHT REAR LIGHT ASSEMBLY
(4007) BROWN ELECTRICAL SYSTEM CONTROLLER CONNECTOR
LOCATED ON ENGINE COMPARTMENT SIDE OF ESC
(4301) FORWARD CHASSIS CONNECTOR
LOCATED IN ENGINE COMPARTMENT NEAR LEFT FRAME RAIL
(9303) STOP/TAIL/TURN CONNECTOR
LOCATED ON LEFT LIGHT ASSEMBLY
(9800) REAR/CENTER CHASSIS CONNECTOR
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Table 289 Marker, Park And Tail Lights Circuit Tests

611 14 4 3 Marker, park and tail lamps, less than normal low
611 14 4 4 Marker, park and tail lamps, greater than normal high
611 14 4 6 Marker, park and tail lamps has current flow
when output commanded off
611 14 4 1 Marker, park and tail lamps open circuit
This fault is the result of an open in the circuits between the marker,
park and tail lamps circuits and the ESC.
611 14 4 2 Marker, park and tail lamps over current
This fault may be the result of a short in the circuits between the marker, park and tail
lamps and the ESC. It could also be caused by an excessive load on the circuits.
NOTE – Disconnecting connectors will cause new open circuit faults to be logged.
Clear all faults after connections have been restored.
Clear DTC’s. Disconnect stop tail and turn connector (9303), then turn on the park light
switch and check for fault. If the fault has not reoccurred, there is a short or an overload in
the tail lights. If the fault reoccurs, there is a short in one of the other circuits or in the ESC.
NOTE – With sealed beam headlamps, as used with Severe Service trucks, the
terminals at the headlamps are not sealed - in this application the terminals of the
headlamps and the terminals in the headlamp connector must be totally coated with
Grafo grease 2643099R1
Clear DTC’s. Disconnect left headlight harness connector (8001), then turn on
the park light switch and check for fault. If the fault has not reoccurred, there
is a short or an overload in the left front marker lights. If the fault reoccurs,
there is a short in one of the other circuits or in the ESC.
Clear DTC’s. Disconnect right headlight harness connector (8000), then turn on
the park light switch and check for fault. If the fault has not reoccurred, there
is a short or an overload in the right front marker lights. If the fault reoccurs,
there is a short in one of the other circuits or in the ESC.
Clear DTC’s. Disconnect brown ESC connector (4007), then turn on park lights and check
for fault. If the fault has not reoccurred, there is a short in the circuits between the ESC
and the marker, park and tail lamps. If the fault reoccurs, there is a short inside the ESC.
Stop Tail and Turn Connector (9303) Voltage Checks
With (9303) disconnected and park lights on.
NOTE – Always check connectors for damage and pushed–out terminals. Also
check turn signal assemblies for damage or corrosion.
NOTE – Always use breakout box ZTSE 4477 to take measurements on ESC
connectors.
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Table 289 Marker, Park And Tail Lights Circuit Tests (cont.)
(9303) cavity NOTE – A load device, If voltage is missing, check for open or
D to ground such as a test light, must short in circuits between brown ESC
be used in parallel with connector (4007) terminal H and stop
voltmeter probes to read tail and turn connector cavity D. Also
an accurate voltage. insure proper voltage out of ESC.
12 ± 1.5 volts Refer to ESC Replacement in this manual.

(See ESC REPLACEMENT, page 124)
(9303) cavity NOTE – A load device, If voltage is missing, check for open
D to cavity E such as a test light, must in circuits between (9303) cavity
be used in parallel with E and ground.
12 ± 1.5 volts
Refer to Marker, Park and Tail Lamps.
When the ESC is commanded to turn the tail lights on, the ESC will provide 12 volts to the lights from ESC
connector (4007) terminal H to left stop tail and turn connector (9303) terminal D. Voltage to right tail light
connector (72) terminal B is provided on circuit S68C from left tail light connector (71) terminal B.
Ground for the tail lights is supplied from ground stud 2 (4006) to left stop tail and turn connector (9303)
terminal E. Ground to right tail light connector (72) terminal E is provided on circuit S10–GC from left tail
light connector (71) terminal E.
When the ESC is commanded to turn the side and front marker lights on, the ESC will provide 12 volts to the
lights from ESC connector (4007) terminal H to circuit M58B. Circuit M58B is split on circuit M58D to right
headlight/turn signal connector (8000) terminal E. Circuit M58B is also split to circuit M58C to left headlight/turn
signal connector (8001) terminal E.
The ground circuit path is from ground stud 2 (4006) to circuit M10–GA. Circuit M10–GA is split on circuit
M52–GA to right headlight /turn signal connector (8000) terminal B. Circuit M10–GA is also split to circuit
M52–GB to left headlight/turn signal connector (8001) terminal E.
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Figure 424 Headlights, Front and Side Marker Lights (Not Severe Service)
1. FRONT PARK LIGHT
2. SIDE MARKER LIGHT
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Figure 425 Headlights, Front and Side Marker Lights (Severe Service)
1. FRONT PARK LIGHT
2. STANDARD SIDE MARKER LIGHT
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Figure 426 Optional Side Marker/Turn Signal Lights (Severe Service)

1. OPTIONAL SIDE MARKER/TURN SIGNAL LIGHT
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Figure 427 Rear Tail Light Connector Locations

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4. DOME AND MAP LIGHTS

Figure 428 Dome and Map Lights Function Diagram

2. MAP LIGHT
3. MAP LIGHT
4. FRONT DOME LIGHT
5. REAR DOME LIGHT (CREW CAB ONLY)
6. FRONT DOOR SWITCHES
7. REAR DOOR SWITCHES (CREW CAB ONLY)
8. COURTESY LAMPS
Refer to Dome and Map Lights Function Diagram.
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The dome lights are controlled by the door switch(es). Individual dome light(s) can also be turned on by
their dome light switch.
The dome light output from the ESC has theater style dimming capability, which can be disabled with
programming. The lights will remain on if a door, with a switch mounted in the cab opening, is open. As soon
as all doors are closed, and the dome light switch is off, the light will remain on at a modified level for 20
seconds or until the ignition has been started. At that time, the lights will dim gradually until the light is off.
With theater lighting disabled the dome light(s) will go off as soon as the doors are shut.
On January 28, 2003, the ESC software was revised. Prior to the revision, a door with a plunger type switch
that was not fully latched would not turn off the dome light. If left on for an extended period of time, the dome
light will drain the batteries. Now the dome light power will be cut back to 1% after 10 minutes. Cycling the
door plunger or key switch will reactivate the dome light.
The remote keyless entry (RKE) also turns on the light for a timed period when the ’unlock’ button is pressed,
and turns off the light when the ’lock’ button is pressed
When a door is opened or closed the courtesy lights (located under the dash) will operate the same as
the dome lights.
The map lights are controlled by the switches on the lights.
4.2. DIAGNOSTICS
If the dome light(s) or map lights fail to operate from their individual switches, the problem is most likely
in the power circuits or the switches to the lights.
The door with a plunger type switch that was not fully latched, the dome light power will be cut back to 1%
after 10 minutes.
If the dome lights stay on when the doors are closed and the dome light switches are off, the problem is most
likely a defective door switch, a short in wiring between the door switch and the EGC, or a problem in the EGC.
Should the lights fail to come on when a door is opened, the problem could be attributed to an open in the wiring
between the door switches and the ESC, open or shorted output wiring between the ESC and the dome lights.
The ESC has an internal virtual fuse software algorithm to protect output circuits in an over current situation.
A diagnostic trouble code will be logged if there is an over current caused by a short to ground or excessive
load (too many accessories) on the circuits between the ESC and the dome lights.
If individual lights are inoperative the problem must be attributed to faulty lamps or open wiring to the individual
lamps.
An electronic service tool, running the "INTUNE" diagnostic software, can be used to command the ESC to
turn on the lights and monitor activation of the dome light switch(es). The software will also display diagnostic
trouble codes. See the diagnostic software manual for details on using the software.
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Dome Light Preliminary Check
Table 290 Dome Light Preliminary Check

POINTS SPEC.
1. On Verify the dome lights Visually Lights Go to Locate and repair
and map lights operate check operate next cause of inoperative
from their individual operation of correctly. step. light. Check for
switches. lights. blown fuse, short
circuit, open circuit or
defective switch.
2. On Verify the dome lights Visually Dome Go to Check ESC for
operate correctly when check dome light next software revision V22.
a door is held opened. light. power step. Program or replace
will be ESC.
cut back
to 1%
after 10
minutes.
Cycling
the door
plunger
or key
switch will
reactivate
the dome
light.
3. On Verify operation of any Visually Dome Go to Locate open in
dome light(s) from other check dome light(s) next circuits to door
doors. light. operate step. switch(es) which are
correctly not operating correctly.
with other
door(s).
4. On If more than one light Visually All work Go to Dome light feature is
is connected to dome check if all lights next operating correctly.
light circuits (rear work lights are not step. Problem does not
dome lights or courtesy are operating operating exist or is intermittent.
lights), are all lights correctly. correctly. (Check for inactive
inoperative? diagnostic trouble
codes.)
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Table 290 Dome Light Preliminary Check (cont.)

POINTS SPEC.
5. On Locate open in circuits
to inoperative dome
lights.
6. On Check for diagnostic Read display No dome Go to Go to dome light circuit
trouble codes. (See on odometer. light door checks. (See DOME
Diagnostic Trouble diagnostic switch LIGHT CIRCUITS,
Codes, page 861) trouble inputs. page 864)
codes are (See
active. DOOR
SWITCH
INPUTS
INTO
ESC,
page
862)
Table 291 Dome Light Circuits

fault in the dome light circuits.
611 14 10 1 Dome Light Under Current (open circuit, 1601 pin C).
This fault is the result of an open in the circuits between the the ESC and the dome/courtesy lights.
Inspect dome light circuits (See DOME LIGHT CIRCUITS, page 864) for proper operation
A diagnostic trouble code will only be logged for shorts on circuits from the ESC to the dome/courtesy lights.
611 14 10 2 Dome Light Over Current (Short Circuit)
This fault is the result of a short or overload on the circuits between the ESC and the dome/courtesy lights.
Inspect dome light circuits (See DOME LIGHT CIRCUITS, page 864) for proper operation
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Table 291 Dome Light Circuits (cont.)

611 14 10 3 Dome Light lamps, less than normal low current
but more than open circuit
611 14 10 4 Dome Light lamps, greater than normal high current
and less than fusing current
611 14 10 6 Dome Light lamps has current flow when output
commanded off
4.3. DOOR SWITCH INPUTS INTO ESC

Refer to Door Switch Circuits to ESC.
Several options are available for door switches. Options range from one switch on the drivers door to
switches on every door.
A problem in the door switch circuit(s) will prevent the lights from operating when one or both doors are
opened. A problem in the door switch circuits could be attributed to a defective switch, a problem in the
ESC, a short circuit or an open circuit.
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Figure 429 Door Switch Circuits to ESC (Connectors Viewed From Mating End) — Always Refer To
Circuit Diagram Book For Latest Circuit Information
(1600) 36–WAY ESC CONNECTOR
(2000) ROOF CONNECTOR
LOCATED NEAR DRIVER SIDE A PILLAR
(2111) RIGHT DOOR DOME SWITCH CONNECTOR
LOCATED IN PASSENGER SIDE B PILLAR
(2112) LEFT DOOR DOME SWITCH CONNECTOR
LOCATED IN DRIVER SIDE B PILLAR
(2113) RIGHT CREW DOOR DOME SWITCH CONNECTOR
LOCATED IN PASSENGER SIDE C PILLAR (CREW CAB ONLY)
(2114) LEFT CREW DOOR DOME SWITCH CONNECTOR
LOCATED IN DRIVER SIDE C PILLAR (CREW CAB ONLY)
Table 292 Door Switch Circuit Tests

FAULTS
There are no diagnostic trouble codes associated with door switch circuits.
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Table 292 Door Switch Circuit Tests (cont.)

Harness connector 12 ± 1.5 volts with ignition If voltage is missing, check for open
cavity A to ground. on, 5 ± .5 with ignition off. in circuits D63A or A63A. Also check
for short in circuits D63A, A63A or
circuits to other door switches.
Also insure proper voltage out of ESC.

Harness connector <.3 volts Zero volt reference level signal.
cavity B to ground.
Harness connector 12 ± 1.5 volts with ignition If voltage is missing, check for open in
cavity A to cavity B. off. 5 ± .5 with ignition off. circuits between ESC connector (1600)
cavity D and dome switch connector
cavity B. A missing zero volt reference
level from the ESC will cause several
other features to be inoperative.
Door Switch (2112) Resistance Checks
Check at door switch.

Resistance between <1 ohm with door open. If resistance is incorrect replace
door switch connector >50K ohms with piece of defective switch.
pins A and B. steel in front of switch.
If the door switch and door switch circuits check good proceed to the dome light
circuit checks (See DOME LIGHT CIRCUITS, page 864).
Refer to Door Switch Circuits to ESC.
A proximity switch is used for the door switch(es). When steel passes in front of the switch it will open. When
the door is opened the switch will close.
The ESC monitors the voltage at ESC connector (1600). When a door switch closes, a zero volt reference
signal from the ESC will be applied through the door switch back to the ESC. This will cause the voltage
to drop and the ESC will turn the dome light(s) on.
4.4. DOME LIGHT CIRCUITS

cycled.
Refer to Dome Light Circuits.
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A fault in the dome, courtesy or map light circuits will be apparent when the lights don’t come on. The ESC
will also log a diagnostic trouble code (DTC) when there is a short in any of the dome light circuits from the
ESC. Problems in the dome light circuits can be caused by burned out lamps, a blown fuse, a short, an
open, or a problem in the ESC. Problems in the map light circuits can be caused by burned out lamps, a
blown fuse, a short or an open circuit.
Figure 430 Dome Light Circuits (Connectors Viewed From Mating End) — Always Refer To Circuit
Diagram Book For Latest Circuit Information
(F12) DOME LIGHT FUSE
LOCATED IN CAB FUSE BLOCK (1011)
(1553) DRIVERS COURTESY LIGHT CONNECTOR
LOCATED BEHIND DRIVERS COURTESY LIGHT IN INSTRUMENT PANEL
(1553) PASSENGERS COURTESY LIGHT CONNECTOR
LOCATED BEHIND PASSENGERS COURTESY LIGHT IN INSTRUMENT PANEL
(1601) BROWN ESC CONNECTOR
(2000) ROOF CONNECTOR
(2115) REAR DOME LIGHT CONNECTOR
LOCATED NEAR DRIVER SIDE A PILLAR AT HEADLINER
(2116) DOME LIGHT CONNECTOR
LOCATED BEHIND DOME LIGHT ASSEMBLY
(2117) DOME READING LIGHT CONNECTOR
LOCATED BEHIND DOME/READING LIGHT ASSEMBLY
(2502) CONSOLE/ROOF CONNECTOR
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Table 293 Dome and Map lights Circuit Tests

611 14 10 3 Dome Light lamps, less than normal low current
611 14 10 4 Dome Light lamps, greater than normal high current
611 14 10 6 Dome Light lamps has current flow when
611 14 10 2 Dome Light Over Current (Short Circuit)
NOTE – Disconnecting connectors will cause new open circuit faults to be logged. Clear
all faults after connections have been restored.
Disconnect dome light connector (2116) and close all doors. Cycle key switch and
clear DTC’s. Open the drivers door and check for fault. If the fault has not reoccurred,
there is a short or an overload in the front dome light. If the fault reoccurs, there is
a short in other dome or courtesy light circuits or in the ESC.
Perform the same procedure on the remaining dome light and courtesy light connectors
until the short circuit is isolated. If the active fault remains active, there is a short in the
circuits between the ESC and dome light(s) or a short inside the ESC.
Disconnect brown ESC connector (1601) and close all doors. Cycle key switch
and clear DTC’s. Open the drivers door and check for fault. If the fault has not
reoccurred, there is a short in the circuits between the ESC and dome light(s). If
the fault reoccurs, there is a short inside the ESC.
611 14 10 1 Dome Light Under Current (Open Circuit)
Dome Light Connector (2116) Voltage Checks
Check with ignition on, drivers door open and dome light connector disconnected.

Cavity C to ground 12 ± 1.5 volts If voltage is missing, check for blown
fuse F12 or open or short in circuits
between cavity C and F12.
Cavity F to ground 12 ± 1.5 volts If voltage is missing, check for open
in circuits between cavity F and ESC
connector (1601) cavity C.
Cavity C to 12 ± 1.5 volts If voltage is missing, check for open
cavity B in ground circuits between cavity B
and ground stud (1852).
Refer to Dome Light Circuits.
When the front dome light or map lights are operated from the manual switches, power for the dome and
map lights is provided from fuse F12 through circuit A63D, roof connector (2000) terminal 11, circuit D63D,
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console roof connector (2502) terminal C, circuit C63D and dome lamp connector (2116) terminal C to the
switches on the dome light and map lights.
Ground for the dome light and map lights is supplied from ground terminal (1852) to the dome light and
map lights.
Power to the front dome light (when a door is opened) is supplied from brown ESC connector (1601) terminal
C and dome light connector (2116) terminal F to the dome light.
When the rear dome light is operated from the manual switch, power for the dome light is provided from fuse
F12 and rear dome lamp connector (2115) terminal A to the switch on the dome light.
Power to the rear dome light (when a door is opened) is supplied from brown ESC connector (1601) terminal
C and rear dome light connector (2115) terminal A to the dome light.
Ground for the rear dome light is supplied from ground terminal (1852) and rear dome lamp connector (2115)
terminal B to the rear dome light switch.
Power to the optional courtesy lights (when a door is opened) is supplied from brown ESC connector (1601)
terminal C to drivers courtesy light (1553) terminal A passenger courtesy light (1554) terminal A.
Ground for the courtesy lights is supplied from ground terminal (1552) to passenger courtesy light (1554)
terminal B.
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Figure 431 Dome Light Wiring

1. ROOF HARNESS TO ROOF CONNECTOR (2000)
(2111) RIGHT DOOR DOME SWITCH CONNECTOR
(2112) LEFT DOOR DOME SWITCH CONNECTOR
(2113) RIGHT CREW DOOR DOME SWITCH CONNECTOR
(2114) LEFT CREW DOOR DOME SWITCH CONNECTOR
(2115) REAR DOME LIGHT CONNECTOR
(2116)/(2117) DOME READING LIGHT CONNECTOR
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Figure 432 Courtesy Light Locations

1. PASSENGER COURTESY LIGHT
2. DRIVER COURTESY LIGHT
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5. FOG LIGHT SYSTEM

Figure 433 Fog Lights Function Diagram

1. FOG LIGHTS
3. SWITCH DATA LINK
4. FOG LIGHT SWITCH (IN SWITCH PACK)
Refer to Fog Lights Function Diagram.
Fog lights are rectangular halogen lights mounted in the bumper opening and are available with either
amber or clear lenses.
When the fog light switch is turned on the switch pack will send a message, on the switch data link, to the ESC
requesting the fog lights to be turned on. If the key is in the ignition position, the headlights are on and in the
low beam position the ESC will provide voltage to power the fog lights. If the high beams are selected the
voltage to the fog lights will be interrupted by the ESC until the low beams are turned on.
The ESC will also send a message back to the switch pack to illuminate the fog light switch “on” light.
5.2. DIAGNOSTICS
Should the fog lights fail to operate, the problem could be attributed to a faulty switch in the switch pack, a
faulty switch pack or open or shorted output wiring between the ESC and the fog lights.
A problem with the mechanical portion of the switch or the switch contacts may cause the ESC to command
the switch on lamp to blink.
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The ESC will also log faults for switch errors or switch pack errors, identified by location. Switch locations will
vary depending on vehicle configuration. The ESC is programmed to recognize the location and function of
the switch.
cycled.
A diagnostic trouble code will be logged if there is an over current (short to ground or excessive load) or an
open in the circuits between the ESC and the fog lights.
An electronic service tool, running the "INTUNE" diagnostic software, can be used to check operation of
the fog lights and monitor activation of the fog light switch. See the diagnostic software manual for details
Fog Light Preliminary Check
Table 294 Fog Light Preliminary Check

POINTS SPEC.
1. On Verify fog lights Visually Fog lights Go to next Fog lights are
are inoperative. check fog are inoper- step. operating. Problem
(Ignition on, lights. ative. does not exist or is
headlights on, low intermittent. (Check
beam selected and for inactive diagnostic
fog light switch on.) trouble codes.)
common to several
features.)
3. On Are both fog lights Visually Both fog Go to next Check specific circuits
inoperative? check if lights are step. of the inoperative light
both fog inoper- for open circuits.
lights are ative.
inoper-
ative.
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Table 294 Fog Light Preliminary Check (cont.)

POINTS SPEC.
4. On Check for fog Read No fog Go to next Go to fault detection
light diagnostic display on light diag- step. management. (See
trouble codes. (See odometer. nostic FAULT DETECTION
Diagnostic Trouble trouble MANAGEMENT, page
Codes, page 872) codes are 873)
active.
5. Check for switch No Go to fault
pack faults. multiplexed detection
switch manage-
Problem may be diag- ment. (See
in multiplexed nostic FAULT
switches. Check trouble DETECTION
for switch diagnostic codes are MANAGEMENT,
trouble codes. (See active. page 873)
Diagnostic Trouble
Codes, page 872)
Table 295 Fog Light Circuits

Diagnostic trouble codes starting with 625 625 series diagnostic trouble codes relate to switch pack faults.
Refer to the switch pack module section.
611 14 3 2 Fog light over current
This fault may be the result of a short in the circuits between the fog lights and the ESC.
It could also be caused by an excessive load on the circuit.
611 14 3 1 Fog light open circuit
This fault is the result of an open in circuits between the fog lights and the ESC.
Check for burned out bulb.

611 14 3 3 Fog light lamps, less than normal low current but
more than open circuit
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Table 295 Fog Light Circuits (cont.)

611 14 3 4 Fog light lamps, greater than normal high current
611 14 3 6 Fog light lamps has current flow when output commanded off

cycled.
Refer to Fog Light Circuits From ESC.
A fault in the fog light circuits will be apparent when the lights don’t come on. The ESC will also log a diagnostic
trouble code (DTC) when there is a short in any of the circuits to the fog light. Problems in the fog light circuits
can be caused by burned out lamps, a blown fuse, a short, an open, or a problem in the ESC.
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Figure 434 Fog Light Circuits From ESC (Connectors Viewed From Mating End) — Always Refer To
(4006) GROUND STUD
(8200) RIGHT FOG LIGHT CONNECTOR
LOCATED BEHIND RIGHT FOG LIGHT
(8201) LEFT FOG LIGHT CONNECTOR
LOCATED BEHIND LEFT FOG LIGHT
(8800) GROUND ADAPTER
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Table 296 Fog Lights Circuit Tests

FAULTS
611 14 3 3 Fog light lamps, less than normal low current
611 14 3 4 Fog light lamps, greater than normal high current
611 14 3 6 Fog light lamps has current flow when output
commanded off
611 14 3 2 Fog light over current (Short Circuit)
611 14 3 1 Fog light under current (Open Circuit)
Fog Light Connector (8201) Voltage Checks
Check with ignition on, headlights on, low beams selected and fog light switch on.
The virtual fuse in the ESC will trip during a short. To reset the fuse, the key switch must
be cycled.
(8201) cavity A to NOTE – A load device, If voltage is missing, check for
ground such as a test light, must open or short in circuits M64B,
be used in parallel with M64, J64A or M64A.
an accurate voltage. Also insure proper voltage out of ESC.
12 ± 1.5 volts Refer to ESC Replacement in this manual.

(8201) cavity B to 0 volts Ground circuit, no voltage expected.
ground
(8201) Pin A to NOTE – A load device, If voltage is missing, check for open
cavity B such as a test light, must in ground circuits and connectors
be used in parallel with between ground stud (4006) and
voltmeter probes to read the fog light connector.
12 ± 1.5 volts
Fog Light Connector (8200) Voltage Checks
Check with ignition on, headlights on, low beams selected and fog light switch on.

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Table 296 Fog Lights Circuit Tests (cont.)

(8200) cavity B to 0 volts Ground circuit, no voltage expected.
ground
(8200) cavity A to NOTE – A load device, If voltage is missing, check for open
cavity B such as a test light, must in ground circuits and connectors
be used in parallel with between ground adapter (8801) and
voltmeter probes to read the fog light connector.
12 ± 1.5 volts

Refer to Fog Light Circuits From ESC.
The fog light switch communicates with the ESC. When it is in the on position and the headlights are in low
beam the ESC will turn on the fog lights.
The ESC will supply 12 volts to system controller brown connector (4007) terminal A, circuit J86A, forward
chassis connector (4301) terminal 20 and circuit M64 to a tie point. From the tie point the circuits are split on
M64B to left fog light connector (8201) terminal A and M64A to right fog light connector (8200) terminal A.
Ground for the fog lights is supplied from ground stud (4006) on circuits J11–GJ, J11–G, forward chassis
connector (4301) terminal 13 and circuit M10–GA to tie point CS5. From CS5 the circuits are split on M64–GA
to left fog light connector (8201) terminal B and M64–G to right fog light connector (8200) terminal B.
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Figure 435 Fog Light Wiring

(8000) RIGHT HEADLIGHT CONNECTOR
(8001) LEFT HEADLIGHT CONNECTOR
(8302) HORN CONNECTOR
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6. HEADLIGHT SYSTEM
Figure 436 Headlights Function Diagram

1. HEADLIGHTS
3. DRIVETRAIN 1939 DATA LINK (FROM ELECTRONIC GAUGE CLUSTER)
4. DIRECT HEADLIGHT ENABLE CIRCUIT FROM EGC
5. ELECTRONIC GAUGE CLUSTER
6. HEADLIGHT SWITCH (IN ELECTRONIC GAUGE CLUSTER)
7. DIMMER SWITCH (PART OF TURN SIGNAL ASSEMBLY)
Refer to Headlights Function Diagram.
The headlight system consists of the headlights, headlight switch, dimmer switch, flash to pass, day time
running lights (mandatory for Canada, optional for USA) and the optional “lights on with wipers feature”.
The fender mounted headlights are a one lamp system and share a molded cavity with the turn signals. The
headlight switch is a 3–position (off/parking lights/headlights) rocker type located below the EGC. When the
key is in the ignition position and the headlight switch is on the EGC will communicate with the ESC on the
drivetrain 1939 data link. The ESC supplies voltage to the headlights as requested.
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While the key is not in the ignition position, the headlights will only operate in the low beam mode. This is
enabled by a direct circuit from the EGC to the ESC, which is not dependant on the data link. This also acts as a
fail-safe to activate the low beam headlights when communication on the drivetrain 1939 data link is interrupted.
The dimmer and flash to pass switches are located in the turn signal assembly. Pulling the turn signal lever
toward the driver as far as it will go, while the headlights are on, will switch the headlights between hi-beam
and low-beam operation.
When the key is on and the headlights are off, pulling the turn signal slightly toward the driver and releasing the
turn signal lever will flash the headlights.
When the key is on and the headlights are on, pulling the turn signal slightly toward the driver and releasing the
turn signal lever will momentarily switch the headlights between hi-beam and low-beam operation.
The programmable day time running light feature allows the vehicle to operate in a “lights on” condition at
all times without driver input. This system operates the headlights at partial illumination, but still helps to
increase visibility even in bright sunshine. The daytime running lights will go off when the park brake is
set or the ignition is turned off.
When the programmable “lights on with wipers feature” is enabled the low beam headlights and park lights will
be turned on by the ESC anytime the windshield wipers are activated, except during momentary wash/wipe.
The lights will remain on after the wipers are turned off until the headlight switch is turned on and off or the
key is turned off.
If the vehicle is equipped with a remote keyless entry, the ESC will also turn the headlights on or off as required.
6.2. DIAGNOSTICS
Should the lights fail to operate, the problem could be attributed to a faulty switch in the EGC, a faulty switch
pack in the EGC a faulty EGC, open circuits or shorted circuits. The ESC has an internal virtual fuse software
algorithm to protect output circuits in an over current situation.
Should the lights fail to switch between high and low beams or the flash to pass fail to operate, the problem
could be attributed to a faulty switch in the turn signal assembly, open circuits, shorted circuits or a problem
in the ESC.
A diagnostic trouble code will be logged if there is an over current (short to ground or excessive load) or an
open in the circuits between the ESC and the headlights.
lights and monitor activation of the turn/hazard signal switches and stop light switch(es). See the diagnostic
software manual for details on using the software.
The diagnostic software will also identify if the daytime running light or lights on with wipers features are
activated.
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Headlight Preliminary Check
Table 297 Headlight Preliminary Check

POINTS SPEC.
1. On Verify headlights are Visually Headlights Go to next Headlights are
malfunctioning. check are step. operating correctly.
headlights. malfunc- Problem does not
tioning. exist or is intermittent.
(Check for inactive
diagnostic trouble
codes.)
common to several
features.)
3. On Are both high Visually Both high Go to next Check specific circuits
beam or both check if both beam or step. of the inoperative light
low beam lights high beam both low for open circuits.
malfunctioning? or both low beam
beam lights lights are
are malfunc- malfunc-
tioning? tioning.
4. On Check for diagnostic Read display Headlight Go to Go to Headlight circuit
trouble codes. (See on odometer. diagnostic headlight inputs to ESC (See
Diagnostic Trouble codes are outputs HEADLIGHT CIRCUIT
Codes, page 880) present. from ESC INPUTS TO ESC,
(See page 881)
HEADLIGHT
OUTPUTS
FROM
ESC, page
885)
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Table 298 Headlight Circuits

NO DIAGNOSTIC TROUBLE CODE Diagnostic trouble codes are not logged for every
possible fault in the headlight circuits.
There are no diagnostic trouble codes associated with the dimmer switch, flash to pass switch or 3
switch pack in the EGC. Open circuits to an individual headlight will not generate a fault.
An open in the zero volt reference signal to the turn signal switch will cause the wipers to operate at
high speed which will turn on the low beams if the “lights on with wipers” feature is enabled.
611 14 5 1 Headlight low beam open circuit
611 14 5 2 Headlight low beam over current
611 14 5 3 Headlight low beam lamps, less than normal low
611 14 5 4 Headlight low beam lamps, greater than normal high
611 14 5 6 Headlight low beam lamps has current flow when
611 14 7 1 Headlight high beam open circuit
611 14 7 2 Headlight high beam over current
611 14 7 3 Headlight high beam lamps, less than normal low
611 14 7 4 Headlight high beam lamps, greater than normal high
611 14 7 6 Headlight high beam lamps has current flow when
6.3. HEADLIGHT CIRCUIT INPUTS TO ESC

Refer to Headlight Circuit Inputs to ESC.
A fault in the headlight circuit inputs to the ESC will be apparent when the lights don’t operate correctly. There
are no diagnostic trouble codes associated with headlight input circuits to the ESC. Problems in the headlight
input circuits can be caused by faulty switches, a short, an open, or a problem in the ESC or EGC.
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Figure 437 Headlight Circuit Inputs to ESC (Connectors Viewed From Mating End) — Always Refer To
LOCATED ON BACK OF 3 SWITCH PACK
B. ELECTRONIC GAUGE CLUSTER (EGC) CONNECTOR
LOCATED ON EGC CIRCUIT BOARD
(1500) ELECTRONIC GAUGE CLUSTER (EGC) CONNECTOR
LOCATED ON BACK OF EGC
(1800)/(1805) DRIVER CONTROL MODULE (DCM) CONNECTOR
LOCATED TO RIGHT OF LOWER STEERING COLUMN
(1810) TURN SIGNAL SWITCH HARNESS CONNECTOR
LOCATED BEHIND TURN SIGNAL ASSEMBLY
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Table 299 Headlight Switch Inputs to ESC Circuit Tests

THERE ARE NO DIAGNOSTIC TROUBLE CODES ASSOCIATED WITH THESE CIRCUITS
A mechanically defective headlight switch could also prevent the headlight from
operating. Remove the mechanical portion of the switch and attempt to turn the
switch on by pressing the bottom switch contact. If the headlights illuminate, the
mechanical switch assembly should be replaced.
ESC Harness Connector (1600) Voltage Checks
Checks headlight fail-safe circuit input to ESC.
Connect breakout box to harness connector (1600)

Headlight switch 12 ± 1.5 volts with headlight If voltage is missing, check for open
“on”, ESC connector switch “on” or short in circuit A50.
(1600) terminal 14
to ground If no open or shorts are found check
for voltage out of EGC.
Headlight switch NOTE – A load device, Identify source of incorrect voltage
“off”, Terminal 14 such as a test light, must and repair
to ground be used in parallel with
0 volts with headlight

switch “off”
EGC 3 Switch Pack Harness Connector Headlight Voltage Checks
NOTE – If the EGC is working correctly, disconnecting the 3 switch pack connector should
cause the park lights to come on.

3 switch pack 12 ± 1.5 volts If voltage is missing, check for open
harness connector, or shorts in circuits between EGC
pin 3 to ground connector and switch connector.

3 switch pack 0 –.3 volts Low circuit from EGC
harness connector,
pin 9 to ground If voltage is incorrect, check for
open or shorts in circuits between
EGC and switch.
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Table 299 Headlight Switch Inputs to ESC Circuit Tests (cont.)

3 Switch Pack Headlight Resistance Check

Checking for <2 ohms. If there is no continuity, the switch
continuity between pack needs replaced.
pins 3 and 9 of the
switch pack, when
the switch is on.
Turn Signal Switch Harness Connector (1810) Voltage Checks
Check with key in ignition position
Checks high/low beam select input circuits.
(1810) Cavity 3 12 ± 1.5 volts. If voltage is missing, check for open or
to ground short in circuits B52A or A52A.
Headlight dimmer Also insure proper voltage out of ESC.

switch input
(1810) Cavity 4 to 12 ± 1.5 volts. If voltage is missing, check for open or
ground short in circuits B102A or A102A.
Flash to pass switch Also insure proper voltage out of ESC.

input
(1810) Cavity 7 <1 volt. Zero volt reference level circuit, no
to ground voltage expected.
Turn Signal Switch (1810) Resistance Checks
Check with (1810) removed
Checks dimmer and flash to pass switches in turn signal assembly.

(1810) pin 3 to 7 Switching between >50K If resistance is incorrect replace turn
ohms and < 2 ohms as lever signal switch assembly.
is pulled and released.
(1810) pin 4 to 7 Switching between >50K If resistance is incorrect replace turn
ohms and < 2 ohms as lever signal switch assembly.
is pulled and released.
Refer to Input Circuits to ESC.
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When the key is in the ignition position and the headlight switch is turned on, the EGC will communicate with
the ESC through the drivetrain 1939 data link to command the lights on.
The ESC applies 12 volts to terminal 3 (headlight dimmer switch contacts) of turn signal switch (1810) through
circuit A52A, connector (1800)/(1805) and circuit B52A. When the headlight dimmer switch is activated the
ESC will sense this voltage drop to ground through turn signal switch connector (1810) terminal 7, circuit
B9S, circuit B9V, connector (1800)/(1805), circuit A9V, circuit A9H and ESC connector (1600) terminal 3 to
the zero volt reference signal.
The ESC applies 12 volts to terminal 4 (flash to pass switch contacts) of turn signal switch (1810) through
circuit A102A, connector (1800)/(1805) and circuit B102A. When the flash to pass switch is activated the
ESC will sense this voltage drop to ground through turn signal switch connector (1810) terminal 7, circuit
B9S, circuit B9V, connector (1800)/(1805), circuit A9V, circuit A9H and ESC connector (1600) terminal 3 to
the zero volt reference signal.
When the headlight switch is in the on position, 12 volts is applied from EGC connector (1500) terminal
9 to circuit A50 and ESC connector (1600) terminal 14. This signals the ESC To turn on the low beams
even when the key is not in the ignition position.
6.4. HEADLIGHT OUTPUTS FROM ESC

Refer to Circuits From ESC to Headlights.
A fault in the circuits between the ESC and the headlights will be apparent when the lights don’t operate
correctly. The ESC will also log a diagnostic trouble code (DTC) when there is a short in any of the headlight
circuits or an open circuit between the ESC and the headlights. Problems in the circuits between the ESC and
the headlights can be caused by burned out lamps, a short, an open, or a problem in the ESC.
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Figure 438 Circuits From ESC to Headlights (Connectors Viewed From Mating End) — Always Refer
To Circuit Diagram Book For Latest Circuit Information
(4006) GROUND STUD
LOCATED BEHIND RIGHT HEADLIGHT
LOCATED BEHIND LEFT HEADLIGHT
(8800) LEFT GROUND ADAPTER
(8801) RIGHT GROUND ADAPTER
Table 300 ESC Low Beam Outputs to Headlight Circuit Tests

FAULTS
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Table 300 ESC Low Beam Outputs to Headlight Circuit Tests (cont.)
611 14 5 6 Headlight low beam lamps has current flow
611 14 5 2 Low beam over current
This fault may be the result of a short in the circuits between the low beam headlight circuits
and the ESC. It could also be caused by an excessive load on the circuit.
611 14 5 1 Low beam under current
This fault is the result of an open in circuits between the low beam headlight circuits and the ESC.
Check for burned out bulbs.

Left Headlight Connector (8001) Low Beam Voltage Checks
Check with key in ignition position, headlight switch on, low beams selected
and connector (8001) disconnected.
With sealed beam headlamps, as used with severe service vehicles, the terminals at the
headlamps are not sealed - in this application the terminals of the headlamps and the terminals
in the headlamp connector must be totally coated with Grafo grease 2643099R1
NOTE – With sealed beam headlamps, as used with Severe Service trucks, the terminals at
the headlamps are not sealed - in this application the terminals of the headlamps and the
terminals in the headlamp connector must be totally coated with Grafo grease 2643099R1
Headlights in low NOTE – A load device, If voltage is missing, check for
beam. (8001) terminal such as a test light, must open or short in circuits J53A, M53,
C to ground. be used in parallel with M53A or M53B.
an accurate voltage. If no open or shorts are found check
for voltage out of EGC.
12 ± 1.5 volts with headlight
switch “on”
Headlights in low NOTE – A load device, If voltage is missing, check for open in
beam. (8001) terminal such as a test light, must circuits between terminal B and ground.
C to terminal B. be used in parallel with

switch “on”
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Table 300 ESC Low Beam Outputs to Headlight Circuit Tests (cont.)
Headlights in low NOTE – A load device, If voltage is missing, check for open
beam. (8000) terminal such as a test light, must in circuit M53B.
C to ground. be used in parallel with

switch “on”
Headlights in low NOTE – A load device, If voltage is missing, check for open
beam. (8000) terminal such as a test light, must in circuits between terminal B and
C to terminal B. be used in parallel with ground adapter (8800).

switch “on”
Table 301 ESC High Beam Outputs to Headlight Circuit Tests

FAULTS
611 14 7 3 Headlight high beam lamps, less than normal low current
611 14 7 2 High beam over current
This fault may be the result of a short in the circuits between the high beam headlight circuits
611 14 7 1 High beam under current
This fault is the result of an open in circuits between the high beam headlight circuits and the ESC.

Left Headlight Connector (8001) Voltage Checks
Check with key in ignition position, headlight switch on, high beams selected
NOTE – With sealed beam headlamps, as used with Severe Service trucks, the terminals at the
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Table 301 ESC High Beam Outputs to Headlight Circuit Tests (cont.)
Headlights in high NOTE – A load device, such as a If voltage is missing, check for open
beam. (8001) terminal test light, must be used in parallel or short in circuits J52A, M52B,
A to ground. with voltmeter probes to read an M52C or M52D.
accurate voltage.
If no open or shorts are found check
12 ± 1.5 volts with headlight for voltage out of EGC.
switch “on”
Headlights in high NOTE – A load device, such as a If voltage is missing, check for open in
beam. (8001) terminal test light, must be used in parallel circuits between terminal B and ground.
A to terminal B. with voltmeter probes to read an
accurate voltage.

switch “on”
beam. (8000) terminal test light, must be used in parallel in circuit M52D.
A to ground. with voltmeter probes to read an
accurate voltage.

switch “on”
beam. (8000) terminal test light, must be used in parallel in circuits between terminal B and
A to terminal B. with voltmeter probes to read an ground adapter (8800).
accurate voltage.

switch “on”
Refer to Circuits From ESC to Headlights.
When low beams are requested, the ESC will supply 12 volts to system controller front connector (4007)
terminal 5, circuit J53A, forward chassis connector (4301) terminal 5 and circuit M53 to tie point CS3. From
CS3 the circuits are split on M53A to left headlight connector (8001) terminal C and M53B to right headlight
connector (8000) terminal C.
When high beams are requested, the ESC will supply 12 volts to system controller front connector (4007)
terminal 2, circuit J52A, forward chassis connector (4301) terminal 4 and circuit M52B to tie point CS4. From
CS4 the circuits are split on M52C to left headlight connector (8001) terminal A and M52D to right headlight
connector (8000) terminal A.
Ground for the headlights is supplied from ground stud (4006) on circuits J11–GJ, forward chassis connector
(4301) terminal 13 and circuit M11–G to tie point CS5. From CS5 the circuits are split on M11–GB to left
headlight connector (8001) terminal B and M11–GA to right headlight connector (8000) terminal B.
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Figure 439 Turn Signal Assembly

(1810) TURN SIGNAL ASSEMBLY CONNECTOR ( BEHIND STEERING COLUMN SHROUD)
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Figure 440 Headlight Connector Locations (Dash Panel From Engine Compartment)
2. REAR CHASSIS CONNECTOR (9700)
3. CHASSIS HARNESS
5. ENGINE CONNECTOR
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Figure 441 Headlight Wiring

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1. HEADLIGHT ASSEMBLY
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1. HEADLIGHT ASSEMBLY
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7. PANEL LIGHTS
Figure 444 Panel Lights Function Diagram

1. ELECTRICAL SYSTEM CONTROLLER (ESC)
2. DRIVETRAIN 1939 DATA LINK BETWEEN ELECTRONIC GAUGE CLUSTER (EGC)
AND ESC
3. EGC
4. DIMMER CIRCUITS CONTROLLED BY PANEL LIGHT SWITCH
5. DIMMER SWITCH MOUNTED IN 3 SWITCH PACK MOUNTED IN EGC
6. DOOR PODS
7. SWITCH DATA LINK
Refer to Panel Lights Function Diagram
Panel lights are low wattage bulbs that illuminate gauges and other miscellaneous items. The panel light
switch provides input to the EGC which generates the voltage to dim/brighten the panel lights for the gauge
clusters, speedometer/tachometer module, cigar lighter, door pods, heater control, etc.
Most panel lights receive a control voltage directly from the EGC. The door pods receive dimmer control
messages from the ESC on the switch data link.
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7.2. DIAGNOSTICS
If the panel lights do not respond to the dimmer switch the problem could be attributed to a faulty panel light
dimmer switch, a problem in the EGC, open circuits or shorted circuits.
If the panel lights in a door pod fail to operate correctly, while the other panel lights work, the problem must be
in the pod or the ESC.
Panel Light Preliminary Check
Table 302 Panel Light Preliminary Check

POINTS SPEC.
1. On Verify panel lights are Visually Panel light Go to Panel lights are
operating incorrectly. check panel is inoper- next operating correctly.
lights. ative. step. Problem does not exist
or is intermittent.
2. On Determine if any Visually No other Go to Identify and repair
other features are check features next condition causing
malfunctioning that may for other are step. several features to
have common circuits. malfunc- malfunc- operate incorrectly.
(Example: Missing tioning tioning.
ground common to features.
several features.)
3. On Are all panel lights Visually All panel Go to Check specific circuits
operating incorrectly? check if all lights are next of the inoperative lights
panel lights operating step. for open circuits.
are operating incorrectly.
incorrectly.
4. On Are panel lights Visually Panel Go to Go to panel light circuit
illuminating when park check if panel lights next outputs from EGC.
lights are turned on? lights illumi- illumi- step. (See PANEL LIGHT
nate. nate. OUTPUT FROM EGC,
page 900)
5. On Do panel lights respond Visually Panel Panel Go topanel light
correctly to activation check if lights lights are circuit outputs from
of the panel dimmer panel lights respond working EGC.(See PANEL
switch? respond correctly. correctly. LIGHT SWITCH
to panel INPUTS TO EGC,
dimmer page 897).
switch.
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Table 303 Panel Light Circuits

There are no faults for panel light circuits
7.3. PANEL LIGHT SWITCH INPUTS TO EGC

Refer to Panel Light EGC and ESC Input Circuits.
A problem in the panel light switch circuits will be apparent when the panel lights are always on and the switch
has no effect on the intensity of the panel lights. There are no diagnostic trouble codes associated with the
switch circuits in the EGC. Loss of the drivetrain 1939 data link between the EGC and ESC will cause several
problems to occur simultaneously and the check electrical system lamp will illuminate. Go to the section on
the drivetrain 1939 data link to troubleshoot this condition. Problems in the Panel light circuits in the
EGC can be caused by a short circuit between the 3 switch pack and the EGC, an open circuit between the 3
switch pack and the EGC, a faulty switch, or a problem in the EGC.
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Figure 445 Panel Light EGC and ESC Input Circuits—Always Refer to Circuit Diagram Book for
Latest Circuit Information
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A mechanically defective panel light switch could also prevent the panel light from operating. Remove
the mechanical portion of the switch and attempt to turn the switch on by pressing the microswitches.
If the panel lights respond, the mechanical switch assembly should be replaced.
3 Switch Pack Harness Connector Panel Light Voltage Checks
NOTE – If the EGC and switch are working correctly, disconnecting the 3 switch pack connector
should cause the panel lights to come on.

3 switch pack harness 12 ± 1.5 volts If voltage is missing, check for open
connector, cavity 3 to ground or shorts in circuits between EGC

3 switch pack harness <1 volt Dimmer down circuit between
connector, cavity 4 to ground. switch and EGC.


3 switch pack harness <1 volt Dimmer up circuit between switch
connector, cavity 5 to ground and EGC.


3 Switch Pack Panel Light Resistance Check

Check resistance between <1 ohm. If there is no continuity, the switch
pins 3 and 4 of the switch pack needs replaced.
pack, when the dimmer
down switch is pressed.
Check resistance between <1 ohm. If there is no continuity, the switch
pins 3 and 5 of the switch pack needs replaced.
pack, when the dimmer up
switch is pressed.
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Refer to Panel Light EGC and ESC Input Circuits.
The panel light switch is wired directly to the EGC circuit board. When the panel light dimmer switch is pressed
down, 12 volts from pin 3 from the EGC will be connected to pin 4. This will cause the EGC to lower the panel
light voltage. When the panel light dimmer switch is pressed up, 12 volts from pin 3 from the EGC will be
connected to pin 5. This will cause the EGC to raise the panel light voltage.
7.4. PANEL LIGHT OUTPUT FROM EGC

Refer to Panel Light Outputs from EGC.
A fault in the circuits between the EGC and the panel lights will be apparent when the lights don’t operate
correctly. There are no diagnostic trouble codes associated with the panel lights. Problems in the circuits
between the EGC and the panel lights throughout the vehicle may be caused by burned out lamps, a short,
an open, a blown fuse or a problem in the EGC.
Panel lights in the door pods are controlled by messages communicated between the EGC and the ESC on the
drivetrain 1939 datalink and messages between the ESC and the door pods on the switch data link. Problems
with the data links will cause more severe problems than loss of panel lights.
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Figure 446 Panel Light Outputs from EGC (Connectors Viewed From Mating End) — Always Refer to
Circuit Diagram Book for Latest Circuit Information
(1002) PANEL LIGHT ADAPTER
LOCATED IN INSTRUMENT PANEL
(1011) CAB FUSE BLOCK
LOCATED IN INSTRUMENT PANEL (PASSENGER SIDE)
(1500) ELECTRONIC GAUGE CLUSTER CONNECTOR
LOCATED ON BACK OF GAUGE CLUSTER
Table 305 Panel Light Circuit Tests

No Diagnostic Trouble Codes There are no diagnostic trouble codes for
panel light circuits.
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Table 305 Panel Light Circuit Tests (cont.)

Panel Light Fuse (1011) Voltage Checks
Check with ignition key on, park lights on and fuse F9 removed. Press and hold the dimmer
up button for 15 seconds to insure panel lights are at full intensity.

(1011) fuse block 1, 12 ± 1.5 volts If voltage is missing, check for open in
terminal C1 to ground. circuit A62M or short in circuits A62N,
A62C, A62E, or A62A.
If no shorts or opens are present,

the ESC must be faulty.
Panel Light Buss Bar (1002) Voltage Checks
Check with ignition key on, park lights on, fuse F9 installed and buss bar cover removed.
NOTE – If the fuse is blown check for shorts on circuit A62N and other circuits connected to
the buss bar. Repair the short and replace the fuse.
Press and hold the dimmer up button for 15 seconds to insure panel lights are at full intensity.

Panel Light Buss Bar 12 ± 1.5 volts If voltage is missing, check for open in
(1002) cavity A to circuit A62N. Insure fuse F9 is not blown.
ground.
Refer to Panel Light Outputs from EGC.
A variable voltage, controlled by the panel dimmer switch but generated in the EGC, is supplied at gauge
cluster connector (1500) terminal 1 and circuit A62 to a tie point. At the tie point the circuit splits on circuit
A62C to switch pack connector (1101) terminal C, circuit A62E to radio connector (1300) terminal F, circuit
A62A to the HVAC control connector (1200) terminal A12, and circuit A62M to cab fuse block (1011) terminal
D1 and 5 amp fuse F9. Voltage from the fuse is applied to circuit A62N to panel light adapter (1002). The panel
light adapter is the source of panel light voltage for any other features with panel lights (except the door pods).
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Figure 447 Panel Dimmer Wiring

1. PANEL LIGHT BUSS BAR (1002)
2. F9 PANEL LIGHT FUSE
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8. TRUCK STOP/TURN SIGNAL/HAZARD LIGHT

Figure 448 Stop/Turn Signal/Hazard Light Function Diagram

1. RIGHT FRONT TURN SIGNAL LIGHT
2. LEFT FRONT TURN SIGNAL LIGHT
3. LEFT REAR TURN SIGNAL LIGHT
4. RIGHT REAR TURN SIGNAL LIGHT
5. STOP LIGHT SWITCH, HYDRAULIC BRAKES OR BRAKE SWITCH, AIR BRAKES
6. TURN SIGNAL SWITCH
Refer to the Stop/Turn Signal/Hazard Light Function Diagram.
The ESC controls the turn and stop lights based on inputs from the turn signal switches and brake switch.
A combination turn/stop lamp system is standard on this vehicle. The turn signal overrides the stop lights
on the rear.
The turn signal and hazard lights are selected with the turn signal lever and hazard switch on the steering
column.
On vehicles with hydraulic brakes the stop light signal to the ESC comes from a switch activated by the
brake pedal.
On vehicles with air brakes the stop light signal to the ESC comes from switches, connected to the air brake
lines, activated by brake air pressure. Two switches are used for trucks but only one is used for tractors.
The switches are located near the steering column.
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The ESC has separate outputs supplying current for each front turn lamp and each rear turn/brake lamp.
Additional turn lamps, which only illuminate when turn signals are selected, should be connected to the
front turn signal circuits. Additional lamps required to illuminate with turn signals and brake lights should be
connected to the rear turn signal circuits. The flashing of the turn signals and hazard lights is controlled
by the ESC.
When the hazard lights are activated the turn signal will not affect operation of the lights. Normally, the brake
switches will override the hazards. The ESC can be programmed to allow the hazard lights to override the
rear brake lights.
8.2. DIAGNOSTICS
Should the lights fail to operate correctly the problem could be attributed to faulty input wiring between the
ESC and turn signal/stop light switches, defective switches or faulty output wiring between the ESC and the
turn signal lamps. The ESC has an internal virtual fuse software algorithm to protect output circuits in an
over current situation.
cycled.
A diagnostic trouble code will be logged when there is an over current (short to ground or excessive load) or
open circuit on any of the four light output circuits.
A diagnostic trouble code will be logged if there is an open or short in the brake switch or brake switch circuits.
The lower current limits, which determine when a DTC is set, are programmable. LED stop/turn lamps use far
less current than incandescent lamps. If the truck configuration is changed it may be necessary to reprogram
the lower current limit in the ESC before LED lamps will operate.
Turn/Hazard Signal And Stop Light Preliminary Check
Table 306 Turn/Hazard Signal And Stop Light

POINTS SPEC.
1. On Verify turn/hazard Visually Turn/ Go to Turn/hazard signal
signal and stop lights check turn/ hazard next and stop lights are
are inoperative. hazard signal step. operating. Problem
signal and and stop does not exist or is
stop light. lights intermittent. (Check
operate for inactive diagnostic
incorrectly. trouble codes.)
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Table 306 Turn/Hazard Signal And Stop Light (cont.)

POINTS SPEC.
malfunctioning that for other are step. several features to be
common to several
features.)
3. On If more than one Visually All turn/ Go to Check specific circuits
turn/hazard signal and check if all hazard next of the inoperative light
stop light is connected turn/hazard signal step. for open circuits.
to a circuit, are all signal and and stop
lights inoperative? stop lights lights are
are inoper- inoper-
ative. ative.
4. On Check for diagnostic Read No turn/ Go to Follow directions in the
trouble codes. (See display on hazard next turn/hazard signal and
Diagnostic Trouble odometer. signal step. stop light diagnostic
Codes, page 906) and stop trouble code table.
light (See Table 307, page
diagnostic 907)
trouble
codes are
active.
(See
TURN
SIGNAL/
HAZARD
SWITCH
INPUTS
TO ESC,
page
909)
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Table 307 Turn/Hazard Signal And Stop Light

fault in the turn signal/hazard circuits.
When all left or all right signals are inoperative, and no faults are present, the turn/hazard signal
switches, their circuits to the ESC, or the ESC are most likely at fault.
If hazard flashers don’t work, but the turn signals do, the turn signal/hazard switch is defective.
If hazard flashers do work, but the turn signals don’t, the turn signal/hazard switch is defective.
If hazard flashers and turn signals don’t work, the problem is most likely in the
circuits between the switch and the ESC.
Inspect turn/hazard signal switches (See TURN SIGNAL/ HAZARD SWITCH INPUTS
TO ESC, page 909) for proper operation
When more than one bulb is connected to an ESC output circuit, the ESC will not sense that an
individual bulb or the circuits to that specific bulb are open. Example: There are two bulbs on
the forward turn circuit. One burned out bulb will not set a fault. If the two bulbs are the only
ones on the circuit and they both burn out, an open circuit fault will be set.
When an individual light will not illuminate, check for an open circuit to the specific light.
597 14 1 0 Brake switch stuck in the open or closed position
597 14 2 0 Brake switch inputs do not match
Sets when the vehicle has decelerated to a stop, without brake switch activation.
The brake switch is stuck closed, is not making contact with brake pedal or being activated
by air pressure, or the switch contacts are defective.
Inspect hydraulic brake switch (See HYDRAULIC BRAKE SWITCH INPUTS TO ESC, page 912)or air
brake switch(See AIR BRAKE SWITCH INPUTS TO ESC, page 915) for proper operation
611 14 16 1 Right front turn lamp open circuit
This fault is the result of an open in the circuits between the right front lamps and the ESC.
Inspect right front circuits(See FRONT TURN SIGNAL/HAZARD AND SEPARATE TURN
SIGNAL LIGHT OUTPUTS FROM ESC, page 919) for proper operation
611 14 16 2 Right front turn lamp over current
This fault may be the result of a short in the circuits between the left front lamps and the ESC. It
could also be caused by an excessive load (too many accessories) on the circuit.
Inspect right front circuits (See FRONT TURN SIGNAL/HAZARD AND SEPARATE TURN
SIGNAL LIGHT OUTPUTS FROM ESC, page 919) for proper operation
611 14 16 3 Right front turn lamps, less than normal low current
611 14 16 4 Right front turn lamps, greater than normal high
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611 14 16 6 Right front turn lamps has current flow when
611 14 15 1 Left front turn lamp open circuit
This fault is the result of an open in circuits between the left front lamps and the ESC.
Inspect left front circuits (See FRONT TURN SIGNAL/HAZARD AND SEPARATE TURN SIGNAL
LIGHT OUTPUTS FROM ESC, page 919) for proper operation
611 14 15 2 Left front turn lamp over current
This fault may be the result of a short in the circuits between the left front lamps and the ESC. It
Inspect left front circuits (See FRONT TURN SIGNAL/HAZARD AND SEPARATE TURN SIGNAL
LIGHT OUTPUTS FROM ESC, page 919) for proper operation
611 14 15 3 Left front turn lamps, less than normal low current
611 14 15 4 Left front turn lamps, greater than normal high current
611 14 15 6 Left front turn lamps has current flow when
611 14 14 1 Right rear turn lamp open circuit
This fault is the result of an open in the circuits between the right rear lamps and the ESC.
Inspect right rear circuits (See REAR STOP/TURN SIGNAL/HAZARD LIGHT OUTPUTS
611 14 14 2 Right rear turn lamp over current
This fault may be the result of a short in the circuits between the right rear lamps and the ESC.
It could also be caused by an excessive load (too many accessories) on the circuit.
Inspect right rear circuits (See REAR STOP/TURN SIGNAL/HAZARD LIGHT OUTPUTS
611 14 14 3 Right rear turn lamps, less than normal low current
611 14 14 4 Right rear turn lamps, greater than normal high
611 14 14 6 Right rear turn lamps has current flow when
611 14 13 1 Left rear turn lamp open circuit
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This fault is the result of an open in the circuits between the left rear lamps and the ESC.
Inspect left rear circuits (See REAR STOP/TURN SIGNAL/HAZARD LIGHT OUTPUTS
611 14 13 2 Left rear turn lamp over current
This fault may be the result of a short in the circuits between the left rear lamps and the ESC. It
Inspect left rear circuits (See REAR STOP/TURN SIGNAL/HAZARD LIGHT OUTPUTS
611 14 13 3 Left rear turn lamps, less than normal low current
611 14 13 4 Left rear turn lamps, greater than normal high current
611 14 13 6 Left rear turn lamps has current flow when
612 14 1 1 Brake switch out of range low (Open Circuit)
Brake switch not connected or open circuit in wiring between ESC and switch.
Inspect hydraulic brake switch (See HYDRAULIC BRAKE SWITCH INPUTS TO ESC, page 912) or air
brake switch (See AIR BRAKE SWITCH INPUTS TO ESC, page 915) for proper operation.
Also check wiring harness

612 14 1 2 Brake switch out of range high (Short Circuit)
Circuit between ESC and Brake switch has been shorted to positive voltage.
Inspect hydraulic brake switch (See HYDRAULIC BRAKE SWITCH INPUTS TO ESC, page 912)or air
brake switch (See AIR BRAKE SWITCH INPUTS TO ESC, page 915) for proper operation
Also check wiring harness
8.3. TURN SIGNAL/ HAZARD SWITCH INPUTS TO ESC

There are no detectable faults associated with the turn signal/hazard switches or switch input circuits to the
ESC.
Refer to Turn Signal/Hazard Light Inputs to ESC.
Problems in the switches or circuits will be apparent when all left, all right or all signals cannot be selected.
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Figure 449 Turn Signal/Hazard Light Inputs to ESC (Connectors Viewed From Mating End) — Always
Refer to Circuit Diagram Book for Latest Circuit Information
1. TURN SIGNAL SWITCH – HAZARD CONTACTS
2. RIGHT TURN SIGNAL CONTACTS
3. LEFT TURN SIGNAL CONTACTS
(1800) DRIVER CONTROL MODULE CONNECTOR
(1810) TURN SIGNAL SWITCH HARNESS CONNECTOR
LOCATED ON STEERING COLUMN
Table 308 Turn Signal/Hazard Light Connector Check Chart

No faults will be logged for problems with turn/hazard signal switch inputs to the ESC
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Table 308 Turn Signal/Hazard Light Connector Check Chart (cont.)

Turn/Hazard Signal Switch Harness Connector (1810) Voltage Checks
(Check with ignition key on and turn signal switch disconnected.)
NOTE – With the key off voltage to the switches will be approximately 5 volts
Harness connector 12 ± 1.5 volts If voltage is incorrect, check for open or
(1810), cavity 1 to short in circuits A56A or B56A. Also insure
ground proper voltage out of ESC.

Harness connector 12 ± 1.5 volts If voltage is missing, check for open or
(1810), cavity 2 to short in circuits A57A or B57A. Also insure
ground proper voltage out of ESC.

Harness connector 0 volts Zero volt reference to switches.
(1810), cavity 7 to
ground If voltage is incorrect check for shorts to other
circuits or incorrect signal out of the ESC.
NOTE – If this signal is not present at the

switch connector, the wipers will also be
inoperative. If this signal is incorrect from
the ESC, several features will be inoperative.
Harness connector 12 ± 1.5 volts If voltage is incorrect, check for open in

(1810), cavity 1 to zero volt reference signal circuits B9S,
cavity 7. B9V, A9V or A9H or incorrect zero volt
reference signal from the ESC.
Turn Signal Switch Resistance Checks
(Check with switch disconnected)

Turn signal switch, With hazard switch and Continuity through switch when hazard and turn
pin 2 to pin 7 turn signal off, resistance lever is off, is the result of a failed switch.
should read >50K ohms.
Turn signal switch, With hazard switch and Continuity through switch when hazard and turn
pin 1 to pin 7 turn signal off, resistance lever is off, is the result of a bad switch.
should read >50K ohms.
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Table 308 Turn Signal/Hazard Light Connector Check Chart (cont.)

Turn signal switch, With Hazard switch or No continuity through switch when hazard
pin 2 to pin 7 turn signal on, resistance or right turn lever is on, is the result
should read <2 ohms. of a failed switch.
Turn signal switch, With Hazard switch or No continuity through switch when hazard or
pin 1 to pin 7 turn signal on, resistance left turn lever is on, is the result of a bad switch.
should read < 2 ohms.
Refer to Turn Signal/Hazard Light Inputs to ESC.
The zero volt reference signal is supplied to the turn signal switches on connector (1810) terminal 7 from
the ESC connector (1600) terminal 3.
When the left turn signal is selected the zero volt reference signal is fed from turn signal switch (1810) terminal
1, to ESC connector (1600) terminal 19.
When the right turn signal is selected the zero volt reference signal is fed to ESC connector (1600) terminal 18
from turn signal switch (1810) terminal 2. This signals the ESC that the right turn signal has been requested.
When the hazard switch is selected, two additional contacts close to complete both turn signal inputs to the
ESC. The zero volt reference signal will be sent to pins 18 and 19 of the ESC at the same time. This signals
the ESC that the hazard lights have been requested.
8.4. HYDRAULIC BRAKE SWITCH INPUTS TO ESC

Refer to Hydraulic Brake Switch Inputs to ESC.
While the ignition is on, the ESC will continuously monitor the brake switch(es) and circuits for an open
condition or a short to ground. The ESC will also log a diagnostic trouble code (DTC) if it determines the
vehicle has decelerated to 0 mph (0 kmh) without brake activation or has accelerated to 35 mph (56 kph)
while the switch is closed.
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Figure 450 Hydraulic Brake Switch Inputs to ESC (Connectors Viewed From Mating End) — Always
Refer to the Circuit Diagram Book for Latest Circuit Information
1. HYDRAULIC BRAKE SWITCH
LOCATED NEAR BRAKE PEDAL LEVER
2. ZENER DIODE
3. 150 OHM RESISTOR
(1600) SYSTEM CONTROLLER CONNECTOR
(1814) STOP LIGHT SWITCH CONNECTOR
LOCATED TO LEFT OF LOWER STEERING COLUMN
Table 309 Hydraulic Brake Stop/Turn Signal/Hazard Light Input Check Chart
597 14 1 0 Brake Switch Stuck
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Table 309 Hydraulic Brake Stop/Turn Signal/Hazard Light Input Check Chart (cont.)
612 14 1 1 Brake switch out of range low
612 14 1 2 Brake switch out of range high
Brake Switch Harness Connector (1814) Voltage Checks
(Check with ignition key on and brake switch disconnected.)
(1814), cavity A short in circuits A70C or B70C. Also insure
to ground proper voltage out of ESC.

Harness connector 0 volts Zero volt reference signal to switch.
(1814), cavity B
to ground If voltage is incorrect check for shorts to other
circuits or incorrect signal out of the ESC.
NOTE – If this signal is incorrect from the

ESC, several features will be inoperative.
Harness connector 12 ± 1.5 volts If voltage is incorrect, check for open
(1814), cavity A to in circuits B9VF, B9V, A9V or A9H or
cavity B missing signal from ESC.
NOTE – If this signal is incorrect from the

ESC, several features will be inoperative.
Brake Switch Resistance Checks
(Check with switch disconnected, negative probe of meter connected to pin B

and positive probe connected to pin A)
Brake switch, pin With stop light switch Switch has a resistor in series with contacts. If
B to pin A closed resistance should be resistance is incorrect, replace the switch.
approximately 150 ohms.
Brake switch, pin With stop light switch Switch has a Zener diode in parallel
B to pin A open resistance should be with the switch contacts.
approximately 50K ohms.
Refer to Hydraulic Brake Switch Inputs to ESC.
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On vehicles with hydraulic brakes, the zero volt reference signal from ESC connector (1600) terminal 3, is
supplied to stop light switch (1814) terminal B
When the key is in the ignition position 12 volts from ESC connector (1600) terminal 33 will be applied to stop
light switch (1814) terminal A. When the key is in the off position 5 volts is supplied to stop light switch (1814)
terminal A instead of 12 volts.
A 6.8 volt Zener diode, inside the switch body is wired in parallel with the switch contacts. The diode allows
current to pass through it when the key is in the ignition position and 12 volts is applied to the switch. The diode
prevents current from passing through it when the key is off and 5 volts is applied to the switch. When the key
is on and the brake is not applied, the ESC monitors the voltage drop across the diode and resistor in the
switch. If there is an open in the brake switch circuits there will be no voltage drop and the ESC will set a fault.
A 150 ohm resistor, inside the switch body, is wired in series with the switch. The ESC senses the voltage drop
across this resistor to check for a short to ground in the brake switch circuits between the brake switch and the
ESC. If there is a short, 12 volts from the ESC will be pulled to ground and the ESC will set a fault.
When the brake switch is closed, the voltage drop will change and the ESC will sense that the brake is applied.
8.5. AIR BRAKE SWITCH INPUTS TO ESC

Refer to Brake Switch Inputs to ESC With Air Brakes.
While the ignition is on, the ESC will continuously monitor the brake switch(es) and circuits for an open
condition or a short to ground. The ESC will also log a diagnostic trouble code (DTC) if it determines the
vehicle has decelerated to 0 mph (0 kmh) without brake activation or has accelerated to 35 mph (56 kph)
while the switch is closed.
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Figure 451 Brake Switch Inputs to ESC With Air Brakes (Connectors Viewed From Mating End) —
Always Refer to the Circuit Diagram Book for Latest Circuit Information
1. AIR BRAKE SWITCH(ES)
2. ZENER DIODE
3. 150 OHM RESISTOR
(1600) SYSTEM CONTROLLER CONNECTOR
(1823) STOP LIGHT SWITCH CONNECTOR
(1824) STOP LIGHT SWITCH CONNECTOR – NOT USED ON TRACTOR
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Table 310 Air Brake Switch Input Check Chart

597 14 1 0 Brake Switch Stuck
612 14 1 1 Brake switch out of range low
612 14 1 2 Brake switch out of range high
Air Brake Switch Harness Connector (1823) Voltage Checks
NOTE – Always check connectors for damage or pushed–out terminals.
Always use breakout box ZTSE 4477 to take measurements on ESC connectors.
(1823) cavity A short in circuits A70C, B70C, or B70CA.
to ground Also insure proper voltage out of ESC.

(1823) cavity B
to ground If voltage is incorrect check for
shorts to other circuits or incorrect
signal out of the ESC.
NOTE – If this signal is missing, the

wipers will be on at the high speed
setting.
(1823) cavity A zero volt reference signal circuits B9VG,
to cavity B B9V or A9H or missing signal from ESC.
Air Brake Switch Harness Connector (1824) Voltage Checks
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Table 310 Air Brake Switch Input Check Chart (cont.)

(1824) cavity A short in circuits A70C, B70C, or B70CB.
to ground Also insure proper voltage out of ESC.

(1824) cavity B
to ground If voltage is incorrect check for
shorts to other circuits or incorrect
signal out of the ESC.
NOTE – If this signal is incorrect out

of the ESC, several other features will
also be inoperative.
(1824) cavity A zero volt reference signal circuits B9VH,
to cavity B B9V or A9H or missing signal from ESC.
Brake Switch Resistance Checks
(Check with switch disconnected, negative probe of meter connected to pin

B and positive probe connected to pin A)
Pin B to pin A With stop light switch Switch has a resistor in series with
closed resistance should be contacts. If resistance is incorrect,
approximately 150 ohms. replace the switch.
Pin B to pin A With stop light switch Switch has a Zener diode in parallel
open resistance should be with the switch contacts.
approximately 50K ohms.
NOTE – Two brake switches are used on straight trucks. Only one is used on tractors.
Refer to Brake Switch Inputs to ESC With Air Brakes.
On vehicles with air brakes, the zero volt reference signal is supplied to brake switch 1 (1823) terminal B
and brake switch 2 (1824) terminal B, from ESC connector (1600) terminal 3. (Only one switch is used
in tractor applications).
When the key is in the ignition position, 12 volts will be applied to stop light switch 1 (1823) terminal A and
stop light switch 2 (1824) terminal A. When the key is in the off position 5 volts is supplied to terminal A of
the switch instead of 12 volts.
A 6.8 volt Zener diode, inside the switch body is wired in parallel with the switch contacts. The diode allows
current to pass through it when the key is in the ignition position and 12 volts is applied to the switch. The
diode prevents current from passing through it when the key is off and 5 volts is applied to the switch. When
the key is on and the brake is not applied, the ESC monitors the voltage drop across the diode and resistor in
the switch. If there is an open in the brake switch circuits there will be no voltage drop and the ESC will set
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a fault. The diode is required to block current flow when the key is off, preventing the circuits from putting
a drain on the battery.
A 150 ohm resistor, inside the switch body, is wired in series with the switch. The ESC senses the voltage drop
across this resistor to check for a short to ground in the brake switch circuits between the brake switch and the
ESC. If there is a short, 12 volts from the ESC will be pulled to ground and the ESC will set a fault.
When the brake switch is closed the voltage drop will change and the ESC will sense that the brake is applied.
8.6. FRONT TURN SIGNAL/HAZARD AND SEPARATE TURN SIGNAL LIGHT OUTPUTS
FROM ESC
cycled.
Refer to Front Turn Signal/Hazard Light outputs from ESC.
When the left or right turn signal is selected, the ESC will sense if the left or right signal circuits experience an
over current (short to ground or excessive load) or open circuit (fault will only be logged when there is no current
path through any bulb to ground). The ESC will log an active fault for either of these conditions. The fault will
remain active until the condition causing the fault has been corrected and the affected turn signal is activated.
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Figure 452 Front Turn Signal/Hazard Light outputs from ESC (Connectors Viewed From Mating End)
— Always Refer to the Circuit Diagram Book for Latest Circuit Information
(4000) ENGINE POWER DISTRIBUTION PANEL-TRAILER TURN RELAYS
LOCATED INSIDE ENGINE COMPARTMENT POWER DISTRIBUTION PANEL
(4007) BROWN SYSTEM CONTROLLER CONNECTOR
LOCATED ON ENGINE SIDE OF ESC
(4460M/F) BODY BUILDER CONNECTORS
LOCATED BACK OF CAB NEAR LEFT FRAME RAIL
(8000) RIGHT HEADLIGHT/TURN SIGNAL HARNESS
LOCATED REAR OF HEADLIGHT ASSEMBLY
(8001) LEFT HEADLIGHT/TURN SIGNAL HARNESS
LOCATED REAR OF HEADLIGHT ASSEMBLY
(8800) GROUND ADAPTER #1
(8801) GROUND ADAPTER #2
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Table 311 Front Turn Signal/Hazard Light Connector Check Chart

611 14 16 3 Right front turn lamps, less than normal low current
611 14 16 4 Right front turn lamps, greater than normal high
611 14 16 6 Right front turn lamps has current flow when
611 14 16 2 Right front turn lamp over current (Short Circuit)
NOTE – Disconnecting connectors will cause new open circuit faults to be logged. Clear all
faults after connections have been restored.
Disconnect right headlight/turn signal harness connector (8000). Cycle key switch and clear
DTC’s. Turn on right front turn signal and check for fault. If the fault has not reoccurred,
there is a short or an overload in the turn signal light. If the fault reoccurs, there is a short
in the circuits between the ESC and turn signal light or in the ESC.
Disconnect any other connectors to components that are connected to the right front turn signal
circuits. Cycle key switch and clear DTC’s. Turn on right front turn signal and check for fault. If the
fault has not reoccurred, there is a short or an overload in that component. If the fault reoccurs,
there is a short in the circuits between the ESC and turn signal light or in the ESC.
Disconnect brown ESC connector (4007). Cycle key switch and clear DTC’s. Turn on right turn
signal and check for fault. If the fault has not reoccurred, there is a short in the circuits between
the ESC and turn signal light. If the fault reoccurs, there is a short inside the ESC.
611 14 16 1 Right front turn lamp circuit open
Right Front Turn Signal/Hazard Light Voltage Checks
Check with hazard flashers on and right front headlight turn signal disconnected.
NOTE – In an over current situation, the ESC will not supply voltage until the short or excessive
load has been removed and the key switch has been cycled.
Right turn signal Voltage switching from 12 If voltage is missing, check for open or
connector (8000), pin ± 1.5 volts to 0 volts short in circuits M-57B, J57A or J57AA.
D to ground Check for a short in circuit J57BC to
body builder connectors and body builder
accessories. Check for short in circuit
J57H to trailer turn relays. Also insure
proper voltage out of ESC.

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Table 311 Front Turn Signal/Hazard Light Connector Check Chart (cont.)
Right turn signal 0 Volts Ground circuit.
connector (8000), pin
B to ground
Right turn signal Voltage switching from 12 If voltage is missing, check for open
connector (8000), pin ± 1.5 volts to 0 volts in ground circuits.
B to D
611 14 15 3 Left front turn lamps, less than normal low current
611 14 15 4 Left front turn lamps, greater than normal high
611 14 15 6 Left front turn lamps has current flow when
611 14 15 2 Left front turn lamp over current
With sealed beam headlamps, as used with Severe Service trucks, the terminals at the
headlamps are not sealed - in this application the terminals of the headlamps and the
terminals in the headlamp connector must be totally coated with Grafo grease 2643099R1
Disconnect left headlight/turn signal harness connector (8001). Cycle key switch and clear
DTC’s. Turn on right front turn signal and check for fault. If the fault has not reoccurred,
there is a short or an overload in the turn signal light. If the fault reoccurs, there is a short
in the circuits between the ESC and turn signal light or in the ESC.
Disconnect any other connectors to components that are connected to the right front turn signal
circuits. Cycle key switch and clear DTC’s. Turn on right front turn signal and check for fault. If the
fault has not reoccurred, there is a short or an overload in that component. If the fault reoccurs,
Disconnect brown ESC connector (4007). Cycle key switch and clear DTC’s. Turn on right turn
signal and check for fault. If the fault has not reoccurred, there is a short in the circuits between
the ESC and turn signal light. If the fault reoccurs, there is a short inside the ESC.
611 14 15 1 Left front turn lamp circuit open
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Table 311 Front Turn Signal/Hazard Light Connector Check Chart (cont.)
Left Front Turn Signal/Hazard Light Voltage Checks
Check with hazard flashers on and left front headlight turn signal disconnected.
NOTE – With sealed beam headlamps, as used with Severe Service trucks, the terminals at the
Left turn signal connector Voltage switching from 12 If voltage is missing, check for open or
(8001), pin D to ground ± 1.5 volts to 0 volts short in circuits M-56B, J56A or J56AA.
Check for a short in circuit J56BC to
body builder connectors and body builder
accessories. Check for short in circuit
J57H to trailer turn relays. Also insure

Left turn signal connector 0 Volts Ground circuit
(8001), pin B to ground
Left turn signal connector Voltage switching from 12 If voltage is missing, check for open
(8001), pin B to D ± 1.5 volts to 0 volts in ground circuits.
Refer to Front Turn Signal/Hazard Light outputs from ESC.
The ESC supplies battery voltage to the front turn signal lights.
Voltage for the right front turn signal light is supplied directly from ESC connector (4007) terminal B.
Ground for the light is supplied from ground stud (4006) to right headlight turn signal harness connector
(8000) terminal B.
Voltage for the left front turn signal light is supplied directly from the ESC connector (4007) terminal C to left
headlight turn signal harness connector (8001) terminal D.
Ground for the light is supplied from ground stud (4006) to left headlight turn signal harness connector (8001)
terminal B.
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8.7. REAR STOP/TURN SIGNAL/HAZARD LIGHT OUTPUTS FROM ESC

cycled.
Refer to Rear Stop/Turn Signal/Hazard Light Outputs From ESC.
When the brake light or left or right front turn signal lights are selected, the ESC will sense if the left or right
signal circuits experience an over current (short to ground or excessive load) or open circuit (fault will only be
logged when there is no current path through any bulb to ground). The ESC will log an active fault for either
of these conditions. The fault will remain active until the condition causing the fault has been corrected
and the affected brake or turn signal is activated.
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Figure 453 Rear Stop/Turn Signal/Hazard Light Outputs From ESC (Connectors Viewed From Mating
End) — Always Refer to the Circuit Diagram Book for Latest Circuit Information
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1. LEFT REAR LIGHT ASSEMBLY

2. RIGHT REAR LIGHT ASSEMBLY
(4008) BLUE ELECTRICAL SYSTEM CONTROLLER CONNECTOR
(4450M/F) BODY BUILDER CONNECTORS
LOCATED BACK OF CAB NEAR LEFT FRAME RAIL
(8803) CHASSIS GROUND SPLICE PACK
(9303) STOP/TAIL/TURN CONNECTOR
LOCATED ON LEFT LIGHT ASSEMBLY
(9700) DASH/CENTER CHASSIS CONNECTOR
LOCATED IN ENGINE COMPARTMENT NEAR LEFT FRAME
(9800) CENTER/REAR CHASSIS CONNECTOR
LOCATED BY LEFT FRAME RAIL NEAR REAR AXLES
Table 312 Rear Stop/Turn Signal/Hazard Light Connector Check Chart

611 14 13 3 Left rear turn lamps, less than normal low current
611 14 13 4 Left rear turn lamps, greater than normal high current
611 14 13 6 Left rear turn lamps has current flow when output
commanded off
611 14 13 2 Left rear turn lamp over current (Short Circuit)
NOTE – Disconnecting connectors will cause new open circuit faults to be logged. Clear all faults
after connections have been restored.
NOTE – The virtual fuse in the ESC will trip during a short. To reset the fuse, the key switch must
be cycled.
Turn key “OFF”. Disconnect stop tail and turn connector (9303). Turn on ignition and clear
DTC’s, then turn on left turn signal and check for fault. If the fault has not reoccurred, there
is a short or an overload in the turn signal light. If the fault reoccurs, there is a short in
the circuits between the ESC and turn signal light or in the ESC.
Turn key “OFF”. Disconnect any other connectors to components that are connected to the left rear
turn signal circuits. Turn on ignition and clear DTC’s, then turn on left turn signal and check for fault. If
the fault has not reoccurred, there is a short or an overload in that component. If the fault reoccurs,
Turn key “OFF”. Disconnect blue ESC connector (4008). Turn on ignition, then turn on left turn
signal and check for fault. If the fault has not reoccurred, there is a short in the circuits between the
ESC and right rear turn signal light. If the fault reoccurs, there is a short inside the ESC.
611 14 13 1 Left rear turn lamp circuit open
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Table 312 Rear Stop/Turn Signal/Hazard Light Connector Check Chart (cont.)
Left Rear Stop/Turn Signal/Hazard Light Voltage Checks
Check with hazard flashers on left rear stop tail and turn disconnected.
NOTE – Always check connectors for damage and pushed–out terminals. Also check turn signal
assemblies for damage or corrosion.
(9303) Pin B to ground Voltage switching from 12 If voltage is missing, check for open in circuits
± 1.5 volts to 0 volts R-56B, N56, J56B or J56J. Check for a short or
excessive loads in circuit J56BB to body builder
connectors and body builder accessories. Also
insure proper voltage out of ESC.

(9303) Pin E to ground 0 Volts Ground circuit.
(9303) Pin B to E Voltage switching from 12 If voltage is missing, check for open
± 1.5 volts to 0 volts in ground circuits.
611 14 14 3 Right rear turn lamps, less than normal low current
611 14 14 4 Right rear turn lamps, greater than normal high current
611 14 14 6 Right rear turn lamps has current flow when output
commanded off
611 14 14 2 Right rear turn lamp over current (Short Circuit)
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Table 312 Rear Stop/Turn Signal/Hazard Light Connector Check Chart (cont.)
NOTE – Disconnecting connectors will cause new open circuit faults to be logged. Clear all faults
after connections have been restored.
The virtual fuse in the ESC will trip during a short. To reset the fuse, the key switch must be
cycled.
Disconnect right tail light connector (72). Cycle ignition and clear DTC’s. Turn on right turn signal and
check for fault. If the fault has not reoccurred, there is a short or an overload in the turn signal light. If
the fault reoccurs, there is a short in the circuits between the ESC and turn signal light or in the ESC.
Disconnect any other connectors to components that are connected to the right rear turn signal
circuits. Cycle ignition and clear DTC’s. Turn on right turn signal and check for fault. If the fault
has not reoccurred, there is a short or an overload in that component. If the fault reoccurs, there
is a short in the circuits between the ESC and turn signal light or in the ESC.
Disconnect blue ESC connector (4008). Cycle ignition and clear DTC’s. Turn on right turn signal
and check for fault. If the fault has not reoccurred, there is a short in the circuits between the ESC
and right rear turn signal light. If the fault reoccurs, there is a short inside the ESC.
611 14 14 1 Right rear turn lamp Under Current (Circuit Open)
Right Rear Stop/Turn Signal/Hazard Light Voltage Checks
Check with hazard flashers on and right rear tail light disconnected.
NOTE – Always check connectors for damage and pushed–out terminals. Also check turn signal
assemblies for damage or corrosion.
(72) Pin C to ground Voltage switching from 12 If voltage is missing, check for open in circuit
± 1.5 volts to 0 volts S57B, left rear light assembly and circuits
R57, N57, J57B, and J57J. Check for a short
in circuit J57BB to body builder connectors
and body builder accessories. Also insure

(72) Pin E to ground 0 Volts Ground circuit
(72) Pin C to E Voltage switching from 12 If voltage is missing, check for open
± 1.5 volts to 0 volts in ground circuits.
Refer to Rear Stop/Turn Signal/Hazard Light Outputs From ESC.
Voltage for the right rear turn/stop light is supplied from ESC connector (4008) terminal B to the right turn
light connector (72) terminal C.
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Ground for the right rear turn/stop light is supplied from ground stud (4006) to the right turn light connector (72)
terminal C.
Voltage for the left rear turn/stop light is supplied from ESC connector (4008) terminal C to stop tail and turn
connector (9303) terminal B.
Ground for the left rear turn/stop light is supplied from ground stud (4006) to stop tail and turn connector
(9303) terminal E.
Figure 454 Stop/Turn Signal/Hazard Light Connector Locations (Steering Column Support View)
(1800) DCM CONNECTOR
(1804) THROTTLE POSITION SENSOR
(1807) CLUTCH SWITCH CONNECTOR
(1808) BAP SENSOR
(1810) TURN SIGNAL ASSEMBLY CONNECTOR ( BEHIND STEERING COLUMN SHROUD)
(1811)/(1812) AIR PRESSURE TRANSDUCERS FOR GAUGES
(1813) PARK INDICATION PRESSURE SWITCH
(1814) HYDRAULIC BRAKE STOP LIGHT SWITCH (NOT USED WITH AIR BRAKES)
(1822) BRAKE APPLIED AIR SWITCH
(1823) AIR BRAKE STOP LIGHT SWITCH (NOT USED WITH HYDRAULIC BRAKES)
(1824) AIR BRAKE STOP LIGHT SWITCH (NOT USED WITH HYDRAULIC BRAKES OR
TRACTOR BRAKE SYSTEM)
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Figure 455 Stop/Turn Signal/Hazard Light Connector Locations (Dash Panel From Engine
Compartment)
3. DASH HARNESS
5. ENGINE CONNECTOR
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Figure 456 Stop/Turn Signal/Hazard Light Connector Locations

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1. FRONT PARK LIGHT
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1. FRONT PARK LIGHT
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Figure 459 Optional Side Marker/Turn Signal Lights (Severe Service)

1. OPTIONAL SIDE MARKER/TURN SIGNAL LIGHT
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Figure 460 Rear Chassis Wiring Connector Locations

1. HARNESS TO CENTER CHASSIS WIRING
(9100) FUEL LEVEL SENDER CONNECTOR
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Figure 461 Rear Center Chassis Connector Locations

(9800) REAR CENTER CHASSIS CONNECTOR
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Figure 462 Stop, Tail and Turn Connector Location

(9303) STOP, TAIL AND TURN CONNECTOR
(9812) AXLE TEMPERATURE SENSOR
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Figure 463 (Typical) Rear Signal Light Connector Locations

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9. WORK LIGHTS
Figure 464 Work Light Function Diagram

1. WORK LIGHT
3. DRIVETRAIN 1939 DATA LINK
4. EGC
5. WORK LIGHT SWITCH (IN 3 SWITCH PACK ON EGC)
Refer to the Work Light Function Diagram.
The work light illuminates the fifth wheel area for easier trailer hook-up.
The momentary work light switch is wired directly to the EGC circuit board. When the work light momentary
switch is pushed “on” the electronic gauge cluster will send a message to the ESC, on the drivetrain 1939 data
link, to command the light on and light the switch indicator. The ESC provides power to the work light. When
the switch is pushed “off”, the ESC will turn the light off.
The auxiliary button on the remote key fob will also activate/deactivate this feature.
This feature utilizes a timer function option to turn the work light off after a set amount of time.
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9.2. DIAGNOSTICS
Should the light fail to operate, the problem could be attributed to a faulty switch in the EGC, a faulty switch
pack in the EGC, a problem in the EGC, open or shorted wiring between the ESC and the work light or
an open circuit between the work light and ground.
cycled.
A diagnostic trouble code (DTC) will be logged if there is an over current (short to ground or excessive load) or
an open in the circuits between the ESC and the work light.
A diagnostic trouble code will also be logged if there is a burned out bulb (as long as there is only one lamp
connected to the circuit).
work light and monitor activation of the work light switch. See the diagnostic software manual for details
Work Light Preliminary Check
Table 313 Work Light Preliminary Check

POINTS SPEC.
1. On Verify work light is Visually Work light Go to Work light is
inoperative. check work is inoper- next operating. Problem
light. ative. step. does not exist or is
intermittent. (Check
for inactive diagnostic
trouble codes.)
malfunctioning that for other are step. several features to be
common to several
features.)
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Table 313 Work Light Preliminary Check (cont.)

POINTS SPEC.
3. On If more than one work Visually All work Go to Check specific circuits
light is connected to check if all lights are next of the inoperative light
this circuit, are all work lights inoper- step. for open circuits.
lights inoperative? are inoperative.
ative.
4. On Check for diagnostic Read display No work Go to Go to work light circuit
trouble codes. (See on odometer. light work outputs from ESC.
Diagnostic Trouble diagnostic light (See WORK LIGHT
Codes, page 941) trouble input CIRCUIT OUTPUTS
codes are circuits FROM ESC, page
active. to the 944)
ESC.
(See
WORK
LIGHT
CIRCUIT
INPUTS
TO ESC,
page
942).
Table 314 Work Light Diagnostic Trouble Codes carl

611 14 11 1 Work light open circuit
Refer to Work Lights in the Light Systems section

of this manual. (See WORK LIGHT CIRCUIT
OUTPUTS FROM ESC, page 944)
611 14 11 2 Work light over current
Refer to Work Lights in the Light Systems section

of this manual. (See WORK LIGHT CIRCUIT
OUTPUTS FROM ESC, page 944)
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Table 314 Work Light Diagnostic Trouble Codes carl (cont.)

611 14 11 3 Work light lamps, less than normal low current
611 14 11 4 Work light turn lamps, greater than normal high current
611 14 11 6 Work light turn lamps has current flow when
9.3. WORK LIGHT CIRCUIT INPUTS TO ESC

cycled.
Refer to the Work Light EGC and ESC Input Circuits.
A fault in the input circuits will be apparent when the lights don’t come on and no active faults are present.
The ESC will not log any faults for work light input circuits to the ESC.
Loss of the drivetrain 1939 data link between the EGC and ESC will cause several problems to occur
simultaneously and the check electrical system lamp will illuminate. Go to the section on the drivetrain
1939 data link to troubleshoot this condition.
Problems in the work light input circuits can be caused by a short circuit between the 3 switch pack and the
EGC, an open circuit between the 3 switch pack and the EGC, a faulty switch, or a problem in the EGC.
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Figure 465 Work Light EGC and ESC Input Circuits—Always Refer to Circuit Diagram Book for
Latest Circuit Information

A mechanically defective work light switch could also prevent the work light from operating. Remove
the mechanical portion of the switch and attempt to turn the switch on by pressing the bottom switch
contact. If the work lights illuminate, the mechanical switch assembly should be replaced.
3 Switch Pack Harness Connector Work Light Voltage Checks
NOTE – If the EGC is working correctly, disconnecting the 3 switch pack connector should cause
the park lights to come on.

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Table 315 EGC, 3 Switch Pack Circuit Tests (cont.)

3 switch pack harness 12 ± 1.5 volts If voltage is missing, check for open
connector, pin 3 to ground or shorts in circuits between EGC

3 switch pack harness 0 –.3 volts Low circuit from EGC
connector, pin 7 to ground
If voltage is incorrect, check for
open or shorts in circuits between
EGC and switch.

3 Switch Pack Work Light Resistance Check

Checking for continuity between <1 ohm. If there is no continuity, the switch
pins 3 and 7 of the switch pack, pack needs replaced.
when the switch is on.
Refer to the Work Light EGC and ESC Input Circuits.
The work light switch is wired directly to the EGC circuit board. When the work light switch is turned on, 12
volts on pin 3 from the EGC will pass through the switch to pin 7 back to the EGC. This will cause the EGC to
send a message to the ESC requesting the light to be turned on.
9.4. WORK LIGHT CIRCUIT OUTPUTS FROM ESC

cycled.
Refer toWork Light Outputs from ESC.
A fault in the work light output circuits from the ESC will be apparent when the lights don’t come on and an
active work light fault is active. The ESC will log a diagnostic trouble code (DTC) when there is a short in any
of the circuits between the ESC and the work light or when there is an open in a circuit between the work light
and ground. Problems in the work light circuits can be caused by burned out lamps, a short, an open, a faulty
switch, a problem in the ESC or a problem in the EGC.
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Figure 466 Work Light Outputs from ESC (Connectors Viewed From Mating End) — Always Refer to
Circuit Diagram Book for Latest Circuit Information
(4006) GROUND STUD
(4007) BROWN ELECTRICAL SYSTEM CONTROLLER CONNECTOR
(9718) WORK LIGHT CONNECTOR
LOCATED IN ENGINE COMPARTMENT NEAR LEFT FRAME
LOCATED BELOW BACK OF CAB NEAR LEFT FRAME
LOCATED ON LIGHT MOUNTED ON BACK OF CAB
Table 316 Work Light Circuit Tests carl

611 14 11 3 Work light lamps, less than normal low current
611 14 11 4 Work light lamps, greater than normal high current
611 14 11 6 Work light lamps has current flow when
611 14 11 2 Work light over current
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Table 316 Work Light Circuit Tests carl (cont.)

This fault is logged when there is a short in the circuits between the work light and the ESC or an
excessive load on the circuit caused by too many accessories on the work light circuits.
Disconnect work light connector (9720). Cycle key switch and clear DTC’s. Turn
on work light switch and check for fault. If the fault has not reoccurred, there is a
short or an overload in the work light. If the fault reoccurs, there is a short in the
circuits between the ESC and work light or in the ESC.
Disconnect brown ESC connector (4007). Cycle key switch and clear DTC’s. Then turn on work
light switch and check for fault. If the fault has not reoccurred, there is a short in the circuits
between the ESC and work light. If the fault reoccurs, there is a short inside the ESC.
611 14 11 1 Work light open circuit
This fault is the result of an open in circuits between the work light output of the ESC and ground.
Check for open circuits

Work Light Harness Connector (9720) Voltage Checks
Check with ignition key on, work light on, and work light connector (9720) disconnected.
(9720) Harness 12 ± 1.5 volts If voltage is missing, check for
connector, pin A open in circuit J65.
to ground
Also insure proper voltage out of ESC.

(9720) Harness 0 volts Ground circuit. No voltage expected.
connector, pin B
to ground
(9720) Harness 12 ± 1.5 volts If voltage is missing, check for open
connector, pin A in ground circuit J65–G.
to pin B
Refer to Work Light Outputs from ESC.
The ESC will supply 12 volts from system controller brown connector (4007) terminal F to work light connector
(9720) terminal A.
Ground for the work light is supplied from ground stud (4006) to work light connector (9720) terminal B.
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Figure 467 Work Light Wiring

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10. AUXILIARY HEADLIGHTS

Figure 468 Auxiliary Headlights Function Diagram

1. AUXILIARY HEADLIGHTS
2. STANDARD HEADLIGHTS
3. AUXILIARY HEADLIGHT RELAYS
5. SWITCH DATA LINK
6. AUXILIARY HEADLIGHT SWITCH (IN SWITCH PACK)
Refer to Auxiliary Headlights Function Diagram.
The Auxiliary headlights system allows the driver to switch between standard headlights and auxiliary
headlights mounted above a snowplow. Switching between the lights can only be performed when the key is
on. If the key is turned off while the lights are on they will remain in that state until the key is turned on.
Relays, controlled by the ESC, are used to switch headlight current between the standard headlights and the
auxiliary headlights. The auxiliary headlight switch mounted in a switch pack will communicate with the
ESC to request the lights to be switched.
A separate relay is used for high beam and low beam auxiliary headlight operation.
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All auxiliary lights, other than the headlights, are connected to splices. No switching between standard and
auxiliary headlights occurs on these circuits.
10.2. DIAGNOSTICS
Should the auxiliary headlight system fail to switch from standard to auxiliary headlights, the problem could
be attributed to a faulty switch in the switch pack, a faulty switch pack, failed relays, open circuits or shorted
circuits.
auxiliary headlights and monitor activation of the auxiliary headlight switch. See the diagnostic software
manual for details on using the software.
Auxiliary Headlights Preliminary Check
Table 317 Auxiliary Headlights Preliminary Check

POINTS SPEC.
1. On Verify standard Visually Standard Go to next If standard headlights
headlights lights are check lights are step. are not functioning
operating correctly. standard operating correctly, Go to
headlights. correctly. Headlight System.
(See HEADLIGHT
SYSTEM, page 878)
2. On Check if either Visually At least Go to next Go to Auxiliary
high or low beam check some step. Headlights Circuits
headlights switch switching of lights To ESC. (See
from standard to headlights. switch AUXILIARY
auxiliary when from HEADLIGHTS
selected by auxiliary standard CIRCUITS TO ESC,
headlights switch. to page 951)
(Lights may not auxiliary.
work correctly. Just
look for change
from standard to
auxiliary.)
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Table 317 Auxiliary Headlights Preliminary Check (cont.)

POINTS SPEC.
3. On Are both high beam Visually Both high Go to next Check specific circuits
or both low beam check if both beam or step. of the inoperative light
auxiliary headlights auxiliary both low for open circuits.
inoperative? headlights beam
are inoper- auxiliary
ative. headlights
inoperative.
4. On With the auxiliary Read display No Go to Go to auxiliary
headlights on odometer. diagnostic auxiliary headlights circuit
selected,check trouble headlights outputs to ESC.
for diagnostic codes are circuit (See AUXILIARY
trouble codes. (See active. outputs HEADLIGHTS
Diagnostic Trouble from ESC. CIRCUITS TO ESC,
Codes, page 950) (See page 951)
AUXILIARY
HEADLIGHTS
CIRCUITS
FROM
ESC,
page 953)
Table 318 Auxiliary Headlights Circuits

611 14 5 1 Headlight low beam open circuit
611 14 5 2 Headlight low beam over current
611 14 5 6 Headlight low beam lamps has current flow when
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Table 318 Auxiliary Headlights Circuits (cont.)

611 14 7 1 Headlight high beam open circuit
611 14 7 2 Headlight high beam over current
10.3. AUXILIARY HEADLIGHTS CIRCUITS TO ESC

cycled.
Refer to Auxiliary Headlights Circuits To ESC.
A fault in the headlight switching circuits will be apparent when the lights will not switch between normal and
auxiliary headlights. The ESC will log a diagnostic trouble code (DTC) when there is a short or overload in the
switching circuit between the ESC and the switching relays. Problems in the switching circuits may be the
result of a shorted circuit, an open circuit, failed relays, or a problem in the ESC.
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Figure 469 Auxiliary Headlights Circuits To ESC (Connectors Viewed From Mating End) — Always
Refer To Circuit Diagram Book For Latest Circuit Information
(1012) F19 SWITCH PACK FUSE
LOCATED IN CAB POWER DISTRIBUTION CENTER
(1101) 6 SWITCHES PACK CONNECTOR (TO INSTRUMENT PANEL HARNESS OR
PREVIOUS SWITCH PACK)
LOCATED BEHIND SWITCH PACK
(1101A) 6 SWITCHES PACK CONNECTOR (TO NEXT SWITCH PACK)
LOCATED BEHIND SWITCH PACK
(1500) ELECTRONIC GAUGE CLUSTER (EGC) CONNECTOR
LOCATED ON BACK OF EGC
(1851) GROUND STUD CONNECTOR
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Table 319 Auxiliary Headlights Circuits To ESC 6 Switches Pack Connector Check Chart
Auxiliary Headlights Circuits To ESC 6 Switches Pack Connector (1101) Voltage Checks
This chart assumes there is power to cab fuse block (1012) from the mega fuse.
(1101) Pin B to ground 12 ± 1.5 volts If voltage is missing, check for blown fuse (F19) or open
or short in circuits A12P.
(1101) Pin A to ground 0 volts Ground circuit to pod.
(1101) Pin D to ground Approximately 4.5 volts (+) data link circuit. If voltage is low check for open or
short in circuit A3J(+) or shorted components on data
link.
(1101) Pin E to ground Approximately .2 volt (-) data link circuit. If voltage is low check for open in
circuit A3K(-) or shorted components on data link. If
voltage is high check for crossed data link wires.
If voltage and data link circuits to the pod are good, and a communication fault is still
active, the switch pack should be replaced.
(1101) Pin C to pin A 12 ± 1.5 volts (with Panel dimmer voltage from electronic gauge cluster
park lights on and panel (EGC).
dimmer at maximum).
If voltage is missing check circuits between switch pack
and EGC.
Inoperative panel lights in individual switches should be replaced. If the panel light voltage to the switch
pack is correct, but none of the panel lights operate, the switch pack should be replaced.
Refer to Auxiliary Headlights Circuits To ESC.
Battery voltage to 6 switches pack connector (1101) terminal B is provided from fuse block (1012), fuse
F19 on circuit A12P.
System ground to 6 switches pack connector (1101) terminal A is provided from negative stud (1850) on
circuit A11–GA and A11–GDB.
The switch data link is connected to switch pack connector (1101) terminal D and E from ESC connector (1600)
terminals 29 and 30 on twisted pair A3F(-)/A3E(+), to a splice and on A3K(-)/A3J(+).
Panel light voltage to switch pack connector (1101) terminal C is supplied from EGC connector (1500) on
circuits A62 and A62C.
The Auxiliary headlights switch selects the auxiliary headlights mounted above a snowplow.
10.4. AUXILIARY HEADLIGHTS CIRCUITS FROM ESC

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cycled.
Refer to Auxiliary Headlights Circuits From ESC.
A fault in the auxiliary headlight circuits between the ESC and the headlights will be apparent when the
lights don’t operate correctly. The ESC will also log a diagnostic trouble code (DTC) when there is a short
in any of the headlight circuits or an open circuit between the ESC and the headlights. Problems occurring
in the auxiliary headlights (not affecting normal headlights) can be caused by burned out lamps, a short
to ground or an open circuit.
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Figure 470 Auxiliary Headlights Circuits From ESC (Connectors Viewed From Mating End) — Always
Refer To Circuit Diagram Book For Latest Circuit Information
(4005), (4006) GROUND STUDS
(4305) AUX FORWARD/DASH CONNECTOR
LOCATED BEHIND RIGHT HEADLIGHT
LOCATED BEHIND LEFT HEADLIGHT
(8102) SNOW PLOW HARNESS CONNECTOR
LOCATED NEAR LEFT HEADLIGHT CONNECTOR
(8800) LEFT GROUND ADAPTER
(8801) RIGHT GROUND ADAPTER
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Table 320 Auxiliary Headlight Switching Circuits Tests

Auxiliary High and Low Beam Relay Checks
Check with auxiliary high beam and low beam relays removed, key in ignition position,
headlight switch on and auxiliary headlight switch on.
Bench check auxiliary high Relays energize and there If a relay tests bad, replace it.
and low beam relays. Refer is continuity thorough the
to Bench Checking Relays. closed contacts.
(See BENCH TESTING
RELAYS, page 29)
Measure voltage between 12 ± 1.5 volts with auxiliary If voltage is missing, check for open
aux low beam relay socket headlight switch “on”. or short in circuit J64AB or short to
cavity M2–F2 and ground. ground in circuit J64C.
Measure voltage between 12 ± 1.5 volts with auxiliary If voltage is missing, check for open
aux high beam relay socket headlight switch “on”. or short in circuit J64AB or short to
cavity M2–J2 and ground. ground in circuit J64C.
Measure voltage between 12 ± 1.5 volts with auxiliary If voltage is missing, check for
aux high beam relay socket headlight switch “on”. open in circuit J64–GA or J64–G
cavity M2–J2 and M2–G1 to ground stud (4005).
Table 321 Auxiliary Low Beam Headlight Circuit Tests

FAULTS
611 14 5 6 Headlight low beam lamps has current flow
611 14 5 2 Low beam over current
This fault may be the result of a short in the circuits between the low beam headlight circuits
611 14 5 1 Low beam under current
This fault is the result of an open in circuits between the low beam headlight circuits and the ESC.

Snow Plow Connector (8102) Low Beam Voltage Checks
NOTE – Verify headlight bulbs are not burned out before proceeding.
Check with key in ignition position, headlight switch on, low beams selected
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Table 321 Auxiliary Low Beam Headlight Circuit Tests (cont.)

Headlights in low beam. 12 ± 1.5 volts with headlight If voltage is missing, check for
(8102) terminal C to ground. low beams switched “on” open or short to ground in circuits
J64LO or M64LO.

circuits between (8102) and the
auxiliary headlamps
Headlights in low beam. 12 ± 1.5 volts with headlight If voltage is missing, check for open in
(8102) terminal C to low beams switched “on” circuits between terminal B and ground.
terminal B.
Table 322 Auxiliary High Beam Headlight Circuit Tests

FAULTS
611 14 7 6 Headlight high beam lamps has current flow
611 14 7 2 High beam over current
This fault may be the result of a short in the circuits between the high beam headlight circuits
611 14 7 1 High beam under current
This fault is the result of an open in circuits between the high beam headlight circuits and the ESC.

Snow Plow Connector (8102) High Beam Voltage Checks
NOTE – Verify headlight bulbs are not burned out before proceeding.
Check with key in ignition position, headlight switch on, high beams selected
Headlights in high beam. 12 ± 1.5 volts with headlight If voltage is missing, check for open or
(8102) terminal A to ground. high beams switched “on” short to ground in circuits J64HI or M64HI.

circuits between (8102) and the
auxiliary headlamps
Headlights in high beam. 12 ± 1.5 volts with headlight If voltage is missing, check for open in
(8102) terminal A to low beams switched “on” circuits between terminal B and ground.
terminal B.
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Refer to Auxiliary Headlights Circuits From ESC.
When low auxiliary headlights are requested, the ESC will supply 12 volts to the coils of auxiliary high beam
micro relay (4002) and auxiliary low beam micro relay (4002).
This will cause both relays to energize switching headlight voltage to the auxiliary headlights.
Ground for the auxiliary headlights is supplied from ground stud (4006) to ground adapter (8800) and cavity B
of snowplow connector (8102).
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Figure 471 Headlight Connector Locations (Dash Panel From Engine Compartment)
1. FORWARD CHASSIS CONNECTOR (4301) AND AUX FORWARD/DASH CONNECTOR
(4305)
3. CHASSIS HARNESS
5. ENGINE CONNECTOR
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Figure 472 Headlight Wiring

(4305) AUX FORWARD/DASH CONNECTOR
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12 TRANSMISSIONS 961
Table of Contents
1. MANUAL TRANSMISSIONS. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .965

1.2. DIAGNOSTICS. .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .965
1.3. BACK-UP LIGHT SWITCH.. . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . .965
1.4. VEHICLE SPEED SENSOR. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .967
Circuit Function. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .967
Testing Vehicle Speed Sensor. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. .968
1.5. TRANSMISSION TEMPERATURE SENSOR. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .969
2. ALLISON® MD TRANSMISSION. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .971

2.2. DIAGNOSTICS. .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .972
2.3. DIAGNOSTIC TROUBLE CODES (DTC). . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .973
2.4. ECU POWER AND DATA LINK CIRCUITS. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .973
2.5. NEUTRAL SIGNAL CIRCUITS . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . .976
2.6. BACK-UP LIGHT CIRCUITS . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .978
2.7. SHIFT SELECTOR CIRCUITS. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . .980
3. AUTO NEUTRAL.. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .987

3.2. AUTO NEUTRAL ENABLE. .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .989
3.3. AUTO NEUTRAL RELAY CIRCUITS.. . . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . .990
3.4. AUTO NEUTRAL LIGHT RELAY CIRCUITS. . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .991
3.5. CRANK INHIBIT RELAY CIRCUITS.. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .992
4. LCT (ALLISON® 2000 SERIES™) TRANSMISSION. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .994

4.1. CIRCUIT FUNCTIONS . . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .994
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962 12 TRANSMISSIONS
4.2. DIAGNOSTICS. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . ..994

4.3. DIAGNOSTIC TROUBLE CODES (DTC). . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . .995
4.4. TCM POWER AND DATA LINK CIRCUITS. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . ..995
4.5. NEUTRAL AND BACK-UP LIGHT CIRCUITS .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..998
Extended Description. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .1000
4.6. SHIFT SELECTOR CIRCUITS . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . .1000
Fault Detection Management. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .1000
4.7. COMPONENT LOCATIONS. .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .1004
5. EATON® AUTOSHIFT™ TRANSMISSION. .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .1007

5.1. CIRCUIT FUNCTIONS. .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .1007
5.2. DIAGNOSTICS. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . ..1007
5.3. DIAGNOSTIC TROUBLE CODES (DTC). .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. .1008
5.4. AUTOSHIFT SELECTOR POWER CIRCUITS. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .1009
Extended Description. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. ..1011
5.5. AUTOSHIFT SELECTOR DATA LINK CIRCUITS. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .1012
5.6. AUTOSHIFT ECU POWER CIRCUITS.. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .1013
5.7. AUTOSHIFT RELAY CIRCUITS. .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . .1015
5.8. AUTOSHIFT BACK-UP LIGHT CIRCUITS. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .1017
5.9. VEHICLE SPEED SENSOR. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .1019
Circuit Function.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. ..1020
Testing Vehicle Speed Sensor. . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . .1020
5.10. COMPONENT LOCATIONS.. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .1022
6. EATON® LIGHTNING™ TRANSMISSION. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .1024

6.1. CIRCUIT FUNCTIONS. .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .1024
6.2. DIAGNOSTICS. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . ..1025
6.3. DIAGNOSTIC TROUBLE CODES (DTC). .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. .1025
6.4. LIGHTNING SHIFTER POWER CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1026
6.5. LIGHTNING DATA LINK CIRCUITS. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .1028
6.6. LIGHTNING ECU POWER CIRCUITS. .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . .1030
6.7. LIGHTNING BACK-UP LIGHT CIRCUITS.. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .1031
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6.8. VEHICLE SPEED SENSOR. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..1033

Circuit Function. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .1034
Testing Vehicle Speed Sensor. . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . .1034
6.9. TRANSMISSION OIL TEMPERATURE SENSOR. . . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . ..1035
6.10. COMPONENT LOCATIONS. . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . ..1036
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1. MANUAL TRANSMISSIONS
The manual transmission interfaces with the vehicle electrical system through a vehicle speed sensor, and
back-up light switch.
Vehicles with a transmission temperature gauge will also have a temperature sensor on the transmission.
1.2. DIAGNOSTICS
The ESC will set a diagnostic trouble code for a short to ground in the transmission temperature sensor
circuits. It is not able to detect an open circuit.
The ESC is not able to detect faults in the back-up light circuits. A fault in the back-up light circuits will be
apparent when the transmission is shifted into reverse and the lights don’t come on.
The engine controller will monitor the vehicle speed circuits for failures. A fault in the vehicle speed sensor
circuits will be apparent when the speedometer is inoperative and the yellow “ENGINE” warning lamp is on.
1.3. BACK-UP LIGHT SWITCH

When the transmission is shifted into reverse, the back up light switch should close to provide voltage
for the back up lamps.
A fault in the back-up circuits should be suspected if the back-up lights do not come on when the transmission
is shifted into reverse. Problems in the back–up light circuits can be caused by open or short circuits,
a blown fuse, or failed switch.
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Figure 473 Back Up Switch Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
(4705) TRANSMISSION/DASH CONNECTOR
LOCATED IN ENGINE COMPARTMENT NEAR WIPER MOTOR BRACKET
(4810) BACKUP LIGHT TURN SIGNAL SPLICE CONNECTOR
LOCATED IN ENGINE COMPARTMENT NEAR PDC
(7500) BACK UP LIGHT SWITCH CONNECTOR
LOCATED ON MANUAL TRANSMISSION
Table 323 Back Up Light Circuit Checks

Back Up Light Switch Connector (7500) Power Checks
Check with ignition on and (7500) disconnected.

Back up switch harness 12 ± 1.5 volts. If voltage is incorrect, check for blown 10A
connector (7500), cavity transmission fuse or open or short to ground
A to ground. in circuit J71B or J71.
Back up switch harness 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit L71C
connector (7500), cavity or J71AA to back up/turn signal splice (4810).
A to cavity B.
Also check circuits through back up lamps to ground.
If voltages are correct, consider replacing the back up switch.
Ignition voltage is supplied to the back up light switch connector (7500), terminal A, from the 10 amp back up
light fuse in the engine compartment power distribution center (PDC).
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When the transmission is shifted into reverse, the switch will close supplying ignition voltage to the lamp circuits.
1.4. VEHICLE SPEED SENSOR

Refer to Speedometer (See SPEEDOMETER, page 252) for procedures to isolate speedometer problems to
the sensor circuits.
Refer to the applicable engine manual for troubleshooting circuits from the engine controller to the sensor.
Circuit Function
Figure 474 Transmission Vehicle Speed Sensor Circuits—Always Refer to Circuit Diagram Book
for Latest Circuit Information
(6007) I6 ENGINE ECM BLACK CONNECTOR
LOCATED ON ENGINE CONTROLLER
(6012) (6021) V8 ENGINE ECM CONNECTOR
(7601) TRANSMISSION SPEED SENSOR
LOCATED ON MANUAL TRANSMISSION
(7800) ENGINE/TRANSMISSION
LOCATED IN ENGINE COMPARTMENT NEAR ENGINE CONTROLLER
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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 floor 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 324 Testing Vehicle Speed Sensor

STEP KEY ACTION TEST SPEC. YES-IN NO-OUT OF SPEC.
POINTS SPEC.
1. Off Inspect VSS for Go to next
damage before step.
performing this test.
2. Off Disconnect engine VSS, 600 to 800 Go to next Replace the vehicle
harness (7601) from terminal ohms. step. speed sensor (VSS).
VSS and use test A to B.
leads to measure
resistance between
terminal A and B of
sensor connector.
3. Off Measure resistance VSS, >100K Go to next Replace the vehicle
to ground at both term. 1 ohms. step. speed sensor (VSS).
sensor terminals. and 2 to
ground.
4. Off Block front wheels Go to next
and place rear axles step.
on floor stands.
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Table 324 Testing Vehicle Speed Sensor (cont.)

POINTS SPEC.
5. Off Use AC voltmeter Go to next
with sufficient length step.
leads to avoid
personal contact
with rotating vehicle
wheels during test.
Connect meter leads
to test leads.
6. Off Run engine at VSS, >2.0 volts VSS Replace the VSS.
idle speed, with across AC checks
transmission in terminals. good.
high gear. Measure
voltage across the
two sensor terminals.
1.5. TRANSMISSION TEMPERATURE SENSOR

Refer to Transmission Oil Temperature Gauge (See TRANSMISSION OIL TEMPERATURE GAUGE, page
266) for troubleshooting procedures.
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Figure 475 Transmission Harness

1. TRANSMISSION DASH CONNECTOR (4705)
2. ENGINE/TRANSMISSION CONNECTOR (7800)
3. DRIVETRAIN 1939 TERMINATOR
4. TO TRANSMISSION
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Figure 476 Typical Manual Transmission Wiring

1. (7500) BACK-UP LIGHT SWITCH
2. (7601) VEHICLE SPEED SENSOR
2. ALLISON® MD TRANSMISSION
Discussion of the MD transmission In this section is limited to the transmission electronic control unit (ECU)
power circuits and data link connectivity. For detailed information on transmission diagnostics, refer to the
Allison service manual.

The MD transmission ECU interfaces with the vehicle on the Drive Train 1939 Data Link and several discrete
circuits.
A backup lamp relay converts the low backup signal from the ECU to a 12 volt signal and powers the back up
lamps.
The ECU receives power from a clean battery feed in the battery box.
A backup lamp relay converts the low backup signal from the ECU to a 12 volt signal and powers the back up
lamps.
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The neutral signal from the transmission ECU is communicated to the ESC and the engine controller.
The vehicle speed signal is provided by the ECU on circuits to the engine controller.
2.2. DIAGNOSTICS
The ESC will log a DTC and command the “CHECK TRANS” lamp on if communication with the transmission
ECU is lost.
The transmission ECU has its own diagnostic system which will turn on the “CHECK TRANS” lamp when there
is a detectable fault. Diagnostic codes can be read from the lamps on the transmission shift selector or with the
Allison Transmission Diagnostic Tool (ATDT) software. Refer to the applicable troubleshooting manual for
details. If the diagnostic software is unable to communicate with the ECU there may be circuit problems in the
1708 data link. Refer to 1708 Data Link. (See 1708 DATA LINK, page 75)
There are no diagnostic trouble codes (DTC’s) associated with the back-up light circuits. A fault in the back-up
light circuits will be apparent when the transmission is shifted into reverse and the lights don’t come on.
Table 325 MD Preliminary Check

STEP KEY ACTION SPEC. YES-IN SPEC. NO-OUT OF SPEC.
1. On Does the engine crank Engine cranks Go to next Refer to Engine
when the transmission when the step. Cranking. (See
is in neutral? transmission is ENGINE CRANKING,
in neutral. page 385)
2. On Does the “CHECK Lamp turns off Go to next Refer to the applicable
TRANS” lamp turn off after vehicle is step. transmission service
after the vehicle is started. manual.
started.
3. On Are there any active Transmission Go to next Go to ECU Power and
DTC’s associated with communication step. Data Link Circuits.
the transmission? DTC is not active (See ECU POWER
Refer to Diagnostic (no codes). AND DATA LINK
Trouble Codes. CIRCUITS, page 973)
(See DIAGNOSTIC
TROUBLE CODES
(DTC), page 973)
4. On Does the Check Warning lamp Refer to the Go to next step.
Transmission Warning remains on after applicable
Lamp remain bulb check Allison service
illuminated. manual.
5. On Does the shift Check shift Go to next Go to Shift Selector
selector appear to selector step. Circuits. (See
be malfunctioning? for correct SHIFT SELECTOR
operation. CIRCUITS, page 980)
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Table 325 MD Preliminary Check (cont.)

6. On Do the back-up lights Back-up lights Transmission Go to Neutral Signal
come on when the come on when circuits are Light Circuits. (See
transmission is shifted in reverse. functioning. NEUTRAL SIGNAL
into reverse? CIRCUITS , page 976)
Go to next
step. Go to Back-Up
Light Circuits. (See
BACK-UP LIGHT
CIRCUITS , page
978)
If transmission is still not operating correctly, refer to the appropriate Allison service manual.
2.3. DIAGNOSTIC TROUBLE CODES (DTC)

To display ESC diagnostic codes, put the vehicle in diagnostic mode. Set the parking brake and turn the
Ignition key “ON”. Then press the Cruise “ON” switch and the Cruise “Resume” switch. If no diagnostic trouble
codes are present, the cluster odometer will display “NO FAULT”. If diagnostic trouble codes are present,
the gauge cluster will display the total number of faults and cycle to the next diagnostic trouble code after 10
seconds. To manually cycle through the diagnostic trouble code list, press the cluster display select/reset
button. The last character of the diagnostic trouble code will end in “A” for active diagnostic trouble codes
or “P” for previously active diagnostic trouble codes. Turning the ignition key off or releasing the park brake
will take the ESC and the gauge cluster out of the diagnostic mode.
The previously active diagnostic trouble codes may be cleared, while in the diagnostic mode, by turning on the
left turn signal and pressing the cruise on and set switches simultaneously.
Table 326 Transmission Communication Diagnostic Trouble Codes

639 14 2 240 Electronic transmission controller communication has not
been received
2.4. ECU POWER AND DATA LINK CIRCUITS

A fault in the power or data link circuits to the ECU will be apparent when the instrument cluster display does
not correspond to the shift selector position and the check electrical system lamp is illuminated. Problems in the
power and data link circuits can be caused by open or short circuits, a blown fuse, failed switch, a problem in
the ESC, a problem in circuits between the ESC and the solenoid module or a problem in the solenoid module.
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Figure 477 MD ECU Power and Data Link Circuits—Always Refer to Circuit Diagram Book for Latest
Circuit Information
(4001) MINI FUSE BLOCK 10 AMP TRANSMISSION FUSE
LOCATED IN ENGINE COMPARTMENT PDC
(4820) J1708 & 5 VOLT REF SPLICE CONNECTOR
(7104) CLEAN BATTERY FEED
LOCATED IN BATTERY HARNESS
(7202) GRAY ECU “V” CONNECTOR
LOCATED ON ALLISON WTEC TRANSMISSION CONTROL MODULE
(7204) BLACK ECU “S” CONNECTOR
LOCATED ON ALLISON WTEC TRANSMISSION CONTROL MODULE
(7208) J1939 DATA LINK SPLICE CONNECTOR
LOCATED IN ENGINE HARNESS
(9255) TRANSMISSION ECU FEED FUSE CONNECTOR
LOCATED IN BATTERY COMPARTMENT
(9260) BATTERY ECM NEGATIVE CONNECTOR
(9261) BATTERY ECM POSITIVE CONNECTOR
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Table 327 ECU Power and Data Link Checks

ECU Connector (7204) Power Check

TCM harness connector 12 ± 1.5 volts. If voltage is incorrect, check for blown 10A
(7204), cavity 4 to ground transmission fuse or open or short to ground
in circuit L13#104, L13M4 or J13M.
Also check for short to ground in circuit

L13M3 to the NSBU.
ECU Connector (7202) Power Check

ECU harness connector 12 ± 1.5 volts. If voltage is incorrect, check for blown
(7202), cavity 16 to ground. 10A transmission feed fuse or open or
short to ground in circuit N14BB, N92A,
L92#136 or L92C136.
ECU harness connector 12 ± 1.5 volts. If voltage is incorrect, check for blown
(7202), cavity 1 to ground. 10A transmission feed fuse or open or
short to ground in circuit N14BB, N92A,
L92#136 or L92B136.
ECU harness connector 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit
(7202), cavity 1 to cavity 17. N14–GA, N92–G, L92–G, L92#143 or L92B143.
ECU harness connector 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit
(7202), cavity 1 to cavity 32. N14–GA, N92–G, L92–G, L92#143 or L92C143.
If voltages are correct and ECU communication DTC is still active, refer to Drivetrain
Data Link. (See DRIVETRAIN 1939 DATA LINK, page 60)
Ignition voltage is supplied to the black ECU connector (7204), terminal 4, from the 10 amp transmission
fuse in the engine compartment PDC.
Battery voltage to the gray ECU connector (7202) cavities 1 and 16, from the 10 amp transmission feed
fuse in the battery compartment.
Ground is supplied to the gray ECU connector (7202) cavities 17 and 32 from the battery negative terminal.
The drivetrain data link is connected to the black ECU connector (7204) cavities 29, 12 and 13 from the
data link "Y" connector (7208).
The 1708 data link is connected to the black ECU connector (7204) cavities 17 and 1.
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2.5. NEUTRAL SIGNAL CIRCUITS

When the transmission is shifted into neutral, the ECU will apply 12 volts from the gray ECU connector (7202)
terminal 6, to ESC connector (4004) and engine controller connector (6007) pin 26 or (6020) pin 8. The voltage
will cause the engine controller to enable engine cranking as long as the engine isn’t already running.
A fault in the neutral signal circuits should be suspected when the engine will not crank. Problems in the
neutral circuits can be caused by open or short circuits, a failure in the engine controller, or a failure in the ECU.
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Figure 478 Neutral Signal Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
LOCATED ON ENGINE SIDE OF ELECTRICAL SYSTEM CONTROLLER
(6007) I6 ECM CONNECTOR
(6020) V8 ECM CONNECTOR
LOCATED ON TRANSMISSION ECU
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Table 328 Neutral Signal Circuit Checks

Neutral Signal Circuit Checks
Check with ignition on, transmission in neutral and ESC connector (4004) removed.

Remove engine connector 12 ± 1.5 volts. If voltage is incorrect, check for open
(6007) or (6020). Voltage or short to ground in circuit L92#123,
from ESC Connector (4004) L92A123 or J92C123.
cavity 15 to ground.
If circuits check good consider replacing
transmission ECU.
Voltage from (6007) pin 26 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit
or (6020) pin 8, to 12 volts. L92#123 to the engine controller.
If circuit checks good, consider replacing

engine controller. Refer to the applicable
engine troubleshooting manual.
When the transmission is shifted into neutral the ECU will apply a 12 volt signal from the gray ECU connector
(7202) terminal 6 to the ESC and the engine controller
This signal will notify the engine controller that the transmission is in neutral. If the engine is not running the
engine controller will enable the starter to operate.
2.6. BACK-UP LIGHT CIRCUITS

When the transmission is shifted into reverse gear, the ECU will apply a ground from the gray ECU connector
(7202) terminal 4, to the coil of the back up lamp relay causing it to energize. The energized relay will supply
power to the backup lights.
A fault in the back up light relay circuits should be suspected when the back-up lights do not come on when
the transmission is shifted into reverse. Problems in the back–up light circuits can be caused by open or
short circuits, a blown fuse, or a failure in the ECU.
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Figure 479 Back Up Light Relay Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
(4002) BACK UP LIGHT RELAY
(4810) BACK UP LIGHT TURN / SIGNAL SPLICE
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Table 329 Back-Up Light Relay Circuit Checks

Back-Up Light Relay Circuit Power Checks
Check with ignition on and Back Up Light Relay (4002) removed.
Bench check relay and replace if it has failed. Refer to Bench Checking Relays.
(See BENCH TESTING RELAYS, page 29)

Back Up Light Relay (4002), 12 ± 1.5 volts. If voltage is incorrect, check for blown 10A
socket cavity M1–D2 to transmission fuse or open or short to ground
ground. in circuit J71HJ, J71H or J71J.
Back Up Light Relay (4002), 12 ± 1.5 volts. If voltage is incorrect, check for blown 10A
socket cavity M1–D1 to transmission fuse or open or short to ground
ground. in circuit J71HJ, J71H or J71J.
Transmission in neutral. Back 0 volts. If voltage is incorrect, check for short to
Up Light Relay (4002), socket ground in circuit L71#113.
cavity M1–D1 to M1–F2.
Also check for incorrect signal from ECU.
Transmission in reverse. Back 12 ± 1.5 volts. If voltage is incorrect, check for open
Up Light Relay (4002), socket in circuit L71#113.
cavity M1–D1 to M1–F2.
Also check for incorrect signal from ECU.
Power to the back up light relay coil and common contact is supply from the 10 amp transmission fuse.
When the transmission is shifted into reverse, the ECU will apply a ground from the gray ECU connector (7202)
terminal 4, to the coil of the back up lamp relay causing it to energize. The energized relay will supply power
from the normally open contact to the back up lights.
2.7. SHIFT SELECTOR CIRCUITS

The shift selector contains the microprocessor that communicates driver input to the transmission ECU.
The transmission shift selector (420) receives battery power at all times (ignition key on or off) from the
transmission ECU (7204) on pin R. The shift selector (420) receives a ground from the transmission ECU
(7204) on pin P. A chassis ground is also supplied on (420) pins T and V. Circuits connected to shift selector
connector (420) pins A, B, C, D, and E provide signals between the shift selector and the ECU. Panel light
voltage is supplied to (420) pin U.
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Figure 480 Shift Selector Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
(420) SHIFT SELECTOR
(1002) PANEL LIGHT BUSS BAR
LOCATED BEHIND INSTRUMENT PANEL
(1003) GROUND BUSS BAR
LOCATED BEHIND INSTRUMENT PANEL
(4014) PASS THROUGH CONNECTOR
LOCATED ABOVE ESC
(7204) BLACK ECU “S” CONNECTOR
LOCATED ON TRANSMISSION
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Table 330 Shift Selector Circuit Checks

Shift Selector Circuit Checks
Check with ignition on, transmission in neutral and shift selector connector (420) removed.

Harness connector (420) 12 ± 1.5 volts. If voltage is incorrect, check for open or short to
cavity R to ground ground in circuits between (420) cavity R and
black ECU connector (7204) cavity 16. If circuits
check good, ECU may be malfunctioning.
Refer to the applicable Allison manual.
Harness connector (420) 12 ± 1.5 volts. If voltage is incorrect, check for open or short to
cavity R to P ground in circuits between (420) cavity P and
black ECU connector (7204) cavity 32. If circuits
check good, ECU may be malfunctioning.
Refer to the applicable Allison manual.
If voltages are correct the shift selector

may need replaced.
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Figure 481 MD T-Bar Shift Control

1. SHIFT CONTROL LEVER
2. (420) SHIFT SELECTOR CONNECTOR
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Figure 482 MD Push Button Shift Control

1. SHIFT CONTROL PUSH BUTTONS
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Figure 483 MD Transmission Harness (I6 Engine Shown)

1. TRANSMISSION/DASH HARNESS (4705)
2. TRANSMISSION HARNESS
3. CLEAN BATTERY FEED CONNECTOR (7104)
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Figure 484 MD Transmission Wiring

1. DRIVETRAIN 1939 "Y" CONNECTOR (7208) AND TERMINATOR
2. TRANSMISSION HARNESS
3. ENGINE SPEED SENSOR (7603)
4. TRANSMISSION BULKHEAD CONNECTOR (7200)
5. OUTPUT SPEED SENSOR (7605)
6. TO ECU
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Figure 485 MD Transmission ECU Location

1. TRANSMISSION BULKHEAD CONNECTOR (7200)
2. DRIVETRAIN 1939 "Y" CONNECTOR (7208) AND TERMINATOR
3. ENGINE SPEED SENSOR (7603)
4. ECU “S” CONNECTOR BLACK (7204)
5. ECU “V” CONNECTOR GREY (7202)
6. ECU “T” CONNECTOR BLUE (7203)
7. OUTPUT SPEED SENSOR (7605)
3. AUTO NEUTRAL
While the auto neutral feature is activated the transmission will automatically shift into neutral when the park
brake is applied. A warning light in the instrument cluster will illuminate when the shift selector is not in
neutral but the transmission is in neutral.
The auto neutral feature, from the factory, is only available with the Allison MD transmissions. Auto neutral,
using the LCT (Allison 2000 series) transmission, can be installed by body builders. See the Body Builder
book for circuits and information.
Auto neutral is selected with a switch in the switch pack. When the switch is on, the ESC will be requested to
enable auto neutral. The switch indicator will light when the ESC has received the request and will remain
illuminated until the switch is turned off. The switch indicator will flash and auto neutral will be disabled if
there is a switch error.
Refer to the Switch Pack Module section of this manual.(See SWITCH PACK MODULES, page 125)
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Figure 486 Auto Neutral Circuits—Always Refer to Circuit Diagram Book for Latest Circuit Information
(1555) AUTO NEUTRAL WARNING LIGHT
LOCATED IN CAB INSTRUMENT CLUSTER
(4001) AUTO NEUTRAL WARNING LIGHT FUSE BLOCK
LOCATED IN ENGINE POWER DISTRIBUTION CENTER
(4002) WTEC AUTO NEUTRAL RELAY, WTEC AUTO NEUTRAL LIGHT RELAY, CRANK
INHIBIT RELAY BLOCK
LOCATED IN ENGINE COMPARTMENT POWER DISTRIBUTION CENTER (PDC)
(4004) ELECTRICAL SYSTEM CONTROL (ESC) CONNECTOR
LOCATED IN ENGINE COMPARTMENT SIDE OF ESC
LOCATED ON DASH PANEL ABOVE ESC
(7202) ECU “V” GRAY CONNECTOR
LOCATED ON MD TRANSMISSION
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3.2. AUTO NEUTRAL ENABLE

Refer to Auto Neutral Circuits (See Figure 486, page 988).
A fault in the auto neutral enable circuits from the ESC to the ECU will be apparent when a DTC is set.
Problems in the auto neutral enable could be the result of open circuits, shorted circuits a failure in the ECU
or a failure in the ESC.
The auto enable signal, from ESC connector (4004) pin 19, should be generated when the park brake is on
and the auto neutral switch is on.
Table 331 Auto Neutral Enable Circuit Tests

ESC DTC’s
2033 14 7 1 Auto Neutral Enable circuit overloaded. Connector 4004 pin
19 current overload. Too much load attached.
2033 14 7 2 Auto Neutral Enable circuit open. Connector 4004 pin 19 open.
2033 14 7 3 Auto Neutral Enable circuit shorted to ground. Connector
4004 pin 19 shorted to ground.
Auto Neutral Enable Circuit Tests
Check with Gray ECU connector (7202) removed.
Auto neutral switch off and 12 ± 1.5 volts If voltage is missing, check for open or shorts in
park brake off. Harness circuits J92DL, L92DL, L92A117 to the ESC (4004)
connector (7202) cavity 30 to cavity 19.
ground.
Also check for missing signal from ESC.
Auto neutral switch off and 12 ± 1.5 volts If voltage is missing, check for open or shorts in
park brake off. Harness circuits J92DL, L92DL, L92A153 to the ESC (4004)
connector (7202) cavity 12 to cavity 19.
ground.
Auto neutral switch on and 0 volts If voltage is incorrect, ESC is not creating enable
park brake on. Harness signal. Check for missing auto neutral command
connector (7202) cavity 12 to from switch pack or missing park brake signal.
ground.
Reconnect (7202). If voltages are correct and DTC is still active consider replacing transmission ECU.
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The auto neutral enable signal will be a ground when auto neutral is on and the park brake is applied. The
ESC provides this signal from (4004) pin 19 to ECU “V” Gray connector pins 30 and 12.
3.3. AUTO NEUTRAL RELAY CIRCUITS

The de-energized auto neutral relay completes the circuit path for the transmission ECU neutral start signal to
the engine controller DDS input. This signal is 12 volts when the shifter is in neutral and 0 volts when the
transmission is in drive. This inhibits engine cranking while the transmission is not in neutral.
The relay is energized, by a signal from the transmission ECU, when the engine is running and the
transmission is in neutral. The energized relay applies 12 volts to the engine controller DDS input. This
allows engine speed to be changed when the engine is running and the transmission is in neutral (for PTO
operations). The output is also applied to the normally closed contact of the neutral light relay and the neutral
safety switch input to the ESC.
A fault in the auto neutral relay circuits may be present when the engine will not crank while auto neutral is
selected or will crank when transmission is not in neutral. A failure in relay circuits could also prevent the engine
from increasing RPM during PTO operations. Problems in the auto neutral relay circuits could be attributed to
open or short circuits, a blown fuse, a failure in the transmission ECU or a failure in the engine controller.
Table 332 Auto Neutral Relay Power Checks

Auto Neutral Relay Socket (4002) Power Checks
Check with ignition on and auto neutral relay (4002) removed.

Relay socket cavity M2–C1 12 ± 1.5 volts If voltage is missing, check for open or shorts in
to ground. circuit J92J or open auto neutral fuse.
Relay socket cavity M2–C2 12 ± 1.5 volts If voltage is missing, check for open in circuit J92JA.
to ground.
Relay socket cavity M2–C2 With engine on If voltage is incorrect, check for open in
to M2-A1. and transmission in circuit J92A114 or L92A114. Also check for
neutral, 12 ± 1.5 volts. missing signal from ECU.
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Table 332 Auto Neutral Relay Power Checks (cont.)

Relay socket cavity M2–B1 With shifter in neutral If voltage is incorrect, check for open in
to ground. and transmission in circuit J92HM5, J92C123 or L92A123. Also
neutral, 12 ± 1.5 volts. check for short to ground in circuits J92HM5,
J92C123, L92A123, J92HM4 or J92AY. Insure
signal from ECU is present.
Relay socket cavity M2–A2 With transmission If voltage is incorrect, check for open in circuit
to ground. in neutral and, 12 ± J17BC. Also check for short to ground in
1.5 volts. circuits J17BC, J17BD, J17B or L17B. Insure
signal from ESC is present.
If voltage is missing from the ESC consider replacing the ESC.
Power to the auto neutral relay coil and common contact is supply from the 5 amp auto neutral fuse.
The relay is energized by a low signal from ECU “V” gray connector (7202) pin 2. The low signal is generated
when the engine is running and the transmission is in neutral.
The de-energized relay provides a circuit path for the neutral start signal from the ECU. This will be 12 volts
when the transmission is in neutral or 0 volts when the transmission is in gear. The signal is applied to the
engine controller drive line disengagement switch (DDS) input. 12 volts will signal the engine controller that
the transmission is in neutral.
The energized relay applies 12 volts to the engine controller DDS input when the engine is on and the
transmission is in neutral. This will allow the engine to increase RPM when a power take off is engaged.
3.4. AUTO NEUTRAL LIGHT RELAY CIRCUITS

The output on the common contact of the auto neutral light relay is 12 volts when the shifter is in not in neutral
(auto neutral active) and the transmission is in neutral. The output is 0 volts when the transmission is in drive.
The output is applied to the engine controller ECM input to inhibit engine cranking while the transmission is not
in neutral. The output is also applied to the normally closed contact of the neutral light relay.
A fault in the auto neutral light relay circuits may be present when the auto neutral warning light does not
illuminate when auto neutral is active. Problems in the auto neutral light relay circuits could be attributed to
open or short circuits or a failure in the transmission ECU.
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Table 333 Auto Neutral Light Relay Power Checks

Auto Neutral Light Relay Socket (4002) Power Checks
Check with ignition on and auto neutral light relay (4002) removed.

Relay socket cavity With transmission in If voltage is missing, check for open in circuit
M2–H3 to ground. neutral, 12 ± 1.5 volts J17BD. Check for shorts in circuit J17BD,
J17BC, J17B or L17B.
Relay socket cavity With transmission in If voltage is missing, check for open in
M2–H3 to M2–G3. neutral, 12 ± 1.5 volts circuit J92–GJ.
Relay socket cavity With transmission in If voltage is missing, check for open in
M2–H3 to M2–G3. neutral, 12 ± 1.5 volts circuit J92APA, circuit A28B, Auto neutral
lamp or circuit A28–GC.
Relay socket cavity With shifter in neutral If voltage is missing, check for open in circuit J92AY,
M2–H3 to ground. and transmission in J92C123 or L92A123 Also check for short to ground
neutral, 12 ± 1.5 volts in circuits J92HM5, J92C123, L92A123, J92HM4
or J92AY. Insure signal from ECU is present.
If signal from ECU is missing, consider replacing the ECU. Refer to the Allison transmission manual.
The de-energized relay will pass the 12 volt neutral safety switch signal from ESC connector (4004) pin 15 to
illuminate the auto neutral light.
Ground for the relay coil is supplied from ground stud (4005).
The relay is energized by the 12 volt neutral start signal from the transmission ECU. This will turn off the auto
neutral light. It will only be illuminated when the transmission is in neutral and the shifter is not in neutral.
3.5. CRANK INHIBIT RELAY CIRCUITS

The crank inhibit relay insures there is no chance of cranking the engine when the transmission shift lever is
not in neutral. The relay contacts are installed in series with the starter switch circuits to the coil of the starter
relay. The relay is energized by the neutral start signal from the transmission ECU.
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A fault in the auto neutral light relay circuits may be present when the auto neutral warning light does not
illuminate when auto neutral is active. Problems in the auto neutral light relay circuits could be attributed to
open or short circuits or a failure in the transmission ECU.
Table 334 Crank Inhibit Relay Power Checks

Crank Inhibit Relay Socket (4002) Power Checks
Check with ignition on and crank inhibit relay (4002) removed.

Relay socket cavity With shifter in neutral and If voltage is missing, check for open in
M1–F4 to ground. transmission in neutral, circuit J92HM4, J92C123 or L92A123 Also
12 ± 1.5 volts check for short to ground in circuits J92HM5,
J92C123, L92A123, J92HM4 or J92AY. Insure
signal from ECU is present.
Relay socket cavity With transmission in neutral, If voltage is missing, check for open in
M1–F4 to M1–D3. 12 ± 1.5 volts circuit J17–GR1 to ground.
Relay socket cavity With shifter in neutral, If voltage is missing, check for open in circuit
M1–D4 to ground. transmission and key in start J17 or A17 to key switch circuits.
position, 12 ± 1.5 volts
Relay socket cavity With shifter in neutral, If voltage is missing, check for open or shorts
M1–D4 to M1–F3. transmission and key in start to ground in circuit J17SA, starter relay coil,
position, 12 ± 1.5 volts circuit J17S or starter circuits.
The relay is installed in between the key switch circuits and the starter relay circuits to insure the engine
cannot be cranked when the transmission is in gear.
Ground is supplied to the relay coil from ground stud (4005).
The relay is energized by the 12 volt neutral start signal from the transmission ECU when the shifter is in
neutral and the transmission is in neutral.
The energized relay will connect the key switch start circuits and the starter relay circuits to allow engine
cranking.

Refer to MD T-Bar Shift Control (See Figure 481, page 983), MD Push Button Shift Control (See Figure 482,
page 984) MD Transmission Harness (I6 Engine Shown) (See Figure 483, page 985), MD Transmission Wiring
(See Figure 484, page 986) and MD Transmission ECU Location (See Figure 485, page 987).
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4. LCT (ALLISON® 2000 SERIES™) TRANSMISSION

Discussion of the LCT (Allison 2000 Series) transmission In this section is limited to the transmission control
module (TCM) power circuits, data link connectivity, signals from the neutral safety back up (NSBU) switch
and circuits to the shift selector control. For detailed information on transmission diagnostics, refer to the
Allison service manual.

The LCT transmission interfaces with the vehicle electrical system via the transmission control module (TCM),
the neutral safety back up (NSBU) switch and the shift selector control.
The TCM communicates on the drivetrain 1939 data link to interface with the engine controller, electrical
system controller and the air ABS controller.
The NSBU, mounted on the transmission, is controlled by the gear select cable. It interfaces with the vehicle
electrical system to provide a neutral signal to the engine controller. It also provides voltage for the back-up
lights.
The shift selector has an integral economy switch. The switch will light when economy mode is selected.
4.2. DIAGNOSTICS
The ESC will log a DTC if communication with the TCM is lost.
The transmission control unit has its own diagnostic system which will turn on the “CHECK TRANS” lamp
when there is a detectable fault. Diagnostic codes can only be read with the Allison Transmission Diagnostic
Tool (ATDT) software. There are no provisions for flash codes. Refer to Allison troubleshooting manual
TS3192EN for details.
A problem in the neutral start circuits will prevent the engine from cranking. Refer to Engine Cranking. (See
ENGINE CRANKING, page 385)
Table 335 LCT Preliminary Check

2. On Are there any active Transmission Go to next Go to TCM Power and
DTC’s associated with communication step. Data Link Circuits.
the transmission? DTC is active. (See TCM POWER
Refer to Diagnostic AND DATA LINK
Trouble Codes. CIRCUITS, page 995)
(See DIAGNOSTIC
TROUBLE CODES
(DTC), page 995)
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Table 335 LCT Preliminary Check (cont.)

3. On Does the “CHECK Lamp turns off Go to next Refer to the applicable
TRANS” lamp turn off after vehicle is step. transmission service
after the vehicle is started. manual.
started.
4. On Do the back-up lights Back-up lights Go to next Go to Neutral And
come on when the come on when step. Back-Up Light
transmission is shifted in reverse. Circuits. (See
into reverse? NEUTRAL AND
BACK-UP LIGHT
CIRCUITS , page
998)
5. On Is the economy mode Economy Transmission Go to Shift Selector
indicator in the economy mode indicator circuits are Circuits. (See
switch illuminating when illuminates when functioning. SHIFT SELECTOR
economy is selected. economy mode CIRCUITS , page
is selected. 1000)

To display diagnostic codes, put the vehicle in diagnostic mode. Set the parking brake and turn the Ignition
key “ON”. Then press the Cruise “ON” switch and the Cruise “Resume” switch. If no diagnostic trouble

been received
4.4. TCM POWER AND DATA LINK CIRCUITS

A fault in the power or data link circuits to the TCM will be apparent when the instrument cluster display does
not correspond to the shift selector position and the check electrical system lamp is illuminated. Problems in the
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power and data link circuits can be caused by open or short circuits, a blown fuse, failed switch, a problem in
the ESC, a problem in circuits between the ESC and the solenoid module or a problem in the solenoid module.
Figure 487 TCM Power and Data Link Circuits—Always Refer to Circuit Diagram Book for Latest
Circuit Information
LOCATED IN BATTERY HARNESS
(7208) J1939 DATA LINK SPLICE CONNECTOR
LOCATED IN ENGINE HARNESS
(7305) GRAY ECU “J1” CONNECTOR
LOCATED ON ALLISON LCT TRANSMISSION CONTROL MODULE
(9255) TRANSMISSION ECU FEED FUSE CONNECTOR
(9260) BATTERY ECM NEGATIVE CONNECTOR
(9261) BATTERY ECM POSITIVE CONNECTOR
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Table 337 TCM Power and Data Link Checks

TCM Connector (7305) Power Checks


L13M3 to the NSBU.

L13M3 to the NSBU switch.
(7305), cavity 3 to ground. transmission feed fuse or open or short to ground
in circuit N14BB, N92A or L92#103.
TCM harness connector 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit
(7305), cavity 3 to cavity 5. N14–GA, N92–G, L92–G or L92#105.
TCM harness connector 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit
(7305), cavity 3 to cavity 1. N14–GA, N92–G, L92–G or L92#101.
TCM Connector (7305) Data Link Checks

TCM harness connector Approximately 2.5 If voltage is missing check for open or short to
(7305), cavity 29 to ground. volts. ground in (+) data link circuits between harness
connector and J1939 splice (7208).
TCM harness connector Approximately 2.5 If voltage is missing check for open or
(7305), cavity 32 to ground. volts. short to ground between harness connector
and J1939 splice (7208).
If voltages are correct and TCM is not operating correctly, refer to the Allison 2000 service manual .
Ignition voltage to TCM connector (7305) cavity 4 and 2 from the 10 amp transmission fuse in the engine
compartment PDC.
Battery voltage to TCM connector (7305) cavity 3 from the 10 amp transmission feed fuse in the battery
compartment.
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Ground for the TCM is supplied to TCM connector (7305) cavities 1 and 5 from the battery negative terminal.
The drivetrain data link is connected to TCM connector (7305) cavities 29, 31 and 32.
4.5. NEUTRAL AND BACK-UP LIGHT CIRCUITS

A shift cable connects the shift selector to the transmission gear select shaft. The NSBU is mounted on the
shaft. When the shaft is in the neutral position the neutral contacts off the NSBU switch should close. When
the shaft is in the reverse position, the back up light contacts of the NSBU should close.
A fault in the back-up circuits should be suspected when the back-up lights do not come on when the
transmission is shifted into reverse. Problems in the back–up light circuits can be caused by open or short
circuits, a blown fuse, or failed NSBU.
A fault in the neutral circuits should be suspected when the engine will not start. Problems in the neutral circuits
can be caused by open or short circuits, a blown fuse, a failed NSBU, or a problem in the engine controller.
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Figure 488 Neutral Safety Back Up (NSBU) Switch Circuits—Always Refer to Circuit Diagram Book
(4001) MINI FUSE BLOCK 10 AMP XMSN FUSE
(4001) MINI FUSE BLOCK 10 AMP BACKUP LAMPS FUSE
(4810) BACK UP LIGHT TURN / SIGNAL SPLICE CONNECTOR
(6007) ECM CONNECTOR (I6 ENGINE)
LOCATED ON I6 ENGINE
(7301) NEUTRAL SAFETY BACK UP (NSBU) SWITCH
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Table 338 Neutral And Back-Up Light Circuit Checks

NSBU Connector (7301) Power Checks

NSBU harness connector 12 ± 1.5 volts. If voltage is incorrect, check for blown 10A
(7301), cavity E to ground. transmission fuse or open or short to ground
in circuit J13M, L13M4 or L13M3.
NSBU harness connector 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit
(7301), cavity E to G. L17E to the engine controller.
NSBU harness connector 12 ± 1.5 volts. If voltage is incorrect, check for blown
(7301), cavity C to ground. 10A back up light fuse or open or short to
ground in circuit L71 or J71.
NSBU harness connector 12 ± 1.5 volts. If voltage is incorrect, check for open in
(7301), cavity C to F. circuit L71A or J71AA to the back up light
and turn signal splice 4810.
If voltages are correct, consider replacing NSBU switch. Refer to the Allison 2000 Service manual
Ignition voltage is supplied to the NSBU switch connector (7301), terminal E, neutral contacts from the 10 amp
transmission fuse in the engine compartment PDC.
When the transmission is shifted into neutral, the neutral switch will close supplying ignition voltage to the
engine controller. The engine controller will use this signal to enable the engine to crank.
Ignition voltage is supplied to the NSBU switch connector (7301), terminal C, back up light contacts from the
10 amp back up light fuse in the engine compartment PDC.
When the transmission is shifted into reverse, the back up light switch will close supplying ignition voltage to
power the back up lights.
4.6. SHIFT SELECTOR CIRCUITS

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Figure 489 LCT Dash Mounted Shift Selector

A shift cable connects the shift selector to the transmission gear select shaft.
The shift selector contains an economy switch used to enable the economy mode of the transmission. The
selector also contains a lock out solenoid used for some models that will prevent the selector from being
moved out of park unless the foot brake is applied.
When the economy switch in the shift selector is closed the signal ground from the TCM will be applied to the
economy mode enable input to the TCM. The switch will also illuminate the indicator in the switch.
A fault in the economy mode switch circuits should be suspected when the economy mode indicator does not
illuminate when economy mode is selected.
Problems in the economy mode circuits can be caused by open or short circuits, a blown fuse, or failure
in the TCM.
The Interlock for Shifter with Park Position feature will be controlled by the presence of the ignition signal,
service brake applied signal, and transmission in park signal.
When the ignition signal is present, the transmission is in the ’Park’ position, and the service brake is
depressed, the relay driver, which sinks current through the shifter interlock solenoid, will be activated and
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the shifter interlock solenoid will unlock. When the shifter interlock solenoid unlocks, the transmission can be
shifted out of the ’Park’ position.
If the ignition signal is present and a loss of J1939 data occurs from the transmission to the ESC, then the
relay driver that controls the shifter interlock solenoid will become active.
If the ignition signal is present and the service brake switch is defective or stuck, then the relay driver that
controls the shifter interlock solenoid will become active.
A fault in the selector circuits should be suspected when the economy switch doesn’t illuminate when it is
selected. Problems in the selector circuits can be caused by open or short circuits, a blown fuse, or failure in
the selector assembly.
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Figure 490 Shift Selector Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
LOCATED IN INSTRUMENT PANEL
(1012) CAB FUSE BLOCK F17 10 AMP FUSE
LOCATED IN CAB PDC
(1600) ELECTRICAL SYSTEM CONTROLLER
LOCATED ON CAB SIDE OF ELECTRICAL SYSTEM CONTROLLER
(1828) LCT TRANSMISSION SHIFTER SELECTOR CONNECTOR
LOCATED ON BACK OF LCT SHIFT SELECTOR
LOCATED ABOVE ELECTRICAL SYSTEM CONTROLLER
(7305) TRANSMISSION CONNECTOR
Table 339 Shift Selector Circuit Checks

Shift Selector Connector (1828) Power Checks

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Table 339 Shift Selector Circuit Checks (cont.)

Shift selector harness connector 12 ± 1.5 volts. If voltage is incorrect, check for blown
(1828), cavity C to ground. fuse F17 or open or short to ground
in circuit A92VA.
Shift selector harness connector 12 ± 1.5 volts. If voltage is incorrect, check for open in
(1828), cavity C to B. circuit A62–GC to ground splice (1003).
If voltages are correct and shift selector is not powered, consider replacing shift selector.
Power to the shift selector is provided to (1828) terminal C from cab fuse F17.
Ground for the shift selector is provided to (1828) terminal B from ground adapter (1003).
Ground from the ESC (1600) terminal 6 is provided to shift selector (1828) terminal D, when the ignition key is
on, the service brake pedal is depressed, and the transmission in park signal.
Figure 491 LCT Shift Control

1. ECONOMY MODE SWITCH
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Figure 492 LCT Transmission Harness

1. HARNESS TO TRANSMISSION
(4705) TRANSMISSION / DASH CONNECTOR
(7801) DRIVE TRAIN DATA LINK "Y" TO TRANSMISSION "Y"
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Figure 493 LCT Transmission Wiring

1. HARNESS TO TCM
(7208) TRANSMISSION DATA LINK CONNECTOR AND TERMINATOR
(7301) NSBU CONNECTOR
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Figure 494 LCT Transmission TCM Location

1. LCT TRANSMISSION CONTROL MODULE (TCM)
2. HARNESS TO TCM (7305)
3. HARNESS TO OUTPUT SPEED SENSOR (7600)
5. EATON® AUTOSHIFT™ TRANSMISSION

Discussion of the EATON AUTOSHIFT transmission In this section is limited to the transmission ECU power
circuits, power circuits to the shift selector control and drive train 1939 data link connectivity. For detailed
information on transmission diagnostics, refer to the appropriate EATON service manual.

The autoshift transmission interfaces with the vehicle electrical system via the ECU, the shift selector control,
back up light switch and an Eaton Autoshift relay.
The transmission communicates on the drivetrain 1939 data link to interface with the engine controller,
electrical system controller and the air ABS controller. The drivetrain 1939 data link is connected to the
shift control in the cab.
5.2. DIAGNOSTICS
The ESC will log a DTC if data link communication with the transmission shifter is lost.
The transmission has its own diagnostic system which will turn on the “SERVICE” lamp on the autoshift display
when there is a detectable fault. Diagnostic codes can be read with flash codes on the display. Refer to
the appropriate EATON service manual for details.
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Table 340 Autoshift Preliminary Check

2. On Does the autoshift Autoshift display Go to next Refer to Autoshift
display appear to have has power. step. selector Power
power? Circuits. (See
AUTOSHIFT
SELECTOR POWER
CIRCUITS, page
1009)
3. Off Are there any active Transmission Go to next Go to Autoshift
DTC’s associated with communication step. selector data link
the transmission? DTC is not circuits. (See
Refer to Diagnostic active. AUTOSHIFT
Trouble Codes. SELECTOR DATA
(See DIAGNOSTIC LINK CIRCUITS, page
TROUBLE CODES 1012)
(DTC), page 1008)
Go to Autoshift ECU
Power Circuits. (See
AUTOSHIFT ECU
POWER CIRCUITS,
page 1013)
Go to Autoshift
Relay Circuits. (See
AUTOSHIFT RELAY
CIRCUITS, page
1015)
4. Off Is the transmission Transmission Go to next Refer to the Eaton
warning light in the EGC warning lamp is step. Autoshift service
illuminated? not illuminated. manual.
5. On Do the back-up lights Back-up lights Transmission Go to Back-Up
come on when the come on when circuits are Autoshift Light
transmission is shifted in reverse. functioning. Circuits. (See
into reverse? Autoshift BACK-UP
Go to next LIGHT CIRCUITS,
step. page 1017)

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been received.
5.4. AUTOSHIFT SELECTOR POWER CIRCUITS

A fault in the power circuits to the Autoshift selector will be apparent when the autoshift display does not
respond to shift selections. Problems in the selector circuits could be attributed to open or short circuits, a
blown fuse, a failed EATON Autoshift relay or a failure in the selector assembly.
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Figure 495 Autoshift Selector Power Circuits—Always Refer to Circuit Diagram Book for Latest
Circuit Information
(1012) CAB FUSE BLOCK (EATON AUTOSHIFT RELAY)
(1013) CAB FUSE BLOCK #3, F29, 5 AMP FUSE
(7905) EATON AUTOSHIFT SELECTOR CONNECTOR
LOCATED ON AUTOSHIFT SELECTOR
(7906) EATON AUTOSHIFT DISPLAY CONNECTOR
LOCATED ON AUTOSHIFT DISPLAY
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Table 342 Autoshift Selector Power Checks

Autoshift Selector Power Connector (7905) Power Checks

Selector harness 12 ± 1.5 volts. If voltage is incorrect, check for blown 5A
connector (7905), cavity transmission fuse F29 or open or short to
C1 to ground ground in circuit A49E or A92Y.

A49C or A92R.
EATON Autoshift Relay Checks
Check with ignition on and EATON Autoshift relay removed.
Relay socket cavity A4 12 ± 1.5 volts. If voltage is incorrect, check for open or short
(relay 30) to ground. in circuit A49C to fuse F29.
Relay socket cavity C4 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit
(relay 86) to ground. A92DW to Autoshift selector (7905) cavity C3.
Relay socket cavity A4 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit
(relay 30) to A3 (relay 85. A92–GA to Autoshift selector (7905) cavity A3.
Relay socket cavity A4 12 ± 1.5 volts. If voltage is incorrect, check for open in circuit A17Q
(relay 30) to C3 (relay 87). to Autoshift selector (7905) cavity A2.
If voltages or circuits are correct and Autoshift selector is not powering up,
refer to the EATON Autoshift manual.
Autoshift display connector (7906) cavity 1 is supplied ignition voltage from fuse F29 in the cab PDC.
Autoshift selector connector (7905) cavity C1 is supplied ignition voltage from fuse F29 in the cab PDC.
EATON Autoshift relay, common terminal 30, is supplied Ignition voltage from fuse F29 in the cab PDC.
The autoshift relay is energized by signals from the selector. When the relay energizes it supplies ignition
voltage to the selector and to the clutch switch.
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5.5. AUTOSHIFT SELECTOR DATA LINK CIRCUITS

A fault in the data link circuits to the Autoshift selector will be apparent when communication DTC is active.
Problems in the data link circuits could be attributed to open or short circuits, or a failure in the selector
assembly.
Figure 496 Autoshift Selector Data Link Circuits—Always Refer to Circuit Diagram Book for Latest
Circuit Information
(1600) ELECTRICAL SYSTEM CONTROLLER (ESC) CONNECTOR
(1652) DRIVETRAIN J1939 EATON AUTOSHIFT SHIFTER CONNECTOR
LOCATED ON EATON AUTOSHIFT
(1657M) DRIVETRAIN J1939 TERM. RESISTOR CONNECTOR
LOCATED ON DASH PANEL
(7905) EATON AUTOSHIFT SELECTOR CONNECTOR
LOCATED ON AUTOSHIFT SELECTOR
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Table 343 Autoshift Selector Data Link Checks

Autoshift Selector Data Link Connector (7905) Voltage Checks

Selector harness connector Approximately 3 If voltage is missing, check for open or short
(7905), cavity G1 to ground volts. to ground in circuit A5AV(+).
Selector harness connector Approximately 3 If voltage is missing, check for open or short
(7905), cavity G2 to ground volts. to ground in circuit A5AV(-).
If voltages are correct and EATON Autoshift ECU communication DTC is still active, refer to
Drivetrain Data Link. (See DRIVETRAIN 1939 DATA LINK, page 60)
The drivetrain data link is connected to the EATON Autoshift selector connector (7905) cavities G1 and G2
from the J1939 EATON Autoshift shifter connector (1652).
5.6. AUTOSHIFT ECU POWER CIRCUITS

A fault in the power circuits to the autoshift ECU might be present when the autoshift display “SERVICE”
warning lamp illuminates. Problems in the ECU power circuits could be attributed to open or short circuits, a
blown fuse, or a failed ECU.
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Figure 497 Autoshift ECU Power Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
(4001) MINI FUSE BLOCK 30 AMP EATON AUTOSHIFT FUSE
(4006) GROUND STUD
LOCATED ON ENGINE
(7901) AUTOSHIFT ECU POWER
Table 344 ECU Power Checks

ECU Power Connector (7901) Power Checks

ECU power harness 12 ± 1.5 volts. If voltage is incorrect, check for blown 30A
connector (7901), cavity EATON autoshift fuse or open or short to
B to ground ground in circuit L14AW or J14AW.
ECU power harness 12 ± 1.5 volts. If voltage is incorrect, check for open in
connector (7901), cavity circuit L11–GAM or J11–GAM.
B to A
If voltages are correct and ECU is not operating correctly, refer to the EATON Autoshift service manual .
Battery voltage is supplied to ECU power connector (7901) cavity B from the 30 amp EATON Autoshift fuse in
the engine compartment PDC.
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Ground for the ECU is supplied to ECU power connector (7901) cavity A from the engine ground stud.
5.7. AUTOSHIFT RELAY CIRCUITS

The EATON Autoshift relay provides an input to the engine controller signalling that the transmission is in
neutral. The Autoshift selector will energize the relay when the transmission is in neutral. The energized relay
supplies 12 volts to the drive line disengagement signal (DDS) input to the engine controller. This signals
the engine controller that the transmission is not in gear causing the engine controller to provide a ground
to the starter relay coil.
A problem in the EATON Autoshift relay circuit could be attributed to open or short circuits, a blown fuse,
or a failed ECM.
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Figure 498 Eaton Autoshift Relay Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
(1012) CAB FUSE BLOCK (EATON AUTOSHIFT RELAY)
(1013) CAB FUSE BLOCK #3, F29, 5 AMP FUSE
LOCATED ABOVE ELECTRICAL SYSTEM CONTROLLER IN DASH PANEL
(4705) TRANSMISSION DASH CONNECTOR
(6020) V8 ECM CONNECTOR
(7800) ENGINE/TRANSMISSION CONNECTOR
LOCATED NEAR ENGINE CONTROLLER
(7905) AUTOSHIFT SELECTOR CONNECTOR
LOCATED BEHIND AUTOSHIFT SELECTOR
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Table 345 Autoshift Relay Circuit Voltage Check Chart

Autoshift Relay Circuit Voltage Checks
Check with ignition key on and autoshift relay removed.
Relay socket cavity A4 12 ± 1.5 volts. If voltage is incorrect, check for blown
(relay 30) to ground. fuse F29, short to ground or open in
circuit A49C to fuse F29.
Transmission in gear, relay 12 ± 1.5 volts. If voltage is incorrect, check for open or
socket cavity C4 (relay short to ground in circuit A92DW or missing
86) to ground. voltage from Autoshift selector.
Transmission in gear, relay 12 ± 1.5 volts. If voltage is incorrect, check for open in
socket cavity C4 (relay 86) circuit A92–GA or missing ground signal
to cavity A3 (relay 85). from Autoshift selector.
Relay socket cavity C3 (relay 12 ± 1.5 volts. If voltage is incorrect, check for open or short
87) to cavity A3 (relay 85). to ground in circuit A17C, A17Q, J17C, L17C,
or K17E to engine controller. Also check for
missing voltage from engine controller.
Refer to the Eaton Autoshift Relay Circuits.
When the key switch is in the ignition position and the transmission is in neutral, battery voltage will be applied
to the relay common contact 30 and normally closed contact 87 to the ECM DDS circuit.
The autoshift selector provides ground to the relay coil contact 85.
When the transmission is shifted out of neutral, the autoshift selector will apply 12 volts from connector (7905)
terminal C3 to relay coil contact 86. This will energize the relay.
The energized relay will remove voltage from the ECM DDS circuits. This will cause the ECM to disable
engine cranking.
5.8. AUTOSHIFT BACK-UP LIGHT CIRCUITS

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Figure 499 Back Up Switch Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
LOCATED ON AUTOSHIFT TRANSMISSION


Back up switch harness 12 ± 1.5 volts. If voltage is incorrect, check for blown
connector (7502), cavity 10A transmission fuse or open or short
A to ground. to ground in circuit J71 or L71.
Back up switch harness 12 ± 1.5 volts. If voltage is incorrect, check for open
connector (7502), cavity in circuit L71A or J71A to back up/turn
A to cavity B. signal splice (4810).
Also check circuits through back

up lamps to ground.
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Refer to the applicable engine manual for troubleshooting circuits from the engine controller to the sensor
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Circuit Function
Figure 500 Transmission Vehicle Speed Sensor Circuits—Always Refer to Circuit Diagram Book
(6007) I6 ENGINE ECM BLACK CONNECTOR
(6012), (6021) V8 ENGINE ECM CONNECTOR
(7609) TRANSMISSION SPEED SENSOR
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POINTS SPEC.
1. Off Inspect VSS for damage Go to
before performing this next
test. step.
2. Off Disconnect engine VSS, 600 Go to Replace the vehicle
harness (7609) from terminal to 800 next speed sensor (VSS).
VSS and use test leads A to B. ohms. step.
to measure resistance
between terminal A and
B of sensor connector.
3. Off Measure resistance to VSS, >100K Go to Replace the vehicle
ground at both sensor term. 1 ohms. next speed sensor (VSS).
terminals. and 2 to step.
ground.
4. Off Block front wheels and Go to
place rear axles on floor next
stands. step.
5. Off Use AC voltmeter with Go to
sufficient length leads to next
avoid personal contact step.
wheels during test.
Connect meter leads to
test leads.
6. Off Run engine at VSS, >2.0 VSS Replace the VSS.
idle speed, with across volts AC checks
transmission in high terminals. good.
gear. Measure voltage
across the two sensor
terminals.
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Figure 501 Eaton Autoshift Shift Selector

1. SHIFT CONTROL BUTTONS
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Figure 502 Eaton Autoshift Transmission Harness

1. TRANSMISSION/DASH CONNECTOR (4705)
3. DRIVETRAIN 1939 DATA LINK TERMINATING RESISTOR (DATA LINK CONNECTION
FOR TRANSMISSION IS AT SELECTOR)
4. TO TRANSMISSION HARNESS
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Figure 503 Eaton Autoshift Manual Transmission Wiring

1. FROM ENGINE HARNESS
2. HARNESS TO BACK UP SWITCH (7502)
(7609) TRANSMISSION SPEEDOMETER SENSOR
(7901) ECU POWER CONNECTOR
6. EATON® LIGHTNING™ TRANSMISSION

Discussion of the EATON LIGHTNING transmission In this section is limited to the transmission ECU power
circuits, power circuits to the shift Lightning ECM and drive train 1939 data link connectivity. For detailed
information on transmission diagnostics, refer to the appropriate EATON service manual.

The lightning transmission interfaces with the vehicle electrical system via the Eaton Lightning ECM, the shift
control lever, back up light switch and the engine ECU.
The transmission communicates on the drivetrain 1939 data link to interface with the engine controller,
electrical system controller and the air ABS controller. The drivetrain 1939 data link is connected to the
shift control in the cab.
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6.2. DIAGNOSTICS
The ESC will log a DTC if data link communication with the transmission shifter is lost.
The transmission has its own diagnostic system which will turn on the “SERVICE” lamp on the lightning display
when there is a detectable fault. Diagnostic codes can be read with flash codes on the display. Refer to
the appropriate EATON service manual for details.
Table 348 Lightning Preliminary Check

2. On Does the lightning Lightning display Go to next Refer to Lightning
display appear to have has power. step. Shifter Power Circuits.
power? (See Lightning Shifter
POWER CIRCUITS,
page 1026)
3. Off Are there any active Transmission Go to next Go to Lightning data
DTC’s associated with communication step. link circuits. (See
the transmission? DTC is not Lightning DATA LINK
Refer to Diagnostic active. CIRCUITS, page
Trouble Codes. 1028)
(See DIAGNOSTIC
TROUBLE CODES Go to Lightning
(DTC), page 1025) ECU Power Circuits.
(See Lightning ECU
POWER CIRCUITS,
page 1030)
4. Off Is the transmission Transmission Go to next Refer to the Eaton
warning light in the EGC warning lamp is step. Lightning service
illuminated? not illuminated. manual.
5. On Do the back-up lights Back-up lights Transmission Go to Lightning
come on when the come on when circuits are Back-Up Light
transmission is shifted in reverse. functioning. Circuits. (See
into reverse? LIGHTNING
Go to next BACK-UP LIGHT
step. CIRCUITS, page
1031)

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been received.
6.4. LIGHTNING SHIFTER POWER CIRCUITS

A fault in the power circuits to the Lightning shifter will be apparent when the lightning display does not respond
to shift selections. Problems in the shifter circuits could be attributed to open or short circuits, a blown fuse,
a failed EATON Lightning jumper or a failure in the shifter assembly.
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Figure 504 Lightning Shifter/ECM Power Circuits—Always Refer to Circuit Diagram Book for Latest
Circuit Information
(4001) MINI FUSE BLOCK, F1 & F2, EATON LIGHTNING FUSES
(4005) BOTTOM DASH GROUND
LOCATED IN CAB DASH
(4713) DASH/TRANSMISSION CONNECTOR
(7105) EATON LIGHTNING SHIFTER JUMPER CONNECTOR
LOCATED ON LIGHTNING TRANSMISSION
(7106) EATON LIGHTNING ECM POWER CONNECTOR
Table 350 Lightning Shifter Power Checks

Lightning Shifter Jumper Connector (7105) Power Checks

Shifter Jumper harness 12 ± 1.5 volts. If voltage is incorrect, check for open or short
connector (7105), cavity to ground in circuit L92EA.
A to ground
connector (7105), cavity to ground in circuit L92EB.
C to ground
connector (7105), cavity to ground in circuit L92EC.
B to ground
If voltages or circuits are correct and Lightning Shifter is not powering up, refer to
the EATON Lightning service manual.
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Lightning Shifter jumper connector (7105) cavity A is supplied voltage from Lightning ECM power connector
(7106) cavity D3.
Lightning Shifter jumper connector (7105) cavity C is supplied voltage from Lightning ECM power connector
(7106) cavity E3.
Lightning Shifter jumper connector (7105) cavity B is supplied voltage from Lightning ECM power connector
(7106) cavity F3.
6.5. LIGHTNING DATA LINK CIRCUITS

A fault in the data link circuits to the Lightning ECM will be apparent when communication DTC is active.
Problems in the data link circuits could be attributed to open or short circuits, or a failure in the shifter assembly.
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Figure 505 Lightning Data Link Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
(1600) ELECTRICAL SYSTEM CONTROLLER (ESC) CONNECTOR
(4103) DASH CONNECTOR
LOCATED IN ENGINE COMPARTMENT ABOVE ESC
(6013) CAT ECM CONNECTOR
(7106) EATON LIGHTNING ECM CONNECTOR
(7107) DRIVETRAIN J1939 TERM. RESISTOR CONNECTOR
LOCATED ON DASH PANEL
(7800) ENGINE/TRANSMISSION CONNECTOR
LOCATED NEAR ENGINE CONTROLLER
Table 351 Lightning Data Link Checks

Lightning ECM Data Link Connector (7106) Voltage Checks

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Table 351 Lightning Data Link Checks (cont.)

Lightning ECM harness Approximately 3 If voltage is missing, check for open or short
connector (7106), cavity volts. to ground in circuit L5E(+).
C1 to ground
Lightning ECM harness Approximately 3 If voltage is missing, check for open or short
connector (7106), cavity volts. to ground in circuit L5E(-).
C2 to ground
If voltages are correct and EATON Lightning ECU communication DTC is still active, refer to
Drivetrain Data Link. (See DRIVETRAIN 1939 DATA LINK, page 60)
The drivetrain data link is connected to the EATON Lightning ECM connector (7106) cavities C1 and C2 from
the J1939 EATON Lightning shifter jumper connector (7105).
6.6. LIGHTNING ECU POWER CIRCUITS

A fault in the power circuits to the lightning ECU might be present when the lightning display “SERVICE”
warning lamp illuminates. Problems in the ECU power circuits could be attributed to open or short circuits, a
blown fuse, or a failed ECU.
Figure 506 Lightning ECU Power Circuits—Always Refer to Circuit Diagram Book for Latest Circuit
Information
(4001) MINI FUSE BLOCK, F1 & F2, EATON LIGHTNING FUSES
(4005) BOTTOM DASH GROUND
LOCATED IN CAB DASH
(4713) DASH/TRANSMISSION CONNECTOR
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Table 352 ECU Power Checks

ECU Power Connector (7106) Power Checks

ECU power harness 12 ± 1.5 volts. If voltage is incorrect, check for blown
A1 to ground ground in circuit L14AA or J14AA.

L14AA or J14AA.
ECU power harness 12 ± 1.5 volts. If voltage is incorrect, check for blown
B1 to ground ground in circuit L13AA or J13AA.

L13AA or J13AA.
connector (7106), cavity circuit L11–GB or J11–GB.
A1 to A3
connector (7106), cavity circuit L11–GC or J11–GC.
B1 to B3
If voltages are correct and ECU is not operating correctly, refer to the EATON Lightning service manual .
Battery voltage is supplied to ECU power connector (7106) cavity B1 from the EATON Lightning fuse F2 in
Battery voltage is supplied to ECU power connector (7106) cavity A1 from the EATON Lightning fuse F1 in
Ground for the ECU is supplied to ECU power connector (7106) cavity A3 from the engine ground stud.
Ground for the ECU is supplied to ECU power connector (7106) cavity B3 from the engine ground stud.
6.7. LIGHTNING BACK-UP LIGHT CIRCUITS

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Figure 507 Lightning Back Up Switch Circuits—Always Refer to Circuit Diagram Book for Latest
Circuit Information
(7503) BACK UP LIGHT CONNECTOR


Back up switch harness 12 ± 1.5 volts. If voltage is incorrect, check for blown
connector (7502), cavity 10A transmission fuse or open or short
A to ground. to ground in circuit J71 or L71.
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Table 353 Back Up Light Circuit Checks (cont.)

Back up switch harness 12 ± 1.5 volts. If voltage is incorrect, check for open
connector (7502), cavity in circuit L71A or J71A to back up/turn
A to cavity B. signal splice (4810).

up lamps to ground.
Back Up Light Connector (7503) Power Checks

Back up light harness 12 ± 1.5 volts. If voltage is incorrect, check for blown
connector (7503), cavity transmission fuse or open or short to
A to ground. ground in circuit J71D or L71D.
Back up light harness 12 ± 1.5 volts. If voltage is incorrect, check for open
connector (7503), cavity in circuit L71E, J71E, N71 or R71 to
A to cavity B. stop, tail & turn signal (9303A).

up lamps to ground.
Ignition voltage is supplied to the back up light connector (7503), terminal A, from the back up light fuse in the
engine compartment power distribution center (PDC).

Refer to the applicable engine manual for troubleshooting circuits from the engine controller to the sensor
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Circuit Function
Figure 508 Lightning Transmission Vehicle Speed Sensor Circuits—Always Refer to Circuit Diagram
Book for Latest Circuit Information
(6013) ENGINE ECM CONNECTOR
(7612) EATON SPEED SENSOR
(7613) TRUCK SPEED SENSOR
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POINTS SPEC.
1. Off Inspect VSS for damage Go to
before performing this next
test. step.
2. Off Disconnect engine VSS, 600 Go to Replace the vehicle
harness (7613) from terminal to 800 next speed sensor (VSS).
VSS and use test leads A to B. ohms. step.
to measure resistance
between terminal A and
B of sensor connector.
3. Off Measure resistance to VSS, >100K Go to Replace the vehicle
ground at both sensor term. 1 ohms. next speed sensor (VSS).
terminals. and 2 to step.
ground.
4. Off Block front wheels and Go to
place rear axles on floor next
stands. step.
5. Off Use AC voltmeter with Go to
sufficient length leads to next
avoid personal contact step.
wheels during test.
Connect meter leads to
test leads.
6. Off Run engine at VSS, >2.0 VSS Replace the VSS.
idle speed, with across volts AC checks
transmission in high terminals. good.
gear. Measure voltage
across the two sensor
terminals.
6.9. TRANSMISSION OIL TEMPERATURE SENSOR

Refer to Transmission Oil Temperature Gauge (See TRANSMISSION OIL TEMPERATURE GAUGE, page
266) for troubleshooting procedures.
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Figure 509 Eaton Lightning Transmission Harness

1. TRANSMISSION/DASH CONNECTOR (4713)
3. DRIVETRAIN 1939 DATA LINK TERMINATING RESISTOR
4. TO TRANSMISSION HARNESS
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Figure 510 Eaton Lightning Manual Transmission Wiring

1. FROM ENGINE HARNESS
2. (7105) EATON LIGHTNING SHIFTER JUMPER
3. (7703) TRANSMISSION OIL TEMP SENSOR
4. (7612) EATON SPEED SENSOR
5. (7106) EATON LIGHTNING ECM
6. (7502) BACK UP LIGHT SWITCH
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13 HEATER AND AIR CONDITIONER (HVAC) 1039
Table of Contents
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1040 13 HEATER AND AIR CONDITIONER (HVAC)
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13 HEATER AND AIR CONDITIONER (HVAC) 1041
Refer to theHVAC service manual section S160254 for information on the HVAC electrical system.
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1042 13 HEATER AND AIR CONDITIONER (HVAC)
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14 DIAGNOSTIC TROUBLE CODES (DTC) 1043
Table of Contents
1. DIAGNOSTICS. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . ..1045
1.1. ON-LINE DIAGNOSTICS.. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . . .. . .. . ..1045
Check Electrical System Light.. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..1045
Gauges. . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . ..1045
Flashing Switch Lamps. . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . . .. .1045
1.2. OFF- LINE DIAGNOSTICS. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . ..1045
1.3. OFF-BOARD DIAGNOSTICS. .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . ..1046
1.4. DIAGNOSTIC TROUBLE CODE (DTC) LIST. . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . ..1047
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1044 14 DIAGNOSTIC TROUBLE CODES (DTC)
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1. DIAGNOSTICS
1.1. ON-LINE DIAGNOSTICS
On-line Diagnostics are automatically performed while the key is in the accessory or ignition position. Any
faults encountered will be entered in the active diagnostic trouble code list.
Check Electrical System Light
The check electrical system light will turn on for 5 seconds after the gauge sweep, on power up. If there is an
active fault the light will stay on for an extra minute. If a fault occurs during operation of the vehicle the light will
come on for 1 minute. This will alert the driver that an active fault exists.
If the check electrical system light comes on and stays on after the gauge sweep is completed there is an
active diagnostic trouble code (DTC) or there is no communication between the EGC and ESC.
If the EGC loses communication with the ESC or engine controller the check electrical system light will turn on
and stay on. The light will be accompanied by 10 short beeps from the EGC alarm.
Gauges
Gauge warning lamps will illuminate and be accompanied by the appropriate alarm when gauge readings
exceed preset limits. Gauges will also respond when the ESC is not receiving input from sensors.
Flashing Switch Lamps
Several features activated by switches in the switch packs are programmed to flash the indicator lamp in the
switch when there is a switch malfunction or a malfunctioning feature.
Not all switches will respond the same. Generally a malfunctioning switch will cause the indicator to flash at a
slow rate. A problem with the feature will cause the indicator to flash at a fast rate. Refer to the section on the
particular feature for details on how the switch indicator responds to failures.
1.2. OFF- LINE DIAGNOSTICS

NOTE – Diagnostic messages from the engine controller, antilock brake system or transmission are not
displayed on the electronic gauge cluster (EGC) digital display.
Placing the electronic gauge cluster (EGC) in diagnostic mode will allow the EGC to display active and
previously active diagnostic messages from the electrical system controller (ESC) or from the EGC itself.
To engage the diagnostic mode turn the Ignition key ON (or in accessory), then press the Cruise ON switch
and the Cruise RESUME switch simultaneously. If no faults are present, the gauge cluster display will read NO
FAULTS. If faults are present, the gauge cluster will display a message with the number of faults, followed by
the diagnostic codes. Refer to Diagnostic Trouble Code Display. This procedure will also initiate the diagnostic
flash codes for the engine controller and the hydraulic ABS controller. The display will show each DTC for
10 seconds, then automatically scroll to the next entry and continue to cycle through the faults. To manually
cycle through the fault list, press the cluster SELECT/RESET button.
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Figure 511 Diagnostic Trouble Code Display

1. BYTE 7 FIELD
2. BYTE 8 FIELD
3. SPN FIELD
4. FMI FIELD
5. ACTIVE/PREVIOUSLY ACTIVE STATUS INDICATOR
6. COMPILED FORMAT OF DIAGNOSTIC TROUBLE CODE
Diagnostic trouble codes (DTC) will end with an “A” while the code is active. The code will remain active as
long as the feature affected is active and the fault is present. If the feature is turned off or the fault is removed,
the trouble code will be moved to the “previously active” list and the code will end with a “P”. For example:
when the work light is turned on and there is an open an active circuit fault code (611 14 11 1 A) will be
logged. When the light is turned off the code will become previously active. The fault still exists, but the
code will not go active until the light is turned on.
While in the diagnostic mode, previously active diagnostic trouble codes may be cleared by turning the left turn
signal ON and pressing the Cruise ON switch and the Cruise SET switch simultaneously.
Diagnostic codes for the engine controller and hydraulic ABS controller will not be cleared with this procedure.
To exit the diagnostic mode, cycle the key switch or release the parking brake.
1.3. OFF-BOARD DIAGNOSTICS

The diagnostic service tool, running the INTUNE software, can be used to view and clear ESC diagnostic
trouble codes (DTC). Other diagnostic software can be used to view and clear engine controller, ABS and
transmission diagnostic trouble codes. Refer to the applicable supplier service manual for information on their
diagnostic software and tools.
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1.4. DIAGNOSTIC TROUBLE CODE (DTC) LIST

Table 355 Diagnostic Trouble Code (DTC) List
ESC
Byte Byte Connector
SPN FMI 7 8 and Pin # Condition Description/Comments/Probable Cause(s)
70 14 1 0 1600/4004/ Connector #4004 Pin 32 MD — Air Powered Park Brake is stuck.
Bus 1602
16/32/16 Connector #1600 & 1602 Pin 16 Bus Redundant Door
Occurs when the park brake switch does not match the spring
apply air release (SAAR) chamber travel sensor. This indicates
the park brake cannot be applied or cannot be released.
Refer to Service Park Brake warning lamp (See SERVICE PARK

BRAKE WARNING LAMP, page 220)in the Electronic Gauge
Cluster section of this manual.
Refer to Air Actuated Park Brake (See Diagnostic Trouble

Codes, page 816)in the Chassis Accessories section of this
manual.
70 14 1 1 1600/4004/ Connector #4004 Pin 32 MD — Air Powered Park Brake is not
Bus 1602 operating.
16/32/16
Connector #1600 & 1602 Pin 16 Bus Redundant Door
Occurs when the park brake switch is not set within 5 seconds
of the receipt of the Park as the requested gear. This failure
would indicate a failure in the auto apply relay or in the air lines
between the auto apply relay and the Park Brake switch.
Refer to Service Park Brake warning lamp (See SERVICE PARK

BRAKE WARNING LAMP, page 220)in the Electronic Gauge
Refer to Air Actuated Park Brake (See Diagnostic Trouble

Codes, page 816)in the Chassis Accessories section of this
manual.
597 14 1 0 Hyd or Air Brake switch is stuck in the open or closed position
n/4091 –
1600 Air Occurs if the wheel based vehicle speed increases from 0 kph to
w/4091 — 72 kph two times without the brake switch opening or decreases
4004 Bus – from 72 kph to 0 kph two times without the brake switch closing.
1602/33
Defective brake switch
Refer to hydraulic brake switch (See HYDRAULIC BRAKE

SWITCH INPUTS TO ESC, page 912) or air brake switch (See
AIR BRAKE SWITCH INPUTS TO ESC, page 915) in the Light
Systems section of this manual.
S082504
Table 355 Diagnostic Trouble Code (DTC) List (cont.)

ESC
Byte Byte Connector
597 14 2 0 Hyd or Air Brake switch inputs do not match
n/4091 –
1600 Air Occurs if the comparison of the inputs indicates a mismatch in
w/4091 — the analog and digital signals.
4004 Bus –
1602/33 Occurs if there is a high resistance in the wire harness, defective
brake switch or a defective Electronic System Controller (ESC).

598 14 1 0 1600/17 Upper Clutch Switch stuck in the open or closed position
Occurs if the vehicle speed increases from 0 kph to 72 kph

without a change in state of the clutch switch.
Defective upper clutch switch
Refer to Clutch Switch(See CLUTCH SWITCH, page 564) in the

Cab Features section of this manual.
610 14 1 0 1600/12 Ignition feed error.
Loss of Ignition feed for 10 seconds while the engine is running
Refer to ESC Power and Ground. (See ESC POWER AND

GROUND, page 91)
610 14 2 0 1600/2 Accessory feed error.
Loss of Accessory feed for 10 seconds while the engine is

running
Refer to ESC Power and Ground. (See ESC POWER AND

GROUND, page 91)
611 14 1 1 1601/G Connector #1601 Pin #G Mirror heat under current
Connector #1601 Pin #G Bus Left Front and Rear Red Flashers
under current
The Current from this output is below 0.5 A
Open circuit
Refer to Heated Mirrors in the Cab Features section of this

manual.
S082504

ESC
Byte Byte Connector
611 14 1 2 1601/G Connector #1601 Pin #G Mirror heat over current
over current
The output behaves like a 20 amp type III circuit breaker.
Short to ground or overload

manual.
611 14 1 3 1601/G Connector #1601 Pin #G Mirror heat less than normal low
less than normal low current but more than open circuit

manual.
611 14 1 4 1601/G Connector #1601 Pin #G Mirror heat greater than normal high
greater than normal high current and less than fusing current

manual.
611 14 1 6 1601/G Connector #1601 Pin #G Mirror heat has current flow when
has current flow when output commanded off

manual.
S082504

ESC
Byte Byte Connector
611 14 2 1 4008/Bus Connector #4008 Pin #A Solenoid power under current
1604 A
Connector # 1604 Pin #A Bus (Left Front Amber PWL) under
current
The current from this output is below 0.5 A
Open circuit
Refer to Air Solenoid Modules(See ESC– SOLENOID POWER

CIRCUIT, page 737) in the Chassis Features section of this
manual.
611 14 2 2 4008/Bus Connector #4008 Pin #A Solenoid power over current
1604 A
Connector # 1604 Pin #A Bus (Left Front Amber PWL) over
current
Refer to ESC-Solenoid Power Circuit(See ESC– SOLENOID

POWER CIRCUIT, page 737) in the Chassis Features section of
this manual.
611 14 2 3 4008/Bus Connector #4008 Pin #A Solenoid power less than normal low
1604 A current but more than open circuit
Connector # 1604 Pin #A Bus (Left Front Amber PWL) less than
normal low current but more than open circuit

this manual.
611 14 2 4 4008/Bus Connector #4008 Pin #A Solenoid power greater than normal
1604 A high current and less than fusing current
Connector #1604 Pin #A (Left Front Amber PWL) greater than

normal high current and less than fusing current

this manual.
S082504

ESC
Byte Byte Connector
611 14 2 6 4008/Bus Connector #4008 Pin #A Solenoid power has current flow when
1604 A output commanded off
Connector #4008 Pin #A BUS (Left Front Amber PWL) has

current flow when output commanded off

this manual.
611 14 3 1 4007/Bus Connector #4007 Pin #A Fog light / Spare 1 under current
1603 A
Connector #1603 Pin #A Bus Right Front and Rear Red Flashers
under current
Open circuit
Refer to Fog Lights(See FOG LIGHT SYSTEM, page 870) in the

Light Systems section of this manual.
611 14 3 2 4007/Bus Connector #4007 Pin #A Fog light / Spare 1 over current
1603 A
over current

611 14 3 3 4007/Bus Connector #4007 Pin #A Fog light / Spare 1 less than normal
1603 A low current but more than open circuit
less than normal low current but more than open circuit

S082504

ESC
Byte Byte Connector
611 14 3 4 4007/Bus Connector #4007 Pin #A Fog light / Spare 1 greater than normal
1603 A high current and less than fusing current
greater than normal high current and less than fusing current

611 14 3 6 4007/Bus Connector #4007 Pin #A Fog light / Spare 1 has current flow
1603 A when output commanded off
has current flow when output commanded off

611 14 4 1 4007/Bus Connector #4007 Pin #H Park light under current
1603 H
Open circuit
Refer to Marker, Park and Tail Lamps(See MARKER, PARK

AND TAIL LAMPS, page 844) in the Light Systems section of
this manual.
611 14 4 2 4007/Bus Connector #4007 Pin #H Park light over current
1603 H

this manual.
611 14 4 3 4007/Bus Connector #4007 Pin #H Park light less than normal low current
1603 H but more than open circuit

this manual.
S082504

ESC
Byte Byte Connector
611 14 4 4 4007/Bus Connector #4007 Pin #H Park light greater than normal high
1603 H current and less than fusing current

this manual.
611 14 4 6 4007/Bus Connector #4007 Pin #H Park light has current flow when output
1603 H commanded off

this manual.
611 14 5 1 4007/Bus Connector #4007 Pin #D Low beam under current
1603 D
The current from this output is below 0.5 A
Open circuit
Refer to Headlight System(See HEADLIGHT SYSTEM, page

878) in the Light Systems section of this manual.
611 14 5 2 4007/Bus Connector #4007 Pin #D Low beam over current
1603 D
The output behaves like a 20 amp type I circuit breaker

611 14 5 3 4007/Bus Connector #4007 Pin #D Low beam less than normal low current
1603 D but more than open circuit

611 14 5 4 4007/Bus Connector #4007 Pin #D Low beam greater than normal high
1603 D current and less than fusing current

611 14 5 6 4007/Bus Connector #4007 Pin #D Low beam has current flow when
1603 D output commanded off
Refer to Headlight System in the Light Systems section of this

manual. (See HEADLIGHT SYSTEM, page 878)
S082504

ESC
Byte Byte Connector
611 14 6 1 4008/Bus Connector #4008 Pin #F Wiper power under current
1604 F
Connector #1604 Pin #F Bus (Wiper power) output under current
Open circuit
Refer to Wiper Motor Circuits (See WIPER MOTOR CIRCUITS,

page 551) in the Cab Feature section of this manual.
611 14 6 2 4008/Bus Connector #4008 Pin #F Wiper power over current
1604 F
Connector #1604 Pin #F Bus (Wiper power) output over current

611 14 6 3 4008/Bus Connector #4008 Pin #F Wiper power less than normal low
1604 F current but more than open circuit
Connector #1604 Pin #F Bus (Wiper power) less than normal

low current but more than open circuit

611 14 6 4 4008/Bus Connector #4008 Pin #F Wiper power greater than normal high
1604 F current and less than fusing current
Connector #1604 Pin #F Bus (Wiper power) greater than normal

high current and less than fusing current

611 14 6 6 4008/Bus Connector #4008 Pin #F Wiper power has current flow when
1604 F output commanded off
Connector #1604 Pin #F Bus (Wiper power) has current flow


S082504

ESC
Byte Byte Connector
611 14 7 1 4007/Bus Connector #4007 Pin #G High beam under current
1603 G
Open circuit

611 14 7 2 4007/Bus Connector #4007 Pin #G High beam over current
1603 G

611 14 7 3 4007/Bus Connector #4007 Pin #G High beam less than normal low
1603 G current but more than open circuit

611 14 7 4 4007/Bus Connector #4007 Pin #G High beam greater than normal high
1603 G current and less than fusing current

611 14 7 6 4007/Bus Connector #4007 Pin #G High beam has current flow when
1603 G output commanded off

611 14 9 1 4008/Bus Connector #4008 Pin #G A/C Clutch under current
1604 G
Connector #1604 Pin #G (Left Rear Amber Flashers) under
current
Open circuit
Refer to AC Compressor Circuits in the HVAC service manual

section S16025.
S082504

ESC
Byte Byte Connector
611 14 9 2 4008/Bus Connector #4008 Pin #G A/C Clutch over current
1604 G
Connector #1604 Pin #G (Left Rear Amber Flashers) over
current
The output behaves like a 10 Amp type III circuit breaker.

section S16025.
611 14 9 3 4008/Bus Connector #4008 Pin #G A/C Clutch less than normal low
1604 G current but more than open circuit
Connector #1604 Pin #G (Left Rear Amber Flashers) less than


section S16025.
611 14 9 4 4008/Bus Connector #4008 Pin #G A/C Clutch greater than normal high
1604 G current and less than fusing current
Connector #1604 Pin #G (Left Rear Amber Flashers) greater

than normal high current and less than fusing current

section S16025.
611 14 9 6 4008/Bus Connector #4008 Pin #G A/C Clutch has current flow when
1604 G output commanded off
Connector #1604 Pin #G (Left Rear Amber Flashers) has current

flow when output commanded off

section S16025.
611 14 10 1 1601/C Connector #1601 Pin #C Dome light under current
Connector #1601 Pin #C (BUS Right Rear Amber PWL) under

current
Open circuit
Refer to dome light circuits (See DOME LIGHT CIRCUITS, page

S082504

ESC
Byte Byte Connector
611 14 10 2 1601/C Connector #1601 Pin #C Dome light over current
Connector #1601 Pin #C (BUS - Right Rear Amber PWL) over

current

611 14 10 3 1601/C Connector #1601 Pin #C Dome light less than normal low
Connector #1601 Pin #C (BUS - Right Rear Amber PWL) less

than normal low current but more than open circuit

611 14 10 4 1601/C Connector #1601 Pin #C Dome light greater than normal high
Connector #1601 Pin #C (BUS - Right Rear Amber PWL) greater


611 14 10 6 1601/C Connector #1601 Pin #C Dome light has current flow when
Connector #1601 Pin #C (BUS - Right Rear Amber PWL) has

current flow when output commanded off

S082504

ESC
Byte Byte Connector
611 14 11 1 4007/Bus Connector #4007 Pin #F Work light under current
1603 F
Connector #1603 Pin #F (Right Front Amber PWL’s) under
current
Open circuit
Refer to Work Lights (See WORK LIGHT CIRCUIT OUTPUTS

FROM ESC, page 944) in the Light Systems section of this
manual.
611 14 11 2 4007/Bus Connector #4007 Pin #F Work light over current
1603 F
Connector #1603 Pin #F (Right Front Amber PWL’s) over current

manual.
611 14 11 3 4007/Bus Connector #4007 Pin #F Work light less than normal low current
1603 F but more than open circuit
Connector #1603 Pin #F (Right Front Amber PWL’s) less than


manual.
611 14 11 4 4007/Bus Connector #4007 Pin #F Work light greater than normal high
1603 F current and less than fusing current
Connector #1603 Pin #F (Right Front Amber PWL’s) greater


manual.
S082504

ESC
Byte Byte Connector
611 14 11 6 4007/Bus Connector #4007 Pin #F Work light has current flow when output
1603 F commanded off
Connector #1603 Pin #F (Right Front Amber ’s) has current flow

manual.
611 14 12 1 4007/Bus Connector #4007 Pin #E Electric horn under current
1603 E
Open circuit
Refer to Electric Horn (See ELECTRIC HORN CIRCUIT

OUTPUTS FROM ESC, page 500) in the Cab Feature section of
this manual.
611 14 12 2 4007/Bus Connector #4007 Pin #E Electric horn over current
1603 E

this manual.
611 14 12 3 4007/Bus Connector #4007 Pin #E Electric horn less than normal low
1603 E current but more than open circuit

this manual.
611 14 12 4 4007/Bus Connector #4007 Pin #E Electric horn greater than normal high
1603 E current and less than fusing current

this manual.
611 14 12 6 4007/Bus Connector #4007 Pin #E Electric horn has current flow when
1603 E output commanded off

this manual.
S082504

ESC
Byte Byte Connector
611 14 13 1 4008/Bus Connector #4008 Pin #C Left rear turn lamp under current
1604 C
Connector #1604 Pin #C (Left rear turn lamp) under current
Blown bulb or open circuit
Refer to Rear Stop/Turn Signal/Hazard Light Outputs From ESC

(See REAR STOP/TURN SIGNAL/HAZARD LIGHT OUTPUTS
manual.
611 14 13 2 4008/Bus Connector #4008 Pin #C Left rear turn lamp over current
1604 C
Connector #1604 Pin #C (Left rear turn lamp) over current
Refer to Rear Stop/Turn Signal/Hazard Light Outputs From

ESC(See REAR STOP/TURN SIGNAL/HAZARD LIGHT
OUTPUTS FROM ESC, page 924) in the Light Systems section
of this manual.
611 14 13 3 4008/Bus Connector #4008 Pin #C Left rear turn lamp less than normal
1604 C low current but more than open circuit
Connector #1604 Pin #C (Left rear turn lamp) less than normal

of this manual.
611 14 13 4 4008/Bus Connector #4008 Pin #C Left rear turn lamp greater than normal
1604 C high current and less than fusing current
Connector #1604 Pin #C (Left rear turn lamp) greater than


of this manual.
S082504

ESC
Byte Byte Connector
611 14 13 6 4008/Bus Connector #4008 Pin #C Left rear turn lamp has current flow
1604 C when output commanded off
Connector #1604 Pin #C (Left rear turn lamp) has current flow

of this manual.
611 14 14 1 4008/Bus Connector #4008 Pin #B Right rear turn lamp under current
1604 B
Connector #1604 Pin #B (Right rear turn lamp) under current

of this manual.
611 14 14 2 4008/Bus Connector #4008 Pin #B Right rear turn lamp over current
1604 B
Connector #1604 Pin #B (Right rear turn lamp) over current

of this manual.
611 14 14 3 4008/Bus Connector #4008 Pin #B Right rear turn lamp less than normal
1604 B low current but more than open circuit
Connector #1604 Pin #B (Right rear turn lamp) less than normal

of this manual.
S082504

ESC
Byte Byte Connector
611 14 14 4 4008/Bus Connector #4008 Pin #B Right rear turn lamp greater than
1604 B normal high current and less than fusing current
Connector #1604 Pin #B (Right rear turn lamp) greater than


of this manual.
611 14 14 6 4008/Bus Connector #4008 Pin #B Right rear turn lamp has current flow
1604 B when output commanded off
Connector #1604 Pin #B (Right rear turn lamp) has current flow

of this manual.
611 14 15 1 4007/Bus Connector #4007 Pin #C Left front turn lamp under current
1603 C
Blown bulbs or open circuit

ESC(See FRONT TURN SIGNAL/HAZARD AND SEPARATE
TURN SIGNAL LIGHT OUTPUTS FROM ESC, page 919) in the
611 14 15 2 4007/Bus Connector #4007 Pin #C Left front turn lamp over current
1603 C
Refer to left front circuits (See FRONT TURN SIGNAL/HAZARD

AND SEPARATE TURN SIGNAL LIGHT OUTPUTS FROM
ESC, page 919) in the Light Systems section of this manual.
611 14 15 3 4007/Bus Connector #4007 Pin #C Left front turn lamp less than normal
1603 C low current but more than open circuit

S082504

ESC
Byte Byte Connector
611 14 15 4 4007/Bus Connector #4007 Pin #C Left front turn lamp greater than normal
1603 C high current and less than fusing current

611 14 15 6 4007/Bus Connector #4007 Pin #C Left front turn lamp has current flow
1603 C when output commanded off

611 14 16 1 4007/Bus Connector #4007 Pin #B Right front turn lamp under current
1603 B
Refer to right front circuits (See FRONT TURN SIGNAL/HAZARD

611 14 16 2 4007/Bus Connector #4007 Pin #B Right front turn lamp over current
1603 B

611 14 16 3 4007/Bus Connector #4007 Pin #B Right front turn lamp less than normal
1603 B low current but more than open circuit

611 14 16 4 4007/Bus Connector #4007 Pin #B Right front turn lamp greater than
1603 B normal high current and less than fusing current

S082504

ESC
Byte Byte Connector
611 14 16 6 4007/Bus Connector #4007 Pin #B Right front turn lamp has current flow
1603 B when output commanded off

612 14 0 1 1600/2 Connector #1600 Pin #2 Ignition out of range low
Shorted to ground or open
Refer to ESC Power and Ground.(See ESC POWER AND

GROUND, page 91)
612 14 0 2 1600/2 Connector #1600 Pin #2 Ignition out of range high
Shorted high
Refer to ESC Power and Ground.(See ESC POWER AND

GROUND, page 91)
612 14 1 1 1600/33 Connector #1600 Pin #33 Brake switch out of range low
Shorted to ground.

612 14 1 2 1600/33 Connector #1600 Pin #33 Brake switch out of range high
Shorted high or open circuit

612 14 2 1 1600/17 Connector #1600 Pin #17 Upper Clutch Switch out of range low
Shorted to ground.
Refer to Clutch Switch (See CLUTCH SWITCH, page 564) in

the Cab Features section of this manual.
S082504

ESC
Byte Byte Connector
612 14 2 2 1600/17 Connector #1600 Pin #17 Upper Clutch Switch out of range high
Refer to Clutch Switch (See CLUTCH SWITCH, page 564) in

the Cab Features section of this manual.
612 14 3 1 1600/16 Connector #1600 Pin #16 Secondary Air Sensor / Spare out of
range low
Short to ground, open circuit
Secondary Air Pressure Gauge (See SECONDARY AIR

PRESSURE GAUGE, page 292)
612 14 3 2 1600/16 Connector #1600 Pin #16 Secondary Air Sensor / Spare out
of range high
Shorted high
Secondary Air Pressure Gauge (See SECONDARY AIR

612 14 4 1 1600/15 Connector #1600 Pin #15 Primary Air Sensor / Auxiliary Air
Sensor out of range low
Short to ground, open circuit
For vehicles with air brakes, refer to Primary Air Pressure Gauge
(See PRIMARY AIR PRESSURE GAUGE, page 283).
For vehicles with hydraulic brakes, refer to Auxiliary Air Pressure

Gauge (See AUXILIARY AIR PRESSURE GAUGE, page 300).
612 14 4 2 1600/15 Connector #1600 Pin #15 Primary Air Sensor / Auxiliary Air
Sensor out of range high
Shorted high
For vehicles with air brakes, refer to Primary Air Pressure Gauge
(See PRIMARY AIR PRESSURE GAUGE, page 283).
For vehicles with hydraulic brakes, refer to Auxiliary Air Pressure

Gauge (See AUXILIARY AIR PRESSURE GAUGE, page 300).
S082504

ESC
Byte Byte Connector
612 14 5 1 1600/10 Connector #1600 Pin #10 Analog cruise switch input out of
range low
Connector #1600 Pin #10 (Bus - Diags/flashers/Entrance Door

Input) out of range low
Shorted to ground or open circuit
Refer to Cruise Control .
The EGC cannot be put in diagnostic mode when there is a fault

in these circuits. The INTUNE software must be used to view
this DTC.
612 14 5 2 1600/10 Connector #1600 Pin #10 Analog cruise switch input out of
range high
Connector #1600 Pin #10 (Bus - Diags/flashers/Entrance Door

Input) out of range high
Shorted high
Refer to Cruise Control .
The EGC cannot be put in diagnostic mode when there is a fault

in these circuits. The INTUNE software must be used to view
this DTC.
612 14 23 1 4004/Bus Connector #4004/Bus 1602 Pin #4 Fuel level sensor out of
1602 4 range low
Bus — Not Used
This code is associated with a short to ground on the fuel level

sensor on the storage tank for dual tank vehicles.
Shorted to ground.
Refer to Fuel Transfer System (See FUEL TRANSFER PUMP

SYSTEM, page 687) in the Chassis Features section of this
manual.
S082504

ESC
Byte Byte Connector
1602 4 range high
Bus — Not Used
This code is associated with a short to accessory or open

circuit on the fuel level sensor on the storage tank for dual tank
vehicles.
Refer to Fuel Transfer System (See FUEL TRANSFER PUMP

SYSTEM, page 687) in the Chassis Features section of this
manual.
612 14 24 1 4004/Bus Connector #4004 Pin #23 Hydraulic ABS warning lamp input
1602 23 out of range low
Connector #1602 Pin #23 (Bus Wheel Chair Lift Solenoid) open
circuit
Open circuit
Refer to ABS indicator (See ABS WARNING LAMP, page 225)

in the Electronic Gauge Cluster section of this manual.
612 14 24 2 4004/Bus Connector #4004 Pin #23 Hydraulic ABS warning lamp input
1602 23 out of range high
Connector #1602 Pin #23 (Bus Wheel Chair Lift Solenoid)

shorted to battery
Shorted high
Refer to ABS indicator (See ABS WARNING LAMP, page 225)

in the Electronic Gauge Cluster section of this manual.
1602 5 range low
This code is associated with a short to ground on the fuel level

sensor on the draw tank for both single tank and dual tank
vehicles.
Shorted to ground.
Refer to Fuel Level Gauge (See FUEL LEVEL GAUGE, page

258) in the Electronic Gauge Cluster section of this manual.
S082504

ESC
Byte Byte Connector
1602 5 range high.
This code is associated with a short to accessory or open circuit

on the fuel level sensor on the draw tank for both single tank
and dual tank vehicles.
Shorted high or open circuit.
Refer to Fuel Level Gauge (See FUEL LEVEL GAUGE, page

258) in the Electronic Gauge Cluster section of this manual.
612 14 27 1 4004/Bus Connector #4004/Bus 1602 Pin #6 Outlet HVAC thermistor out
1602 6 of range low
Bus — Not Used
Shorted to ground.
Refer to AC Refrigerant Thermistors in the HVAC

Troubleshooting in S16025.
612 14 27 2 4004/Bus Connector #4004/Bus 1602 Pin #6 Outlet HVAC thermistor out
1602 6 of range high
Bus — Not Used
Thermistor open circuit.

612 14 29 1 4004/Bus Connector #4004/Bus 1602 Pin #7 Inlet HVAC thermistor out of
1602 7 range low
Bus — Not Used
Shorted to ground.

S082504

ESC
Byte Byte Connector
612 14 29 2 4004/Bus Connector #4004/Bus 1602 Pin #7 Inlet HVAC thermistor out
Bus — Not Used
Thermistor open circuit.

612 14 30 1 4004/Bus Connector #4004/Bus 1602 Pin #27 Switched 5 volt sensor
1602 27 supply out of range low
Shorted to ground or open circuit
All air gauges and air brake switches will be inoperative.
Refer to ESC Switched 5 Volt Sensor Supply. (See ESC

SWITCHED 5 VOLT SENSOR SUPPLY, page 93)
612 14 30 2 4004/Bus Connector #4004/Bus 1602 Pin #27 Switched 5 volt sensor
1602 27 supply out of range high
Shorted high
All air gauges and air brake switches will be inoperative.
Refer to ESC Switched 5 Volt Sensor Supply. (See ESC

SWITCHED 5 VOLT SENSOR SUPPLY, page 93)
612 14 31 1 4004/Bus Connector #4004/Bus #1602 Pin #8 (MD)HVAC high side
1602 8 pressure sensor out of range low
Connector #1602 Pin #8 (Bus Crossing gate disable) out of

range low
Short to ground or open circuit
Refer to AC Pressure Transducer in the HVAC Troubleshooting

in S16025.
Refer to Bus Crossing gate in the BUS Troubleshooting in

S08290.
S082504

ESC
Byte Byte Connector
612 14 31 2 4004/Bus Connector #4004/Bus #1602 Pin #8 (MD)HVAC high side
1602 8 pressure sensor out of range high
Connector #1602 Pin #8 (Bus Crossing gate disable) out of

range high
Shorted high
Refer to AC Pressure Transducer in the HVAC Troubleshooting

in S16025.
Refer to Bus Crossing gate in the BUS Troubleshooting in

S08290.
612 14 32 1 4004/Bus Connector #4004/Bus #1602 Pin #1 Rear Axle Oil Temperature
1602 1 out of range low
Bus — Not Used
Shorted to ground or open circuit.
Refer to Rear-Rear Axle Temperature Gauge(See REAR-REAR

AXLE OIL TEMPERATURE GAUGE, page 272).
612 14 32 2 4004/Bus Connector #4004/Bus #1602 Pin #1 Rear Axle Oil Temperature
1602 1 out of range high
Bus — Not Used
Shorted high.
Refer to Rear-Rear Axle Temperature Gauge(See REAR-REAR

AXLE OIL TEMPERATURE GAUGE, page 272) .
612 14 33 1 4004/Bus Connector #4004/Bus #1602 Pin #10 Engine Oil
1602 10 Temperature/Power Park Brake out of range low
Bus — Not Used
Refer to Engine Oil Temperature Gauge(See ENGINE OIL

TEMPERATURE GAUGE, page 248) in the Electronic Gauge
Refer to Air Application Gauge(See AIR APPLICATION GAUGE,

page 318) in the Electronic Gauge Cluster section of this
manual.
S082504

ESC
Byte Byte Connector
612 14 33 2 4004/Bus Connector #4004/Bus #1602 Pin #10 Engine Oil
1602 10 Temperature/Power Park Brake out of range high
Bus — Not Used
Shorted high
Refer to Engine Oil Temperature Gauge(See ENGINE OIL

TEMPERATURE GAUGE, page 248) in the Electronic Gauge

manual.
612 14 34 1 4004/Bus Connector #4004/Bus 1602 Pin #2 Forward Rear Axle
1602 2 Temperature out of range low
Bus — Not Used
Shorted to ground.
Refer to Forward-rear axle temperature gauge (See

FORWARD-REAR AXLE OIL TEMPERATURE GAUGE, page
277)
612 14 35 1 4004/Bus Connector #4004/Bus 1602 Pin #13 (Brake Application Air) out
1602 13 of range low
Bus — Not Used

manual.
612 14 35 2 4004/Bus Connector #4004/Bus 1602 Pin #13 (Brake Application Air) out
Bus — Not Used
Shorted high

manual.
S082504

ESC
Byte Byte Connector
612 14 36 1 4004/Bus Connector #4004/Bus 1602 Pin #3 (Transmission Oil
1602 3 Temp/Spare) out of range low
Shorted to ground.
Refer to Transmission Oil Temperature Gauge (See

TRANSMISSION OIL TEMPERATURE GAUGE, page 266)
613 14 1 1 N/A HVAC Control Head air inlet fault
This is a motor fault in the evaporator module. This motor

controls the door in the evaporator module duct.
Motor in the wrong position or jammed.
Refer to Recirculation Motor in the HVAC service manual section

S16025.
613 14 1 2 N/A HVAC Control Head hot/cold temp. mix control fault
This is a motor fault in the heater module. This motor controls

the door in the heater module/blower scroll.
Refer to Temperature Actuator in the HVAC service manual

section S16025.
613 14 1 3 N/A HVAC Control Head mode control fault.
This is a motor fault in the kinematic network. This motor

controls the doors in the kinematic network of the heater module.
Refer to Mode Actuator in the HVAC service manual section

S16025.
613 14 1 4 N/A HVAC Control Head multiple motor faults.
2 or more motor faults.
Refer to HVAC Control Head in the HVAC service manual

section S16025.
S082504

ESC
Byte Byte Connector
613 14 1 5 N/A HVAC Control Head diagnostic circuit loss of communication
with the ESC.
Open circuit, short to ground or shorted high.
Refer to HVAC Control Head in the HVAC service manual

section S16025.
613 14 1 6 N/A AC service soon
At the current operating ambient temperature the system has

lost enough charge that service should be performed to insure
continued AC performance.
Refer to HVAC Diagnostics in the HVAC service manual section

S16025.
613 14 1 7 N/A AC service now - low charge

lost so much charge that the compressor must be shut off to
prevent damage to it or other system components.

S16025.
613 14 1 8 N/A AC service now - very low charge

lost so much charge that the compressor must be shut off to
prevent damage to it or other system components.

S16025.
613 14 1 9 N/A AC service now - burst pipe
An almost complete loss of charge has occurred due to pipe or

other component rupture. The compressor is shut off so that
no damage will occur.

S16025.
S082504

ESC
Byte Byte Connector
613 14 1 10 N/A AC service now - fan problem/clogged pipe
At the current operating ambient temperature the engine fan isn’t

working, one of the AC lines has become plugged or the system
is over-charged. The compressor is shut off to prevent damage.

S16025.
613 14 1 11 N/A AC service now - compressor failure
The compressor is not functioning

S16025.
613 14 1 12 N/A AC service now - rapid cycling
The compressor clutch is cycling faster than once every 15

seconds. The compressor is not allowed to operate.

S16025.
614 14 1 1 1600/ Electronic Gauge Cluster #1 checksum error fixed by reteach.
34,35,36
The configuration checksum in the cluster did not match
the teach/reteach checksum in the ESC. This situation was
corrected by the teach/reteach operation.
Refer to EGC section.

614 14 1 2 1600/ Electronic Gauge Cluster #1 checksum error could not be fixed.
34,35,36
The configuration checksum in the cluster did not match the
teach/reteach checksum in the ESC. This situation could not be
Defective cluster

614 14 23 1 1600/ Electronic Gauge Cluster #1 checksum error fixed by reteach.
34,35,36
The configuration checksum in the cluster did not match
S082504

ESC
Byte Byte Connector
614 14 23 2 1600/ Electronic Gauge Cluster #1 checksum error could not be fixed.
34,35,36
The configuration checksum in the cluster did not match the
Defective cluster

614 14 40 1 1600/ Auxiliary Gauge Switchpack #1 checksum error fixed by reteach.
34,35,36
The configuration checksum in the AGSP did not match
Refer to the AGSP Preliminary System Check (See AGSP

PRELIMINARY SYSTEM CHECK, page 162) section of this
manual.
614 14 40 2 1600/ Auxiliary Gauge Switchpack #1 checksum error could not be
34,35,36 fixed.
The configuration checksum in the AGSP did not match the

Defective AGSP

manual.
625 14 5 0 1600/ Switch Pack #4 not communicating with the ESC (Lower half
29,30 of 12 pack)
The ESC sets the status of the switches in switch pack #4 to

there default values.
Switch data link fault.
Refer to the Switch Pack Module section of this manual. (See

SWITCH PACK MODULES, page 125)
S082504

ESC
Byte Byte Connector
625 14 5 17 1600/ Switch Pack #4 Switch #1, microswitch inputs are in an invalid
29,30 state. Both microswitches are not depressed.
The ESC sets the status of switch pack #4 switch #1 to its

default value.
Switch actuator

29,30 state. Both microswitches are depressed.

default value.
Faulty microswitch

29,30 state. Top microswitch depressed, bottom microswitch not
depressed.

default value.
Switch actuator

29,30 state. Top microswitch not depressed, bottom microswitch
depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector
625 14 5 21 1600/ Switch Pack #4 Switch #1. The switch should be empty but one
29,30 or both microswitches is pressed.
The ESC sets the status of Switch Pack #4 Switch #1 to its

default value.
Switch actuator or faulty microswitch.


default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator


default value.


default value.
Switch actuator


default value.
Faulty microswitch

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.


default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.

S082504

ESC
Byte Byte Connector

default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.


default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator


default value.

625 14 6 0 1600/ Switch Pack #3 not communicating with the ESC (Upper half
29,30 of 12 pack)

there default values
Switch data link fault


default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.

S082504

ESC
Byte Byte Connector

default value.
Switch actuator


default value.
Faulty microswitch

depressed.
Switch actuator

depressed.
Switch actuator


default value.

S082504

ESC
Byte Byte Connector

default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.


default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator


default value.


default value.
Switch actuator


default value.
Faulty microswitch

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.


default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.

S082504

ESC
Byte Byte Connector
625 14 7 0 1600/ Switch pack #2 not communicating with the ESC
29,30


default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator


default value.


default value.
Switch actuator


default value.
Faulty microswitch

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.


default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.

S082504

ESC
Byte Byte Connector

default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.


default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator


default value.


default value.
Switch actuator


default value.
Faulty microswitch

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.

625 14 15 0 1600/ Switch pack #1 not communicating with the ESC
29,30

S082504

ESC
Byte Byte Connector

default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.


default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator


default value.


default value.
Switch actuator


default value.
Faulty microswitch

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.


default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator


default value.

S082504

ESC
Byte Byte Connector

default value.
Switch actuator


default value.
Faulty microswitch

depressed.

default value.
Switch actuator

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector

default value.


default value.
Switch actuator


default value.
Faulty microswitch
Switch actuator

depressed.

default value.
Switch actuator

S082504

ESC
Byte Byte Connector
depressed.

default value.
Switch actuator


default value.

625 14 64 0 1600/ Front passenger side Door Pod not communicating with the ESC
29,30
The status message from the door pod has not been received
by the ESC
Refer to the Front Power Windows and Locks section of this

manual.
625 14 64 7 1600/ Front passenger side Door Pod window motor failure
29,30
The window motor drive circuit is not functioning
This could be a short in the window motor, an open in the

window motor or a jammed window.

manual.
S082504

ESC
Byte Byte Connector
625 14 64 8 1600/ Front passenger side Door Pod door lock motor failure
29,30
The Door Lock Actuation Solenoid is not functioning
This could be a short in the solenoid, open in the solenoid, or a

jammed solenoid.

manual.
625 14 64 9 1600/ Front passenger side Door Pod module failure
29,30
A failure has occurred in the Door Pod module circuitry.
Defective door pod.

manual.
625 14 65 0 1600/ Rear passenger side Door Pod not communicating with the ESC
29,30
by the ESC
Refer to the Crew Cab Rear Power Windows And Locks section
of this manual.
625 14 65 7 1600/ Rear passenger side Door Pod window motor failure
29,30

of this manual.
625 14 65 8 1600/ Rear passenger side Door Pod door lock motor failure
29,30

jammed solenoid.
of this manual.
S082504

ESC
Byte Byte Connector
625 14 65 9 1600/ Rear passenger side Door Pod module failure
29,30
Defective door pod.
of this manual.
625 14 66 0 1600/ Rear driver side Door Pod not communicating with the ESC
29,30
by the ESC
of this manual.
625 14 66 7 1600/ Rear drivers side Door Pod window motor failure
29,30

of this manual.
625 14 66 8 1600/ Rear drivers side Door Pod door lock motor failure
29,30

jammed solenoid.
of this manual.
625 14 66 9 1600/ Rear drivers side Door Pod module failure
29,30
Defective door pod
of this manual.
S082504

ESC
Byte Byte Connector
625 14 130 0 1600/ Front drivers side Door Pod not communicating with the ESC
29,30
by the ESC

manual.
625 14 130 7 1600/ Front drivers side Door Pod window motor failure
29,30


manual.
625 14 130 8 1600/ Front drivers side Door Pod door lock motor failure
29,30

jammed solenoid.

manual.
625 14 130 9 1600/ Front drivers side Door Pod module failure
29,30
Defective door pod

manual.
627 14 1 1 4010/ A ESC power supply #1 open circuit
Open Circuit
Refer to the ESC Power and Ground(See ESC POWER AND

GROUND, page 91) section of this manual.
S082504

ESC
Byte Byte Connector
639 14 0 240 1600/ Engine retarder torque not being communicated from the ECM
34,35,36 or transmission retarder torque not being communicated from
Allison WTEC transmission
PGN 61440–SA 15 or 16
Refer to the appropriate Allison manual or engine diagnostic

manual.
Refer to the Transmission section of this manual.

639 14 1 240 1600/ ABS controller not communicating with the ESC
34,35,36
PGN 61441–SA 11
Refer to the Air ABS Power and Data Link section of this manual.
(See AIR ABS POWER AND DATA LINK CIRCUITS, page 637)
639 14 2 240 1600/ Electronic transmission controller communication has not been
34,35,36 received
PGN 61442–SA 3

639 14 3 240 1600/ Accelerator position not communicated to the ESC
34,35,36
PGN 61443–SA 0
Refer to information for the engine in this vehicle in Engine

section of this manual.
639 14 4 240 1600/ Engine speed not communicated to the ESC
34,35,36
PGN 61444–SA 0

639 14 5 240 1600/ Current gear, range inhibit and check transmission lamps not
34,35,36 communicated to the ESC.
PGN 61445–SA 3
Refer to the applicable transmission manual for this vehicle.
S082504

ESC
Byte Byte Connector
639 14 8 240 1600/ Electronic pressure mode indicator not communicated to the
34,35,36 ESC
PGN 61448–SA 0

639 14 33 239 1600/ 34, EGC not communicating with the ESC or AGSP not
35, 36 communicating with the ESC
PGN 61148–DA 33 —SA 23 or 40
Refer to EGC Power and Data Link Troubleshooting. (See EGC

POWER AND DATA LINK CIRCUITS, page 164)
639 14 82 254 1600/ Pyrometer Ammeter not communicating to the ESC
34,35,36
PGN 65106–SA 10
Refer to information for the Pyrometer Ammeter module (PAM)

in this vehicle in Chassis Features section of this manual.
639 14 192 254 1600/ Fuel filter status not communicated to the ESC
34,35,36
PGN 65216–SA 00
Refer to information for the Fuel filter in this vehicle in Chassis

Features section of this manual.
639 14 202 254 1600/ Engine Lamp information not communicated to the ESC
34,35,36
PGN 65226–SA 0

639 14 228 254 1600/ Wait to start lamp information not communicated to the ESC
34,35,36
PGN 65252–SA 0

S082504

ESC
Byte Byte Connector
639 14 230 253 1600/ Full Power Park Brake information not communicating to the
34,35,36 ESC
PGN 64998–SA 08
Refer to information for the Full Power Park Brake in this vehicle
in Chassis Features section of this manual.
Refer to Full Power Park Brake in the Full Power Park Brake
639 14 241 254 1600/ Cruise control enable, active, state and vehicle speed not
34,35,36 communicated to the ESC
PGN 65265–SA 0

639 14 250 254 1600/ Brake message is not being communicated to the ESC
34,35,36
PGN 65274–SA 08
Refer to information for the brake in this vehicle in Chassis

Features section of this manual.
Refer to Full Power Brake in the Full Power Brake

639 14 251 254 1600/ Retarder overheat lamp information not communicated to the
34,35,36 ESC
PGN 65275–SA 3
Refer to the applicable manual for the transmission on this

vehicle.

639 14 255 254 1600/ Water in fuel indicator not communicating to the ESC
34,35,36
PGN 65279–SA 0
Refer to information for the Water in fuel indicator in this vehicle

in Chassis Features section of this manual.
S082504

ESC
Byte Byte Connector
1231 14 0–255 3 4004/Bus Unconfigured Source Address
1602 34,
35,36 Something with the source address in Byte 7 is broadcasting on
the data link and the ESC is not configured to expect it.
Unexpected or incorrectly addressed module is on the data link.
Refer to the Remote Power Module(See REMOTE POWER

MODULE, page 767) section of this manual.
1231 14 34 1 4004/Bus RASM #1 not communicating with the ESC
1602 34,
35,36 Failed Source Address/Message Time-out
PGN 65441–SA 34
Drivetrain J1939 data link, an improperly addressed RASM

module, or a missing RASM module that the ESC is expecting
Refer to the Air Solenoid (7–Pack)(See REMOTE AIR

SOLENOID MODULE (7–PACK), page 756) section of this
manual.
1231 14 34 2 4004/Bus More than one RASM responds back as RASM #1
1602 34,
35,36 Multiple Source Address
PGN 65441–SA 234

manual.
1231 14 209 1 4004/Bus Remote engine speed control module is not communicating
1602 34, with the ESC
35,36
Failed Source Address/Message Time-out
PGN 65441–SA 234
Drivetrain J1939 data link, an improperly addressed RESCM

module, or a missing RESCM module that the ESC is expecting
Refer to Remote Engine Speed Control Module(See REMOTE

AIR SOLENOID MODULE (7–PACK), page 756).
S082504

ESC
Byte Byte Connector
1231 14 209 2 4004/Bus More than one Remote engine speed control module with the
1602 34, same source address is responding to the ESC.
35,36
Multiple Source Address
PGN 65441–SA 234

ENGINE SPEED CONTROL MODULE (RESCM), page 418).
1231 14 225 1 4004/Bus RPM #1 not communicating with the ESC
1602 34,
PGN 65313–SA 225
Drivetrain J1939 data link, an improperly addressed RPM

module, or a missing RPM module that the ESC is expecting

1231 14 225 2 4004/Bus More than one RPM responds back as RPM #1
1602 34,
PGN 65313–SA 225

1602 34,
PGN 65313–SA 226


S082504

ESC
Byte Byte Connector
1602 34,
PGN 65313–SA 226

1602 34,
PGN 65313–SA 228


1602 34,
PGN 65313–SA 228

1602 34,
PGN 65313–SA 231


1602 34,
PGN 65313–SA 231

S082504

ESC
Byte Byte Connector
1231 14 234 1 4004/Bus RASM #2 not communicating with the ESC
1602 34,
PGN 65441–SA 234
Drivetrain J1939 data link, an improperly addressed RASM

module, or a missing RASM module that the ESC is expecting

manual.
1231 14 234 2 4004/Bus More than one RASM responds back as RASM #2
1602 34,
PGN 65441–SA 234

manual.
1542 14 1 1 4009/ A ESC power supply #2 open circuit
Open Circuit
Refer to the ESC Power and Ground(See ESC POWER AND

GROUND, page 91) section of this manual.
1557 0 1 1 N/A ESC internal fault software main loop time exceeded.
There are too many features and the main loop is exceeding its
maximum execution time. Truck may work partially or not at all.
This indicates ESC is incapable of handling this configuration.
Software configuration too big.
Refer to the Electrical System Controller(See ELECTRICAL

SYSTEM CONTROLLER, page 85) section of this manual.
1705 14 101 3 N/A EGC gauge location 1 (tachometer) out of range high
Data for this gauge is above the value that the gauge can
display. For example: a value exceeding the gauge maximum
scale value.
Refer to the Electronic Gauge Cluster(See Table 23, page 146)

S082504

ESC
Byte Byte Connector
1705 14 101 4 N/A EGC gauge location 1 (tachometer) out of range low
Data for this gauge is below the minimum value the gauge can
display. For example: the lowest scale value on the gauge.
Refer to Tachometer (See TACHOMETER, page 255)

1705 14 101 5 N/A EGC gauge location 1 (tachometer) sensor fault
There is a problem with the sensor that provides the data for
this gauge.

1705 14 101 6 N/A EGC gauge location 1 (tachometer) data unavailable
The data that this gauge displays should be, but is not available
at this time.

1705 14 102 3 N/A EGC gauge location 2 (speedometer) out of range high
scale value.
Refer to Speedometer (See SPEEDOMETER, page 252)

1705 14 102 4 N/A EGC gauge location 2 (speedometer) out of range low

1705 14 102 5 N/A EGC gauge location 2 (speedometer) sensor fault
this gauge.

1705 14 102 6 N/A EGC gauge location 2 (speedometer) data unavailable
at this time.
S082504

ESC
Byte Byte Connector
1705 14 103 3 N/A EGC gauge location 3 (engine coolant temperature) out of range
high
scale value.
Refer to Engine Coolant Temperature Gauge. (See ENGINE

COOLANT TEMPERATURE GAUGE, page 242)
1705 14 103 4 N/A EGC gauge location 3 (engine coolant temperature) out of range
low

1705 14 103 5 N/A EGC gauge location 3 (engine coolant temperature) sensor fault
this gauge.

1705 14 103 6 N/A EGC gauge location 3 (engine coolant temperature) data
unavailable
at this time.

1705 14 104 3 N/A EGC gauge location 4 out of range high
scale value.
The gauge in this location is optional.

S082504

ESC
Byte Byte Connector
1705 14 104 4 N/A EGC gauge location 4 out of range low
The gauge in this location can be any optional gauge.

1705 14 104 5 N/A EGC gauge location 4 sensor fault
this gauge.

1705 14 104 6 N/A EGC gauge location 4 data unavailable
at this time.

1705 14 105 3 N/A EGC gauge location 5 (oil pressure) out of range high
scale value.
Refer to Engine Oil Pressure Gauge. (See ENGINE OIL

1705 14 105 4 N/A EGC gauge location 5 (oil pressure) out of range low

S082504

ESC
Byte Byte Connector
1705 14 105 5 N/A EGC gauge location 5 (oil pressure) sensor fault
this gauge.

1705 14 105 6 N/A EGC gauge location 5 (oil pressure) data unavailable
at this time.

scale value.


this gauge.

S082504

ESC
Byte Byte Connector
at this time.

1705 14 107 3 N/A EGC gauge location 7 (fuel level) out of range high
scale value.
Refer to Fuel Level Gauge. (See FUEL LEVEL GAUGE, page

258)
1705 14 107 4 N/A EGC gauge location 7 (fuel level) out of range low

258)
1705 14 107 5 N/A EGC gauge location 7 (fuel level) sensor fault
this gauge.

258)
1705 14 107 6 N/A EGC gauge location 7 (fuel level) data unavailable
at this time.

258)
S082504

ESC
Byte Byte Connector
On vehicles with air brakes this is the primary air gauge.
On vehicles with hydraulic brakes this can be any optional gauge
scale value.


this gauge.

at this time.

S082504

ESC
Byte Byte Connector
1705 14 109 3 N/A EGC gauge location 9 (volts) out of range high
scale value.
Refer to Voltmeter. (See VOLTMETER, page 239)

1705 14 109 4 N/A EGC gauge location 9 (volts) out of range low

1705 14 109 5 N/A EGC gauge location 9 (volts) sensor fault
this gauge.

1705 14 109 6 N/A EGC gauge location 9 (volts) data unavailable
at this time.

On vehicles with air brakes this is the secondary air gauge.
scale value.

S082504

ESC
Byte Byte Connector

this gauge.

at this time.

1705 14 150 1 N/A ESC not communicating with the EGC.
Loss of communication in excess of 10 seconds.
Drivetrain J1939 data link.

S082504

ESC
Byte Byte Connector
1705 14 150 2 N/A Engine Controller not communicating with the EGC.
Refer to the Electronic Engine Controls section of this manual.

2023 14 101 5 N/A EGC gauge location 1 (tachometer) sensor fault to primary EGC
or (101) or secondary EGC (201)
201
this gauge.

2023 14 101 6 N/A EGC gauge location 1 (tachometer) data unavailable to primary
or EGC (101) or secondary EGC (201)
201
at this time.

2023 14 101 7 N/A EGC gauge location 1 (tachometer) data missing to primary
201
The data for this gauge is not being transmitted on the datalink.

2023 14 102 5 N/A EGC gauge location 2 (speedometer) sensor fault to primary
202
this gauge.

2023 14 102 6 N/A EGC gauge location 2 (speedometer) data unavailable to
or primary EGC (102) or secondary EGC (202)
202
at this time.
S082504

ESC
Byte Byte Connector
2023 14 102 7 N/A EGC gauge location 2 (speedometer) data missing to primary
202

2023 14 103 5 N/A EGC gauge location 3 (engine coolant temperature) sensor fault
or to primary EGC (103) or secondary EGC (203)
203
this gauge.

or unavailable to primary EGC (103) or secondary EGC (203)
203
at this time.

or missing to primary EGC (103) or secondary EGC (203)
203

2023 14 104 5 N/A EGC gauge location 4 sensor fault to primary EGC (104) or
or secondary EGC (204)
204
this gauge.

S082504

ESC
Byte Byte Connector
2023 14 104 6 N/A EGC gauge location 4 data unavailable to primary EGC (104) or
204
at this time.

2023 14 104 7 N/A EGC gauge location 4 data missing to primary EGC (104) or
204

2023 14 105 5 N/A EGC gauge location 5 (oil pressure) sensor fault to primary EGC
205
this gauge.

2023 14 105 6 N/A EGC gauge location 5 (oil pressure) data unavailable to primary
205
at this time.

2023 14 105 7 N/A EGC gauge location 5 (oil pressure) data missing to primary
205

S082504

ESC
Byte Byte Connector
2023 14 106 5 N/A EGC gauge location 6 sensor fault to primary EGC (106) or
206
this gauge.

2023 14 106 6 N/A EGC gauge location 6 data unavailable to primary EGC (106) or
206
at this time.

2023 14 106 7 N/A EGC gauge location 6 data missing to primary EGC (106) or
206

2023 14 107 5 N/A EGC gauge location 7 (fuel level) sensor fault to primary EGC
207
this gauge.

258)
2023 14 107 6 N/A EGC gauge location 7 (fuel level) data unavailable to primary
207
at this time.

258)
S082504

ESC
Byte Byte Connector
2023 14 107 7 N/A EGC gauge location 7 (fuel level) data missing to primary EGC
207

258)
2023 14 108 5 N/A EGC gauge location 8
or
208 Primary/Auxiliary Air Pressure Gauge sensor fault to Primary
EGC (108) or Secondary EGC (208)
this gauge.

or
208 Primary/Auxiliary Air Pressure Gauge data unavailable to
Primary EGC (108) or Secondary EGC (208)
at this time.

S082504

ESC
Byte Byte Connector
or
208 Primary/Auxiliary Air Pressure Gauge data missing to Primary

or
209 Voltmeter sensor fault to primary EGC (109) or secondary EGC
(209)
this gauge.

or
209 Voltmeter data unavailable to primary EGC (109) or secondary
EGC (209)
at this time.

or
209 Voltmeter data missing to primary EGC (109) or secondary EGC
(209)
S082504

ESC
Byte Byte Connector
or
210 Secondary Air Pressure Gauge sensor fault to Primary EGC
(110) or Secondary EGC (210)
this gauge.

or
210 Secondary Air Pressure Gauge data unavailable to Primary
at this time.

or
210 Secondary Air Pressure Gauge data missing to Primary EGC
(110) or Secondary EGC (210)

S082504

ESC
Byte Byte Connector
2023 14 150 1 N/A Loss of data link from ESC to primary EGC (150) or secondary
or EGC (250)
250

2023 14 150 2 N/A Engine Controller not communicating with the primary EGC
250

2023 14 150 8 N/A ABS warning light malfunction on primary EGC (150) or
250
Refer to the ABS warning light(See ABS WARNING LAMP, page
225) section of this manual.
2023 14 150 9 N/A Trailer ABS warning light malfunction on primary EGC (150) or
250
Refer to the Trailer ABS Lamp (See TRAILER ABS LAMP, page
200) section of this manual.
2023 14 50, 1 N/A ESC not communicating with AGSP 1 (50), AGSP 2 (20), AGSP
40, 3 (30), or AGSP 4 (40).
30,
or Loss of communication in excess of 10 seconds.
20

2023 14 50, 10 N/A Ignition signal from datalink from ESC does not match hardwired
40, ignition signal on AGSP 1 (50), AGSP 2 (20), AGSP 3 (30), or
30, AGSP 4 (40).
or
20 Ignition Circuit to ESC/AGSP.
S082504

ESC
Byte Byte Connector
2023 14 1, 5 N/A Gauge location 1 sensor fault on AGSP 1 (1), AGSP 2 (11),
11, AGSP 3 (21), or AGSP 4 (31).
21,
31 There is a problem with the sensor that provides the data for
this gauge.

manual.
2023 14 1, 6 N/A Gauge location 1 data unavailable on AGSP 1 (1), AGSP 2 (11),
11, AGSP 3 (21), or AGSP 4 (31).
21,
31 The data that this gauge displays should be, but is not available
at this time.

manual.
2023 14 1, 7 N/A Gauge location 1 data missing on AGSP 1 (1), AGSP 2 (11),
11, AGSP 3 (21), or AGSP 4 (31).
21,
31 The data for this gauge is not being transmitted on the datalink.

manual.
12, AGSP 3 (22), or AGSP 4 (32).
22,
this gauge.

manual.
12, AGSP 3 (22), or AGSP 4 (32).
22,
at this time.

manual.
S082504

ESC
Byte Byte Connector
12, AGSP 3 (22), or AGSP 4 (32).
22,

manual.
13, AGSP 3 (23), or AGSP 4 (33).
23,
this gauge.

manual.
13, AGSP 3 (23), or AGSP 4 (33).
23,
at this time.

manual.
13, AGSP 3 (23), or AGSP 4 (33).
23,

manual.
2033 14 1 0 1601/A Connector 1601 pin A, ((MD), (BUS) Stop Arm Cmd). There is a
load on this pin that has been configured as Unused.
Connector 1601 pin A is drawing current and it is configured

as Unused.
An unexpected load is attached to this pin.
S082504

ESC
Byte Byte Connector
2033 14 1 1 1601/A Connector 1601 pin A, ((MD), (BUS) Stop Arm Cmd). Output
overloaded
Connector 1601 pin A current overload.
Too much load attached.

open circuit.
Connector 1601 Pin A open
Open circuit.
shorted to ground.
Connector 1601 Pin A shorted to ground.
Shorted to ground.
2033 14 2 0 1601/E Connector 1601 pin E, ((MD)/(BUS) Lamp test reverse lamps)
There is a load on this pin that has been configured as Unused.
Connector 1601 pin E is drawing current and it is configured

as Unused.

Output overloaded
Connector 1601 pin E current overload.

Output open circuit.
Connector 1601 Pin E open.
Open circuit.
Output shorted to ground.
Connector 1601 Pin E shorted to ground.
Shorted to ground.
S082504

ESC
Byte Byte Connector
2033 14 3 0 1600/11 Connector 1600 pin 11. There is a load on this pin that has been
configured as Unused.
Connector 1600 Pin#11. Bus - Electric Door Control Open

Command, there is a load on this pin that has been configured
as Unused
Connector 1600 pin 11 is drawing current and it is configured

as Unused.
Connector 1600 Pin#11. Bus - Electric Door Control Open

Command, is drawing current and it is configured as unused

2033 14 3 1 1600/11 Connector 1600 pin 11. Output overloaded
Connector 1600 Pin#11. BUS - Electric Door Open Output

overloaded
Connector 1600 pin 11 current overload.
Connector 1600 Pin#11. BUS - Electric Door Open current

overloaded

2033 14 3 2 1600/11 Connector 1600 pin 11. Output open circuit.
Connector 1600 Pin#11. BUS - Electric Door Open Output open

circuit
Connector 1600 Pin 11 open.
Connector 1600 Pin#11. BUS - Electric Door Open circuit open
Open circuit.
2033 14 3 3 1600/11 Connector 1600 pin 11. Output shorted to ground.
Connector 1600 Pin#11. BUS - Electric Door Open Output

shorted to ground
Connector 1600 Pin 11 shorted to ground.
Connector 1600 Pin#11. BUS - Electric Door Open shorted to

ground
Shorted to ground.
S082504

ESC
Byte Byte Connector
2033 14 4 0 1600/6 Connector 1600 pin 6. There is a load on this pin that has been
Connector 1600 Pin#6. BUS - Fog Light Command

as Unused.
Connector 1600 Pin#6. BUS - Fog Light Command is drawing

current and it is configured as unused

2033 14 4 1 1600/6 Connector 1600 pin 6. MD — Park Position Solenoid Output
overloaded
Connector 1600 Pin#6. BUS - Fog Light Command Output

overloaded
Connector 1600 pin 6 current overload
Connector 1600 Pin#6, BUS - Fog Light Command Output,

current overload

open circuit.
Connector 1600 Pin#6. BUS - Fog Light Command Output open

circuit
Connector 1600 Pin#6, BUS - Fog Light Command Output, open
Open circuit.
S082504

ESC
Byte Byte Connector
shorted to ground.
Connector 1600 Pin#6. BUS - Fog Light Command Output

shorted to ground
Connector 1600 Pin#6, BUS - Fog Light Command Output,

shorted to ground
Shorted to ground.
2033 14 5 0 1600/4 Connector 1600 Pin#4. (Bus - Park Brake Relay) There is a load
on this pin that has been configured as Unused

as Unused.

2033 14 5 1 1600/4 Connector 1600 Pin#4. (Bus - Park Brake Relay) Output
overloaded
Connector 1600 pin 4 current overload

2033 14 5 2 1600/4 Connector 1600 Pin#4. (Bus - Park Brake Relay) Output open
circuit
Open circuit.
2033 14 5 3 1600/4 Connector 1600 Pin#4. (Bus - Park Brake Relay) Output shorted
to ground
Shorted to ground.
S082504

ESC
Byte Byte Connector
2033 14 6 0 4004/Bus Connector 4004 pin 17. There is a load on this pin that has been
1602 17 configured as Unused.
BUS Connector 1602 Pin#17. Electric Door Control Closed,

there is a load on this pin that has been configured as Unused
Connector 4004/Bus 1602 pin 17 is drawing current and it is

Bus Connector 1602 pin 17, Bus Electric Door Control, is

drawing current and it is configured as unused

2033 14 6 1 4004/Bus Connector 4004 pin 17. MD — Body Trailer Marker & Tail lamp
1602 17 relay is Output overloaded
Bus Connector 1602 pin 17, Bus Electric Door Control, is Output
overloaded
Connector 4004/Bus 1602 pin 17 current overload
Bus Connector 1602 pin 17, Bus Electric Door Control, current
overload

1602 17 relay is Output open circuit.
Bus Connector 1602 pin 17. Bus Electric Door Control, Output
open circuit
Connector 4004/Bus 1602 Pin 17 open.
Bus Connector 1602 pin 17. Bus Electric Door Control, open
Open circuit.
S082504

ESC
Byte Byte Connector
1602 17 relay is Output shorted to ground.
Bus Connector 1602 pin 17. Bus Electric Door Control, Output
shorted to ground.
Connector 4004/Bus 1602 Pin 17 shorted to ground.
Bus Connector 1602 pin 17. Bus Electric Door Control, shorted
to ground
Shorted to ground.
2033 14 7 0 4004/Bus Connector 4004/Bus 1602 pin 19. There is a load on this pin that
1602 19 has been configured as Unused.
Connector #1602 Pin # 19. (Bus - Air solenoid power) There is a

load on this pin that has been configured as Unused

as Unused.

2033 14 7 1 4004/Bus Connector 4004/Bus 1602 pin 19. Output overloaded.
1602 19
Connector #1602 Pin # 19. (Bus - Air solenoid power) Output
overloaded

2033 14 7 2 4004/Bus Connector 4004/Bus 1602 pin 19. Output open circuit.
1602 19
open circuit
Open circuit.
2033 14 7 3 4004/Bus Connector 4004/Bus 1602 pin 19. Output shorted to ground.
1602 19
shorted to ground
Shorted to ground.
S082504

ESC
Byte Byte Connector
Bus Connector 1602 Pin#20. Wiper high speed relay, there is a


Bus Connector 1602 Pin#20. Wiper high speed relay, is drawing


1602 20
Bus Connector 1602 Pin#20. Wiper high speed relay, Output
overloaded
Connector 4004/Bus 1602 pin 20 current overload.
Bus Connector 1602 Pin#20 Wiper high speed relay current

overloaded

1602 20
Bus Connector 1602 Pin#20. Wiper high speed relay Output
open circuit
Bus Connector 1602 Pin#20. Wiper high speed relay Output

open circuit
Open circuit.
1602 20
Bus Connector 1602 Pin#20. Wiper high speed relay Output,
Output shorted to ground
Bus Connector 1602 Pin#20. Wiper high speed relay Output,

Output shorted to ground
Shorted to ground.
S082504

ESC
Byte Byte Connector
Connector #1602 Pin #21 (Bus - Stop Relay ) There is a load on

this pin that has been configured as Unused

as Unused.

1602 21
Connector #1602 Pin #21 (Bus - Stop Relay ) Output overloaded

1602 21
Connector #1602 Pin #21 (Bus - Stop Relay ) Output open circuit
Open circuit.
1602 21
Connector #1602 Pin #21 (Bus - Stop Relay ) Output shorted
to ground
Shorted to ground.
2033 14 10 0 4004/Bus Connector 4004/Bus 1602 pin 22. There is a load on this pin
1602 22 that has been configured as Unused. (4 Pack Air Solenoid
Channel 3)

Refer to the 4– pack air solenoid module(See AIR SOLENOID

MODULE (4–PACK), page 743) section of this manual.
S082504

ESC
Byte Byte Connector
2033 14 10 1 4004/Bus Connector 4004/Bus 1602 pin 22. Output overloaded. (4 Pack
1602 22 Air Solenoid Channel 3)
Too much load attached, defective relay or 4 pack air solenoid

module.

2033 14 10 2 4004/Bus Connector 4004/Bus 1602 pin 22. Output open circuit. (4 Pack
Connector 4004/Bus 1602 Pin 22 open
Open circuit, defective relay or 4 pack air solenoid module.

2033 14 10 3 4004/Bus Connector 4004/Bus 1602 pin 22. Output shorted to ground. (4
1602 22 Pack Air Solenoid Channel 3)
Shorted to ground, defective relay or 4 pack air solenoid module.

2033 14 10 4 4004/Bus Connector 4004/Bus 1602 Pin 22. Power to solenoid pack has
1602 22 been disabled due to this solenoid being shorted to ground. This
condition causes all solenoids in the solenoid pack to report as
being shorted to ground. This fault indicates the true cause of
the solenoid pack shut-down.
Power to the solenoid pack has been turned off due to a short
in solenoid 3.

S082504

ESC
Byte Byte Connector
Bus connector 1602 pin#23. Wheelchair Lift solenoid, there is a


Bus connector 1602 pin#23, Wheelchair Lift solenoid, is drawing


1602 23
Bus connector 1602 pin#23, Wheelchair Lift solenoid, Output
Overloaded
Bus connector 1602 pin#23, Wheelchair Lift solenoid, current

Overloaded

1602 23
Bus connector 1602 pin#23, Wheelchair Lift solenoid, Out put
open circuit
Bus connector 1602 pin#23, Wheelchair Lift solenoid, open
Open circuit.
1602 23
Bus connector 1602 pin#23, Wheelchair Lift solenoid, Output
shorted to ground
Bus connector 1602 pin#23, Wheelchair Lift solenoid, shorted

to ground
Shorted to ground.
S082504

ESC
Byte Byte Connector
Channel 2)



module.


Shorted to ground. Defective relay or 4 pack air solenoid module.
Refer to the 4– pack air solenoid module (See AIR SOLENOID

S082504

ESC
Byte Byte Connector
in solenoid 2.

Bus connector 1602 pin#25, Park Position Unlock solenoid,

there is a load on this pin that has been configured as Unused

Bus connector 1602 pin#25, Park Position Unlock solenoid, is

drawing current and it is configured as unused

1602 25
Output overloaded
Connector 4004/Bus 1602 pin 25 current overload
Bus connector 1602 pin#25, Park Position Unlock solenoid

current overload
S082504

ESC
Byte Byte Connector
2033 14 13 2 4004/Bus Connector 4004/Bus 1602 pin 25. Output open circuit
1602 25
Output open circuit
Bus connector 1602 pin#25, Park Position Unlock solenoid, open
Open circuit.
1602 25
Output Shorted to ground

Shorted to ground
Shorted to ground.


1602 29

1602 29
Open circuit.
2033 14 14 3 4004/Bus Connector 4004/Bus 1602 pin 29. Output shorted to ground
1602 29
Shorted to ground.
S082504

ESC
Byte Byte Connector
Channel 4)



module.



S082504

ESC
Byte Byte Connector
in solenoid 4.

Channel 1)



module.


S082504

ESC
Byte Byte Connector

in solenoid 1.

2034 14 1 1 N/A Remote Air Solenoid Module #1 - Output #1 - Valve ON when
commanded OFF.
Refer to the Testing Individual Solenoids(See TESTING

INDIVIDUAL SOLENOIDS, page 760) section of this manual.
2034 14 1 2 N/A Remote Air Solenoid Module #1 - Output #1 - Valve OFF when
commanded ON.

2034 14 1 3 N/A Remote Air Solenoid Module #1 - Output #1 - Open Circuit coil
or valve not installed.
Install solenoid or refer to theTesting Individual Solenoids(See

TESTING INDIVIDUAL SOLENOIDS, page 760) section of this
manual.
S082504

ESC
Byte Byte Connector
2034 14 1 4 N/A Remote Air Solenoid Module #1 - Output #1 - Unknown remote
air solenoid.
An air Solenoid is installed in this position but is not configured.
Remove solenoid or reprogram ESC to recognize the solenoid.

manual.
commanded OFF.

commanded ON.

Install solenoid or refer to the Testing Individual Solenoids(See

manual.
air solenoid.

manual.
commanded OFF.

S082504

ESC
Byte Byte Connector
commanded ON.


air solenoid.

manual.
commanded OFF.

commanded ON.


manual.
S082504

ESC
Byte Byte Connector
air solenoid.

manual.
commanded OFF.

commanded ON.


manual.
air solenoid.

manual.
commanded OFF.

S082504

ESC
Byte Byte Connector
commanded ON.


manual.
air solenoid.

manual.
commanded OFF.

commanded ON.


manual.
S082504

ESC
Byte Byte Connector
air solenoid.

manual.
2040 14 1 1 N/A AGSP #1 Switch #1, microswitch inputs are in an invalid state.
Both microswitches are not depressed.
The ESC sets the status of AGSP #1 Switch #1 to the default

value.
Replace switch acturator

manual.
Both microswitches are depressed.

value.
Replace faulty microswitch

manual.
Top microswitch depressed, bottom microswitch not depressed.

value.

manual.
S082504

ESC
Byte Byte Connector
Top microswitch not depressed, bottom microswitch depressed.

value.
Replace switch actuator
Refer to the AGSP Preliminary System Check(See AGSP

manual.
2040 14 1 5 N/A AGSP #1 Switch #1, This switch should be empty but one or
both of the microswitches is pressed.

value.
Replace switch actuator or faulty microswitch

manual.

value.

manual.

value.

manual.
S082504

ESC
Byte Byte Connector

value.

manual.

value.

manual.

value.

manual.

value.

manual.
S082504

ESC
Byte Byte Connector

value.

manual.

value.

manual.

value.

manual.

value.

manual.
S082504

ESC
Byte Byte Connector

value.

manual.

value.

manual.

value.

manual.

value.

manual.
S082504

ESC
Byte Byte Connector

value.

manual.

value.

manual.

value.

manual.

value.

manual.
S082504

ESC
Byte Byte Connector

value.

manual.

value.

manual.

value.

manual.

value.

manual.
S082504

ESC
Byte Byte Connector

value.

manual.

value.

manual.

value.

manual.
2209 14 1 1 N/A Remote Engine Speed Control Module Digital Output #1 -
Output failure

2209 14 1 4 N/A Remote Engine Speed Control Module Digital Output #1 - Data
mismatch

S082504

ESC
Byte Byte Connector
Output failure

mismatch

Output failure

mismatch

2209 14 4 2 N/A Remote Engine Speed Control Module Analog Input #1 -
Shorted to Battery

2209 14 4 3 N/A Remote Engine Speed Control Module Analog Input #1 - shorted
to ground.

2209 14 5 2 N/A Remote Engine Speed Control Module Analog Input #2 -
Shorted to Battery

2209 14 5 3 N/A Remote Engine Speed Control Module Analog Input #2 - shorted
to ground.

S082504

ESC
Byte Byte Connector
2209 14 5 4 N/A Remote Engine Speed Control Module Analog Input #2 - Data
mismatch

2209 14 6 1 N/A Remote Engine Speed Control Module Vbat Supply-Output
Failure

2225 14 1 1 N/A RPM #1 output pin A over current
The output behaves like a 20 amp type III circuit breaker. (MS3 -
open circuit, MS2 - open circuit, MS1 - connected to zero volt
reference)

2225 14 2 1 N/A RPM #1 output pin B over current
reference)

2225 14 3 1 N/A RPM #1 output pin C over current
reference)

S082504

ESC
Byte Byte Connector
2225 14 4 1 N/A RPM #1 output pin D over current
reference)

2225 14 5 1 N/A RPM #1 output pin E over current
reference)

2225 14 6 1 N/A RPM #1 output pin H over current
reference)

The output behaves like a 20 amp type III circuit breaker. (MS3
- open circuit, MS2 - connected to zero volt reference, MS1
- open circuit)

S082504

ESC
Byte Byte Connector
- open circuit)

- open circuit)

- open circuit)

- open circuit)

S082504

ESC
Byte Byte Connector
- open circuit)

- connected to zero volt reference, MS2 - open circuit, MS1
- open circuit)

- open circuit)

- open circuit)

S082504

ESC
Byte Byte Connector
- open circuit)

- open circuit)

- open circuit)

open circuit, MS2 - open circuit, MS1 - open circuit)

S082504

ESC
Byte Byte Connector





S082504

ESC
Byte Byte Connector
commanded OFF.

commanded ON.


manual.
air solenoid.

manual.
commanded OFF.

commanded ON.


manual.
S082504

ESC
Byte Byte Connector
air solenoid.

manual.
commanded OFF.

commanded ON.


manual.
air solenoid.

manual.
commanded OFF.

commanded ON.

S082504

ESC
Byte Byte Connector

manual.
air solenoid.

manual.
commanded OFF.

commanded ON.


manual.
air solenoid.

manual.
commanded OFF.

S082504

ESC
Byte Byte Connector
commanded ON.


manual.
air solenoid.

manual.
commanded OFF.

commanded ON.


manual.
air solenoid.

manual.
S082504
S082504
Printed in the United States of America

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11 LIGHT SYSTEMS 827

1. BACK-UP LIGHTS. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .831

2. ROOF CLEARANCE AND MARKER OR SUNSHADE LIGHTS.. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .838

3. MARKER, PARK AND TAIL LAMPS. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .844

4. DOME AND MAP LIGHTS. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .858

5. FOG LIGHT SYSTEM. . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .870

Diagnostic Trouble Codes.. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. ..872

6. HEADLIGHT SYSTEM. .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. .878

7. PANEL LIGHTS. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . ..895

8. TRUCK STOP/TURN SIGNAL/HAZARD LIGHT.. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. ..904

9. WORK LIGHTS. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .939

10. AUXILIARY HEADLIGHTS.. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .948

Figure 410 Back–Up Lights Function Diagram

1.3. FAULT DETECTION MANAGEMENT

Refer to the Back–Up Lights Connector Diagram

Table 284 Back–Up Lights Circuit Tests

Check with ignition on, transmission in reverse and (9303) disconnected.

Table 284 Back–Up Lights Circuit Tests (cont.)

1.4. EXTENDED DESCRIPTION

1.5. COMPONENT LOCATIONS

Figure 413 Rear Chassis Wiring Connector Locations

Figure 414 Rear Center Chassis Connector Locations

Figure 415 Stop, Tail and Turn Connector Location

Figure 416 (Typical) Rear Signal Light Connector Locations

2. ROOF CLEARANCE AND MARKER OR SUNSHADE LIGHTS

2.3. FAULT DETECTION MANAGEMENT

Refer to Roof Clearance and Marker or Sunshade Lights.

2.4. EXTENDED DESCRIPTION

Roof Clearance and Marker Lights

2.5. COMPONENT LOCATIONS

Figure 419 Roof Clearance and Marker Lights

Figure 420 Sunshade Lights

3. MARKER, PARK AND TAIL LAMPS

Figure 421 Marker, Park and Tail Lights

Marker, Park and Tail Lights Preliminary Check

Table 286 Marker, Park and Tail Lights Preliminary Check

Diagnostic Trouble Codes

Table 287 Marker, Park and Tail Lights

Table 287 Marker, Park and Tail Lights (cont.)

3.3. MARKER, PARK AND TAIL LIGHT INPUTS TO ESC

Refer to Park Light EGC and ESC Input Circuits.

Table 288 EGC, 3 Switch Pack Circuit Tests

Table 288 EGC, 3 Switch Pack Circuit Tests (cont.)

Check with ignition key on and 3 switch pack disconnected.

NOTE – Always check connectors for damage and pushed–out terminals.

Also insure proper voltage out of EGC.

Also insure proper voltage out of EGC.

NOTE – Always check connectors for damage and pushed–out terminals.

3.4. MARKER, PARK AND TAIL LIGHT OUTPUTS FROM ESC

Refer to Marker, Park and Tail Lamps.

Table 289 Marker, Park And Tail Lights Circuit Tests

With (9303) disconnected and park lights on.

12 ± 1.5 volts Refer to ESC Replacement in this manual.

Refer to Marker, Park and Tail Lamps.

3.5. COMPONENT LOCATIONS

Figure 426 Optional Side Marker/Turn Signal Lights (Severe Service)

Figure 427 Rear Tail Light Connector Locations

4. DOME AND MAP LIGHTS

Figure 428 Dome and Map Lights Function Diagram

Refer to Dome and Map Lights Function Diagram.