Electrical System Troubleshooting Guide 9800

SERVICE MANUAL
TRUCK SERVICE MANUAL
ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 9800 MODEL
Model: 9800
Start Date: 11/01/1998
s08270, Formerly CTS-5304
10/18/2002
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Copyright © 10/18/2002 Navistar, Inc.
TRUCK SERVICE MANUAL i
Table of Contents
SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GROUP 08 ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CTS-5304-1 1 POWER DISTRIBUTION AND GROUND SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CTS-5304-2 2 CAB ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
CTS-5304-3 3 BATTERY, CHARGING AND CRANKING SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
CTS-5304-4 4 ETHER START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
CTS-5304-5 5 FAN SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
CTS-5304-6 6 CUMMINS M11E AND N14E ENGINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
CTS-5304-7 7 CUMMINS ISM ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
CTS-5304-8 8 DETROIT DIESEL SERIES 60 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
CTS-5304-9 9 CHASSIS ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361
CTS-5304-10 10 LIGHT SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387
CTS-5304-11 11 SLEEPER ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469
CTS-5304-12 12 HEATER AND AIR CONDITIONER (CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .487
CTS-5304-13 13 HEATER AND AIR CONDITIONER BLOWER WITH STANDARD TEMPERATURE
CONTROL (SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .509
CTS-5304-14 14 HEATER AND AIR CONDITIONER BLOWER WITH THERMOSTAT
TEMPERATURE CONTROL (SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .531
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ii TRUCK SERVICE MANUAL
s08270
TRUCK SERVICE MANUAL 1
Use with Circuit Diagram Book CTS-5254W
Refer to CTS-5219 for Spicer Automate® 10–Speed Transmission Troubleshooting
Refer to CTS-5258 for Gauges and Warning Lights.
Refer to CTS-5257 for Speedometer/ Tachometer Diagnostics and Service
Refer to CTS-5247 for Bendix M-21, 22 ABS Modulator Assembly Troubleshooting.
Refer to CTS-5248 for Bendix ATR-2 ABS/Traction Control Relay Valve Troubleshooting
Refer to CTS-5249 for Bendix EC-16 ABS Controller Troubleshooting.
Refer to CTS-5252 for Bendix ABS Air Brake System Troubleshooting, 9800
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2 TRUCK SERVICE MANUAL
SAFETY INFORMATION
IMPORTANT – Read the following before starting the service procedure.
The information contained in this International Service Manual Section was current at the time of printing
and is subject to change without notice or liability.
You must follow your company safety procedures when you service or repair equipment. Be sure to understand
all of the procedures and instructions before you begin work on the unit.
International uses the following types of notations to give warning of possible safety problems and to give
information that will prevent damage to the equipment being serviced or repaired.
WARNING – A warning indicates procedures that must be followed exactly. Personal injury
or possible death can occur if the procedure is not followed.
CAUTION – A caution indicates procedures that must be followed exactly. If the procedure is not
followed, damage to equipment or components can occur.
NOTE – A note indicates an operation, procedure or instruction that is important for correct service.
Some procedures require the use of special tools for safe and correct service. Failure to use these special
tools when required can cause injury to service personnel or damage to vehicle components.
This service manual section is intended for use by professional technicians, NOT a “do-it-yourselfer.” It is
written to inform these technicians of conditions that may occur on some vehicles, or to provide information
that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume
that the service section applies to your vehicle. See your International Truck Dealer for information on whether
this service section applies to your vehicle.
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1 POWER DISTRIBUTION AND GROUND SYSTEMS 3
Group ELECTRICAL
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1. START FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2. ACCESSORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.3. BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
(B1) Battery Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
(B2) Battery Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.4. 3+1 BATTERY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.5. GROUND ADAPTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.6. IGNITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.7. PANEL LIGHTS ADAPTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.1. START FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2. ACCESSORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.3. (B1) BATTERY STUD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.4. (B2) BATTERY STUD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.5. 3 +1 BATTERY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.6. GROUND ADAPTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.7. IGNITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.8. PANEL LIGHTS ADAPTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4. COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
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4 1 POWER DISTRIBUTION AND GROUND SYSTEMS
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Model: 9800
1. DESCRIPTION
The primary power distribution points in the electrical wiring are the batteries, battery stud (B1), key switch
(452), accessory adapters A1(516), A2(581), and A3(593), battery adapters B1(517) and B2(529), ignition
adapters I1(518), I2(607), and I3(496), panel lights feed adapters L1(504), L2(586), and L5(508), and main
fuse block.
Primary ground points are ground adapters G1(454), G2(455), G3(456), G4(457), G5(533), G6(616), left cab
ground (429), right cab ground (404), panel lights adapter L3 (505), L4 (587), and ground stud (499).
For power distribution and ground diagrams, and fuse/circuit chart, refer to Electrical Circuit Diagram Manual
CTS-5254W.
2. OPERATION
2.1. START FEED
Power from battery stud (B1) is applied to circuits 14BH and 14C, 25A fuse F7-A, and circuit 15 to the key
switch (452).
On vehicles with push button start, the engine is made to crank by placing the key switch in the ignition
position, and depressing the push button switch (94). This causes power to flow through the key switch, circuit
17, the push button switch (94), and circuit 17B to the start feed adapter (509).
On vehicles with key switch starting, the engine is made to crank by holding the key switch in the start
position. This causes power to flow through the key switch, and circuit 17 to the start feed adapter (509).
From the start feed adapter (509), power flows through circuit 17A, connector (102), and circuit 17A to the
start magnetic switch.
2.2. ACCESSORY
Power from battery stud (B1) is applied to circuits 14BH and 14C, 25A fuse F7-A, and circuit 15 to the key switch
(452). When the key switch is placed in the accessories position, power is applied to circuit 12M, and 10A
radio and CB fuse F5-B, and power is also applied to circuits 12 and 12D to the A2 accessories adapter (581).
With the key switch in accessories position, power is also applied to circuits 12 and 12AC, and the coil of the
accessories feed relay (446-R15). The relay is grounded through circuits 12-GH, 82-GD, and 11-GD to the left
cab ground (429). This energizes the relay and allows power to flow from the battery stud (B1) through circuits
14K and 14AJ, 25A fuse F4-B, circuit 14BB, the N.O. contacts of relay (446-R15), and circuit 12AF to a splice.
From the splice power flows through circuit 12L to the defroster fans and power mirror 15A fuse F5-A. From
the splice power also flows through circuit 12AD to the A3 accessories adapter (593).
With the key switch in accessories position, power is also applied to circuits 12 and 12AH, the A1 accessories
adapter (516), and power is applied to circuit 12F and the wiper intermittent relay (444).
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2.3. BATTERY
(B1) Battery Stud
Power from the batteries and the output of the alternator flows through circuit 14, the 150A megafuse, and
circuit 14BM to battery stud (B1). Power then flows through circuit 14K to a splice. From the splice, power
is applied to the following circuits: 14AN and 10A work light fuse F1-D, 14BH and 14BC to the 10A ABS
power fuse F8-B, 14BH and 14C to the 25A key switch fuse F7-A, 14BH and 14L to the 15A left turn relay
fuse F7-B and the 15A right turn relay fuse F7-C, 14BH and 14AF to 30A trailer stop light relay fuse F7-D,
14BH and 14V to B1 battery adapter (517).
From the B1 battery adapter (517), power is applied to the following circuits: 14BL to the 15A DRL fuse F10-B
[location may vary], 14AD to 10A Qualcomm fuse F10-A [location may vary], 14AV to 25A electric window
fuse F10-A [location may vary], and 14BD to the 25A window relay fuse F10-A [location may vary], and 14PA
to 5A data display fuse F10-A [location may vary].
The B1 battery stud also supplies power to circuit 14K and a splice. Power from the splice is applied to the
following circuits: 14AJ, 25A fuse F4-B, and circuit 14BB to the accessories feed relay, 14AL and 15A wiper
relay circuit breaker F6-B, 14AL and 5A diagnostics data link fuse F6-A, 14R and 30A ignition relay fuse, 14J
and 20A flasher fuse F2-D, 14AM and 15A horn and radio fuse F5-C, and 14AN and 10A work light fuse F1-D.
(B2) Battery Stud
Power from the batteries and the output of the alternator flows through circuit 14, the 150A megafuse, and
circuit 14BM to battery stud (B1), and a copper bus bar [except on optional 3+1 system] to the (B2) battery
stud. From the (B2) battery stud, power is applied to the following circuits: 14W, 14X, and 30A heater fan
fuse F1-A, 14W, 14Z, and 10A A/C control relay fuse F1-B, 14W, 14Z, and 20A heater control relay fuse
F1-C, 14W, 14B, and 30A trailer tail light relay fuse F3-C, 14W, 14B, and 10A headlight/trailer lights switch
fuse F3-D, and 14W, 14T, and 15A luggage lights and cigar lighter fuse F2-A, and 14W, 14T, and 10A cab
and courtesy lights fuse F2-B.
From the (B2) battery stud, power is also applied to the following circuits: 14H, 14AP and 25A sleeper fuse
F8-D, 14H, 14E and 20A trailer marker relay fuse F3-A, 14H, 14E, and 20A stop light switch fuse F3-B, 14H,
14AA, and 20A power source fuse F5-D, 14H, 14M, and 10A owner/operator option fuse F4-C, 14H, 14M, and
20A owner/operator option fuse F4-D, and 14H, 14AH, and the B2 battery adapter (529).
From the (B2) battery stud, power is also applied to circuits: 14AU and 30A sleeper high and medium speed
relay, and 14AU and 15A bunk blower relay.
From the (B2) battery stud, power is also applied to circuits: 14D and 10A headlight switch circuit breaker
F6-C, and 14D and 20A headlight relay circuit breaker F6-D.
2.4. 3+1 BATTERY SYSTEM

With the optional 3+1 system, the copper bus bar is removed from between the (B1) and (B2) battery studs
and a 7 volt magnetic switch is inserted between the deep cycle battery and the other vehicle batteries. Thus
the deep cycle battery is used to supply the circuits attached to the (B2) battery stud, and the other batteries
are reserved for cranking when the engine is to be started.
The circuitry is as follows: the (B2) battery stud receives power from the deep cycle battery through a
black battery cable, circuit 14AC, a 150A megafuse, circuit 14AB, connector (537), and circuit 14AB with
the ignition key off. With the ignition key in the on position, battery stud (B2) receives power from both the
black battery cable from the deep cycle battery, and the magnetic switch and red battery cable from the
other vehicle batteries.
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The (B1) battery stud receives power from the vehicle batteries [less the deep cycle battery if applicable],
over the red battery cable, a 10 GA fusible link, circuits 2 and 14, connector (N/L) [with Cummins N14 only],
circuit 14, the 150A megafuse, and circuit 14BM.
2.5. GROUND ADAPTERS

A ground cable from the vehicle batteries is attached to a ground stud (G) at the rear of the cranking motor.
From this ground stud a ground circuit 2-G is attached to the ground stud (G) at the rear of the alternator.
Circuit 11-GX provides a ground path to the alternator ground stud (G) for the right cab ground stud (404). A
ground path is provided to right cab ground stud (404) by circuits: 11-GA and 11-G for the G1 ground adapter
(454), 11-GAR and 11-GB for the G2 ground adapter (455), 11-GC and 11-GB for the G3 ground adapter
(456), and 75-G and 11-G for the heater control panel.
The left cab ground stud (429) is not directly connected to the right cab ground stud (404), but instead relies on
the aluminum cab panels to conduct and provide a ground path. A ground path is provided to the left ground
stud (429) by circuits: 11-GE for the G6 ground adapter (616), 11-GH and 11-GF for the G5 ground adapter
(533), 11-GY and 11-GI for the G4 ground adapter (457).
2.6. IGNITION
When the key switch (452) is moved to the start or ignition position, power from the (B1) battery stud flows
through circuits 14BH and 14C, 25A fuse F7-A, circuit 15, the contacts of the key switch, and circuit 13 to a
splice. From the splice, power flows through circuit 13B, 10A fuse F4-A, and circuit 13D to a splice. From
the splice, power is applied to the following circuits: 13E to the I3 ignition adapter (496), 47 to speedo and
tach gauges, 28A to the right gauge cluster, 28B to the left gauge cluster, 28C to warning lights alarm, and 27
to the voltmeter.
With the key switch in the start or ignition position, power also flows through circuit 13, and 13A to the coil of
the ignition relay (462-R1). This energizes the relay which is grounded through circuits 11-GN and 11-GB to the
right cab ground stud (404). With the relay energized, power flows from the (B1) battery stud through circuits
14K and 14R, 20A fuse F2-C, circuit 14S, the N.O. contacts of relay (462-R1), and circuit 13H to a splice.
From the splice power flows through circuit 13T to heater control relay (463-R5), and power flows through
circuit 13P, I2 ignition adapter (607), and circuit 13AJ to the USA DRL 10A fuse F10-A [location may vary].
From the splice power flows through circuit 13F to I1 ignition adapter (518). From (518) power flows to the
following circuits: 13PA to the 5A Detroit Pro Driver display fuse F10-B [location may vary], or Cummins Pro
Driver display fuse F10-A [location may vary], 13R to the 5A Detroit Horton or Kysor fan fuse F10-A [location
may vary], 94AJ to the trailer ABS relay (483), 13L to the 10A ether start fuse F10-A [location may vary], 13W
to the 10A ABS power relay F9-D, 13AB to the 10A pyrometer fuse F10-A [location may vary], and 13M to
the 10A Qualcomm fuse F10-C [location may vary].
From the splice power also flows through circuit 16A to connector (102), thus feeding the engine ECM, optional
Spicer Automate transmission, heated air dryer, heated fuel filter, and back-up lights.
2.7. PANEL LIGHTS ADAPTER

Power from the headlight switch (410) and panel lights switch (416) is applied to the L1 panel lights feed
adapter (504), L2 panel lights feed adapter (586), and L5 panel lights feed adapter (508). Power from adapter
(504) is applied to circuits 62BW and 62T to the cigar lighter light, and from the lighter, circuit 62AK to the L5
panel lights feed adapter (508).
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Power from L1 panel lights adapter (504) is also applied to the following circuits: 66BB and 62BE to sleeper
fluorescent light switch (563), 62AJ and the left window switch (420), 62V to a splice and circuits 62N, 62J, 62K
and 62L, going to the engine brake and cruise switches, 62AX going to the push button start light (541), 62BN
going to a splice and circuits 62AL and 62AM going to the driver and passenger right side window switch,
circuit 62AY going to the ether start switch (451) and circuit 62BW to a splice. From the splice, power is applied
to circuit 62T and the cigar lighter panel light, circuit 62B to the right gauge cluster panel lights, circuit 62C to
the left gauge cluster, circuit 62D, 62E to the tachometer and 62F and 62G to the speedometer.
From L2 panel lights feed adapter (586), power is applied to circuit 62AN and the fog light switch (414) and
circuit 62AD to a splice. From the splice, power is applied to circuit 62AW going to the work light switch (25),
circuit 62AT going to the key switch light (495), circuit 62AP going to the dome light switch (439), circuit 62P
going to the heater control panel light (84), and circuit 62X going to the heated mirror switch (415).
Panel light switch (416) applies power to circuit 62A, 62S and a splice. From the splice, power is applied to
circuits: 62AR to the trailer lights switch (409), 62AS to the headlight switch (410), and 62AV to the right
motorized mirror switch (540).
Panel light switch (416) applies power to circuit 62A and a splice. From the splice power is applied to the
following circuits: 62AF to the wipe/wash switch (408), 62AG to the wiper switch (407), 62BA to the sleeper
dome light switch (589), and 62W to the panel light switch (416).
The ground path for the panel light switch (416) panel light is circuit 62-GW to a splice, and the ground path for
the panel light switch dimmer’s integrated circuit is circuit 11-GS to a splice. Other circuits that are grounded
through the splice are: 62-GAG to the windshield wiper switch (407), 62-GAF windshield wipe/wash switch
(408), and 62-GBA to the sleeper dome light switch (589). The splice is grounded through circuit 11-GLC, L3
panel lights ground adapter (505), and circuits 11-GP, 11-GLA, and 11-GD to the left cab ground stud (429).
The following circuits are also grounded through L3 panel lights adapter (505): 62-GAX to push button start
switch light (541), 62-GAY to the panel light of ether start switch (451), and 11-GJ to cruise control switch
circuits 62-GJ and 62-GK, engine brake circuits 62-GN and 62-GL, and engine override diagnostics circuit
62-GBK. Adapter (505) is grounded through circuits 11-GP, 11-GLA, and 11-GD to left cab ground stud (429).
Circuit 62-GAV from the right motor mirror switch (540) panel light, circuit 62-GAR from the trailer lights switch
(409) panel light, and circuit 62-GAS from the headlight switch (410) panel light are connected to a splice. The
splice is grounded through circuits 11-GLA, and 11-GD to left cab ground stud (429).
Circuit 62-GAN from the fog light switch (414) panel light is connected to L4 panel lights ground adapter (587),
circuits 11-GAK, 11-GLA, 11-GD, and the left cab ground stud (429).
Circuit 65-G from the work light switch (25) panel light, circuit 78-G from the heated mirrors switch (415)
panel light, circuit 63-G and 62-GAP from the dome light switch (439) and panel light, and circuit 62-GAT
from the key switch (495) panel light are connected to circuits 11-GLB, 11-GAK, 11-GLA, and 11-GD to left
cab ground stud (429).
3. TROUBLESHOOTING
A. Before beginning these test procedures, make sure the vehicle batteries are at 75% state of
charge (SOC) or higher. This represents an open circuit voltage (OCV) of 12.4 volts. Batteries
with an OCV of 12 volts or less are either completely discharged or have a dead cell.
B. Before beginning these test procedures, check any light or indicator lamp filaments that are
suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks.
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C. Before beginning these test procedures, inspect all connectors for loose or damaged pins,
wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 -
ELECTRICAL in the CTS-5000 Master Service Manual.
D. When the technician determines that a fuse is blown, while checking its condition, he is directed
to locate the cause of the overload condition and to repair it. While no further instruction on this
procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections
of the circuit by disconnecting connectors, and measure the resistance to ground to find the circuit
that is shorted to ground. Then locate the damaged spot in the wire or connector and repair.
E. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not
covered in detail. It is assumed that the technician knows to check for a malfunctioning switch,
relay, or solenoid.
3.1. START FEED

Table 1 Start Feed
STEP KEY ACTION TEST SPEC. YES- IN NO-OUT OF
POINTS SPEC. SPEC.
1. Off At battery stud (B1), (B1) to gnd. 12 ± 1.5 Go to next Locate cause of
measure voltage to volts. step. low or no voltage
ground. in circuit 14BM,
150A megafuse,
circuit 14, conn.
(780) W/ N14,
circuits 14 and 2,
10 GA fusible link,
and 4/0 cable from
batteries, then
repair.
2. Off At fuse F7–A, measure F7–A to gnd. 12 ± 1.5 Go to next Locate cause of
voltage to ground. volts. step. low or no voltage
in circuit 14BH or
14C, then repair.
3. Off Remove 25A fuse F7–A < 1 ohm. Go to next Locate cause of
F7–A and check for step. overload condition,
open condition. then repair.
Replace fuse.
4. Off Disconnect key switch (452), 15 to 12 ± 1.5 Go to next Locate cause of
connector (452) and gnd. volts. step. low or no voltage
re-install fuse F7–A. in circuit 15, then
At (452) circuit 15, repair.
measure voltage to
ground.
5. Off With key switch (452) (452), BAT to < 1 ohm. Go to next Replace defective
disconnected and in IGN. step. key switch.
the ignition position,
measure resistance
from terminal BAT to
IGN.
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Table 1 Start Feed (cont.)

POINTS SPEC. SPEC.
disconnected and held ST. step. key switch.
in the start position,
measure resistance
ST.
7. Off Reconnect key switch Go to next Go to Step 9.
(452). Does vehicle step.
have push button
start?
8. On With key switch in (509) to gnd. 12 ± 1.5 Go to Step Locate cause of
ignition position, volts. 10. low or no voltage
measure voltage from in circuit 17, start
start feed adapter switch (94), or
(509) to ground circuit 17B, then
while depressing start repair.
button.
9. On With key switch held in (509) to gnd. 12 ± 1.5 Go to next Locate cause of
start position, measure volts. step. low or no voltage
voltage from start in circuit 17, then
feed adapter (509) to repair.
ground.
10. On At cranking motor Mag. switch, 12 ± 1.5 Start feed Locate cause of
magnetic switch and 17A to gnd. volts. circuits low or no voltage
circuit 17A, measure check in circuit 17A,
voltage to ground while good. conn. (102), or
depressing start button 17A to the mag.
or turning key switch to switch, then repair.
start position.
3.2. ACCESSORY
Table 2 Accessory
POINTS SPEC. SPEC.
150A megafuse,
circuit 14, conn.
(780) W/ N14,
circuits 14 and 2,
10 GA fusible link,
and 4/0 cable from
batteries, then
repair.
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Table 2 Accessory (cont.)

POINTS SPEC. SPEC.
2. Off At fuse F7–A, measure F7–A to gnd. 12 ± 1.5 Go to next Locate cause of
voltage to ground. volts. step. low or no voltage
in circuit 14BH or
14C, then repair.
3. Off Remove 25A fuse F7–A < 1 ohm. Go to next Locate cause of
F7–A and check for step. overload condition,
open condition. then repair.
Replace fuse.
re-install fuse F7–A. in circuit 15, then
At (452) circuit 15, repair.
measure voltage to
ground.
disconnected and in IGN. step. key switch.
the ignition position,
measure resistance
IGN.
disconnected and held ACC. step. key switch.
in the start position,
measure resistance
ACC.
7. Off/ On Reconnect key switch (516) to gnd. 12 ± 1.5 Go to next Locate cause of
(452) and move key volts. step. low or no voltage
switch to accessories in circuit 12 or
position. At A1 12AH, then repair.
accessories adapter
(516), measure voltage
to ground.
8. On With key switch still in (581) to gnd. 12 ± 1.5 Go to next Locate cause of
accessories position, volts. step. low or no voltage
at A2 accessories in circuit 12 or 12D,
adapter (581), then repair.
measure voltage to
ground.
9. On With key switch still in (593) to gnd. 12 ± 1.5 Accessories Go to next step.
accessories position, volts. power
at A3 accessories distribution
adapter (593), circuits
measure voltage to check
ground. good.
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Table 2 Accessory (cont.)

POINTS SPEC. SPEC.
10. Off Remove accessories (446–R15), 12 ± 1.5 Go to next Locate cause of
feed relay (446–R15), 14BB to gnd. volts. step. low or no voltage
and at circuit 14BB, in circuit 14BB,
measure voltage to 25A fuse F4–B,
ground. or circuits 14AJ or
14K from battery
stud (B1), then
repair.
11. On Move key switch to (446–R15), 12 ± 1.5 Go to next Locate cause of
accessories position, 12AC to gnd. volts. step. low or no voltage
and at (446–R15) in circuit 12 or
circuit 12AC, measure 12AC, then repair.
voltage to ground.
12. Off Bench test accessories (446–R15), < 1 ohm. Go to next Replace defective
feed relay (446–R15) pin 30 to 87A. step. accessories feed
by measuring relay (446–R15).
resistance from pin
30 to 87A.
13. Off Bench test accessories Energized < 1 ohm. Go to next Replace defective
feed relay (446–R15) relay step. accessories feed
by applying +12 volts (446–R15), relay (446–R15).
to pin 86, ground to pin 30 to 87.
pin 85, and measuring
resistance from pin 30
to 87.
14. Off/ On Re-install accessories (593) to gnd. 12 ± 1.5 Accessories Locate cause of
feed relay (446–R15), volts. power low or no voltage
move key switch distribution in circuit 12AF or
to accessories circuits 12AD, then repair.
position, and at A3 check
accessories adapter good.
to ground.
3.3. (B1) BATTERY STUD

Table 3 (B1) Battery Stud
POINTS SPEC. SPEC.
150A megafuse,
circuit 14, conn.
(780) W/ N14,
circuits 14 and
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Table 3 (B1) Battery Stud (cont.)

POINTS SPEC. SPEC.
2, 10 GA fusible
link, and 4/0 cable
from batteries, then
repair.
2. Off At 10A fuse F1–D, F1–D, 14AN 12 ± 1.5 Go to next Locate cause of
measure voltage from to gnd. volts. step. low or no voltage
circuit 14AN to ground. in circuit 14AN or
14K, then repair.
3. Off At 30A fuse F2–C, F2–C, 14R to 12 ± 1.5 Go to next Locate cause of
measure voltage from gnd. volts. step. low or no voltage
circuit 14R to ground. in circuit 14R, then
repair.
4. Off At 20A fuse F2–D, F2–D, 14J to 12 ± 1.5 Go to next Locate cause of
circuit 14J to ground. in circuit 14J, then
repair.
5. Off At 25A fuse F4–B, F4–B, 14AJ 12 ± 1.5 Go to next Locate cause of
measure voltage from to gnd. volts. step. low or no voltage in
circuit 14AJ to ground. circuit 14AJ, then
repair.
6. Off At 5A fuse F6–A, F6–A, 14AL 12 ± 1.5 Go to next Locate cause of
circuit 14AL to ground. circuit 14AL, then
repair.
7. Off At 15A fuse F5–C, F5–C, 14AM 12 ± 1.5 Go to next Locate cause of
circuit 14AM to ground. circuit 14AM, then
repair.
8. Off At 25A fuse F7–A, F7–A, 14C to 12 ± 1.5 Go to next Locate cause of
circuit 14C to ground. in circuit 14C or
14BH, then repair.
9. Off At 15A fuse F7–B F7–B or 12 ± 1.5 Go to next Locate cause of
or F7–C, measure F7–C, 14L volts. step. low or no voltage
voltage from circuit to gnd. in circuit 14L, then
14L to ground. repair.
10. Off At 30A fuse F7–D, F7–D, 14F to 12 ± 1.5 Go to next Locate cause of
circuit 14F to ground. in circuit 14F, then
repair.
11. Off At 30A fuse F8–B, F8–B, 14BC 12 ± 1.5 Go to next Locate cause of
circuit 14BC to ground. circuit 14BC, then
repair.
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POINTS SPEC. SPEC.
12. Off At (B1) battery adapter (517), 14V to 12 ± 1.5 Go to next Locate cause of
(517), measure voltage gnd. volts. step. low or no voltage
from circuit 14V to in circuit 14V, then
ground. repair.
13. Off (B1) battery stud
distribution circuits
check good.
3.4. (B2) BATTERY STUD

Table 4 (B2) Battery Stud
POINTS SPEC. SPEC.
ground. in copper bus bar,
circuit 14BM, 150A
megafuse, circuit
14, conn. (780)
W/ N14, circuits 14
and 2, 10GA fusible
link, and 4/0 cable
from batteries, then
repair.
2. Off At 30A fuse F1–A, F1–A, 14X to 12 ± 1.5 Go to next Locate cause of
measure voltage from gnd. volts. step. low or no voltage in
circuit 14X to ground. circuit 14X or 14W,
then repair.
3. Off At 10A fuse F1–B, F1–B, 14Z to 12 ± 1.5 Go to next Locate cause of
circuit 14Z to ground. in circuit 14Z, then
repair.
4. Off At 15A fuse F2–A, F2–A, 14T to 12 ± 1.5 Go to next Locate cause of
circuit 14T to ground. in circuit 14T, then
repair.
5. Off At 20A fuse F3–A, F3–A, 14E to 12 ± 1.5 Go to next Locate cause of
measure voltage from gnd. volts. step. low or no voltage in
circuit 14E to ground. circuit 14E or 14H,
then repair.
6. Off At 30A fuse F3–C, F3–C, 14B to 12 ± 1.5 Go to next Locate cause of
circuit 14B to ground. in circuit 14B, then
repair.
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POINTS SPEC. SPEC.
7. Off At 20A fuse F5–D, F5–D, 14AA 12 ± 1.5 Go to next Locate cause of
circuit 14AA to ground. circuit 14AA, then
repair.
8. Off At 10A fuse F4–C, F4–C, 14M to 12 ± 1.5 Go to next Locate cause of
circuit 14M to ground. in circuit 14M, then
repair.
9. Off At 10A fuse F6–C, F6–C, 14D to 12 ± 1.5 Go to next Locate cause of
circuit 14D to ground. in circuit 14D, then
repair.
10. Off At 25A fuse F8–D, F8–D, 14AP 12 ± 1.5 Go to next Locate cause of
circuit 14AP to ground. circuit 14AP, then
repair.
11. Off At 30A fuse F10–A, F10–A, 14AU 12 ± 1.5 (B2) Locate cause of
measure voltage from to gnd. volts. batt. stud low or no voltage in
circuit 14AU to ground. distribution circuit 14AU, then
circuits repair.
check
good.
3.5. 3 +1 BATTERY SYSTEM

Table 5 3+1 Battery System
POINTS SPEC. SPEC.
1. Off At 7V isolated battery 7V mag < 1 ohm. Go to next Locate open or
magnetic switch, switch, 7–G step. poor connection
measure resistance to gnd. in circuit 7–G,
from circuit 7–G to then repair.
ground.
2. Off At mag. switch and Mag. sw., 1/0 12 ± 1.5 volts. Go to next Locate cause of
1/0 red cable, measure red cable to step. low or no voltage
voltage to ground. gnd. in 1/0 red cable,
then repair.
3. Off At mag. switch and Mag. sw., 4 Approx. 12 Go to next Locate cause of
4 or 6 GA black wire, or 6 GA black volts (same step. no or low voltage
measure voltage to wire to gnd. as deep cycle in 4 or 6 GA black
ground. battery.) wire, then repair.
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Table 5 3+1 Battery System (cont.)

POINTS SPEC. SPEC.
4. Off Measure voltage Mag. sw., 1/0 Less than or Go to Step Go to next step.
across large terminals GA red to 6 greater than 7.
of the mag. switch (1/0 GA red. 0 volts.
GA red wire to 6 GA
red wire).
5. On Start engine and at Mag. sw., 7 Approx. Go to next Locate cause of
7V isolated battery to gnd. 7 volts step. low or no voltage
magnetic switch, (pulsating in circuit 7, one
measure voltage from DC). way conn., or
circuit 7 to ground. circuit 7, then
repair.
6. Off Remove battery cables Mag. sw., > 100K Go to next Replace mag.
and at 7V mag. switch, across large ohms. step. switch; it is not
measure resistance term. opening the
across large terminals. circuit.
7. Off/ On Reconnect any Mag. sw., 0 volts. 3+1 Turn off
disconnected circuits across large battery key switch,
and start vehicle. term. circuits disconnect
Measure voltage check battery cables,
across large terminals good. and replace
of 7V mag. switch. defective
magnetic switch.
3.6. GROUND ADAPTERS

Table 6 Ground Adapters
POINTS SPEC. SPEC.
1. Off Measure resistance of Alt. (G), < 1 ohm. Go to next Locate open or
circuit 11–GX between 11–GX to step. poor connection
alternator terminal (G) (404). in circuit 11–GX,
and right cab ground then repair.
stud (404).
2. Off Measure resistance (404), 11–G < 1 ohm. Go to next Locate open or
of circuits 11–G and to (454), step. poor connection
11–GA between right 11–GA. in circuit 11–GA
cab ground stud (404) or 11–G, then
and G1 ground adapter repair.
(454).
3. Off Measure resistance (404), 11–GB < 1 ohm. Go to next Locate open or
of circuit 11–GB and to (455), step. poor connection
11–GAR between right 11–GAR. in circuit 11–GB
cab ground stud (404) or 11–GAR, then
(455).
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Table 6 Ground Adapters (cont.)

POINTS SPEC. SPEC.
4. Off Measure resistance (404), 11–GB < 1 ohm. Go to next Locate open or
of circuits 11–GB and to (456), step. poor connection
11–GC between right 11–GC. in circuit 11–GC,
cab ground stud (404) then repair.
and G3 ground adapter
(456).
5. Off Measure resistance (429), 11–GI < 1 ohm. Go to next Locate open or
of circuits 11–GI and to (457), step. poor connection
11–GY between left 11–GY. in circuit 11–GY
cab ground stud (429) or 11–GI, then
(457).
6. Off Measure resistance (429), 11–GF < 1 ohm. Go to next Locate open or
of circuits 11–GF and to (533), step. poor connection
11–GH between left 11–GH. in circuit 11–GF
cab ground stud (429) or 11–GH, then
(533).
7. Off Measure resistance of (429), 11–GE < 1 ohm. Ground Locate open or
circuit 11–GE between to (616), adapter poor connection
left cab ground stud 11–GE. connections in circuit 11–GE,
(429) and G6 ground check then repair.
adapter (616). good.
3.7. IGNITION
Table 7 Ignition
POINTS SPEC. SPEC.
ground. in circuit 14, 150A
megafuse, or
circuit 14BM from
alternator battery
stud (B), then
repair.
2. Off At fuse F7–A and F7–A, 14C to 12 ± 1.5 Go to next Locate cause of
circuit 14C, measure gnd. volts. step. low or no voltage
voltage to ground. in circuit 14BH or
14C, then repair.
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Table 7 Ignition (cont.)

POINTS SPEC. SPEC.
at circuit 15, measure in circuit 15 or 25A
voltage to ground. fuse F7–A, then
repair.
4. Off/ On Bench test key switch (452), BAT to < 1 ohm. Go to next Replace defective
(452) by placing it in IGN. step. key switch.
the ignition position
and measuring
resistance from
terminal BAT to IGN.
5. On Bench test key switch (452), BAT to < 1 ohm. Go to next Replace defective
(452) by holding it in IGN. step. key switch.
the start position and
measuring resistance
IGN.
6. Off/ On With key switch in F4–A, 13B to 12 ± 1.5 Go to next Locate cause of
the OFF position, gnd. volts. step. low or no voltage
reconnect its in circuit 13B or
connector. Move 13, then repair.
key switch to ignition
position and at fuse
F4–A and circuit 13B,
measure voltage to
ground.
7. On With key switch in (496), 13E to 12 ± 1.5 Go to next Locate cause of
ignition position, at gnd. volts. step. low or no voltage
I3 ignition adapter in circuit 13E or
(496) and circuit 13E, 13D, or 10A fuse
measure voltage to F4–A, then repair.
ground.
8. Off Remove ignition relay (462–R1), 12 ± 1.5 Go to next Locate cause of
(462–R1) and at circuit 14S to gnd. volts. step. low or no voltage
14S, measure voltage in circuit 14S, 30A
to ground. fuse F2–C, circuit
14R or circuit 14K,
then repair.
9. Off At relay socket (462–R1), 12 ± 1.5 Go to next Locate open or
(462–R1), measure 14S to volts. step. poor connection in
voltage from circuit 11–GN. circuit 11–GN or
14S to 11–GN. 11–GB to right cab
ground stud (404),
then repair.
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Table 7 Ignition (cont.)

POINTS SPEC. SPEC.
10. On Move key switch (462–R1), 12 ± 1.5 Go to next Locate cause of
to ignition position, 13A to gnd. volts. step. low or no voltage
and at relay socket in circuit 13A, then
(462–R1) and circuit repair.
13A, measure voltage
to ground.
11. Off Bench test ignition (462–R1), pin < 1 ohm. Go to next Replace defective
relay (462–R1) by 30 to 87A. step. relay.
from pin 30 to 87A.
12. Off Bench test ignition Energized < 1 ohm. Go to next Replace defective
relay (462–R1) by relay step. relay.
applying +12 volts to (462–R1), pin
pin 86, ground to pin 30 to 87.
85, and measuring
resistance from pin 30
to 87.
13. Off/ On Re-install ignition (518) to gnd. 12 ± 1.5 Go to next Locate cause of
relay (462–R1), move volts. step. low or no voltage
key switch to ignition in circuit 13H or
position, and at I1 13F, then repair.
ignition adapter (518),
measure voltage to
ground.
14. On With key switch in (607) to gnd. 12 ± 1.5 Ignition Locate cause of
ignition position, at I2 volts. power low or no voltage
ignition adapter (607), distribution in circuit 13P, then
measure voltage to circuits repair.
ground. check
good.
3.8. PANEL LIGHTS ADAPTER

Table 8 Panel Lights Adapter
POINTS SPEC. SPEC.
1. Off Disconnect panel (416), 62 to 12 ± 1.5 Go to next Locate cause of
light switch connector gnd. volts. step. low or no voltage
(416), move headlight in circuit 62 or
switch to park light 68C from 15A fuse
position, and at F8–C, then repair.
connector (416) circuit
62, measure voltage
to ground.
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Table 8 Panel Lights Adapter (cont.)

POINTS SPEC. SPEC.
2. Off With switches still set, (416), 62 to 12 ± 1.5 Go to next Locate open or
at connector (416), 11–GS. volts. step. poor connection
measure voltage from in circuit 11–GS,
circuit 62 to 11–GS. 11–GLC, 11–GP,
11–GLA, or 11–GD
to left cab ground
stud (429), then
repair.
3. Off Reconnect switch (416), 62A to 11 ± 1.5 Go to next Replace defective
(416), move headlight gnd. volts. step. panel light switch
switch to park light (416).
position, move
dimmer to bright
position, and at switch
terminal and circuit
62A, measure voltage
to ground.
4. Off With switches still (504) to gnd. 11 ± 1.5 Go to next Locate cause of
set, at L1 panel lights volts. step. low or no voltage in
feed adapter (504), circuit 62A, 62S, or
measure voltage to 62AE, then repair.
ground.
set, at L2 panel lights volts. step. low or no voltage
feed adapter (586), in circuit 62M, then
measure voltage to repair.
ground.
set, at L5 panel lights volts. step. low or no voltage
feed adapter (508), in circuit 62BW,
measure voltage to 62T, or 62AK, then
ground. repair.
7. Off Move headlight switch (505) to gnd. < 1 ohm. Go to next Locate open or
to OFF position, and step. poor connection
at L3 panel lights in circuit 11–GP,
ground adapter (505), 11–GLA, or 11–GD
measure resistance to to left cab ground
ground. stud (429), then
repair.
8. At L4 panel lights (587) to gnd. < 1 ohm. Main panel Locate open or
ground adapter (587), light circuits poor connection
Off
measure resistance to check good. in circuit 11–GAK,
ground. then repair.
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4. COMPONENT LOCATIONS
A1 Accessory Adapter (516). . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Center
B1 Battery Adapter (517). . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Center
B7 Battery Feed Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Under Mag Switch Cover Near Battery Box
F1 Fuseblock (462). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Panel
F10 Fuseblock (464). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Panel [May be located between
F9 (463) and F13 (464)]
G1 Ground Adapter (454). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Right
G2 Ground Adapter (455). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Right Gauge Cluster
G4 Ground Adapter (457). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Left Gauge Cluster
G5 Ground Adapter (533). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Center
G6 Ground Adapter (616). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Cluster, Right
I1 Ignition Adapter (518). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Cluster, Right
I2 Ignition Adapter (607). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Speedo/Tach Cluster
I3 Ignition Adapter (496). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Right Gauge Cluster
L1 LED Panel Lt Feed Adapt (504). . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
L2 LED Panel Lt Feed Adapt (586). . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
L3 LED Panel Lt Gnd Adapt (505). . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
L4 LED Panel Lt Gnd Adapt (587). . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
L5 LED Panel Lt Feed Adapt (508). . . . . . . . . . . . . . . . . .. . . . . . Behind Right Gauge Cluster
Megafuse, 150A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Fuse Panel
(B1) Battery Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Power Distribution Panel
(B2) Battery Stud/Deep Cycle Stud. . . . . . . . . . . . . . . . .. . . . . . At Power Distribution Panel
(J5) Starter Mag Sw. Gnd Junction. . . . . . . . . . . . . . . . . .. . . . . . Under Mag Switch Cover Near Battery Box
(94) Push Button Start Switch. . . . . . . . . . . . . . . . . . . . . . .. . . . . . To Left of Key Switch at Base of Right Wing Panel
(102) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Cab Floor, Ft. Rt, 1/2 replaced by (338) W/Series
60
(404) Right Cab Ground Stud. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Right Hand Cowl Inner Panel
(410) Headlight Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(416) Panel Lights Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(429) Left Cab Ground Stud. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left Hand Cowl Inner Panel
(446–R15) Accessory Feed Relay. . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Panel
(452) Key Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Base of Dash, Right Wing Panel
(454) G1 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Right
(455) G2 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Right Gauge Cluster
(457) G4 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Left Gauge Cluster
(462–R1) R1 Ignition Relay . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Center
(463) F6 Through F9 Fuseblock. . . . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Panel
(463) F10 Through F13 Fuseblock. . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Panel
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(496) I3 Ignition Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Right Gauge Cluster

(504) L1 LED Panel Lt. Feed Adapt.. . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(505) L3 LED Panel Lt. Gnd Adapt.. . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(508) L5 LED Panel Lt. Feed Adapt.. . . . . . . . . . . . . . . .. . . . . . Behind Right Gauge Cluster
(509) Start Feed Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(516) A1 Accessory Adapter. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Center
(517) B1 Battery Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Center
(518) I1 Ignition Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Cluster, Right
(533) G5 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Center
(537) 3+1 Feed Connection. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Under Cab Floor at Right Front
(586) L2 LED Panel Lt. Feed Adapt. . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(587) L4 LED Panel Lt. Gnd Adapt. . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(607) I2 Ignition Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Speedo/Tach Cluster
(616) G6 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Cluster, Right
Refer to Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8Figure 9, Figure 10, Figure
11, Figure 12, and Figure 13.
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Figure 1 Power Distribution Center — 9800 SFA and SBA
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Figure 3 Relay Location
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Figure 5 Fuse and Circuit Breaker Location
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Figure 6 Fuse and Circuit Breaker Location
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Figure 8 Cab Wiring — 9800 SFA and SBA
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Figure 13 Switch and Panel Light Mounting — 9800
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1. TRAILER LIGHT SWITCH

2. HEADLIGHT SWITCH
3. DIMMER SWITCH
4. DOME LIGHT SWITCH
5. OPTIONAL SWITCHES:
POWER MIRROR — LH
POWER MIRROR — RH
FOG LIGHT
ELECTRIC WINDOW — LH
ELECTRIC WINDOW — RH
ETHER START
TRAILER AUX.
AIR SHIELD LIGHT
MIRROR HEATER
DIAGNOSTIC, ENGINE OVERRIDE
CRUISE OFF/ON DIAGNOSTIC ON/OFF
LIGHTED MANUAL FAN OVERRIDE
CAB OPERATOR SPARE
6. WIPER IDENTIFICATION (WITH AIR WIPER ONLY)
7. WINDSHIELD WASHER IDENTIFICATION (WITH AIR WIPERS ONLY)
8. WIPER IDENTIFICATION (WITH AIR WIPERS ONLY)
9. KEY SWITCH IDENTIFICATION PANEL LIGHT
10. ENGINE START IDENTIFICATION PANEL LIGHT
11. CRUISE SET/RESUME SWITCH
12. CRUISE ON/OFF SWITCH
13. ENGINE BRAKE SELECT SWITCH
14. ENGINE BRAKE ON/OFF SWITCH
15. WINDSHIELD WIPER INTERMITTENT/ WASHER SWITCH
16. WINDSHIELD WIPER HI/LO SWITCH
17. SLEEPER DOME LIGHT SWITCH
18. WORK LIGHT SWITCH
19. SWITCH MOUNTING PLATE
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2 CAB ACCESSORIES 37
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.1. CIGAR LIGHTER (CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.2. ELECTRIC WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.3. WINDSHIELD DEFROSTER FANS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.4. HORN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.5. MIRRORS - HEATED AND LIGHTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.6. HEATED MIRRORS AND MOTORIZED RIGHT MIRROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.7. DUAL AXIS MOTORIZED MIRRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.8. CB POWER SOURCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.9. CB RADIO ACCOMMODATION PACKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
1.10. RADIO AND CAB SPEAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
1.11. ELECTRIC WINDSHIELD WIPER WITH INTERMITTENT WIPE AND WASH. . . . . . . . . . . . . . . . . . .40
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
2.2. ELECTRIC WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
2.4. HORN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.5. MIRRORS - HEATED AND LIGHTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.6. HEATED MIRRORS AND MOTORIZED RIGHT MIRROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.7. DUAL AXIS MOTORIZED MIRRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.8. CB POWER SOURCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.9. CB RADIO ACCOMMODATION PACKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
2.10. RADIO AND CAB SPEAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3.2. ELECTRIC WINDOW LEFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
3.3. ELECTRIC WINDOW RIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3.5. HORN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
3.6. MIRRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Heated and Lighted Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Heated Mirrors and Motorized Right Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Dual Axis Motorized Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
3.7. CB POWER SOURCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3.8. CB RADIO ACCOMMODATIONS PACKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3.9. RADIO AND CAB SPEAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
4. COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
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38 2 CAB ACCESSORIES
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Model: 9800
1. DESCRIPTION
1.1. CIGAR LIGHTER (CAB)
The Cigar Lighter circuit provides power to the Cigar Lighter or other item plugged into the lighter socket. The
socket is located to the right of the steering column.
1.2. ELECTRIC WINDOWS

Left
A switch located in the instrument panel switch cluster provides a means for the driver to raise and lower the
driver side window by energizing the left side electric window motor.
Right
A switch located in the instrument panel switch cluster provides a means for the driver to raise and lower the
passenger side window by energizing the right side electric window motor. The passenger is provided a switch,
at the right-hand side of the front kick panel, for raising and lowering the window also.
1.3. WINDSHIELD DEFROSTER FANS

Single or dual windshield defroster fans are available, and are header mounted on swivel brackets. Thus they
can be switched on (at the fan) and directed onto the windshield to clear away moisture.
1.4. HORN
The electric horn is located in the grille of the truck and provides a means of signaling or warning other
vehicle drivers.
1.5. MIRRORS - HEATED AND LIGHTED

Optional heated, or heated and lighted mirrors are available for the left and right sides.
1.6. HEATED MIRRORS AND MOTORIZED RIGHT MIRROR

Optional heated left mirror and heated and motorized right mirror are available.
1.7. DUAL AXIS MOTORIZED MIRRORS

Optional dual axis motorized mirrors are available.
1.8. CB POWER SOURCE

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

An optional Citizens Band radio accommodation package is available that provides a speaker, and speaker
and power connections to be connected to the customer furnished CB radio.
1.10. RADIO AND CAB SPEAKERS

An optional radio and cab speaker package is available. It consists of a left front and right front coaxial
speaker in the cab.
1.11. ELECTRIC WINDSHIELD WIPER WITH INTERMITTENT WIPE AND WASH

The electric windshield wipers have a two-speed motor and intermittent wipe feature, and are self parking
when they are turned off.
2. OPERATION
Power is continuously supplied to B2 battery stud, circuits 14W and 14T, 15A fuse F2-A, and circuit 84 to the
cigar lighter socket. A ground path is provided to the socket by circuits 84-G and 11-GD. Thus when the cigar
lighter element is pushed into the socket, the circuit is completed, causing the cigar lighter element to heat
up and pop out, which in turn opens up the circuit.
2.2. ELECTRIC WINDOWS

Left
With the key switch (452) on or in the accessories position, power is applied to accessories adapter A1 (516),
circuit 12Y, and left side electric window relay (448). Thus current flows through the relay coil and circuits
12-GY and 11-GAT to the G2 ground adapter (455). This energizes the relay and applies power from the B1
battery adapter (517) to circuit 14AV, 25A fuse F10-A (location may vary), circuit 83F, and the relay. Power is
then applied to the N.O. contacts, circuit 83J, and the left side power window switch (420).
With the window switch in the down position, power flows through the switch, circuit 83DA, connector (437),
circuit 83D, connector (57), and a red wire to the window motor. A ground path is applied to the motor by way of
a blue wire, connector (57), circuit 83C, connector (437), circuit 83CA, switch (420), circuits 83-GA and 11-GAT
to the G2 ground adapter (455), thus causing the motor to run, and the window to move in the down direction.
With the window switch in the up position, power flows through the switch, circuit 83CA, connector (437), circuit
83C, connector (57), and a blue wire to the window motor. A ground path is applied to the motor by way of a
red wire, connector (57), circuit 83D, connector (437), circuit 83DA, switch (420), circuits 83-GA and 11-GAT to
the G2 ground adapter (455), thus causing the motor to run, and the window to move in the up direction.
Right
With the key switch (452) on or in the accessories position, power is applied to accessories adapter A1 (516),
circuit 12W, and right side electric window relay (449). Thus, current flows through the relay coil and circuits
12-GW and 11-GAU to the G3 ground adapter (456). This energizes the relay and applies power from the B1
battery adapter (517) to circuit 14BD, 25A fuse F10-A (location may vary), circuit 83, and the relay. Power is
then applied to the N.O. contacts, circuit 83H, and the right side power window passenger switch (506).
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With the passenger switch in the down position, power flows through the switch, circuit 83D, connector (403),
circuit 83D, connector (16), a white wire, connector (34), and a red wire to the window motor. A ground path is
applied to the motor by way of a black wire, connector (34), a black wire, connector (16), circuit 83C, connector
(403), circuit 83C, switch (506), circuit 83A, switch (413), circuits 83-G and 11-GAU to the G3 ground adapter
(456), thus causing the motor to run, and the window to move in the down direction.
With the passenger switch in the up position, power flows through the switch, circuit 83C, connector (403),
circuit 83C, connector (16), a black wire, connector (16), connector (34), and a black wire to the window motor.
A ground path is applied to the motor by way of a red wire, connector (34), a white wire, connector (16), circuit
83D, connector (403), circuit 83D, switch (506), circuit 83B, switch (413), circuits 83-G and 11-GAU to the G3
ground adapter (456), thus causing the motor to run, and the window to move in the up direction.
With the driver’s switch in the down position, power flows through circuit 83E, the switch, circuit 83B, switch
(506), circuit 83D, connector (403), circuit 83D, connector (16), a white wire, connector (34), and a red
wire to the window motor. A ground path is applied to the motor by way of a black wire, connector (34), a
black wire, connector (16), circuit 83C, connector (403), circuit 83C, switch (506), circuit 83A, switch (413),
circuits 83-G and 11-GAU to the G3 ground adapter (456), thus causing the motor to run, and the window
to move in the down direction.
With the driver’s switch in the up position, power flows through circuit 83E, the switch, circuit 83A, switch (506),
circuit 83C, connector (403), circuit 83C, connector (16), a black wire, connector (34), and a black wire to
the window motor. A ground path is applied to the motor by way of a red wire, connector (34), a white wire,
connector (16), circuit 83D, connector (403), circuit 83D, switch (506), circuit 83B, switch (413), circuits 83-G
and 11-GAU to the G3 ground adapter (456), thus causing the motor to run, and the window to move in
the up direction.

When the key switch is moved to the ignition on or accessories position, the accessories feed relay (446)
is energized. Thus, power is made available to circuits 12AF, 12L, 15A fuse F5-A, circuit 76, roof harness
connector (19), circuit 76, and circuit 76A to connector (560) and 76B to connector (561). When the left fan
switch is moved to low or high speed position, power flows through connector (560), a black circuit, the fan
switch contacts, the fan motor winding, the other black circuit, connector (560), and circuits 76-GA and 11-GAA
to cab roof ground (J3). When the right fan switch is moved to low or high speed position, power flows
through connector (561), a black circuit, the fan switch contacts, the fan motor winding, the other black circuit,
connector (561), and circuits 76-GB and 11-GAA to cab roof ground (J3).
2.4. HORN
With the key switch in the on or off position, power is supplied to (B1) battery stud, circuits 14K and 14AM, 15A
fuse F5-C, and circuit 85 to the horn relay (463-R7) contacts. From the relay contacts and circuit 85, power is
supplied to the relay coil by a jumper 85A. When the horn button is depressed, a ground path is provided to
the horn relay by way of circuit 85C, horn button connector (N/L), circuit 85A, connector (N/L), a black wire,
connector (N/L), a black wire, steering wheel slip ring, a black wire, and the horn button to cab ground. Thus
the horn relay will become energized and power will flow through the relay contacts, and circuit 85B to the horn
and connector (214). The ground path for the horn is through circuits 85-G and 11-GI to ground stud (429).
2.5. MIRRORS - HEATED AND LIGHTED

With the key switch (452) in the ignition or accessory position, the accessory feed relay (446) is energized.
The energized relay then provides power to circuits 12AF and 12L, 15A fuse F5-A, and circuit 78 to the heated
mirror switch (415). When the switch is moved to the on position, power is applied to circuit 78A going to the left
door harness connector (437), and circuit 78B going to the right door harness connector (403). From connector
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(437) power flows through circuit 78A, connector (31), the green wire, the left mirror heating element, the white
wire, connector (31), and circuit 11A to ground (J9), thus causing the left mirror to heat up. From connector
(403) power flows through circuit 78A, connector (31), the green wire, the right mirror heating element, the
white wire, connector (31), and circuit 11A to ground (J14), thus causing the right mirror to heat up.
When the headlight switch (410) is placed in the parking lights or headlights position, the trailer tail lights relay
(464-R9) will be energized. With the relay energized, power will flow through circuits 68E and 68B, 15A fuse
F8-C, circuits 68C and 58F, and a connector (N/L). From the connector, power flows through circuit 58F to the
left door harness connector (437) and through circuit 58B to the right door harness (403). From connector (437)
power flows through circuit 58B, connector (31), a yellow wire, left mirror light, a white wire, another white wire,
connector (31), and circuit 11A to ground (J9), thus causing the left mirror light to illuminate. From connector
(403) power flows through circuit 58B, connector (31), a yellow wire, right mirror light, a white wire, another
white wire, connector (31), and circuit 11A to ground (J14), thus causing the right mirror light to illuminate.
2.6. HEATED MIRRORS AND MOTORIZED RIGHT MIRROR

With the key switch (452) in the ignition or accessory position, the accessory feed relay (446) is energized.
The energized relay then provides power to circuits 12AF and 12L, 15A fuse F5-A, and circuit 78 to the heated
mirror switch (415). When the switch is moved to the on position, power is applied to circuit 78A going to the left
door harness connector (437), and circuit 78B going to the right door harness connector (403). From connector
(437) power flows through circuit 78A, connector (31), the green wire, the left mirror heating element, the white
wire, connector (31), and circuit 11A to ground (J9), thus causing the left mirror to heat up. From connector
(403) power flows through circuit 78A, connector (31), the green wire, the right mirror heating element, the
white wire, connector (31), and circuit 11A to ground (J14), thus causing the right mirror to heat up.
Circuit 78 also feeds power to circuit 78D going to the right motorized mirror switch (540). When the switch is
moved in the left direction, power is applied to circuit 78F, connector (403), circuit 78F, connector (31), and the
yellow wiring going to the mirror motor. The ground path is through the white wire, connector (31), circuit 78E,
connector (403), circuit 78E, switch (540), circuits 78-GB, 11-GLA, 11-GD, and left cab ground stud (429), thus
causing the mirror to rotate to the left. When the switch is moved in the right direction, power is applied to
circuit 78E, connector (403), circuit 78E, connector (31), and the white wiring going to the mirror motor. The
ground path is through the yellow wire, connector (31), circuit 78F, connector (403), circuit 78F, switch (540),
circuits 78-GB, 11-GLA, 11-GD, and left cab ground stud (429), thus causing the mirror to rotate to the right.
2.7. DUAL AXIS MOTORIZED MIRRORS

When the key is in the on or accessory position, the dual axis motorized mirror switch 951 receives power from
the A3 accessory adapter (501), through 10A fuse F10-A, on circuit 78D, through connector (951). Twisting the
mirror control switch knob selects which mirror will be controlled. Positioning the L/R switch to the Left or Right
position will cause the controlled mirror to move to the Left or Right. Positioning the U/D switch to the Up or
Down position will cause the controlled mirror to move Up or Down. Ground for the circuits is supplied from
GND Adapter (593) on circuit 78-GB through connector (951).
Use the DUAL AXIS MOTORIZED MIRROR circuit diagrams, in CTS-5254W, to determine which circuits are
energized to move the mirrors.

With the key switch in the on or off position, power is supplied to (B2) battery stud, circuits 14H and 14AA,
20A fuse F5-D, and circuit 86J to CB radio power receptacle (40) or to CB radio power terminal. The ground
path for the power terminals is circuits 86-GAJ, 86-GJ and 11-GB to the right cab ground stud (404), and the
ground path for the receptacle is circuit 86-GJ and circuit 11-GB to right cab ground stud (404), thus providing
a 12 volt CB radio power source.
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2.9. CB RADIO ACCOMMODATION PACKAGE

With the key switch (452) in the ignition or accessories position, power is supplied to circuit 12M, 10A fuse
F5-B, circuit 86CE, connector (19), circuit 86CE, connector (740), and circuit 86AT to the customer supplied
CB radio. The ground path for the radio is circuit 86-GAT, connector (740), circuits 86-GCE and 11-GAA to
cab roof ground (J3). A green wire, connector (774), and a green wire provide a signal path to the Navistar
provided CB speaker. A black wire, connector (774), and a yellow wire provide a signal return path to the CB
radio, thus providing power and audio hook-ups to the customer provided CB radio.

Power is continuously supplied to B1 battery adapter, circuits 14K and 14AM, 15A fuse F5-C, circuit 88B,
connector (20), and the yellow wire to the radio, thus providing continuous power to maintain the clock and
station memory programming. A ground circuit is provided through the black wire, connector (21), and
circuits 86-GB and 11-GLB to panel ground adapter L4 (587). When the key switch (452) is in the ignition or
accessories position, power is supplied to circuit 12M, 10A fuse F5-B, circuit 86, connector (20), and a red wire
to the radio, thus providing power to the radio/cassette player.
A signal path is provided through a white wire connector (20), circuit 86A, connector (739), circuit 86A,
connector (52), and the green wire to the left front speaker. The return path is through a black wire, connector
(52), circuit 86B, connector (739), circuit 86B, connector (20), and the white/black wire to the radio.
A signal path is provided through a gray wire connector (20), circuit 86C, connector (739), circuit 86C,
connector (18), and the green wire to the right front speaker. The return path is through a black wire, connector
(18), circuit 86D, connector (739), circuit 86D, connector (20), and the gray/black wire to the radio.

When key switch (452) is moved to the ignition or accessories position, power is applied to circuits 12 and
12F, and the wiper intermittent relay (444). The ground path for the relay is circuits 12-GF, 82-GA, 12-GH,
82-GD, 11-GD, and left cab ground stud (429). Thus the wiper intermittent relay (444) is energized and power
is applied by (B1) battery stud to circuits 14K and 14AL, 15A resetting fuse F6-B, circuit 82K, N.O. contacts of
relay (444), and circuit 82 to the intermittent switch (408). Power is also applied by the N.O. contacts to circuits
82A and 82B, and wiper switch (407).
With the key switch in ignition or accessories position, and the wiper switch in the low speed position, power
flows from switch (407) through circuit 82E, connector (507), and the green wire to the windshield wiper motor
low speed winding. The ground path for the motor is the brown wire, connector (507), circuits 82-GD and
11-GD, and left cab ground stud (429), thus causing the wiper motor to run at low speed.
With the key switch in ignition or accessories position, and the wiper switch in the high speed position, power
flows from switch (407) through circuit 82D, connector (507), and the red wire to the windshield wiper motor
high speed winding. The ground path for the motor is the brown wire, connector (507), circuits 82-GD and
11-GD, and left cab ground stud (429), thus causing the wiper motor to run at high speed.
With the key switch in ignition or accessories position, and the wiper switch in the off position, power flows from
switch (407) through circuit 82C, connector (507), the black wire to the windshield wiper motor park switch,
the blue wire, connector (507), circuit 82F, N.C. contacts of relay (445), circuit 82H, switch (407), circuit
82E, connector (507), and the green wire to the windshield wiper motor low speed winding. The ground
path for the motor is the brown wire, connector (507), circuits 82-GD and 11-GD, and left cab ground stud
(429), thus causing the wiper motor to run at low speed to the park position where it will stop when the
park switch contacts open up.
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When the wiper intermittent switch (408) is set and the end of the delay cycle is reached, the circuit will be
completed and power will flow through switch (408) and circuit 82J to the wiper relay (445), energizing the
relay. Thus power will flow through relay (445), circuit 82H, wiper switch (407), circuit 82E, connector (507),
the green wire, and the wiper motor low speed winding.
The ground path for the motor is the brown wire, connector (507), circuits 82-GD and 11-GD, and left cab
ground stud (429), thus causing the wiper motor to start running at low speed and shortly thereafter the
intermittent switch (408) will open the circuit, and de-energize relay (445). Thus the self parking circuitry
(described in a previous paragraph) will take over and return the wipers to park position. Then the cycle will
start over.
When the wiper intermittent switch (408) is moved to the wash position, the circuit is completed and power
will flow through switch (408), circuit 87A, connector (24), and the red wire to the windshield washer pump.
The ground path for the washer motor is the brown wire, connector (24), circuits 87-G and 11-GD to left cab
ground stud (429). Thus the washer pump will supply washer fluid to the windshield while the switch is
held in the wash position.
3. TROUBLESHOOTING
C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires,
etc. Refer to section in GROUP 08 - ELECTRICAL in the CTS-5000 Master Service Manual.
relay, or solenoid.

Table 9 Cigar Lighter (Cab)
STEP KEY ACTION TEST SPEC. YES- IN NO-OUT OF SPEC.
POINTS SPEC.
1. Off At battery stud (B2), B2 to gnd. 12 ± 1.5 Go to Locate cause of
measure voltage to volts. next step. low or no voltage
ground. in circuit 14, 150A
megafuse, or circuit
14BM [black wire,
circuit 14AC, 150A
megafuse or circuit
14AB with 3+1
system], then
repair.
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Table 9 Cigar Lighter (Cab) (cont.)

POINTS SPEC.
2. Off At 15A fuse F2–A and F2-A, 14T 12 ± 1.5 Go to Locate cause of
circuit 14T, measure to gnd. volts. next step. no or low voltage
voltage to ground. in circuit 14T, then
repair.
3. Off At cigar lighter socket, Cigar lighter 12 ± 1.5 Go to Locate cause of
measure voltage from socket, 84 to volts. next step. no or low voltage
circuit 84 to ground. gnd. in 15A fuse F2–A
or circuit 84, then
repair.
4. Off At cigar lighter socket, Cigar lighter 12 ± 1.5 Go to Locate open or poor
measure voltage from socket, 84 volts. next step. connection in circuit
circuit 84 to 84-G. to 84-G. 84-G or 11-GD, then
repair.
5. Off Cigar lighter circuits
check good. If cigar
lighter element fails
to heat up, replace
element.
3.2. ELECTRIC WINDOW LEFT

Table 10 Electric Window Left
STEP KEY ACTION TEST SPEC. YES-IN NO-OUT OF
POINTS SPEC. SPEC.
1. Off/ On Remove window relay (448), 12Y 12 ± 1.5 Go to next Locate cause of
(448), move key to gnd. volts. step. low or no voltage
switch to accessories in circuit 12Y from
position, and at (448) A1 accessories
circuit 12Y, measure adapter (516), then
voltage to ground. repair.
2. On With key switch still in (448), 12Y to 12 ± 1.5 Go to next Locate open or
accessories position, 12–GY. volts. step. poor connection in
at (448) measure circuit 12–GY or
voltage from circuit 11–GAT, or poor
12Y to 12–GY. ground supply at
G2 ground adapter
(455), then repair.
3. Off At 25A left window Fuse F10–A, 12 ± 1.5 Go to next Locate cause of
fuse F10–A [location 14AV to gnd. volts. step. low or no voltage
may vary] and circuit in circuit 14AV from
14AV, measure voltage B1 battery adapter
to ground. (517), then repair.
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Table 10 Electric Window Left (cont.)

POINTS SPEC. SPEC.
4. Off At window relay socket (448), 83F 12 ± 1.5 Go to next Locate cause of
(448), measure voltage to gnd. volts. step. no or low voltage
from circuit 83F to in circuit 83F from
ground. 25A fuse F10–A
[location may
vary], then repair.
5. Off Bench test window Relay, term. < 1 ohm. Go to next Replace defective
relay (448) by 30 to 87A. step. window relay.
from terminal 30 to
87A.
6. Off Bench test window Energized < 1 ohm. Go to next Replace defective
relay (448) by applying relay, term. step. window relay.
+12 volts to terminal 30 to 87.
86, ground to pin
85, and measuring
resistance from
terminal 30 to 87.
7. Off/ On Re-install window relay (420), 83J 12 ± 1.5 Go to next Locate cause of
(448) and disconnect to gnd. volts. step. low or no voltage
window switch (420). in circuit 83J, then
Move key switch to repair.
accessories position
and at connector (420)
circuit 83J, measure
voltage to ground.
8. Off At connector (420) (420), 83–GA < 1 ohm. Go to next Locate open or
circuit 83–GA, to gnd. step. poor connection in
measure resistance circuit 83–GA, then
to ground. repair.
9. Off Bench test window Switch < 1 ohm. Go to next Replace defective
switch (420) by holding in down step. window switch.
in the down position position,
and measuring term. 1 to 2.
resistance from
terminal 1 to 2.
resistance from
terminal 4 to 5.
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Table 10 Electric Window Left (cont.)

POINTS SPEC. SPEC.
11. Off Bench test window Switch in < 1 ohm. Go to next Replace defective
switch (420) by holding up position, step. window switch.
in the up position and term. 2 to 3.
from terminal 2 to 3.
13. Off/ On Reconnect window (57), 83D to 12 ± 1.5 Go to next Locate cause of
switch (420), gnd. volts. step. low or no voltage in
disconnect motor circuit 83D, conn.
connector (57) and (437), or circuit
move key switch to 83DA, then repair.
accessories position.
At (57) circuit 83D,
measure voltage to
ground while holding
switch (420) in up
position.
14. On With switches still (57), 83D to 12 ± 1.5 Go to next Locate open or
set, at (57) measure 83C. volts. step. poor connection in
voltage from circuit circuit 83C, conn.
83D to 83C. (437), or circuit
83CA, then repair.
15. On Reconnect connector Go to next Replace left
(57). Circuits to left step. window motor.
window motor check
good. Does motor
function properly?
16. Off Circuits and motor
check good.
3.3. ELECTRIC WINDOW RIGHT

Table 11 Electric Window Right
POINTS SPEC. SPEC.
1. Off/ On Remove window relay (449), 12W 12 ± 1.5 Go to next Locate cause of
(449), move key to gnd. volts. step. low or no voltage
switch to accessories in circuit 12W from
position, and at (449) A1 accessories
circuit 12W, measure adapter (516), then
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Table 11 Electric Window Right (cont.)

POINTS SPEC. SPEC.
2. On With key switch still in (449), 12W 12 ± 1.5 Go to next Locate open or
accessories position, to 12–GW. volts. step. poor connection in
at (449) measure circuit 12–GW or
voltage from circuit 11–GAU, or poor
12W to 12–GW. ground supply at
G3 ground adapter
(456), then repair.
3. Off At 25A window fuse Fuse F10–A, 12 ± 1.5 Go to next Locate cause of
F10–A [location may 14BD to gnd. volts. step. low or no voltage in
vary] and circuit 14BD, circuit 14BD from
measure voltage to B1 battery adapter
ground. (517), then repair.
4. Off At window relay socket (449), 83 to 12 ± 1.5 Go to next Locate cause of
(449), measure voltage gnd. volts. step. no or low voltage
from circuit 83 to in circuit 83 from
ground. 25A fuse F10–A
[location may
vary], then repair.
5. Off Bench test window Relay, term. < 1 ohm. Go to next Replace defective
relay (449) by 30 to 87A. step. window relay.
from terminal 30 to
87A.
6. Off Bench test window Energized < 1 ohm. Go to next Replace defective
relay (449) by applying relay, term. step. window relay.
+12 volts to terminal 30 to 87.
86, ground to pin
85, and measuring
resistance from
terminal 30 to 87.
7. Off/ On Re-install window (506), 83H 12 ± 1.5 Go to next Locate cause of
relay (449) and to gnd. volts. step. low or no voltage
disconnect passenger in circuit 83H, then
window switch (506). repair.
Move key switch to
accessories position
and at connector (506)
circuit 83H, measure
voltage to ground.
8. On With key switch still in (413), 83E 12 ± 1.5 Go to next Locate cause of
accessories position, to gnd. volts. step. low or no voltage
at switch connector in circuit 83E, then
(413) circuit 83E, repair.
measure voltage to
ground.
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POINTS SPEC. SPEC.
9. Off Disconnect window (413), 83–G < 1 ohm. Go to next Locate open or
switch (413) and at to gnd. step. poor connection in
circuit 83–G, measure circuit 83–G, then
resistance to ground. repair.
resistance from
terminal 1 to 2.
resistance from
terminal 4 to 5.
resistance from
terminal 1 to 2.
resistance from
terminal 4 to 5.
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POINTS SPEC. SPEC.
18. Off Reconnect passenger (506), 83B < 1 ohm. Go to next Locate open or
switch (413) and at to gnd. step. poor connection in
switch connector (506) circuit 83B, then
circuit 83B, measure repair.
resistance to ground.
19. Off At switch connector (506), 83A < 1 ohm. Go to next Locate open or
(506) circuit 83A, to gnd. step. poor connection in
measure resistance to circuit 83A, then
ground. repair.
20. Off Disconnect motor (34), black < 1 ohm. Go to next Locate open or
connector (34) and wire to gnd. step. poor connection in
at black wire that is black wire, conn.
part of door harness, (16), circuit 83C,
measure resistance to conn. (403), or
ground. circuit 83C from
switch (506), then
repair.
21. Off At connector (34) (34), white < 1 ohm. Go to next Locate open or
and white wire that is wire to gnd. step. poor connection in
part of door harness, white wire, conn.
measure resistance to (16), circuit 83D,
ground. conn. (403), or
circuit 83D from
switch (506), then
repair.
22. On Reconnect connector Go to next Replace right
(34). Circuits to right step. window motor.
window motor check
good. Does motor
function properly?
23. Off Circuits and motor
check good.
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Table 12 Windshield Defroster Fans
POINTS SPEC. SPEC.
1. On Move key switch to F5–A, 12L 12 ± 1.5 Go to next Locate cause of no
accessories position, to gnd. volts. step. or low voltage in
and at 15A fuse F5–A circuit 12L or 12AF
and circuit 12L, measure from accessories
voltage to ground. feed relay (446),
then repair.
2. On Disconnect connector (560), 76A 12 ± 1.5 Go to next Locate cause of
(560) and at circuit 76A, to gnd. volts. step. low or no voltage
measure voltage to in circuit 76, conn.
ground. (19), circuit 76 or
76A from 15A fuse
F5–A, then repair.
3. On At connector (560) (560), < 1 ohm. Go to next Locate open or
circuit 76–GA, measure 76–GA to step. poor connection in
resistance to ground. gnd. circuit 76–GA or
11–GAA to J3 cab
roof ground, then
repair.
4. On Reconnect left fan motor Go to next Repair or replace
connector (560). Circuits step. left defroster fan.
to left fan motor check
good. Does motor run in
low and high speeds?
5. On Disconnect connector (561), 76B 12 ± 1.5 Go to next Locate cause of
(561) and at circuit 76B, to gnd. volts. step. low or no voltage
measure voltage to in circuit 76B, then
ground. repair.
6. On At connector (561) (561), < 1 ohm. Go to next Locate open or
circuit 76–GB, measure 76–GB to step. poor connection in
resistance to ground. gnd. circuit 76–GB, then
repair.
7. On Reconnect right fan motor Go to next Repair or replace
connector (561). Circuits step. right defroster fan.
to right fan motor check
good. Does motor run in
low and high speeds?
8. Off Fan circuits check good.
Move key switch to off
position.
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3.5. HORN
Table 13 Horn
POINTS SPEC.
1. Off At 15A fuse F5–C and F5-C, 14AM 12 ± 1.5 Go to next Locate cause of
circuit 14AM, measure to gnd. volts. step. low or no voltage in
voltage to ground. circuit 14AM or 14K
from battery stud
(B1), then repair.
2. Off Remove horn relay (463)/R7, 85 12 ± 1.5 Go to next Locate cause of
(463–R7) and at circuit to gnd. volts. step. no or low voltage in
85, measure voltage to circuit 85 or 15A fuse
ground. F5–C, then repair.
3. Off At relay socket (463)/R7, 12 ± 1.5 Go to next Locate cause of
(463–R7) circuit 85A, 85A to gnd. volts. step. no or low voltage
measure voltage to in circuit 85A, then
ground. repair.
4. Off At relay socket (463)/R7, < 1 ohm. Go to next Locate open or poor
(463–R7) circuit 85C, 85C to gnd. step. connection in circuit
measure resistance 85C, conn. (N/L),
to ground while an circuit 85A, conn.
assistant depresses (N/L), black wire,
the horn button. conn. (N/L), black
wire, slip ring, black
wire, or horn button
to chassis ground,
then repair.
5. Off Re-install horn relay (214), 85B to 12 ± 1.5 Go to next Locate cause of
(463–R7). Disconnect gnd. volts. step. low or no voltage
connector (214), and in circuit 85B, then
at circuit 85B, measure repair.
voltage to ground while
an assistant depresses
the horn button.
6. Off At horn connector (214), 85B to 12 ± 1.5 Go to next Locate open or poor
(214), measure voltage 85–G. volts. step. connection in circuit
from circuit 85B 85–G or 11–GI, then
to 85–G while an repair.
assistant depresses
the horn button.
7. Off Reconnect connector
(214). Horn circuits
check good. If horn
fails to sound, replace
horn.
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3.6. MIRRORS
Heated and Lighted Mirrors
Table 14 Heated and Lighted Mirrors

POINTS SPEC.
1. On Move key switch to F5-A, 12L to 12 ± 1.5 Go to next Locate cause of
accessories position, gnd. volts. step. low or no voltage in
and at 15A fuse circuit 12AF or 12L
F5–A and circuit 12L, from accessories
measure voltage to relay (466), then
ground. repair.
2. Off Disconnect mirror Switch (415), < 1 ohm. Go to next Replace defective
switch (415) and term. 5 to 6. step. mirror switch (415).
with switch in the on
position, measure
resistance from
terminal 5 to 6.
3. Off/ Disconnect left (31), 78A to 12 ± 1.5 Go to next Locate cause of
On heated/ lighted mirror gnd. volts. step. low or no voltage in
connector (31), circuit 78A, conn.
move key switch to (437), or 78A, then
accessories position, repair.
move mirror switch
to on position, and at
circuit 78A, measure
voltage to ground.
4. On Move headlight F8–C, 68B to 12 ± 1.5 Go to next Locate cause of
switch to parking light gnd. volts. step. low or no voltage in
position, and at 15A circuit 68E or 68B
fuse F8–C and circuit from tail light relay
68B, measure voltage (464–R9), then
to ground. repair.
5. On With switches still set, (31), 58B to 12 ± 1.5 Go to next Locate cause of
at connector (31) and gnd. volts. step. low or no voltage
circuit 58B, measure in circuit 68C, 58F,
voltage to ground. conn. (N/L), circuit
58F, conn. (437), or
circuit 58B from 15A
fuse F8–C, then
repair.
6. On With switches still (31), 58B to 12 ± 1.5 Go to next Locate open or poor
set, at connector (31), 11A. volts. step. connection in circuit
measure voltage from 11A to ground stud
circuit 58B to 11A. (J9), then repair.
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Table 14 Heated and Lighted Mirrors (cont.)

POINTS SPEC.
7. On Circuits to left Go to next Repair or replace
mirror check good. step. mirror.
Reconnect connector
(31). Does mirror light
and heater function?
8. Off/ Disconnect right (31), 78A to 12 ± 1.5 Go to next Locate cause of
On heated/ lighted mirror gnd. volts. step. low or no voltage in
connector (31), circuit 78B, conn.
move key switch to (403), or 78A, then
accessories position, repair.
move mirror switch
to on position, and at
voltage to ground.
9. On Move headlight (31), 58B to 12 ± 1.5 Go to next Locate cause of
switch to parking gnd. volts. step. low or no voltage in
light position, and at circuit 58B, conn.
connector (31) and (403), or circuit 58B
circuit 58B, measure from conn. (N/L),
voltage to ground. then repair.
10. On With switches still (31), 58B to 12 ± 1.5 Go to next Locate open or poor
set, at connector (31), 11A. volts. step. connection in circuit
measure voltage from 11A to ground stud
circuit 58B to 11A. (J14), then repair.
11. Off Circuits to right Mirror Repair or replace
mirror check good. circuits mirror.
Reconnect connector check
(31). Does mirror light good.
and heater function?
Heated Mirrors and Motorized Right Mirror
Table 15 Heated Mirrors and Motorized Right Mirror

POINTS SPEC.
1. On Move key switch to F5-A, 12L to 12 ± 1.5 Go to next Locate cause of
accessories position, gnd. volts. step. low or no voltage in
and at 15A fuse circuit 12AF or 12L
F5–A and circuit 12L, from accessories
measure voltage to relay (446), then
ground. repair.
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Table 15 Heated Mirrors and Motorized Right Mirror (cont.)

POINTS SPEC.
2. Off/ Disconnect mirror (415), 78 to 12 ± 1.5 Go to next Locate cause of
On switch conn. (415), gnd. volts. step. low or no voltage
move key switch to in circuit 78, or 15A
accessories position, fuse F5–A, then
and at circuit 78, repair.
measure voltage to
ground.
3. On Does heated mirror Go to Step Go to next step.
function properly? 12.
4. On With key switch in (415), 78 to 12 ± 1.5 Go to next Locate open or poor
accessories position, 78–G. volts. step. connection in circuit
at switch connector 78–G or 11–GLB
(415), measure voltage to L4 panel lights
from circuit 78 to 78–G. ground adapter
(587) ground
source, then repair.
5. Off Test mirror switch Switch, term. < 1 ohm. Go to next Replace defective
(415) by placing 5 to 6. step. heated mirror switch
in on position, and (415).
6. Off/ Reconnect heated (31), 78A to 12 ± 1.5 Go to next Locate cause of
On mirror switch (415), gnd. volts. step. low or no voltage in
disconnect left side circuit 78A, conn.
connector (31), and (437), or circuit 78A,
move key switch to then repair.
At left side connector
(31) and circuit 78A,
measure voltage to
ground.
7. On With key switch still (31), 78A to 12 ± 1.5 Go to next Locate open or poor
on, at connector (31), 11A. volts. step. connection in circuit
measure voltage from 11A from ground
circuit 78A to 11A. junction (J9), then
repair.
8. Off/ Circuits to left heated Go to next Repair or replace
On mirror check good. step. mirror.
Reconnect mirror. With
switches on, does
mirror heat up?
s08270

POINTS SPEC.
9. Off/ Disconnect right side (31), 78A to 12 ± 1.5 Go to next Locate cause of
On connector (31), and gnd. volts. step. low or no voltage in
move key switch to circuit 78B, conn.
accessories position. (403), or circuit 78A,
At right side connector then repair.
measure voltage to
ground.
10. On With key switch still (31), 78A to 12 ± 1.5 Go to next Locate open or
on, at connector (31), 11A. volts. step. poor connection in
measure voltage from circuit 11A to ground
circuit 78A to 11A. junction (J14), then
repair.
11. Off/ Circuits to right heated Go to next Repair or replace
On mirror check good. step. mirror.
Reconnect mirror. With
switches on, does
mirror heat up?
12. On Does right side Go to Step Go to next step.
motorized mirror 21.
function properly?
13. Off/ Disconnect mirror (540), 78D to 12 ± 1.5 Go to next Locate cause of
On switch connector (540), gnd. volts. step. low or no voltage
and move key switch to in circuit 78D, then
accessories position. repair.
At circuit 78D, measure
voltage to ground.
14. On At connector (540) (540), 78D to 12 ± 1.5 Go to next Locate open or poor
measure voltage from 78–GB. volts. step. connection in circuit
circuit 78D to 78–GB. 78–GB, 11–GLA, or
11–GD to the left
cab ground stud
(429), then repair.
15. Off Bench test mirror Switch (540), < 1 ohm. Go to next Replace defective
switch (540) by moving term. 1 to 2. step. switch.
wiper to the left and
wiper to the left and
s08270

POINTS SPEC.
wiper to the right and
wiper to the right and
19. Off/ Disconnect mirror (31), 78E to 12 ± 1.5 Go to next Locate cause of
On motor connector (31) 78F. volts. step. low or no voltage in
and reconnect switch circuit 78E or 78F,
connector (540). then repair.
With key switch in
accessories position,
at connector (31),
measure voltage from
circuit 78E to 78F while
moving mirror switch in
either direction.
20. On Reconnect motor Go to next Replace defective
connector (31). Does step. mirror motor or
mirror function when mirror assembly.
switches are actuated?
21. Off Mirror circuits check
good.
Dual Axis Motorized Mirrors
Table 16 Dual Axis Motorized Mirrors

POINTS SPEC.
1. Off Check 15A fuse F5-A F5-A < 1 ohm. Go to next Locate cause of
for open condition. step. overload condition,
then repair.
Replace fuse.
2. Off/ Disconnect connector (951), 78D 12 ± 1.5 Go to next Locate cause of
On (951) from motorized to gnd. volts. step. no or low voltage
mirror switch. Turn key in circuit 78D from
on. At connector (951) fuse, then repair.
measure voltage to
ground at circuit 78D.
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Table 16 Dual Axis Motorized Mirrors (cont.)

POINTS SPEC.
3. On At connector (951) (951), 78D to 12 ± 1.5 Go to next Locate open or poor
measure voltage 78–GB. volts. step. connection in circuit
between circuits 78D 78–GB path to
and 78–GB. ground, then repair.
4. Off Turn the mirror switch Mirror switch, < 1 ohm. Go to next Replace the switch.
(951) knob to left A to D, and step.
position. Push the H to C.
knob to up position,
measure resistance
from terminals (A to D)
and (H to C).
(951) knob to left A to C, and step.
position. Push the H to D.
knob to down position,
measure resistance
from terminals (A to C)
and (H to D).
(951) knob to left A to B, and step.
position. Push the H to C.
knob to right position,
measure resistance
from terminals (A to B)
and (H to C).
(951) knob to left A to C, and step.
position. Push the H to B.
knob to left position,
measure resistance
from terminals (A to C)
and (H to B).
(951) knob to right A to E, and step.
position. Push the H to F.
knob to up position,
measure resistance
from terminals (A to E)
and (H to F).
(951) knob to right A to F, and step.
position. Push the H to E.
knob to down position,
measure resistance
from terminals (A to F)
and (H to E).
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POINTS SPEC.
(951) knob to right A to F, and step.
position. Push the H to G.
knob to left position,
measure resistance
from terminals (A to F)
and (H to G).
(951) knob to right A to G, and step.
position. Push the H to F.
knob to right position,
measure resistance
from terminals (A to G)
and (H to F).
12. Off With switch (951) All mirror > 100K Go to next Replace the switch.
in neutral position, switch ohms. step.
measure resistance terminals.
between all of the
terminals.
13. Off/ Reconnect connector Check Left mirror Go to next Go to Step 15.
On (951). Turn ignition key left mirror operates step.
to ACC position. Verify operation. correctly.
operation of the left
mirror.
14. On Verify operation of the Right Mirror Go to Step 17.
right mirror. mirror circuits
operates check
correctly. good.
15. On Disconnect connector (31), 78E to ± 12 volts. Go to next Locate open or
(31) going to the left 78F. step. poor connection in
mirror. Turn the switch circuits 78E, 78F,
knob to the “L” position. 78H, or 78J, then
Have an assistant hold repair.
the switch in the up
position. Measure
voltage from middle
pin of the three small
connectors to the next
pin counter- clockwise
from the middle pin.
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POINTS SPEC.
16. On Have an assistant hold (31), 78F to ± 12 volts. Left mirror Locate open or poor
the switch in the left 58B. circuits connection in circuit
position. Measure check 58B, 78H, 78K, or
voltage between two good. 78F, then repair.
outer pins of the three
small connectors of
connector (31).
17. On Disconnect connector (31), 58B to ± 12 volts. Go to next Locate open or
(31) going to the 78F. step. poor connection in
right mirror. Turn the circuits 58B or 78F,
switch knob to the then repair.
“R” position. Have
an assistant hold
the switch in the up
position. Measure
voltage from middle
pin of the three small
connectors to the next
pin counter- clockwise
from the middle pin.
18. On Have an assistant hold (31), 58B to ± 12 volts. Right mirror Locate open or poor
the switch in the left 78E. circuits connection in circuit
position. Measure check 78E or 58B, then
voltage between two good. repair.
outer pins of the three
small connectors of
connector (31).

Table 17 CB Power Source
POINTS SPEC. SPEC.
1. Off At 20A fuse F5–D and F5-D, 14AA 12 ± 1.5 Go to next Locate cause of no
circuit 14AA, measure to gnd. volts. step. or low voltage in
voltage to ground. circuit 14AA or 14H
from battery stud
(B2), then repair.
2. Off At CB power receptacle (40), 86J 12 ± 1.5 Go to next Locate cause of no
(40) or terminal block, to gnd. volts. step. or low voltage in
measure voltage from circuit 86J or 20A
circuit 86J to ground. fuse F5–D, then
repair.
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Table 17 CB Power Source (cont.)

POINTS SPEC. SPEC.
3. Off At CB power receptacle (40), 86J to 12 ± 1.5 Go to next Locate open or
(40) or terminal block, 86–GJ. volts. step. poor connection
measure voltage from in circuit 86-GJ or
circuit 86J to 86–GJ. 11-GB to right cab
ground stud (404),
then repair.
4. Off CB power source circuits
check good.
3.8. CB RADIO ACCOMMODATIONS PACKAGE

Table 18 CB Radio Accommodations Package
STEP KEY ACTION TEST SPEC. YES-IN NO-OUT OF SPEC.
POINTS SPEC.
1. On Move key switch to F5-B, 12 ± 1.5 Go to next Locate cause of no or
accessories position, and 12M to volts. step. low voltage in circuit
at 10A fuse F5–B and gnd. 12M from key switch
circuit 12M, measure (452), then repair.
voltage to ground.
2. Off/ Disconnect connector (740), 12 ± 1.5 Go to next Locate cause of no or
On (740) and with key switch 86CE to volts. step. low voltage in circuit
in accessories position, gnd. 86CE, conn. (19), or
measure voltage from circuit 86CE from 10A
circuit 86CE to ground. fuse F5–B, then repair.
3. On At connector (740), (740), 12 ± 1.5 Go to next Locate open or poor
measure voltage from 86CE to volts. step. connection in circuit
circuit 86CE to 86–GCE. 86– GCE. 86–GCE or circuit
11–GAA to cab roof
ground (J3), then
repair.
4. Off Move key switch to off (774), 3.5 to 8 Go to next Locate open or short
position, and disconnect black to ohms. step. in green or black wire
speaker connector (774). green. or speaker, then repair
At (774) going to speaker, or replace.
measure resistance from
black wire to green wire.
5. Off CB radio accommodations
package circuitry checks
good.
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Table 19 Radio and Cab Speakers
STEP KEY ACTION TEST POINTS SPEC. YES- IN NO-OUT OF
SPEC. SPEC.
1. Off At 15A fuse F5–C and F5-C, 14AM 12 ± 1.5 Go to next Locate cause of
circuit 14AM, measure to gnd. volts. step. no or low voltage
voltage to ground. in circuit 14AM
or 14K, or battery
stud (B1), then
repair.
2. Off Disconnect connector (20), 88B to 12 ± 1.5 Go to next Locate cause of no
(20) and at circuit 88B, gnd. volts. step. or low voltage in
measure voltage to circuit 88B or 15A
ground. fuse F5–C, then
repair.
3. On Move key switch to (20), 86 to gnd. 12 ± 1.5 Go to next Locate cause of
accessories position, volts. step. low or no voltage
and at connector (20) in circuit 86, 10A
circuit 86, measure fuse F5–B, or
voltage to ground. circuit 12M from
key switch (452),
then repair.
4. Off Disconnect connector (20), 88B to 12 ± 1.5 Go to next Locate open or
(21) and measure (21), 86–GB. volts. step. poor connection
voltage from connector in ground circuit
(20) circuit 88B to 86–GB or 11–GLB
connector (21) circuit to L4 panel ground
86–GB. adapter (587), then
repair.
5. On Do cab speakers Go to Step Go to next step.
6. Off Disconnect left front Across speaker 3.5 to 8 Go to next Replace defective
cab speaker (52) and (52). ohms. step. left front cab
measure resistance of speaker.
speaker.
7. Off Reconnect left front (20), 86A to 3.5 to 8 Go to next Locate open or
cab speaker (52). At 86B. ohms. step. poor connection
connector (20) measure if resistance
resistance from circuit is too high, or
86A to 86B. short to ground if
resistance is too
low in circuit 86A
or 86B, then repair.
8. Off Disconnect right front Across speaker 3.5 to 8 Go to next Replace defective
cab speaker (18) and (18). ohms. step. right front cab
measure resistance of speaker.
speaker.
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Table 19 Radio and Cab Speakers (cont.)

STEP KEY ACTION TEST POINTS SPEC. YES- IN NO-OUT OF
SPEC. SPEC.
9. Off Reconnect right front (20), 86C to 3.5 to 8 Go to next Locate open or
cab speaker (18). At 86D. ohms. step. poor connection
connector (20) measure if resistance
resistance from circuit is too high, or
86C to 86D. short to ground if
resistance is too
low in circuit 86C
or 86D, then repair.
10. On Power and cab speaker Radio and Replace defective
circuits check good. speakers radio.
Does radio play? check
good.

Table 20 Electric Windshield Wiper With Intermittent Wipe And Wash
POINTS SPEC. SPEC.
1. On Do wipers function Go to Step Go to next step.
properly in low and high 26.
speed?
2. Off Remove 15A circuit F6–B, 14AL 12 ± 1.5 Go to next Locate cause of no
breaker F6–B and at to gnd. volts. step. or low voltage in
circuit 14AL, measure circuit 14AL or 14K
voltage to ground. from battery stud
(B1), then repair.
3. Off Re-install circuit breaker (444), 82K 12 ± 1.5 Go to next Locate cause of
F6–B and remove wiper to gnd. volts. step. low or no voltage
intermittent relay (444). in circuit 82K or
At relay socket (444), circuit breaker
measure voltage from F6–B, then repair.
circuit 82K to ground.
4. Off At relay socket (444), (444), 82K 12 ± 1.5 Go to next Locate open or
measure voltage from to 12-GF. volts. step. poor connection
circuit 82K to 12–GF. in circuit 12–GF,
82–GA, 12–GH,
82–GD, or 11–GD
to left cab ground
stud (429), then
repair.
5. On Move key switch to (444), 12F 12 ± 1.5 Go to next Locate cause of
accessories position and to gnd. volts. step. low or no voltage
at relay socket (444), in circuit 12 or 12F
measure voltage from from key switch
circuit 12F to ground. (452), then repair.
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Table 20 Electric Windshield Wiper With Intermittent Wipe And Wash (cont.)
POINTS SPEC. SPEC.
6. Off Bench test wiper Relay (444), < 1 ohm. Go to next Replace defective
intermittent relay (444) term. 30 step. relay.
by measuring resistance to 87A.
from terminal 30 to 87A.
7. Off Bench test wiper Energized < 1 ohm. Go to next Replace defective
intermittent relay (444) relay (444), step. relay.
by applying +12 volts term. 30
to terminal 86, ground to 87.
to terminal 85, and
8. Off/ Remove wiper motor (445), 82A 12 ± 1.5 Go to next Locate cause of
On relay (445), re-install to gnd. volts. step. low or no voltage
wiper intermittent relay in circuit 82A, then
(444), and move key repair.
switch to accessories
position. At relay socket
measure voltage to
ground.
9. Off Bench test wiper motor Relay (445), < 1 ohm. Go to next Replace defective
relay (445) by measuring term. 30 step. relay (445).
resistance from terminal to 87A.
30 to 87A.
10. Off Bench test wiper motor Energized < 1 ohm. Go to next Replace defective
relay (445) by applying relay (445), step. wiper motor relay
+12 volts to terminal term. 30 (445).
86, ground to terminal to 87.
85, and measuring
resistance from terminal
30 to 87.
11. Off/ Disconnect wiper switch (407), 82B 12 ± 1.5 Go to next Locate cause of
On (407), move key switch to to gnd. volts. step. low or no voltage
accessories position, and in circuit 82B, then
at circuit 82B, measure repair.
voltage to ground.
12. Off Test wiper switch (407) Switch < 1 ohm. Go to next Replace defective
by placing it in off (407), term. step. switch.
position and measuring 1 to 2.
1 to 2.
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POINTS SPEC. SPEC.
by placing it in off (407), term. step. switch.
4 to 5.
by placing it in low (407), term. step. switch.
2 to 3.
by placing it in low (407), term. step. switch.
4 to 5.
by placing it in high (407), term. step. switch.
2 to 3.
by placing it in high (407), term. step. switch.
5 to 6.
18. Off/ Reconnect wiper switch (507), 82E 12 ± 1.5 Go to next Locate cause of
On (407) and disconnect to gnd. volts. step. low or no voltage
wiper motor connector in circuit 82E, then
(507). Move key switch repair.
to accessories position,
wiper switch to low
speed position and at
82E, measure voltage to
ground.
19. On With switches still set, (507), 82C 12 ± 1.5 Go to next Locate cause of
at connector (507) and to gnd. volts. step. low or no voltage
circuit 82C, measure in circuit 82C, then
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POINTS SPEC. SPEC.
20. On With key switch in the (507), 82D 12 ± 1.5 Go to next Locate cause of
accessories position, to gnd. volts. step. low or no voltage
and wiper switch in high in circuit 82D, then
position, at connector repair.
(507) and circuit 82D,
measure voltage to
ground.
21. On Move wiper switch to off (445), 82F < 1 ohm. Go to next Locate open or
position. At conn. (507) to gnd. step. poor connection
install a jumper wire from in circuit 82F, then
circuit 82F to ground, repair.
and at relay socket (445)
and circuit 82F, measure
22. On Re-install wiper motor (507), 82E < 1 ohm. Go to next Locate open or
relay (445) and at to 82F. step. poor connection in
connector (507), circuit 82H, then
measure resistance repair.
from circuit 82E to 82F.
23. On Reconnect wiper motor Go to next Replace defective
(507) and move wiper step. motor.
switch to low position.
Does motor run at low
speed?
24. On Move wiper switch to Go to next Replace defective
high speed position. step. motor.
Does motor run at high
speed?
25. Off Move wiper switch to off Go to next Replace park
position. Does motor run step. switch/ motor
until wipers reach park assembly.
position?
26. On Does intermittent Go to Step Go to next step.
wiper feature function 31.
properly?
27. Off/ Disconnect intermittent (408), 82 12 ± 1.5 Go to next Locate cause of
On wiper washer switch to gnd. volts. step. low or no voltage
(408), move key switch in circuit 82, then
to accessories position, repair.
and at circuit 82 measure
voltage to ground.
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POINTS SPEC. SPEC.
28. On With key switch still in (408), 82 to 12 ± 1.5 Go to next Locate open or
accessories position, 82-GB. volts. step. poor connection
at connector (408), in circuit 82–GB
measure voltage from or 11–GLC to L3
circuit 82 to 82–GB. panel lights ground
adapter (505), then
repair.
29. On With key switch still in Go to next Locate open or
accessories position, step. poor connection
momentarily touch in circuit 82J, then
jumper wire from circuit repair.
82 to 82J. Does wiper
motor energize?
30. On Reconnect wiper switch Go to next Replace defective
(408). Do the intermittent step. intermittent wiper
wipers function properly? switch.
31. On Does windshield washer Washer Go to next step.
function properly? circuits
check
good.
32. Off Disconnect washer (24), 87–G < 1 ohm. Go to next Locate open or
pump (24) and at circuit to gnd. step. poor connection in
87–G, measure voltage circuit 87–G, then
to ground. repair.
33. Off/ Disconnect wiper (24), 87A 12 ± 1.5 Go to next Locate cause of
On intermittent switch (408)., to gnd. volts. step. low or no voltage
install a jumper wire from in circuit 87A, then
circuit 82 to 87A, and repair.
move key switch to
At connector (24) and
voltage to ground.
34. On Momentarily reconnect Go to next Replace defective
washer pump motor (24). step. washer motor.
Did washer motor run?
35. On Remove jumper wire, Washer Replace defective
reconnect wiper/ washer circuits intermittent wiper/
switch, and reconnect check washer switch
washer motor. Does good. (408).
washer system function
properly?
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G4 Ground Adapter (457). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Left Gauge Cluster
L1 LED Panel Lt. Feed Adapter (504). . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
L2 LED Panel Lt. Feed Adapter (586). . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
L3 LED Panel Lt. Gnd Adapter (505). . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
L4 LED Panel Lt. Gnd Adapter (587). . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(B1) Battery Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Power Distribution Panel
(B2) Battery Stud/ Deep Cycle Stud. . . . . . . . . . . . . . . . .. . . . . . At Power Distribution Panel
(J3) Roof Ground Junction. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In Roof, Strainer
(J7) Cab Ground Junction. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Left Luggage Compartment on Tunnel
(J9) Ground Junction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Left Side Inst. Panel, Inner Panel, Cowl Side
(J14) Check Strap Ground Junction. . . . . . . . . . . . . . . . .. . . . . . Right Door Check Strap Mounting Bolt
(16) Right Electric Window Motor. . . . . . . . . . . . . . . . . . . .. . . . . . Inside Right Door
(18) Cab Right Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Speaker Pigtail to Roof Harness
(19) Roof Harness #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Left Instrument Panel
(20) Radio Connector #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Radio Pigtail to Cab Harness
(21) Radio Connector #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Radio Pigtail to Cab Harness
(24) Windshield Washer Jumper. . . . . . . . . . . . . . . . . . . .. . . . . . Between Cab Floor, Behind Driver Seat
(31) Htd/Lighted/Rt Motorized Mirror. . . . . . . . . . . . . . . .. . . . . . In Door Exterior (Lt and Rt Side)
(34) Rt Electric Window Motor. . . . . . . . . . . . . . . . . . . . . . .. . . . . . Inside Right Door
(40) Power Source Socket. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Center Instrument Panel
(52) Left Cab Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Speaker Pigtail to Roof Harness
(57) Left Electric Window Motor. . . . . . . . . . . . . . . . . . . . .. . . . . . Inside Left Door
(70) Heated and Motorized Mirror. . . . . . . . . . . . . . . . . . .. . . . . . Left and Right Door Exterior
(214) Electric Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Radiator Access Door
(403) Right Door Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Left Corner
(404) Right Cab Ground Stud. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Right Hand Cowl Inner Panel
(407) Windshield Wiper Switch. . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(408) Windshield Wash/Wipe Delay Switch. . . . . . . .. . . . . . Behind Switch Cluster
(410) Headlight Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(413) Rt Side Power Window Switch. . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(415) Heated Mirror Switch. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(416) Panel Lights Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(420) Left Power Window Switch. . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(429) Left Cab Ground Stud. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left Hand Cowl Inner Panel
(437) Left Door Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Left Corner
(444) Relay R13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Center
(445) Windshield Wiper Motor Relay. . . . . . . . . . . . . . . .. . . . . . In Power Distribution Center
(446) Accessory Feed Relay. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Center
(448) Left Power Window Relay. . . . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Center
(449) Right Power Window Relay. . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Center
(457) G4 Ground Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Left Gauge Cluster
(463–R7) Horn Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Center
(464–R9) Trailer Tail Lights Relay. . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Center
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(504) LED Panel Lights Feed Adapter L1. . . . . . . . . .. . . . . . Behind Switch Cluster
(505) LED Panel Lights Gnd Adapter. . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(506) Passenger Window Switch. . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(507) Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Center
(540) Right Motorized Mirror Switch. . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(560) Left Defroster Fan Connector. . . . . . . . . . . . . . . . .. . . . . . In Header Above Windshield Center
(561) Right Defroster Fan Connector. . . . . . . . . . . . . . .. . . . . . In Header Above Windshield Center
(586) L2 LED Panel Lt Feed Adapter. . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(587) L4 LED Panel Lt Gnd Adapter. . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(739) Radio, Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Cluster, Left Corner
(740) CB Radio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind CB Opening at Roof
(774) CB Speaker Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind CB Speaker
Refer to Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8, Figure 9, Figure 10,
Figure 11, Figure 12, Figure 13, Figure 14, Figure 15, Figure 16, Figure 17, and Figure 18.
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Figure 14 Cab Wiring (Cigar Lighter Effects) — 9800 SFA and SBA
1. CIRCUIT 84, 84–G, 62T, 62AK TO CIGAR LIGHTER
2. SEE FIGURE 10 IN POWER DISTRIBUTION AND GROUND SYSTEMS SECTION
3. MAIN CAB HARNESS
4. BREAKOUTS FOR SWITCH PANEL
5. INSTRUMENT PANEL WING, ASSEMBLY
7. COWL SUPPORT
9. INSTRUMENT HARNESS
10. FUSE PANEL BRACKET
12. FUSE PANEL BRACKET
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Figure 15 Power Window Wiring — 9800
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Figure 18 Windshield Defroster Fan Wiring — 9800
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Figure 19 Electric Horn Wiring — 9800 SFA and SBA
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Figure 20 Mirror Wiring, Heated and Lighted — 9800
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Figure 21 Mirror Wiring, Heated and Lighted — 9800
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Figure 22 Power Source, Cigar Lighter Type (08718) — 9800 SFA and SBA
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Figure 23 Power Source, Two Post Type (08851) — 9800 SFA and SBA
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Figure 24 CB Accommodation Package Wiring — 9800
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Figure 27 Radio/ Entertainment Wiring — 9800 SFA and SBA
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Figure 28 Radio/ Entertainment Wiring — 9800 SFA and SBA
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Figure 29 Windshield Wiper and Washer Wiring — 9800
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Figure 30 Windshield Wiper and Washer Wiring — 9800 With 32 Inch Bunk
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Figure 31 Windshield Wiper and Washer Wiring — 9800 With 53 Inch Bunk
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3 BATTERY, CHARGING AND CRANKING SYSTEMS 89
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
1.1. BATTERY POWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Standard System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
3+1 Isolated Battery System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Remote Start Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
1.2. CHARGING CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Standard System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
1.3. CRANKING MOTOR AND CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Thermal Overcrank Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
2.1. BATTERY POWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Standard System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Remote Start Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
2.2. CHARGING CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Standard System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
2.3. CRANKING MOTOR AND CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Thermal Overcrank Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
3. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
3.1. BATTERIES AND CABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Battery Test Procedure — (Figure 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Battery Cable Voltage Loss Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
3.2. STARTING MOTOR SYSTEM CIRCUITS AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Starter Solenoid Circuit Test - Part 1 (Figure 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Starter Solenoid Circuit Test - Part 2 (Wire Voltage Loss) (Figure 5). . . . . . . . . . . . . . . . . . . . . . . .97
Starter Magnetic Switch Circuit Test - Part 1 (Figure 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Starter Magnetic Switch Circuit Test - Part 2 (Figure 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Starter Motor Replacement Test (Figure 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Testing Thermal Overcrank Protection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
3.3. VEHICLE CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Batteries Undercharged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Alternator Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Alternator Wiring Test (Figure 9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Alternator Replacement Test (Figure 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Amperage Output Test (Figure 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
4. COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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90 3 BATTERY, CHARGING AND CRANKING SYSTEMS
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Model: 9800
1. DESCRIPTION
1.1. BATTERY POWER
Standard System
The vehicle batteries, connected in parallel, provide power via the positive battery cable which is connected
to the cranking motor solenoid “B" terminal. The negative battery terminals are connected to the cranking
motor ground terminal, which is connected to the frame rail. The engine and cab are also grounded with
cables to the frame rail or alternator ground.
3+1 Isolated Battery System
With the 3+1 battery system, three of the vehicle batteries are connected in parallel and provide power via the
positive battery cable to the 7V isolated battery magnetic switch. The fourth battery is grounded with the other
three but provides power through a cable to the other side of the magnetic switch and other circuits to the
(B2) battery stud, thus providing continuous power to the sleeper, and isolating the other three batteries to
reserve their power for engine cranking. The negative battery terminals are connected to the cranking motor
ground terminal, which is connected to the frame rail. The engine and cab are also grounded with cables to the
frame rail or alternator ground.
Remote Start Terminal
An optional remote start terminal allows an external battery power source to either charge the vehicle batteries
or assist in cranking the engine.
1.2. CHARGING CIRCUITS

Standard System
The Delco 22-SI, 12 volt, 100-ampere capacity alternator is standard on this family of vehicles. Other Delco
alternators are available as options. This alternator does not require power from the battery to begin generating
electrical power, thus it is commonly referred to as a “one-wire type Delcotron." This means that if you bolt it on
the engine, thus grounding it, install the drive belt, and start the engine, it will produce electricity at the output
terminal (B) and the connected wire going to the crank motor solenoid and batteries.
With the 3+1 system, the Delco 22-SI, 12 volt, 100-ampere capacity alternator has an additional circuit
connected to it at the (R) terminal (relay terminal). This circuit feeds an output voltage to the 7V isolated
battery magnetic switch, thus reconnecting the three isolated batteries for recharging. These three vehicle
batteries are connected in parallel and to the 7V magnetic switch, thus providing power for cranking and for
other systems when the engine is running. The fourth battery is grounded with the other three but provides
power through a cable to the other side of the magnetic switch and other circuits to the (B2) battery stud, thus
providing continuous power to the sleeper, and isolating the other three batteries to reserve their power for
engine cranking.
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1.3. CRANKING MOTOR AND CIRCUITS

Motor
The Delco 42MT series DR-400 cranking motor is standard for this series of vehicles. It provides the rotation of
the engine crank via the flywheel needed to start the engine.
Circuits
The cranking motor circuits provide power to the cranking motor to turn over the crankshaft of the engine. If all
other systems are operational, the engine will start.
Thermal Overcrank Protection
On vehicles with optional thermal overcrank protection, excessive cranking will cause the cranking motor
temperature to reach a pre-set thermal overcrank limit, and the thermal switch will open. This will cause the
cranking motor to disengage, thus protecting the cranking motor from heat damage. When the cranking motor
cools, the switch will close permitting the cranking motor to operate again.
2. OPERATION
2.1. BATTERY POWER
Standard System
Vehicle batteries are connected in parallel with the positive battery cable connected to the cranking motor
solenoid “B" terminal. The negative battery cable is connected to the cranking motor ground terminal. The
engine and a frame rail are then connected by ground cables to the cranking motor ground.
All but one of the vehicle batteries are connected in parallel. The positive battery cable is connected to the
cranking motor solenoid “B" terminal and to the isolated side of the isolated battery magnetic switch. The other
battery (deep cycle) is connected to the non-isolated side of the isolated battery magnetic switch. Thus when
the engine is not running, power for lights and accessories is drawn from the deep cycle battery and the
remaining batteries are isolated from discharge; consequently, they can be used later by the cranking motor to
start the engine. The negative battery cable is connected to the cranking motor ground terminal. The engine
and a frame rail are then connected by ground cables to the cranking motor ground.
Remote Start Terminal
An optional remote start terminal is connected to the vehicle batteries, which are connected in parallel, and
provides a more accessible connection point for jump-starting and battery charging. The negative cable of the
charging source is just clamped to a paint free location on the frame rail.
To use an external power source to charge the deep cycle battery (with 3+1 system) at the same time as the
cranking batteries, a jumper cable must be used to connect the positive deep cycle battery terminal to the
positive terminal of a cranking battery.
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2.2. CHARGING CIRCUITS

Standard System
The Delcotron integral charging systems are high-output alternators, with an internal diode rectifier and voltage
regulator, producing direct current (DC) to operate vehicle electrical systems and to charge the vehicles
batteries. The Delco 22-SI alternator (100A, 115A or 145A) uses brushes and slip rings.
The one-wire type Delcotron has the alternator output (B) terminal connected to the cranking motor solenoid
which is connected to the positive side of the batteries.
For a complete discussion on operating principles for alternators, refer to GROUP 08 - ELECTRICAL in the
CTS-5000 Master Service Manual for the specific alternator being serviced.
On vehicles with this system, 7 volt output from the alternator (R) terminal is used to energize the isolated
battery magnetic switch whenever the engine is turning the alternator. (Refer also to the POWER
DISTRIBUTION AND GROUND SYSTEMS 3+1 Battery System section.)
2.3. CRANKING MOTOR AND CIRCUITS

Motor
For complete information on operation and servicing of the Delco 42MT type 400 cranking motor and optional
thermal overcrank protection, refer to GROUP 08 - ELECTRICAL in the CTS-5000 Master Service Manual.
Circuits
With the key switch in the START position, or key switch in IGNITION position and push button switch
DEPRESSED on vehicles with optional push button start, voltage is supplied to start feed adapter (509). From
(509) voltage is supplied to circuit 17A, connector (102), and circuit 17A to energize the start magnetic switch.
Voltage from the (B) terminal of the cranking motor solenoid is supplied to the start magnetic switch by way
of a fusible link and circuit 14A. With the start magnetic switch energized, battery voltage is applied through
circuit 17B to energize the cranking motor solenoid.
With the cranking motor solenoid energized, the solenoid engages the cranking motor and battery power
causes the motor to rotate. When the starter switch is released, a spring returns the solenoid to the released
position, and disengages and de-powers the cranking motor.
Thermal Overcrank Protection
On vehicles with the optional thermal overcrank protection system, the start magnetic switch control coil
ground circuit 17D is connected to the normally closed thermal switch (342). The thermal switch is located in
the end of the cranking motor. The thermal switch is grounded through circuits to the engine stud.
If excessive cranking causes cranking motor temperature to reach pre-set thermal overcrank limits, the
thermal switch opens causing the start magnetic switch to de-energize, turning off power to the cranking motor
solenoid (S) terminal, disengaging the cranking motor.
When the cranking motor cools, the switch closes permitting the cranking motor to operate again.
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3. TROUBLESHOOTING
wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 -
of the circuit, by disconnecting connectors, and measure the resistance to ground to find the circuit
relay, or solenoid.
3.1. BATTERIES AND CABLES

The standard battery system for 9800 cabovers consists of three 12V maintenance free batteries. All optional
batteries installed are also maintenance free type.
WARNING – When handling batteries, always wear face or eye protection, have water supply
available, assure good ventilation, and be sure no open flames are present.
Battery Test Procedure — (Figure 1)
Test each battery separately.
1. Disconnect both battery terminals at each battery. Check each battery visually.
2. Examine the hydrometer eye (if no eye go to next step).

a. Eye shows green - go to step 4.
b. Eye shows dark - recharge, then go to step 3.
c. Eye shows yellow - replace battery.
3. Apply a 300A load for 15 seconds. Turn off load and wait one minute.
a. If 12.4V or more - go to step 4.
b. If less than 12.4V - recharge then repeat step 3.
4. Apply a test load equal to 50% of the battery CCA rating at 0°F. After 15 seconds,with the load still
applied, measure and record terminal voltage ________. Turn the load off.
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5. Estimate the battery temperature. If measured voltage does not meet or exceed the value shown in
the following table, replace the battery.
Table 21 Battery Temperature Table

Temp. °F 70°F 50°F 30°F 15°F 0°F
Temp. °C 21°C 10°C -1°C -9°C -18°C
Min. Volts 9.6 9.4 9.1 8.8 8.5
6. Clean all cable ends and terminals of the battery with a wire brush.
Figure 32 Battery Configuration
Battery Cable Voltage Loss Test
Refer to Figure 2.
Slow cranking is often caused by high resistance in the battery cables or connections, especially in cold
weather. After all batteries check good (Battery Test Procedure) and terminals are clean and tight, check the
battery cables. To do this place a specific load on the batteries at the starter and measure the voltage drop in
each cable. This load will be supplied by the adjustable carbon pile.
The voltage drop in the positive cable plus the voltage drop in the negative cable equals the difference
between the battery voltage and the starter voltage due to the cables. The maximum acceptable loss has been
calculated only for the specific load specified in the test.
1. Tighten nuts holding battery cables to the solenoid and starter terminals.
NOTE – The solenoid BAT terminal is at battery voltage when batteries are connected.
2. Connect carbon pile positive lead to start solenoid “B” terminal and negative lead to starter ground terminal
(Figure 2).
3. Connect voltmeter from the starter solenoid “B” terminal to battery positive post.
4. Adjust load to 500A, quickly read and record ______ positive cable voltage. Turn off the load and allow
carbon pile to cool.
5. Connect voltmeter from negative battery post to starter ground terminal. Attach ground lead directly to
stud and not the cable end.
6. Adjust load to 500A, read and record ______ negative cable voltage. Turn off the load.
Positive Cable Voltage Loss (step 4) ________
plus Negative Cable Voltage Loss (step 6) ________
equals Total Cable Loss ________.
If system lossis 0.6V or less, go toSTARTING MOTOR SYSTEM CIRCUITS AND COMPONENTS
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If total cable loss is greater than 0.6V, repair or replace cable(s) with excessive voltage loss and retest.
Figure 33 Battery Cable Voltage Loss Test
To check the interconnecting cables between the batteries, while cranking, measure the terminal voltage of
each battery by touching voltmeter leads to the post of each battery (Figure 3).
If the difference between any two battery readings in the same battery box is more than 0.5 volt or any cable is
warm to the touch, replace the interconnecting cables.
Figure 34 Measure Terminal Voltage of Each Battery
3.2. STARTING MOTOR SYSTEM CIRCUITS AND COMPONENTS

Starter Solenoid Circuit Test - Part 1 (Figure 4)
Starter shifting in and out, or not pulling in, is often caused by high resistance in the starter solenoid circuit.
When the solenoid circuit has excessive voltage loss, the starter pinion sometimes may not engage the
flywheel. If it does engage, it may drop out too soon when battery voltage drops. The solenoid circuit includes
the starter magnetic switch and leads connected to the starter solenoid.
On vehicles withovercrank protection, refer to Testing Thermal Overcrank Protection Systembefore

performing this test.
1. Disconnect circuit 17B from the starter solenoid “S” terminal. Connect the carbon pile positive lead to
circuit 17B and negative lead to the starter ground. Connect the voltmeter positive lead to the solenoid
battery stud and the negative lead to the starter motor ground stud (not to carbon pile clamp).
2. Have an assistant push the start button or turn key switch. The magnetic switch should energize with a
clicking sound. If the switch doesn’t "click," either the switch is defective (refer to Starter Magnetic Switch
Circuit Test — Part 1) or there is no voltage from the key switch circuit.
3. Adjust the carbon pile to 100 amp load. Measure and record cable voltage. Release the start button or
key switch. If the reading is more than .5 volt lower than the value shown in the Table in Battery Test
Procedures, perform that test and Battery Cable Voltage Loss Test.
4. Move the voltmeter negative lead from the starter motor ground stud to the end of circuit 17B that is
connected to the carbon pile. Do not connect to carbon pile clamp.
5. Push and hold the start button again and re-adjust the carbon pile load to 100 amps. Read and record
voltage to the solenoid. Release the start button or key switch.
Cable Voltage (step 3) ________
minus Solenoid Voltage (step 5) ________
equalsCircuit Loss = ________
If circuit lossis 1.0 volt or less, go toStarter Magnetic Switch Circuit Test - Part 1.
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If circuit lossis more than 1.0 volt, go toStarter Solenoid Circuit Test - Part 2.
Figure 35 Starter Solenoid Circuit Test — Part 1
Starter Solenoid Circuit Test - Part 2 (Wire Voltage Loss) (Figure 5)
If the voltage loss in Starter Solenoid Circuit Test, Part 1 was more than 1 volt, the loss is excessive. The loss
may be from loose terminals, corrosion, or a worn out start magnetic switch. To locate the problem:
1. Leave carbon pile connected as in Part 1.
2. Connect DMM positive lead to solenoid “BAT” stud and negative lead to large terminal of magnetic switch.
If voltage shows on meter, move meter lead to the other large magnetic switch terminal.
3. Push start button with key on or turn key switch to start position. Turn on and adjust carbon pile to 100
amp load. Read and record first wire voltage loss. Release start switch.
4. Connect DMM positive lead to other (opposite) large terminal on magnetic switch and negative lead to
circuit 17B (not to carbon pile clamp).
5. Push start button or turn key switch to start position. Turn on and adjust carbon pile to 100 amp load.
Read and record second wire voltage loss. Release start switch.
First Wire Loss (step 3) ________
plus Second Wire Loss (step 5) ________
equals Total Wiring Loss = _________(0.8V maximum loss)
If circuit loss is0.8 volt or less, go to step 6.
If circuit loss ismore than 0.8 volt, repair or replace wire, then go to step 6.
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6. Connect DMM across the two large magnetic switch terminals (battery voltage will show immediately).
7. Push start button or turn key switch to start position. Turn on and adjust carbon pile to 100 amp load.
Read and record ________ voltage loss across the magnetic switch. Release start switch.
8. If the voltage drop is greater than 0.2 volt, replace the magnetic switch.
9. Remove carbon pile. Leave circuit 17B disconnected (use tape to insulate) to perform Starter Magnetic
Switch Circuit Test - Part 1 (below).
Figure 36 Starter Solenoid Circuit Test - Part 2
Starter Magnetic Switch Circuit Test - Part 1 (Figure 6)
A magnetic switch that does not close or drops out too soon can be caused by high resistance or an open in
the control circuit.
1. Disconnect circuit 17B from start solenoid “S” terminal and insulate with tape. Connect voltmeter positive
lead to the starter solenoid BAT stud and negative lead to the starter motor ground stud.
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2. Have an assistant push the start button (with key on) or turn key to start position. You should hear the
magnetic switch relay “click." If not, proceed anyway. Read and record battery cable voltage. Release
start switch.
3. Connect the voltmeter positive lead to the small magnetic switch terminal and the negative lead to the
switch ground screw. (Magnetic switch is internally grounded through the mounting.)
4. Have an assistant push the start button (with key on) or turn key to start position. Read and record
magnetic switch voltage. Release the start switch.
Battery Cable Voltage (step 2) ________
minus Magnetic Switch Voltage (step 4) ________
equals Control Circuit Wiring Loss = ________
If circuit lossis 1.0 volt or less and the magnetic switch closes, circuit is OK.
If circuit lossis 1.0 volt or less and the magnetic switch doesn’t close, replace the switch and repeat the test.
If circuit lossis more than 1.0 volt, go to Starter Magnetic Switch Circuit Test - Part 2 (below).
Figure 37 Starter Magnetic Switch Circuit Test - Part 1
Starter Magnetic Switch Circuit Test - Part 2 (Figure 7)
If Starter Magnetic Switch Circuit Test - Part 1 has shown a voltage loss greater than 1.0V, perform this test
using a digital multimeter (DMM). Leave circuit 17B disconnected from the starter solenoid.
1. With the key on and start button depressed or key switch in start position, and the voltmeter leads in the
positions shown for each step:
a. Measure magnetic switch to starter motor ground. If reading is within 1.0 volt of battery voltage, repair
magnetic switch ground. If reading is not within 1.0 volt of battery voltage, go to Step B.
b. Measure and record ______ solenoid to key voltage.
c. Measure and record ______ key switch voltage.
d. Measure and record ______ key to start button voltage.
e. Measure and record ______ start button voltage.
f. Measure and record ______ start button to magnetic switch voltage.
TOTAL ______ (1.0V MAX. ALLOWED)
If greater than 1.0 volt, repair or replace any circuit or component with excess voltage loss.
If any of the circuits or component checks (B through F) show full battery voltage with the start button
depressed or key switch in start position, then an open circuit exists in the portion of the circuit between the
DMM leads. Repair that portion and connect circuit 17B to the starter solenoid.
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Figure 38 Starter Magnetic Switch Circuit Test - Part 2
Starter Motor Replacement Test (Figure 8)
A. Cold Weather Start Magnetic Switch Problems
If all previous battery tests have been performed, the vehicle batteries and starter wiring have
been checked.
The starter magnetic switch can fail to "hold in" during cold weather cranking due to low voltage,
even though the switches and circuits check OK. With this failure you will hear the starter failing to
stay engaged with the flywheel. It is caused by low system voltage releasing the magnetic switch.
If this condition exists, have an assistant clamp a heavy battery jumper cable between the two big
(5/16") studs on the magnetic switch while cranking.Caution - The studs are battery voltage and
the engine should crank when the jumper is connected. Remove jumper to stop cranking.
If the engine cranks properly with jumper in place, replace the magnetic switch and make sure
starter mounting bolts are tight.
B. Checking Available Voltage At Starter
If all previous battery tests have been performed, the vehicle batteries and starter wiring have
been checked, but the engine still cranks slowly, check available voltage at the starter.
1. While cranking engine, measure voltage between the starter BATT terminal and starter ground.
a. If voltage is 9.0 volts or more, the problem must be in the starter (or engine). Replace the starter.
b. If the voltage is less than 9.0 volts, go to Battery Cable Voltage Loss Test.
2. Check the interconnecting cable between the batteries.
Figure 39 Starter Motor Replacement Test
Testing Thermal Overcrank Protection System
Table 22 Testing Thermal Overcrank Protection System

POINTS SPEC. SPEC.
1. Off Remove connector Thermal < 2 ohms. Go to next Replace the
(342) from thermal switch, step. thermal switch.
switch and measure across
resistance across terminals.
switch terminals
(engine must be cool).
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Table 22 Testing Thermal Overcrank Protection System (cont.)

POINTS SPEC. SPEC.
2. On With key in start (342), 17D 12 ± 1.5 Go to next Go to Starter
position, at connector to gnd. volts. step. Solenoid Circuit
(342) measure voltage Test - Part 1(See
to ground at circuit 17D. Starter Solenoid
Circuit Test -
Part 1 (Figure
4), page 96).
3. On With key in start (342), 17D 12 ± 1.5 Go to next Repair open in
position, at connector to 17-G. volts. step. circuit 17-G.
(342) measure voltage
between circuits 17D
and 17-G.
4. Off Thermal overcrank
circuits check good.
3.3. VEHICLE CHARGING SYSTEM

Batteries Undercharged
Before beginning test procedures: check battery cables and alternator wiring (especially grounds) for clean,
tight connections. Wires and connectors should not be damaged or corroded.
Perform the following checks before removing the alternator from the vehicle.
1. Accessories having been left on for an extended time.
2. Check alternator drive belt tension (refer to GROUP 12 - ENGINE, Cooling in the CTS-5000 Master
Service Manual for belt tension specifications). As a general rule, if the alternator fan can be rotated by
pulling on the fan with one finger, the belt is too loose.
3. Inspect for defective batteries as described in GROUP 08 - ELECTRICAL, Battery Section in the
CTS-5000 Master Service Manual.
4. Wiring defects. Visually check wiring, clamps, and connections for clean, tight connections, free of
damage and corrosion.
5. With the engine OFF, check voltage to ground at the BAT terminal of the alternator. A zero reading
indicates an open in circuit 2, between the alternator and batteries.
6. A defective component or wiring defect may be causing a small current drain that is less than the fuse
rating for the circuit so the fuse does not open. To locate the unwanted current drain:
NOTE – Batteries should be fully charged for the following test.

a. KEY OFF- Turn all accessories and controls off. Disconnect circuit 2 from the alternator B terminal.
b. To check the entire system for current drains, insert the DMM leads in the COM and 10A fused jack on
the meter. Set the meter to DC Amps. Connect the meter in series with the alternator. If the meter
leads are not connected with correct polarity, a (-) amp reading will be present.
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c. Some current draw will be present. If the current draw is less than 0.3A move the lead from the 10A
jack to the 320mA jack to read the exact current flow.
d. Refer to the 12V Power Distribution Battery circuit diagrams in CTS-5254V. Remove the battery
feed fuses one at a time, while monitoring the meter for any change in current flow. Note that some
circuits (such as clock or radio or engine computer, etc.) should be drawing some current. Look for
current draw in circuits that should not be active.
7. PerformAlternator Wiring Test.
Alternator Tests
The alternator output must reach the batteries and accessory loads with a minimum amount of voltage loss.
Any loss slows the rate of charge to the batteries and can cause the batteries to be undercharged. Discharged
batteries can damage the starter and cause vehicle electrical components to operate improperly.
Most alternators control the maximum system voltage using a voltage regulator. Maximum voltage output
is available at the alternator BAT terminal, but if any voltage is lost in the wiring, something less than the
maximum will reach the batteries and load devices. The greatest losses occur when the charging system
is outputting at the maximum rated level (amps).
Alternator Wiring Test (Figure 9)
Instead of using alternator current output this test uses the same amount of current but draws it from the
batteries (must be fully charged). Using the carbon pile load, the current flows in reverse through the circuit
without the engine running.
1. Without the engine running, connect the carbon pile to the alternator output terminal and ground.
NOTE – Alternator output is at battery voltage.
2. Connect voltmeter between alternator output terminal and positive battery terminal.
3. Adjust the carbon pile to alternator rated output (amps). Rated output is stamped on the case or on a tag.
4. Read voltmeter and record positive circuit voltage loss ______. Immediately turn the carbon pile off.
5. Move the voltmeter connections to between the alternator ground and negative battery terminal. Adjust
carbon pile to rated output (amps) of the alternator.
6. Read voltmeter and record negative circuit voltage loss ______. Immediately turn carbon pile off.
Positive Circuit Loss Voltage (step 4) ________
plus Negative Circuit Loss Voltage (step 6) ________
equals System Loss ________
If system loss is 0.7V or less, go toAlternator Replacement Test
If system lossis greater than 0.7V, repair circuit(s) with excessive voltage loss and retest. Then go to
Alternator Replacement Test.
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Figure 40 Alternator Wiring Test
Alternator Replacement Test (Figure 10)
If the wiring tests have been performed (circuits OK), adjust alternator belt and tighten mounting bolts and
ground connections. Batteries must be near full charge with more than 12.4 volts no load voltage.
Voltage Output Test (Figure 10)

1. With vehicle at shop temperature, connect voltmeter between alternator BAT (+) and GND (-) terminals.
2. With NO electrical loads turned on, start the engine. Fast idle engine until voltage stabilizes (does not
increase) for 2 minutes.
3. Check and record alternator output voltage _______V (should not exceed 15.5 volts).
4. If voltage reading is above 15.5V, replace the alternator.
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Figure 41 Alternator Replacement Test
Amperage Output Test (Figure 10)
1. With vehicle at shop temperature, connect carbon pile and clamp-on ammeter as shown (Figure 10).
Clamp around all wires connected to alternator B+ terminal. (To use an ammeter without an induction
clamp, disconnect circuits to alternator B+ terminal and connect meter shunt between alternator B+
terminal and all circuits previously removed.)
CAUTION – Do not connect an ammeter without a high current shunt.
2. With NO electrical loads turned on, start the engine, and speed up and maintain a high RPM.
3. Turn on and adjust carbon pile until ammeter reads its highest value and record ______A.
4. Turn off carbon pile and engine.
5. If reading is zero (no output), the rotor should be magnetized with the alternator hooked up normally. To do
this, momentarily connect a jumper lead from the alternator BAT (+) terminal to the “R” terminal. This
will restore normal residual magnetism.
6. Repeat steps 2, 3, and 4. If output is still zero, replace alternator.
Replacement
Replace alternator if either of the following exists:
A. Output voltage exceeded 15.5V.

B. Output current is not within 10% of the alternator rated output stamped on the alternator.
(B7) Battery Feed Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Under Mag Switch Cover Near Battery Box
(J5) Start Mag Sw. Gnd. Junction. . . . . . . . . . . . . . . . . . .. . . . . . At Starter Mag Switch Mounting Screw
(J8) Cranking Motor Ground Junction. . . . . . . . . . . . . . .. . . . . . Ground Terminal at Engine
(J10) Battery Ground Junction. . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Left Sidemember
(94) Push Button Start Switch. . . . . . . . . . . . . . . . . . . . . . .. . . . . . To Left of Key Switch at Base of Right Wing Panel
(102) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Cab Floor, Ft Rt, 1/2 replaced by (338) W/ Series 60
(338) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Cab Floor Front Right
(342) Thermal Overcrank Protection. . . . . . . . . . . . . . . .. . . . . . At Cranking Motor W/ Series 60
(509) Start Feed Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
Refer to Figure 11, Figure 12, Figure 13, Figure 14, Figure 15, Figure 16, Figure 17, Figure 18, Figure 19,
Figure 20, Figure 21, Figure 22, Figure 23,and Figure 24.
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Figure 42 Battery Cable Installation, Cummins M11E CELECT and 12 Volt System — 9800
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Figure 43 Battery Cable Installation, Cummins M11E CELECT and 12 Volt System and 2, 3, or 4
Twelve Volt Batteries — 9800
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Figure 44 Battery Cable Installation, Cummins N14E Elek Plus 12 Volt System — 9800
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Figure 45 Battery Cable Installation, Detroit Diesel Series 60 Engines and 12 Volt System — 9800
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Figure 46 Battery Cable Installation, Detroit Diesel Series 60 Engines and 12 Volt System and 2,
3, or 4 Twelve Volt Batteries — 9800
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1. SEE FIGURE 14
2. BATTERY TO ECM BATTERY CABLE ASSEMBLY
3. BATTERY TO ECM CABLE CIRCUITS 14C, 14D
4. BATTERY CABLE TO CRANKING MOTOR GROUND
5. POSITIVE, BATTERY TO BATTERY CABLE
6. SPECIAL BATTERY NUT
7. FOURTH BATTERY LOCATION WHEN REQUIRED
8. NEGATIVE, BATTERY TO BATTERY CABLE
9. WITH 2 BATTERY INSTALLATION
10. 15A FUSES
11. CIRCUIT 11–G
12. ECM CABLE TO CIRCUIT 11–G FROM BATTERY
13. BATTERY CABLE TO CRANKING MOTOR BATTERY STUD (SEE VIEW B)
Figure 47 3+1 Isolated Battery System — 9800 SFA and SBA
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1. SEE FIGURE 18
2. 3+1 ISOLATED BATTERY HARNESS (CHASSIS OVERLAY)
3. BRACKET, LOWER STEP MOUNTING W/SBA
4. HARNESS, CHASSIS
5. 3+1 ISOLATED BATTERY HARNESS
6. CIRCUIT 14 AND 11–GX
7. SEE FIGURE 21
8. 3+1 HARNESS W/ RELAY CONNECTION
9. CIRCUIT 7
10. HOSE AND HARNESS RETAINER
11. CROSSMEMBER, CAB UNDERBODY
13. SILL ASSEMBLY, OUTER RIGHT
14. SEE FIGURE 16
15. 3+1 ISOLATED BATTERY HARNESS (CAB OVERLAY)
16. (537)
17. CIRCUIT 14AB
18. HARNESS, CHASSIS
19. BRACKET ASSEMBLY, CAB FRONT MOUNTING
20. ENGINE HARNESS W/ RELAY CONNECTION AND 3+1 EFFECTS
21. CIRCUIT 7, 7A
23. W/ REMOTE SENSING GEN.
24. BRACKET, RADIATOR MOUNTING RIGHT
25. N/ REMOTE SENSING GEN.
26. BRACKET, FRONT SPRING W/ SBA
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Figure 53 Delco Remy 42MT Cranking Motor Wiring (Type 450 — Thermal Overcrank Protection),
Cummins M11 or N14 — 9800
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Figure 54 Delco Remy 42MT Cranking Motor Wiring (Type 450 — Thermal Overcrank Protection),
Detroit Diesel Series 60 — 9800
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Figure 55 Delco Remy 42MT Cranking Motor Wiring (Type 450 — Thermal Overcrank Protection) —
9800
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4 ETHER START 121
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
3. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
3.1. ETHER START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
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122 4 ETHER START
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4 ETHER START 123
Model: 9800
1. DESCRIPTION
When activated, the ether start system injects a measured amount of ether into the engine intake system to
assist starting. The system will only function if the engine temperature is less than approximately 40°F (5°C)
and opens when engine block temperature exceeds 50°F (10°C).
2. OPERATION
When the key switch is in the ignition position, power is supplied to ignition adapter (518), circuit 13L, 10 A
fuse F10-A, circuit 21, and ether start switch (451) is held in the one position, power is supplied to circuit 21H,
connector (102) [(102)/(338) with Detroit Diesel], circuit 21, connector (136), a red wire, and the ether control
valve. If the engine temperature is below 40°F (5°C), the thermal switch contacts will be closed and a ground
path will be provided for the ether control valve. The ground path will be a brown wire, connector (136), circuit
21A, a one-way connector, a brown wire, and the thermal switch to engine ground. This will cause the ether
start valve to spray a premeasured amount of ether.
3. TROUBLESHOOTING
wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 —
relay, or solenoid.
3.1. ETHER START

Refer to circuit diagram ETHER START in CTS-5254W.
NOTE – The engine temperature must be less than approximately 40°F (5°C).
Table 23 Ether Start

STEP KEY ACTION TEST SPEC. YES- I N NO-OUT OF SPEC.
POINTS SPEC.
1. Off Check ether cylinder for Ether in Go to next Replace with new
ether. cylinder. step. cylinder.
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124 4 ETHER START
Table 23 Ether Start (cont.)

STEP KEY ACTION TEST SPEC. YES- I N NO-OUT OF SPEC.
POINTS SPEC.
2. Off Check fuse F10-A F10-A Fuse OK? Go to next Locate cause of
(location may vary). step. overload condition,
then correct.
Replace 10A fuse.
3. Off Remove circuit 21A Go to next
from thermo switch and step.
jumper 21A to engine
ground.
4. On Test operation of ether Ether Replace Leave jumper in
start system. system thermo place and go to next
works? switch. step.
5. On Disconnect ether switch (600), 10 to 12 Go to next Locate cause of no
(600) and measure 21H to volts. step. or low voltage in
voltage from circuit 21H gnd. circuit 21H from fuse
to ground. F10-A, then repair.
6. Off Use ohmmeter to (600), 5 < 5 ohms. Go to next Replace switch
measure resistance and 6. step. and reconnect 21,
across switch (600) 21H, and 21A. Test
terminals 5 and 6 with operation.
switch depressed.
7. Off Reconnect connector Go to next
(600) and remove step.
connector (72).
8. On At connector (72), (72), 21 to 10 to 12 Go to next Locate open in
measure voltage from gnd. volts. step. circuit 21 between
circuit 21 to ground with ether switch and
ether switch depressed. connector (72),
then repair. Test
operation.
9. On At connector (72), (72), 21 to 10 to 12 Replace Locate open in
measure voltage 21A. volts. ether cir. 21A between
between circuit 21 and control ether control valve
21A with ether switch valve and thermo switch,
depressed. assembly. then repair. Test
operation.
(102) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Cab Floor, Ft Rt (1/2 Replace by (338), W/Series
60)
(136) Ether Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At Rear of Cab, at Bottle
(338) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Cab Floor, Front Right
(451) Ether Start On/Off Switch. . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(504) L1 Panel Light Feed Adapter. . . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
(505) L3 Panel Lights Gnd Adapter. . . . . . . . . . . . . . . . .. . . . . . Behind Switch Cluster
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4 ETHER START 125
(518) I1 Ignition Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Center
Refer to Figure 1, Figure 2, Figure 3, Figure 4, and Figure 5.
Figure 56 Ether Start Wiring — 9800

1. CAB HARNESS
2. TO FUSE PANEL — SEE FIGURES 1 THROUGH 7 IN POWER DISTRIBUTION AND
GROUND SYSTEMS SECTION
3. TO SWITCH — SEE FIGURE 13 IN POWER DISTRIBUTION AND GROUND SYSTEMS
SECTION
4. ETHER START INSTRUMENT PANEL
5. (102A)/(102B) OR (102A)/(338) WITH DETROIT DIESEL SERIES 60
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126 4 ETHER START
Figure 57 Ether Start Wiring
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4 ETHER START 127
Figure 58 Ether Start Engine Wiring
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128 4 ETHER START
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4 ETHER START 129
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130 4 ETHER START
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5 FAN SYSTEMS 131
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
1.1. HORTON FAN WITH CUMMINS M11 OR N14 WITH OR WITHOUT AIR CONDITIONING. . . .133
1.2. HORTON ENGINE FAN CONTROLS WITH CUMMINS ISM WITH OR WITHOUT AIR
CONDITIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
1.3. HORTON FAN WITH DETROIT SERIES 60 WITH OR WITHOUT AIR CONDITIONING. . . . . . .133
1.4. KYSOR FAN WITH CUMMINS M11 OR N14 WITH OR WITHOUT AIR CONDITIONING. . . . . .133
1.5. KYSOR ENGINE FAN CONTROLS WITH CUMMINS ISM WITH OR WITHOUT AIR
CONDITIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
1.6. KYSOR FAN WITH DETROIT SERIES 60 WITH OR WITHOUT AIR CONDITIONING. . . . . . . . .133
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
2.2. HORTON FAN WITH CUMMINS ISM WITH OR WITHOUT AIR CONDITIONING. . . . . . . . . . . . . . .134
2.3. HORTON FAN WITH DETROIT SERIES 60 WITH OR WITHOUT AIR CONDITIONING. . . . . . .134
2.5. KYSOR FAN WITH CUMMINS ISM WITH OR WITHOUT AIR CONDITIONING. . . . . . . . . . . . . . . . .135
2.6. KYSOR FAN WITH DETROIT SERIES 60 WITH OR WITHOUT AIR CONDITIONING. . . . . . . . .135
3.2. HORTON FAN WITH CUMMINS ISM WITH OR WITHOUT AIR CONDITIONING. . . . . . . . . . . . . . .137
3.3. HORTON FAN WITH DETROIT DIESEL SERIES 60 WITH OR WITHOUT AIR
CONDITIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
3.5. KYSOR FAN WITH CUMMINS ISM WITH OR WITHOUT AIR CONDITIONING. . . . . . . . . . . . . . . . .141
3.6. KYSOR FAN WITH DETROIT DIESEL SERIES 60 WITH OR WITHOUT AIR
CONDITIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
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132 5 FAN SYSTEMS
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5 FAN SYSTEMS 133
Model: 9800
1. DESCRIPTION
1.1. HORTON FAN WITH CUMMINS M11 OR N14 WITH OR WITHOUT AIR
CONDITIONING
The ECM is used to control the Horton engine cooling fan. Other fan control components include a Horton
fan assembly, normally open (N.O.) ports on a fan solenoid (239), and a normally closed (N.C.) A/C high
pressure switch (240).
1.2. HORTON ENGINE FAN CONTROLS WITH CUMMINS ISM WITH OR WITHOUT
AIR CONDITIONING
1.3. HORTON FAN WITH DETROIT SERIES 60 WITH OR WITHOUT AIR CONDITIONING
1.4. KYSOR FAN WITH CUMMINS M11 OR N14 WITH OR WITHOUT AIR CONDITIONING
The ECM is used to control the Kysor engine cooling fan. Other fan control components include a Kysor
fan assembly, normally closed (N.C.) ports on a fan solenoid (239), and a normally closed (N.C.) A/C high
1.5. KYSOR ENGINE FAN CONTROLS WITH CUMMINS ISM WITH OR WITHOUT AIR
CONDITIONING
1.6. KYSOR FAN WITH DETROIT SERIES 60 WITH OR WITHOUT AIR CONDITIONING
2. OPERATION
CONDITIONING
The Cummins ECM controls the cooling fan clutch by supplying 12 volts and up to 2 amps of current at engine
connector (309) pin C. This power is transferred through the Cummins engine harness and circuit 23D to ECM
connector (239) and the red wire of the fan solenoid, causing it to energize. With the solenoid energized, the
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134 5 FAN SYSTEMS
air supply to the fan clutch will come on, and thus the fan stops. The fan solenoid is grounded through the
black wire and ECM connector (239) of the solenoid, and circuits 23-GA and 11-GU to start motor ground (J8).
The ECM cycles the fan to regulate engine temperature and A/C compressor head refrigerant pressure. The
ECM uses temperature sensors on the engine and input from the A/C pressure switch (240) to determine
these on/off cycles. This input is the application of a ground signal which originates from the common pin
10 of ECM connector (263) and is applied to circuits 97-G and 23-GB, A/C switch or jumper at connector
(240), circuit 23C and Cummins engine connector (309) pin C. The A/C pressure switch is a N.C. switch that
opens up at pressures greater the 300 psi, and thus signals the ECM, by removing the ground signal, to
turn on the engine fan.
2.2. HORTON FAN WITH CUMMINS ISM WITH OR WITHOUT AIR CONDITIONING
The Cummins ECM controls the cooling fan clutch by supplying 12 volts at 31-way interface connector (957)
pin 12. This power is transferred through the Cummins engine harness, 31-way interface connector (957),
and circuit 23D to connector (239) and the red wire of the fan solenoid, causing it to energize. With the
solenoid energized, the air supply to the fan clutch will come on, and thus the fan stops. The fan solenoid is
grounded through the black wire and connector (239) of the solenoid, and circuits 23-GA to 31-way interface
connector (957) pin 13.
ECM uses temperature sensors on the engine and input from the A/C pressure switch (240) to determine these
on/off cycles. This input is the application of a ground signal which originates from ECM connector (957) pin 18
and is applied to circuit 23-GB, A/C switch or jumper at connector (240), circuit 23C, and 31-way interface
connector (957) pin 17. The A/C pressure switch is a N.C. switch that opens up at pressures greater the 300
psi, and thus signals the ECM, by removing the ground signal, to turn on the engine fan.
2.3. HORTON FAN WITH DETROIT SERIES 60 WITH OR WITHOUT AIR CONDITIONING
Power from the ignition adapter (518) is applied to circuit 13R, 10A fuse F10-A (location may vary), circuit 23A,
connector (102)/(338), circuit 23A, and the fan solenoid connector (227) and its red wire. The Detroit Diesel
ECM controls the cooling fan clutch by providing or removing a ground path to the fan solenoid through the
black wire, connector (227) of the fan solenoid, and circuit 23D to the ECM connector (341) pin A2. When
a ground is applied, the solenoid will energize. With the solenoid energized, the air supply to the fan clutch
will be cut off and thus the fan will stop.
on/off cycles. This input is the application of a ground signal which originates from the ECM power ground and
is applied to circuits 97-G and 23-GB, A/C switch or jumper at connector (236), and circuit 23C to the ECM
connector (341). The A/C pressure switch is a N.C. switch that opens up at pressures greater the 275 psi, and
thus signals the ECM to turn on the engine fan, by removing the ground signal.
The Cummins ECM controls the cooling fan clutch by supplying 12 volts to engine connector (309) pin C.
This power is transferred through circuit 23D to connector (239) and the red wire of the fan solenoid. With
the solenoid energized, the air supply to the fan clutch will come on, thus the fan will stop. The fan solenoid
is grounded through the black wire and connector (239) of the solenoid, and circuits 23-GA and 11-GU to
start motor ground (J8).
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5 FAN SYSTEMS 135
on/off cycles. This input is the application of a ground signal which originates from pin 10 of ECM connector
(263) and is applied to circuits 97-G and 23-GB, A/C switch or jumper at connector (240), circuit 23C and
engine connector (309) pin T. The A/C pressure switch is a N.C. switch that opens up at pressures greater the
300 psi, and thus signals the ECM, by removing the ground signal, to turn on the engine fan.
2.5. KYSOR FAN WITH CUMMINS ISM WITH OR WITHOUT AIR CONDITIONING
The Cummins ECM controls the cooling fan clutch by supplying 12 volts to 31-way interface connector (957)
pin 12. This power is transferred through circuit 23D to connector (239) and the red wire of the fan solenoid.
With the solenoid energized, the air supply to the fan clutch will come on, thus the fan will stop. The fan
solenoid is grounded through the black wire and connector (239) of the solenoid, and circuits 23-GA to
31-way interface connector (957) pin 13.
on/off cycles. This input is the application of a ground signal which originates from pin 18 of 31-way interface
connector (957) and is applied to circuit 23-GB, A/C switch or jumper at connector (240), circuit 23C and
31-way interface connector (957) pin 17. The A/C pressure switch is a N.C. switch that opens up at pressures
greater the 300 psi, and thus signals the ECM, by removing the ground signal, to turn on the engine fan.
2.6. KYSOR FAN WITH DETROIT SERIES 60 WITH OR WITHOUT AIR CONDITIONING
Power from the ignition adapter (518) is applied to circuit 13R, 10A fuse F10-A (location may vary), circuit 23A,
connector (102)/(338), circuit 23A, and the fan solenoid connector (227) and its red wire. The Detroit Diesel
ECM controls the cooling fan clutch by providing or removing a ground path to the fan solenoid through the
black wire, connector (227) of the fan solenoid, and circuit 23D to the ECM connector (341) pin A2. When
a ground is applied, the solenoid will energize. With the solenoid energized, the air supply to the fan clutch
will come on and thus the fan will stop.
on/off cycles. This input is the application of a ground signal which originates from the ECM power ground and
is applied to circuits 97-G and 23-GB, A/C switch or jumper at connector (236), and circuit 23C to the ECM
connector (341). The A/C pressure switch is a N.C. switch that opens up at pressures greater the 275 psi, and
thus signals the ECM to turn on the engine fan, by removing the ground signal.
3. TROUBLESHOOTING
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136 5 FAN SYSTEMS
relay, or solenoid.
CONDITIONING
Table 24 Horton Fan With Cummins M11 or N14 With or Without Air Conditioning
STEP KEY ACTION TEST SPEC. YES - IN NO-OUT OF SPEC.
POINTS SPEC.
1. Off Disconnect ECM (263), < 1 ohm. Go to Locate open or poor
connector (263) and 97–G to next connection in circuit
A/C pressure switch (240), step. 97-G or 23–GB.
connector (240). 23–GB.
Measure resistance
from (263) circuit 97–G
to (240) circuit 23–GB.
2. Off Does vehicle have air Go to Go to Step 4.
conditioning? next
step.
3. Off At (240) measure Switch < 1 ohm. Go to Replace defective
resistance across black (240), Step 5. A/C pressure switch.
wires of A/C pressure black wire
switch. to black
wire.
4. Off At (240) measure Jumper < 1 ohm. Go to Replace defective
resistance from black plug (240), next A/C jumper plug.
wire to black wire of A/C black wire step.
pressure switch jumper to black
plug. wire.
5. Off Disconnect Cummins (309), < 1 ohm. Go to Locate open or poor
engine connector cavity T next connection in circuit
(309) and measure to (240), step. 23C, conn. (309) or
resistance from cavity T 23C. air conditioning input
to connector (240) circuit circuit, then repair.
23C.
6. Off/ On Reconnect connector (239), 23D 12 ± 1.5 Go to Locate cause of low
(309) and (240), to gnd. volts. next or no voltage in fan
disconnect connector step. clutch driver circuit,
(239), and start engine. or circuit 23D from
WARNING: Fan will be engine connector
rotating. At connector (309) terminal C,
(239) and circuit 23D, then repair.
measure voltage to
ground. NOTE: Engine
must be cool and when
applicable, A/C should
be turned off.
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5 FAN SYSTEMS 137
Table 24 Horton Fan With Cummins M11 or N14 With or Without Air Conditioning (cont.)
POINTS SPEC.
7. On With engine still running (239), 23D 12 ± 1.5 Go to Locate open or poor
and relatively cool, to 23–GA. volts. next connection in circuit
at connector (239), step. 23–GA or 11–GU
measure voltage from (11–GH with M11),
circuit 23D to 23–GA. then repair.
8. On With engine still running Go to Replace defective
and relatively cool, next fan solenoid.
reconnect fan solenoid step.
connector (239). Does
fan slow or stop rotating?
9. Off Shut off engine. Fan
If fan fails to function
properly, check ECM
programming and A/C
pressure switch opening
pressure.
3.2. HORTON FAN WITH CUMMINS ISM WITH OR WITHOUT AIR CONDITIONING
Table 25 Horton Fan With Cummins ISM With or Without Air Conditioning
POINTS SPEC.
1. Off Disconnect 31–way (957), < 1 ohm. Go to Locate open or poor
interface connector term. 18 next connection in circuit
(957) and A/C pressure and (240), step. 23–GB.
switch connector (240). 23–GB.
Measure resistance
between (957) terminal
18 and (240) circuit
23–GB.
conditioning? next
step.
switch. to black
wire.
plug. wire.
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138 5 FAN SYSTEMS
Table 25 Horton Fan With Cummins ISM With or Without Air Conditioning (cont.)
POINTS SPEC.
5. Off Measure resistance (957), < 1 ohm. Go to Locate open or poor
from (957) cavity 17 and cavity 17 next connection in circuit
connector (240) circuit and (240), step. 23C, conn. (957) or
23C. 23C. air conditioning input
circuit, then repair.
WARNING: Fan will be interface connector
rotating. At connector (957), then repair.
measure voltage to
be turned off.
at connector (239), step. 23–GA, then repair.
circuit 23D to 23–GA.
properly, check ECM
programming and A/C
pressure.
3.3. HORTON FAN WITH DETROIT DIESEL SERIES 60 WITH OR WITHOUT AIR
CONDITIONING
Table 26 Horton Fan With Detroit Diesel Series 60 With or Without Air Conditioning
POINTS SPEC.
conditioning? next
step.
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5 FAN SYSTEMS 139
Table 26 Horton Fan With Detroit Diesel Series 60 With or Without Air Conditioning (cont.)
POINTS SPEC.
2. Off Disconnect connector Switch < 1 ohm. Go to Replace defective
(236) and measure (236), Step 4. A/C pressure switch.
resistance across black black wire
wires of A/C pressure to black
switch connector (236). wire.
3. Off Disconnect connector Jumper < 1 ohm. Go to Replace defective
(236) and measure plug (236), next A/C jumper plug.
resistance from black black wire step.
wire to black wire of A/C to black
pressure switch jumper wire.
plug.
4. Off At connector (236) (236), < 1 ohm. Go to Locate open or
measure resistance 23–GB to next poor connection
from circuit 23–GB to gnd. step. in circuit 23–GB or
ground. 97–G to ECM power
connector ground,
then repair.
5. Off Reconnect connector (341), 23C < 1 ohm. Go to Locate open or poor
(236) and disconnect to gnd. next connection in circuit
connector (341). At step. 23C, then repair.
circuit 23C, measure
6. On Move key switch to F10–A, 12 ± 1.5 Go to Locate cause of
ignition position, and at 13R to volts. next low or no voltage
10A fuse F10–A and gnd. step. in circuit 13H, 13P,
circuit 13R, measure I1 ignition adapter
voltage to ground. (518), or circuit
13R from ignition
relay (462–R1), then
repair.
7. Off/ On Disconnect fan solenoid (227), 23A 12 ± 1.5 Go to Locate cause of low
(227), move key switch to gnd. volts. next or no voltage in 10A
to ignition position, and step. fuse F10–A, circuit
at circuit 23A, measure 23A, connector
voltage to ground. (102)/(338), or circuit
23A, then repair.
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140 5 FAN SYSTEMS
Table 26 Horton Fan With Detroit Diesel Series 60 With or Without Air Conditioning (cont.)
POINTS SPEC.
8. Off/ On Reconnect connector (227), 23A 12 ± 1.5 Go to Locate open or
(341) and (236). Start to 23D. volts. next poor connection
engine. WARNING: Fan step. in circuit 23D, or
will rotate. At connector problem with ECM or
(227), measure voltage programming, then
from circuit 23A to 23D. repair.
9. Off/ On Reconnect fan solenoid Fan Replace defective
(227). With engine circuits solenoid.
still relatively cool and check
A/C shut off, start good.
engine. Does fan Shut off
remain stationary or engine.
rotate slowly?
Table 27 Kysor Fan With Cummins M11 or N14 With or Without Air Conditioning
POINTS SPEC.
1. Off Disconnect ECM (263), < 1 ohm. Go to Locate open or poor
connector (263) and 97–G to next connection in circuit
A/C pressure switch (240), step. 97-G or 23–GB.
connector (240). 23–GB.
Measure resistance
from (263) circuit 97–G
to (240) circuit 23–GB.
conditioning? next
step.
switch. to black
wire.
plug. wire.
5. Off Disconnect Cummins (309), < 1 ohm. Go to Locate open or poor
engine connector cavity T next connection in circuit
(309) and measure to (240), step. 23C, conn. (309) or
resistance from cavity T 23C. air conditioning input
to connector (240) circuit circuit, then repair.
23C.
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5 FAN SYSTEMS 141
Table 27 Kysor Fan With Cummins M11 or N14 With or Without Air Conditioning (cont.)
POINTS SPEC.
WARNING: Fan will be engine connector
measure voltage to
be turned off.
at connector (239), step. 23–GA or 11–GU
measure voltage from (11–GH with M11),
circuit 23D to 23–GA. then repair.
properly, check ECM
programming and A/C
pressure.
3.5. KYSOR FAN WITH CUMMINS ISM WITH OR WITHOUT AIR CONDITIONING
Table 28 Kysor Fan With Cummins ISM With or Without Air Conditioning
POINTS SPEC.
1. Off Disconnect 31–way (957), < 1 ohm. Go to Locate open or poor
interface connector term. 18 next connection in circuit
(957) and A/C pressure and (240), step. 23–GB.
switch connector (240). 23–GB.
Measure resistance
18 and (240) circuit
23–GB.
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142 5 FAN SYSTEMS
Table 28 Kysor Fan With Cummins ISM With or Without Air Conditioning (cont.)
POINTS SPEC.
conditioning? next
step.
switch. to black
wire.
plug. wire.
5. Off Measure resistance (957), < 1 ohm. Go to Locate open or poor
from (957) terminal 17 term. 17 next connection in circuit
and connector (240) and (240), step. 23C, conn. (309) or
circuit 23C. 23C. air conditioning input
circuit, then repair.
WARNING: Fan will be interface connector
measure voltage to
be turned off.
at connector (239), step. 23–GA, then repair.
circuit 23D to 23–GA.
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5 FAN SYSTEMS 143
Table 28 Kysor Fan With Cummins ISM With or Without Air Conditioning (cont.)
POINTS SPEC.
properly, check ECM
programming and A/C
pressure.
3.6. KYSOR FAN WITH DETROIT DIESEL SERIES 60 WITH OR WITHOUT AIR
CONDITIONING
Table 29 Kysor Fan With Detroit Diesel Series 60 With or Without Air Conditioning
POINTS SPEC.
conditioning? next
step.
2. Off Disconnect connector Switch < 1 ohm. Go to Replace defective
(236) and measure (236), Step 4. A/C pressure switch.
resistance across black black wire
wires of A/C pressure to black
switch connector (236). wire.
3. Off Disconnect connector Jumper < 1 ohm. Go to Replace defective
(236) and measure plug (236), next A/C jumper plug.
resistance from black black wire step.
wire to black wire of A/C to black
pressure switch jumper wire.
plug.
4. Off At connector (236) (236), < 1 ohm. Go to Locate open or
measure resistance 23–GB to next poor connection
from circuit 23–GB to gnd. step. in circuit 23–GB or
ground. 97–G to ECM power
connector ground,
then repair.
5. Off Reconnect connector (341), 23C < 1 ohm. Go to Locate open or poor
(236) and disconnect to gnd. next connection in circuit
connector (341). At step. 23C, then repair.
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144 5 FAN SYSTEMS
Table 29 Kysor Fan With Detroit Diesel Series 60 With or Without Air Conditioning (cont.)
POINTS SPEC.
6. On Move key switch to F10–A, 12 ± 1.5 Go to Locate cause of
ignition position, and at 13R to volts. next low or no voltage
10A fuse F10–A and gnd. step. in circuit 13H, 13P,
circuit 13R, measure I1 ignition adapter
voltage to ground. (518), or circuit
13R from ignition
relay (462–R1), then
repair.
7. Off/ On Disconnect fan solenoid (227), 23A 12 ± 1.5 Go to Locate cause of low
(227), move key switch to gnd. volts. next or no voltage in 10A
to ignition position, and step. fuse F10–A, circuit
at circuit 23A, measure 23A, connector
voltage to ground. (102)/(338), or circuit
23A, then repair.
8. Off/ On Reconnect connector (227), 23A 12 ± 1.5 Go to Locate open or
(341) and (236). Start to 23D. volts. next poor connection
engine. WARNING: Fan step. in circuit 23D, or
will rotate. At connector problem with ECM or
(227), measure voltage programming, then
from circuit 23A to 23D. repair.
9. Off/ On Reconnect fan solenoid Fan Replace defective
(227). With engine circuits solenoid.
still relatively cool and check
A/C shut off, start good.
engine. Does fan Shut off
remain stationary or engine.
rotate slowly?
F10 Fuseblock (464). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In Power Distribution Center
(J8) Cranking Motor Ground Junction. . . . . . . . . . . . . . .. . . . . . Ground Terminal at Engine
(102) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Cab Floor, Ft Rt, 1/2 Replace by (338) W/ Series 60
(227) Fan Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Fan Hub, With Series 60
(239) Fan Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . W/ M11 on Fan Hub, W/ N14 on Lt Ft Side of Engine
(240) A/C Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Cab Floor, Ft Rt, 1/2 replace by (338) W/ Series 60
(263) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Cab Floor, Ft Rt, 1/2 replace by (338) W/ Series 60
(309) Cummins Engine Connector. . . . . . . . . . . . . . . . . .. . . . . . Between Engine Harness, Near ECM
(338) Engine Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On Cab Floor Front Right
(341) ECM Connector W/ Series 60. . . . . . . . . . . . . . . . .. . . . . . On Left Side of Engine, at Rear of ECM
(518) Ignition Adapter I1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Instrument Panel, Center
(957) 31–Way Cummins Connector. . . . . . . . . . . . . . . . .. . . . . . Left Side of Engine, Above ECM
Refer to Figure 1, Figure 2, Figure 3, and Figure 4.
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Figure 61 Cummins M11 Celect Engine Wiring (Fan Effects)
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146 5 FAN SYSTEMS
1. ENGINE OIL TEMP. SENDER AND ETHER START CONNECTIONS

2. TEMP. SENSOR CIRCUIT 29A, 29–G
3. SEE FIGURE 15 IN CUMMINS M11E AND N14E ENGINE SECTION
6. (240) CIRCUIT 23C, 23–GB
7. CIRCUIT 77A
8. SEE VIEW R
9. CIRCUIT 23D, 23–GA
10. FAN DRIVE SOLENOID VALVE (239)
11. DEAERATION HOSE
12. CUMMINS M11 CELECT ENGINE HARNESS
14. JUMPER PLUG USED FOR VEHICLES WITHOUT AIR CONDITIONING
15. ENGINE HARNESS (240) CIRCUIT 23C, 23–GB
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5 FAN SYSTEMS 147
Figure 62 Engine Wiring (Fan Effects) Cummins N14 Celect Engines
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148 5 FAN SYSTEMS
1. (N/L) CIRCUIT 77A

2. TO FAN SOLENOID (239) CIRCUIT 23D, 23–GA
3. TO PRESSURE SWITCH (240) CIRCUIT 23C, 23–GB, SEE VIEW P
4. ENGINE HARNESS
7. CRANKING MOTOR
8. CIRCUIT 11–GS
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5 FAN SYSTEMS 149
Figure 63 Engine Wiring (Fan Effects), Cummins ISM Engines
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150 5 FAN SYSTEMS
Figure 64 Engine Wiring (Fan Effects), Detroit Diesel Series 60 Engines
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5 FAN SYSTEMS 151
1. SEE FIGURE 11 IN DETROIT DIESEL SERIES 60 ENGINE SECTION

2. TEMPERATURE SENDER (244) CIRCUIT 29A, 29–G
3. ENGINE HARNESS
5. DEAERATION HOSE
6. PRESSURE SWITCH (236) CIRCUIT 23C, 23–GB, SEE VIEW G
7. CIRCUIT 77A
8. (N/L)
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6 CUMMINS M11E AND N14E ENGINES 153
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
2.1. ECM POWER CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
2.2. ATA DATA LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
2.3. DIAGNOSTIC SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
2.4. ELECTRONIC ACCELERATOR PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
2.5. COOLANT LEVEL SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
2.6. CELECT CRUISE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
2.7. CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
2.8. VEHICLE SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
2.9. BRAKE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
2.10. CELECT ENGINE BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
2.11. ANTILOCK BRAKE INTERFACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
3.1. ONBOARD DIAGNOSTICS WITH ENGINE RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
3.2. PERFORMING A DIAGNOSTIC CHECK WITH THE ENGINE OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
3.3. COMPULINKTM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
3.4. EZ-TECH OR PRO-LINK ELECTRONIC SERVICE TOOL (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
3.5. INSPECTING NAVISTAR ENGINE HARNESS ECM CONNECTOR (263). . . . . . . . . . . . . . . . . . . . . . . .162
3.6. RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
3.7. TESTING RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
3.8. ACCELERATOR PEDAL TPS/IVS — CUMMINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Testing Throttle Position Sensor (TPS) — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Testing Idle Validation Switch (IVS) — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Testing Accelerator Pedal (TPS/IVS) System for "Short or Open" Circuits —
Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Testing TPS/IVS Circuits for Continuity — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Accelerator/ECM Calibration — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
3.9. LOW COOLANT SWITCH — CUMMINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Testing Low Coolant Level Switch and Circuit — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
3.10. POWER SUPPLY CIRCUITS TO ECM — CUMMINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Testing Unswitched Battery Power Circuits and ECM Ground Circuit — Cummins. . . .179
Testing Switched Ignition Power To ECM — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
3.11. SERVICE BRAKE AND CLUTCH SWITCHES — CUMMINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Testing Clutch Switch — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Testing Clutch Switch Circuits for “Open and Short” Condition — Cummins. . . . . . . . . . .186
Testing Clutch Switch Circuits For Continuity — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
Testing Service Brake Switch (5) — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Testing Service Brake Switch Circuits for "Open and Short" Condition — Cummins. . .191
Testing Service Brake Switch Circuits for Continuity — Cummins. . . . . . . . . . . . . . . . . . . . . . . .194
3.12. ENGINE BRAKE — CUMMINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Testing Engine Brake Components and Circuits — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Testing Engine Brake Switches — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
3.13. ATA DATA LINK CONNECTOR (220) AND SPEEDOMETER/TACHOMETER INPUT CIRCUITS
— CUMMINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
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154 6 CUMMINS M11E AND N14E ENGINES
Testing Diagnostic Connector Power and Ground Circuits— Cummins. . . . . . . . . . . . . . . . .197

Testing Data Link Circuits Between Diagnostic Connector, ECM and
Speedometer/Tachometer Unit — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
3.14. DIAGNOSTIC SWITCHES — CUMMINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Testing Diagnostic On/Off Switch and Circuit — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Testing Idle/Diagnostic Switch (265) and Circuits — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . .206
3.15. CRUISE CONTROL — CUMMINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Testing Cruise Control On/Off Switch and Circuits — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . .210
Testing Cruise Set/Resume Switch and Circuits — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
3.16. VEHICLE SPEED SENSOR — CUMMINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Inspecting and Adjusting the Vehicle Speed Sensor (VSS) — Cummins. . . . . . . . . . . . . . . . .213
Testing Vehicle Speed Sensor — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Testing Vehicle Speed Sensor Circuits To ECM — Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
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Model: 9800
1. DESCRIPTION
The M11E/N14E controllers provide many engine/vehicle functions including:
• Cruise/PTO Controls
• Tachometer/Speedometer Input To Gauges
• Idle Shutdown
• Adjustable Low Idle Speed (In-Cab)
• Engine Cooling Fan Control
• Self Diagnostics
• Engine Protection System
• Engine Brake Control
Refer to the Cummins Engine Manual furnished with the vehicle for additional feature information.
Since each engine control system is electronically programmable to individual owner specifications, the
operating parameters will vary from vehicle to vehicle. These parameters include: maximum cruise speed,
shift schedules, governor type (automotive type or variable speed), idle RPM, full engine shutdown as part
of the engine protection system and many others.
The electronic control module (ECM) is the control center of the CELECT system. The ECM receives input
from Cummins and International sensors and switches, processes the information, then uses electrical signals
to control engine and vehicle functions.
The ECM receives inputs from International-installed components including:
• Vehicle Speed Sensor (VSS)

• Throttle Position Sensor (TPS)
• Idle Validation Switch (IVS)
• Service Brake Switch
• Clutch Switch
• Low Coolant Level Switch
• ABS/Traction Control Controller
• CELECT Cab Switches.
The ECM receives information from the sensors and switches and sends signals to the injectors, fuel shut off
valve and engine brake relay.
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2. OPERATION
2.1. ECM POWER CIRCUITS
The ECM is grounded through the Cummins harness, ECM power harness connector (310) and circuit 97-G to
the engine ground stud. The engine ground stud is connected to the cranking motor ground stud, frame rail
and negative battery terminal.
Turning the key switch to the ignition or start position energizes the ignition relay. The relay then applies power
to circuits 16A and 16E, 15A circuit breaker B3, and circuit 16D to the 21-way ECM connector (309).
2.2. ATA DATA LINK

The six pin ATA data link connector (220) allows an electronic service tool (EST) to communicate with the
ECM. The data link carries serial data transmissions between the ECM and the electronic service tool, and
between the ECM and the speedo/tachometer cluster. Thus, the ECM provides vehicle and engine information
to the speedo/tachometer and the EST.
The ATA data link connector (220), which is located on the left instrument panel, has circuits in four of the
six cavities. The data link circuits are a twisted wire pair because twisting the wires helps shield them from
interference. The circuits are as follows:
• Circuit 98A(+) is the positive data link connection, and it is fed by the positive data link connector (514), the
jumper bus bar, circuit 98(+), connector (262), and circuit 98(+) coming from the ECM connector (263).
• Circuit 98C(-) is the negative data link connection, and it is fed by the negative data link connector (515),
the jumper bus bar, circuit 98B(-), connector (262) and circuit 98B(-) coming from the ECM connector (263).
• Circuit 97DL is a 12 volt feed and is fed from the (B1) battery stud, circuits 14K and 14AL, and 5A fuse
F6–A. Thus it provides power for the electronic service tool.
• Circuit 11–GR is connected to the G5 ground adapter (533), and provides a ground for the electronic
service tool.
2.3. DIAGNOSTIC SWITCH

A lighted diagnostic on/off switch is provided for on-board diagnostics. The switch is connected to the ECM
common/ground connection by way of circuits 97-GE, 97-GA, connector (262), circuits 97-GA, 97-G and ECM
connector (263). Moving the switch to the on position closes the switch contacts and applies the ground to
circuit 97AM, connector (262), and circuit 97AM to the Cummins engine connector (309). This tells the ECM
that the diagnostic on/off switch has been turned on. Thus the ECM will switch modes to display fault codes or
the absence of codes by flashing the engine warning light and the stop engine light.
The lighted two-position momentary idle/diagnostic switch is a dual function switch. The switch adjusts the
low engine idle speed and is also used during on-board diagnostics (when the diagnostic switch is in the on
position) to move through the diagnostic fault code list.
The engine idle speed can be adjusted by the switch in increments of 25 rpm by toggling the switch. Maximum
idle speed is 800 rpm and minimum idle speed is 550 rpm. When the idle has been changed and the key
turned off, the new setting is saved in memory. This feature is owner selected and can be turned off with an
electronic service tool.
The switch is connected to the ECM common/ground connection by way of circuits 97-GD, 97-GA, connector
(262), circuits 97-GA, 97-G and ECM connector (263). Momentarily placing the switch in the increment
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position applies ground to circuit 97AV, connector (262), and circuit 97AV to the ECM (263). This causes
the engine idle rpm to increase 25 rpm.
Momentarily placing the switch in the decrement position applies ground to circuit 97AU, connector (262), and
circuit 97AU to the ECM (263). This causes the engine idle rpm to decrease 25 rpm.
2.4. ELECTRONIC ACCELERATOR PEDAL

CELECT engines utilize an electronic accelerator pedal assembly that includes an integrated throttle position
sensor (TPS) and idle validation switch (IVS). The accelerator pedal assembly is serviceable, to the extent that
the IVS switch is replaceable without replacing the whole assembly.
The TPS is attached to the accelerator pedal and acts like a potentiometer. Movement of the pedal results in
a variable signal being sent to the ECM that is proportional to pedal position. A 5 volt signal from the ECM
connector (263) is applied to circuit 99A, connector (262), circuit 99A and the TPS/IVS (306). The variable
wiper signal from TPS/IVS (306) is returned to the ECM over circuit 99, connector (262), circuit 99 and ECM
connector (263). This signal varies with pedal position and tells the ECM the position of the accelerator pedal.
The TPS (306) is grounded through circuit 99–G, connector (262) and circuit 99–G to the ECM (263).
NOTE – Any time the accelerator pedal sensor (TPS) is disconnected from the ECM with the key switch
on, the TPS and ECM must be recalibrated.
The IVS is used to indicate when accelerator pedal is in the low idle position and when the pedal is not in
the low idle position. A ground path for the IVS (306) is provided by circuits 99-GA, 97-GA, connector (262),
circuits 97-GA and 97-G to the ECM (263).
When the accelerator is in the low idle position, the IVS (306) applies a ground signal to circuit 99B, connector
(262), and circuit 99B to the ECM (263). When the accelerator is not in the idle position, the IVS (306) applies
a ground signal to circuit 99C, connector (262), and circuit 99C to the ECM (263).
The ECM analyzes the signals received from the TPS and IVS to make certain that the signals fall within
certain parameters. For example: if the IVS signal indicates that the accelerator pedal is in the idle position,
the ECM expects to see a TPS signal that indicates that no throttle is applied. If it does not see a logical
response from both, a fault code may be logged.
The ECM and accelerator pedal must be calibrated to one another for proper engine response. Therefore,
the ECM and accelerator pedal must be calibrated when the accelerator pedal is initially installed, when an
accelerator pedal is replaced, when a new calibration is downloaded to the ECM, or when the accelerator
pedal wiring is disconnected at the pedal, the cab floor, or the ECM connector. To recalibrate the ECM and the
accelerator pedal, move the key switch to ignition position, slowly move the accelerator pedal from idle position
to fully depressed position and then release. Repeat this cycle two more times to assure proper calibration.
2.5. COOLANT LEVEL SWITCH

The coolant level switch is a fluid level actuated switch that sends two signals to the ECM, thus providing a
warning when coolant is being lost. It is mounted in the coolant surge tank. The coolant level switch is an
electronic switch that operates on the electrostatic or capacitance principle and cannot be tested with a
multimeter. The probe extends into the coolant and produces a change in capacitance when coolant displaces
air immediately surrounding the probe. This change is converted in the switch to an on/off solid state switch
closure indicating the absence or presence of coolant. The switch is electrically insulated providing a slick,
non-fouling surface as well as good electrical characteristics to prevent current flow into the coolant. The low
coolant level switch connects to the engine harness at connector (307). Four circuits from connector (307)
connect the low coolant switch to the ECM through the 21–way ECM connector (309).
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The coolant level switch (307) receives a 5 volt signal on circuit 34B(5V) from the ECM (309). When the
coolant level is above the probe, the switch sends a high signal (3.5 volts minimum) on circuit 34A and a low
signal (0.5 volt maximum) on circuit 34 to the ECM (309).
When the coolant level is below the probe, the switch sends a low signal (0.5 volt maximum) on circuit 34A and
a high signal (3.5 volts minimum) on circuit 34 to ECM (309).
The low coolant level switch is grounded through circuit 34–G to ECM (309).
NOTE – The low coolant level switch cannot be tested with a multimeter in the ohmmeter mode. This is
due to the fact that the switch is an electronic switch and not a mechanical switch.
2.6. CELECT CRUISE CONTROL

The cruise control system has three modes of operation: off, standby and active. The off position of the on/off
switch turns cruise control off. The standby mode occurs when the driver switches the cruise control on/off
switch to the on position. The driver can then achieve the active mode by toggling the set/resume switch
after reaching the desired road speed.
Once the system is active, the driver can accelerate beyond the set speed by depressing the accelerator
pedal. When the pedal is released, the vehicle will slow down and cruise control will reactivate when the
vehicle speed reaches the previously set speed.
Cruise is deactivated, and returns to the standby mode in several ways: the brake or clutch pedal is depressed,
the engine speed (rpm) drops below 1000 rpm, or the vehicle speed (mph) drops below 30 mph.
The resume switch can be used to reactivate cruise at the previous set speed or the set switch can be used
to establish a new set speed.
While in the active mode, the coast feature is used to decrease vehicle speed and establish a new lower set
speed. By holding select switch in the coast position, vehicle speed decreases until the switch is released;
the speed at release becomes the new set speed.
While in the active mode, the accelerate feature is used to increase the vehicle speed and establish a new
higher speed. By holding the select switch in the accel position, vehicle speed increases until the switch is
released; the speed at release becomes the new set speed.
The lighted cruise control on/off switch receives a ground signal on circuits 97-GC, 97-GA, connector (262),
circuits 97-GA, and 97-G from ECM connector (263) terminal 10. In the on position, a ground signal is sent
from switch terminal 6, on circuit 97AE, connector (262), and circuit 97AE to ECM connector (263) terminal 2.
This indicates to the ECM that the cruise control switch is in the on position. In the off position, circuit 97AE
returns to its 12 volt value, indicating to the ECM that the switch is off.
The lighted cruise set/resume switch is a momentary switch. This switch receives a ground signal on circuits
97-GB, 97-GA, connector (262), circuits 97-GA, and 97-G from ECM connector (263) terminal 10.
The cruise selector switch sends a ground signal from the switch terminal 3 by way of circuit 97AB, connector
(262), and circuit 97AB to the ECM connector (263) terminal 12 while in the set/accel position. In the
resume/coast position, the switch sends a ground signal from terminal 1 by way of circuit 97AA, connector
(262), and circuit 97AA to the ECM connector (263) terminal 22.
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2.7. CLUTCH SWITCH

The clutch switch (55) is a N.O. momentary switch and its contacts are held closed when the clutch pedal
is released.
The switch is provided a ground path over circuits 97-GH, 97-GA, connector (262), circuits 97-GA, and 97-G
from ECM connector (263) terminal 10. The clutch switch (55) sends a ground signal by way of circuit 97AH,
connector (262), and circuit 97AH to the ECM connector (263) terminal 4 while the clutch pedal is released.
2.8. VEHICLE SPEED SENSOR

The vehicle speed sensor (225) feeds a VSS signal to the ECM (263) by way of circuits 97AJ and 97AK.
2.9. BRAKE SWITCH

The service brake switch (5) is a normally closed (N.C) air operated switch. Its contacts are closed when the
brakes are not applied, and its contacts open up when the brakes are applied. One terminal of the service
brake switch (5) is connected to circuit 97AL, connector (262), circuit 97AL and the ECM (263). The other
terminal of the switch is connected to ground by way of circuits 97-GF and 97-GA, connector (262), circuits
97-GA and 97-G, connector (N/L), circuits 97-G and 11-G, connector (N/L), and circuit 11-G to the negative
terminal of the batteries.
2.10. CELECT ENGINE BRAKE

The lighted engine brake on/off switch (412) is connected to signal ground by circuits 24-G, 97-GA, connector
(262), circuits 97-GA, and 97-G coming from ECM connector (263) terminal 10. In the on position, this ground
is applied by the switch and circuit 24AD to engine brake selector switch (411).
When switch (411) is placed in the center position, position 1, a ground is applied to circuit 24AE, connector
(262), and circuit 24AE to the ECM (263). This tells the ECM to enable the number 2 brake solenoid, the rear
three cylinders on the M11E engine or the middle two cylinders on the N14E engine when braking is called for.
When switch (411) is placed in position 2, a ground is applied to circuit 24AF, connector (262), and circuit 24AF
to the ECM (263). This tells the ECM to enable the number 1 brake solenoid for the front three cylinders on the
M11E engine or the number 1 and number 3 brake solenoids for the front two and rear two cylinders on the
N14E engine when braking is called for.
2.11. ANTILOCK BRAKE INTERFACE

If the vehicle is equipped with antilock brakes, the ECM (309) shares information with ABS controller module
(627) over circuit 98Z(+), connector (657), and a pink wire. Information is also shared by the ECM (309) over
circuit 98Y(-), connector (657), and a light blue wire.
3. TROUBLESHOOTING
This section includes troubleshooting charts for International-installed circuits and components that are part
of the CELECT Electronic Control system. To begin the troubleshooting process, refer to the appropriate
Cummins manual and follow their directions. If the Cummins diagnostics (fault codes) indicate that the suspect
circuits are Navistar circuits or components, then use the charts in this section.
The EZ-Tech or Pro-Link 9000 EST can also be used to determine if the International switches and components
are working properly. If they are not, use a Fluke digital multimeter (DMM) to troubleshoot the circuits.
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If the Cummins diagnostic codes or the EZ-Tech or the Pro-Link indicates a problem with International-installed
circuits, the diagnostic tables in this chapter provide step-by-step test procedures.
relay, or solenoid.
3.1. ONBOARD DIAGNOSTICS WITH ENGINE RUNNING

All CELECT vehicles have a yellow Engine Warning light and a red Engine Stop light located in the telltale
lights in the instrument cluster. Every time the key is turned to the ignition position, the lights come on for
several seconds as a system self-test and then turn off.
If the warning lights remain on, it is an indication that the ECM has detected a problem. The CELECT system
can show and record certain problems. The problems are shown as fault codes. The fault codes are recorded
in the ECM.
If a fault is detected (becomes active) during vehicle operation, the driver is alerted by the illumination of
either the yellow Engine Warning light or the red Stop Engine light. The yellow Service/Check Engine light
may also be illuminated.
The yellow Engine Warning light turns on to warn the driver of an active component or system fault that should
be serviced as soon as possible to solve the problem, but the situation is not considered an emergency.
The red Stop Engine light turns on to warn the driver that there is a major CELECT system problem and the
vehicle should be stopped and engine shut down as soon as is safely possible.
The yellow Service/Check Engine light (engine protection system) turns on to warn the driver that:
A. Coolant temperature is out of range.

B. Oil temperature is out of range.
C. Oil pressure is out of range.
D. Intake manifold temperature is out of range.
E. Engine coolant level is below the acceptable level.
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3.2. PERFORMING A DIAGNOSTIC CHECK WITH THE ENGINE OFF

A diagnostic check may be performed using the Diagnostic On/Off switch and Idle/ Diagnostic Inc/Dec switch.
Any error codes will be flashed through the red Engine Stop light and yellow Engine Warning light. If no errors
are found, both lights will stay on while the diagnostics switch is on. Consult the Cummins Operation and
Maintenance Manual furnished with the vehicle for exact procedures and fault code information.
To determine the fault codes use the following procedure:
1. Begin the procedure with the engine off.
2. Place the switch key in the off position.
3. Turn the diagnostic on/off switch to the on position.
4. Turn the key switch to run position (not crank).
NOTE – Cummins CELECT engine diagnostics must be run with the engine NOT RUNNING.
If BOTH the yellow Engine Warning and red Engine Stop lights come on momentarily and then go out, it is an
indication that engine faults are present.
If BOTH the yellow Engine Warning and red Engine Stop lights come on and stay on, it is an indication that
no engine faults are present.
5. Yellow Engine Warning light will flash once.
6. There will be a one to two second pause.
7. Red Engine Stop light will flash code with one or two seconds between digits.
NOTE – All Cummins fault codes are 3 digits.
8. Yellow Engine Warning light will flash indicating the end of that fault code, and then start over and
repeat the same fault code.
9. To go to the second fault code, move the Idle/Diagnostic Inc/Dec switch to the Inc position and then
release it. The process will then repeat itself as indicated in Steps 5 through 8.
10. To move back to the last or previous fault code, move the Idle/Diagnostic Inc/Dec switch to the Dec
position and then release it. The process will then repeat itself as indicated in Steps 5 through 8.
11. To stop the diagnostics procedure, correct the faults or move the diagnostic on/off switch to off, and turn
the vehicle key switch to the off position.
For example, the yellow Engine Warning light flashes once. The red Engine Stop light flashes:
FLASH
Digit number one is 1. Then there is a pause.
FLASH — FLASH
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Digit number two is 2. Then there is pause.
FLASH — FLASH — FLASH.
Digit number three is 3. Yellow Engine Warning lamp flashes once. The fault code is 123
3.3. COMPULINKTM
CELECT vehicles have a data link connected to the ATA data link connector (220). The Cummins CompulinkTM
electronic service tool can be connected to the connector to program owner-specified information into
the engine, monitor the system, and aid in troubleshooting the engine. Consult the Cummins CELECT
Troubleshooting and Repair Manual. The CompulinkTM may be available at the nearest Cummins Authorized
Service Center.
CompulinkTMmust be used with a CELECT service cartridge to communicate with a CELECT engine. A
PACE or PT PACER cartridge will not work properly.
NOTE – On the Cummins CompulinkTM, since no alpha characters are available, use the up arrow and
down arrow to move through the alphabet.
3.4. EZ-TECH OR PRO-LINK ELECTRONIC SERVICE TOOL (EST)

The EZ-Tech Pro-Link 9000 EST with the heavy duty standard program can also be used with the Navistar
data link to read active and inactive fault codes through the data link. The use of the DDR or specific codes are
not discussed in this manual as the information is part of the EZ-Tech or Pro-Link 9000 documentation.
The EZ-Tech or Pro-Link 9000 can also be used to monitor operation of various switches and controls and
perform other diagnostic tasks. The specific capabilities and operating instructions are included in the EZ-Tech
or Pro-Link 9000 documentation.
3.5. INSPECTING NAVISTAR ENGINE HARNESS ECM CONNECTOR (263)

1. Remove connector (263) from the ECM, first removing the two capscrews. Carefully pull the connector
straight out of the ECM. The connector pins are numbered (Figure 1) and correspond to the numbers
on the circuit diagrams.
Figure 65 OEM Connector "B"
2. Inspect the connector for pushed back or expanded terminals in the following manner:
a. Insert the tool (Cummins part number 3823383) into each Amp connector (Figure 2). Do not force
the tool into the connector.
b. A terminal that is not pushed back or expanded will have a surface to tool gap (Figure 2) of
approximately 0.050 inch (1.3 mm). If the tool touches the connector, replace the terminal.
c. Push the tool into the terminal until the tool touches the connector (Figure 3). Slowly remove the tool
from the terminal. A small resistance (6 to 10 ounces) must be felt (Figure 4). If the resistance is not
felt, the terminal is expanded and must be replaced.
d. Repeat steps A through C to check for pushed back or expanded terminals for all terminals in the
ECM connector.
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e. Inspect the connector pins in the ECM. If the pins are bent (Figure 5), have a Cummins dealer replace
the ECM.
Figure 66 Tool In Connector
Figure 67 Push Tool into Terminal
Figure 68 Slowly Remove Tool
Figure 69 Inspect Connector Pins
3.6. RELAYS
International circuits use suppressed relays for controlling power to load devices. The suppression feature (a
resistor circuit parallel to the relay coil) prevents voltage spikes from damaging electronic components in the
vehicle. These relays must be replaced with the correct International part.
Relays used in exposed areas such as the engine compartment are sealed relays and have a different part
number than those in the cab. The part number is embossed on the relay. There is also a circuit diagram of the
relay located on the relay body. The terminals are numbered on the relay in the same manner as in the circuit
diagrams. To test the relay, refer toTesting Relay.
3.7. TESTING RELAY

Table 30 Testing Relay
POINTS SPEC.
1. Off With relay removed, Relay, 30 > 100K Go to next Replace the relay.
measure resistance to 87. ohms. step.
between terminals 30
and 87.
2. Off Measure resistance Relay, 30 < 2 ohms. Go to next Replace the relay.
between terminals 30 to 87A. step.
and 87A.
3. Off Connect 12V lead to Go to next Replace the relay.
terminal 85 and ground step.
lead to terminal 86. Does
relay energize with audible
click?
4. Off With relay energized (Step Energized < 2 ohms. Relay Replace the relay.
3), measure resistance relay, 30 tests
between terminals 30 and to 87. good.
87.
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3.8. ACCELERATOR PEDAL TPS/IVS — CUMMINS

The following five tests check the throttle position sensor (TPS), the idle validation switch (IVS) and the related
International cab and engine harness circuits connected to the ECM.
NOTE – The following four tests, Testing Throttle Position Sensor (TPS — Cummins, Testing Idle
Validation Switch (IVS) — Cummins, Testing Accelerator Pedal (TPS/IVS) System for “Short or Open”
Circuits — Cumminsand Testing TPS/IVS Circuits for Continuity — Cummins must be performed in
sequence.
The tests should be performed if a Cummins fault code indicates a problem in the circuits or if an electronic
service tool Indicates that the TPS/IVS is not working properly while monitoring switches. If the electronic
service tool detects a fault with the IVS circuits while monitoring switches, the display would show Idle
Validation Switch = Fault. If a fault is present while monitoring Percent Of Throttle, the percent displayed
does not indicate actual throttle position.
NOTE – Testing Throttle Position Sensor (TPS) — Cummins and Testing Idle Validation Switch (IVS) —
Cummins check operation of the TPS and IVS, but do not check the timing between the two functions,
which is important.
Testing Throttle Position Sensor (TPS) — Cummins
This test checks the TPS circuits in the accelerator pedal assembly. This test will help identify if the resistances
are within specifications and if there are any opens or shorts in the TPS, but will not verify the correct
switching of the IVS and TPS.
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Table 31 Testing Throttle Position Sensor (TPS) — Cummins
POINTS SPEC.
1. Off Disconnect accelerator TPS, A to 2000 to Go to next Replace the TPS/IVS
pedal from cab harness at C. 3000 step. sensor, then
connector (306). At pedal ohms. recalibrate (refer to
side of (306) measure Accelerator/ECM
resistance between Calibration —
terminals A and C with the Cummins).
pedal in the idle position,
then with the pedal fully
depressed.
2. Off With the pedal in the idle TPS, B to 1500 to Go to next Replace the TPS/IVS
position, at connector C. 3000 step. sensor, then
(306) measure resistance ohms. recalibrate (refer to
between terminals B and Accelerator/ECM
C. Calibration —
Cummins).
3. Off With the pedal in the full TPS, B to 250 to Go to next Replace the TPS/IVS
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throttle position, at conn. C. 1500 step. sensor, then
(306), measure resistance ohms, recalibrate (refer to
between terminals B and and < idle Accelerator/ECM
C. Is reading 1000 ohms position Calibration —
less than reading at idle reading Cummins).
position, and between 250 -1000
and 1500 ohms? ohms.
6 CUMMINS M11E AND N14E ENGINES
4. Off At the accelerator pedal, TPS, A, >100K Go to next Replace the TPS/IVS
measure resistance B, C, D ohms. step. sensor, then
between gnd. (metal and E to recalibrate (refer to
part of pedal) and terminals gnd. Accelerator/ECM
A, B, C, D and E. Calibration-
Cummins).
5. Off The TPS sensor checks
good. Proceed to Testing
Idle Validation Switch (IVS)
— Cummins below), which
checks the idle validation
165
Table 31 Testing Throttle Position Sensor (TPS) — Cummins (cont.)
166

POINTS SPEC.
portion of the accelerator
pedal.
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Testing Idle Validation Switch (IVS) — Cummins
This test checks the IVS circuits in the accelerator pedal assembly.
PerformTesting Throttle Position Sensor (TPS) — Cummins above, before performing this test.
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Table 32 Testing Idle Validation Switch (IVS) — Cummins 168

POINTS SPEC.
1. Off Disconnect accelerator TPS/IVS, < 125 Go to next Replace the TPS/IVS
pedal from cab harness at F to E. ohms step. sensor, then
connector (306). At pedal recalibrate. Refer
side of (306) measure to Accelerator/ECM
resistance between Calibration —
terminals F and E with Cummins.
pedal in idle position. Is it
<125 ohms?
2. Off At connector (306) TPS/ IVS, > 100K Go to next Replace the TPS/IVS
measure resistance F to E. ohms. step. sensor, then
between terminals F and E recalibrate (refer to
while slowly depressing the Accelerator/ECM
pedal (idle to full throttle). Calibration —
After approximately 10 Cummins)
degrees of travel, is the
resistance 100K ohms or
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more?
3. Off Remove connector (263) TPS/ IVS, > 100K Go to next Replace the TPS/IVS
from ECM. At connector F to D. ohms. step. sensor, then
(306) measure resistance recalibrate (refer to
between terminals F and Accelerator/ECM
D while the pedal is at idle Calibration —
position. Cummins).
4. Off At connector (306), TPS/ IVS, < 125 Go to next Replace the TPS/IVS
measure resistance F to D. ohms. step. sensor, then

between terminals F and D recalibrate (refer to
while slowly depressing the Accelerator/ECM
pedal (idle to full throttle). Calibration —
After approximately 10 Cummins).
degrees of travel the
resistance should be less
than 125 ohms.
Table 32 Testing Idle Validation Switch (IVS) — Cummins (cont.)
POINTS SPEC.
5. Off At connector (306) TPS/ IVS > 100K Go to next Replace the TPS/IVS
measure resistance metal to ohms step. sensor, then
between metal part of D, E, and recalibrate (refer to
accelerator pedal and F. Accelerator/ECM
terminals D, E and F. Calibration —
Cummins)
6. Off The TPS/IVS pedal
assembly checks good.
Note that this test is not
able to check the timing
between TPS and IVS
functions.
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169
Testing Accelerator Pedal (TPS/IVS) System for "Short or Open" Circuits — Cummins
This test checks the cab and engine harness TPS/IVS circuits for opens, shorts to ground, shorts to "hot"
circuits and shorts to other circuits in the harness.
NOTE – Perform Testing Throttle Position Sensor (TPS) — Cummins and Testing Idle Validation Switch
(IVS) — Cummins before performing this test.
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Table 33 Testing Accelerator Pedal (TPS/IVS) System for “Short or Open” Circuits — Cummins
POINTS SPEC.
1. Off With (306) disconnected, Go to next Replace connector
disconnect connector (263) step. terminals if damaged.
from ECM and inspect If ECM pins are
ECM connector. Refer damaged, have
to Inspecting Navistar Cummins dealer
Engine Harness ECM replace ECM. Refer
Connector (263) — to Accelerator/ECM
Cummins. Connector Calibration —
and ECM pins OK? Cummins to
recalibrate the ECM
to TPS/IVS.
2. Off At connector (263) use (263), > 100K Go to next Locate short to
test leads and measure term. 6, ohms. step. ground, in circuit
resistance to gnd. at 9, 10, 11, where terminal
terminals 6, 9, 10, 11, 18 and 19 resistance is less
18 and 19. Do not use to gnd. than 100K ohms,
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probes or leads other than then repair.
Cummins P/N 3822758
or the connector could be
damaged.
3. Off At connector (263) use (263), > 100K Go to next Locate short between
test leads and measure between ohms. step. any circuits where
resistance between term. 6, 9, resistance between
terminals 6, 9, 11, 18 and 11, 18 and terminals is less than

19 and all other terminals 19 and 100K ohms, then
in (263). all other repair.
term.
4. On At connector (263) use test (263), 6, < or = 1.5 Go toTest Locate short to
leads and measure voltage 9, 10, 11, volts. Chart unwanted voltage
to ground at terminals 6, 9, 18 and 19 below. source in any circuit
10, 11, 18 and 19. to gnd. where more than
1.5 volts is present,
then repair. Refer to
Accelerator/ECM
Calibration —
171
Table 33 Testing Accelerator Pedal (TPS/IVS) System for “Short or Open” Circuits — Cummins (cont.)
172

POINTS SPEC.
Cummins to
recalibrate ECM/
accelerator pedal.
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Testing TPS/IVS Circuits for Continuity — Cummins
This test checks the individual TPS and IVS circuits (cab and engine harness) for correct resistance while
disconnected from the accelerator pedal assembly and ECM.
NOTE – Perform the preceding three tests before performing this test.
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Table 34 Testing TPS/IVS Circuits for Continuity — Cummins 174

POINTS SPEC.
1. Off At ECM connector (263) (306), B < 5 ohms. Go to next Locate cause of
use test lead to jumper to C step. out-of-specification
terminal 11 to 18. At resistance in either
connector (306) measure circuit 99 or 99A(5V),
resistance between then repair. Refer to
terminals B and C. Do Accelerator/ECM
not use probes or leads Calibration —
other than Cummins Cummins to
P/N 3822758 or the recalibrate ECM/
ECM connector could be accelerator pedal.
damaged.
2. Off At connector (263) use test (306), A < 5 ohms. Go to next Locate cause of
lead to jumper terminal to B. step. out-of-specification
11 to 19. At connector resistance in
(306) measure resistance circuit 99-G, then
between terminals A and repair. Refer to
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B. Accelerator/ECM
Calibration —
Cummins to
recalibrate ECM/
accelerator pedal.
3. Off At connector (263) use test (306), B < 5 ohms. Go to next Locate cause of
lead to jumper terminal to D. step. out-of-specification
11 to 9 . At connector resistance in
(306) measure resistance circuit 99C, then
between terminals B and repair. Refer to

D. Accelerator/ECM
Calibration —
Cummins to
recalibrate ECM/
accelerator pedal.
Table 34 Testing TPS/IVS Circuits for Continuity — Cummins (cont.)
POINTS SPEC.
lead to jumper terminal to E. step. out-of- specification
11 to 6. At connector resistance in
(306) measure resistance circuit 99B, then
between terminals B and repair. Refer to
E. Accelerator/ECM
Calibration —
Cummins to
recalibrate ECM/
accelerator pedal.
lead to jumper terminal to F. step. out-of- specification
11 to 10 ). At connector resistance in circuit
(306) measure resistance 99-GA, 97–GA
between terminals B and F. or 97-G, then
repair. Refer to
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Accelerator/ECM
Calibration —
Cummins to
recalibrate ECM/
accelerator pedal.
6. Off If all four of these tests
have been performed and
defects were not noted,

the TPS and IVS circuits
check good. If the problem
is still present, replace
the accelerator pedal. If
this does not correct the
problem, have Cummins
dealer diagnose the ECM
operation.
175
Accelerator/ECM Calibration — Cummins
The electronic accelerator pedal assembly and the ECM must be calibrated when:
A. The pedal assembly is initially installed.

B. The pedal assembly or sensor is replaced.
C. The accelerator pedal is disconnected (at any point in the circuitry) and the key switch is placed in
the on position.
To recalibrate the accelerator pedal and ECM:
A. The vehicle key must be in the on position.

B. Depress the accelerator pedal slowly through the complete range of movement, then release.
Slowly depress and release, three times in this manner. This completes the calibration process.
3.9. LOW COOLANT SWITCH — CUMMINS

First check for proper coolant levels. If coolant levels are not low, this test would be performed if Cummins
diagnostic codes were logged indicating a low coolant condition or other circuit fault.
This test procedure requires a DMM to check the Navistar harness for opens, shorts to ground, or shorts to
other circuits in the Navistar harness. The low coolant sensor has complex circuits and a VOM should not
be used to test the sensor as it may damage the circuits.
Testing Low Coolant Level Switch and Circuit — Cummins
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Table 35 Testing Low Coolant Level Switch and Circuits — Cummins
POINTS SPEC.
1. Off Disconnect 21-way (309) > 100K Go to next Locate short between
connector (309) from between ohms. step. any circuits where
Cummins connector. 34B (5V), resistance between
Disconnect (307) from 34-G, 34A terminals is less than
low coolant switch. At and 34 and 100K ohms, then
connector (309) measure all other repair.
resistance between circuits.
terminals J, K, L and M
(circuits 34B[5V], 34-G,
34A, and 34) and all other
terminals in (309).
2. Off At (309) measure (309), 34B > 100K Go to next Locate short to
resistance to ground (5V), 34-G, ohms. step. ground in any
at terminals J, K, L and M 34A, and circuit(s) where
(circuits 34B[5V], 34-G, 34 to gnd. resistance is less
34A, and 34). than 100K ohms,
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then repair.
3. On At (309) measure voltage (309), < 1.5 Go to next Locate short to
to ground at terminals 34B/(5V), volts. step. unwanted voltage
J, K, L and M (circuits 34-G, 34A source in any
34B[5V], 34-G, 34A and and 34 to circuit(s) where
34). gnd. voltage is more than
1.5V, then repair.
4. Off Measure resistance of 34, 34A, < 5 ohms. Go to next Locate open or
circuits 34, 34A, 34-G 34-G, and step. poor connection in
and 34B(5V) between 34B(5V) circuit(s) if resistance
connectors (307) and between is more than 5 ohms,
(309). (307) and then repair.
(309).
5. Off The low coolant switch
circuits check good. If
problem is still present,
replace low coolant
switch. If problem
177
persists, have Cummins

Table 35 Testing Low Coolant Level Switch and Circuits — Cummins (cont.)
178

POINTS SPEC.
dealer diagnose ECM
operation.
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3.10. POWER SUPPLY CIRCUITS TO ECM — CUMMINS

This test checks the unswitched battery power feed to the ECM and the ECM ground circuit that is part of the
Battery Feed Harness. If applicable, check the two 10A fuses before performing this test.
NOTE – Batteries must be fully charged before performing this test.
Testing Unswitched Battery Power Circuits and ECM Ground Circuit — Cummins
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Table 36 Testing Unswitched Battery Power Circuits and ECM Ground Circuit — Cummins 180

POINTS SPEC.
1. Off Check ECM power harness Go to Correct poor
connections at starter next step. connections.
(circuit 97, 97A and 97-G)
and at connector (310) for
clean, tight connections.
Connections good?
2. Off If applicable, check the two ECM < 5 ohms. Go to Locate cause of
10 amp fuses located in the fuses. next step. overload condition,
engine harness for open then correct. Replace
condition. with correct rated
fuse.
3. Off Disconnect ECM power 97 and 10 to 12 Go to Locate cause of low
connector (310) from 97A to volts. next step. or no voltage in circuit
Cummins engine harness. gnd. 97 or 97A from B+
Measure voltage to ground terminal of starter,
at circuits 97 and 97A. then repair.
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Battery voltage present?
4. Off At connector (310) (310), 97 10 to 12 Go to Locate open or high
measure voltage between to 97-G. volts. next step. resistance in circuit
circuits 97 and 97-G. 97-G between (310)
Battery voltage present? and engine ground
stud, then repair.
5. On At connector (310) (310), 97 > 7 volts. Go to Locate cause of
measure voltage between to 97-G next step. excess voltage drop
circuits 97 and 97-G while while in cranking circuit,

cranking engine. cranking. then repair.
6. Off Unswitched battery power
circuits and ECM ground
circuit at connector (310)
checks good.
Testing Switched Ignition Power To ECM — Cummins
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Table 37 Testing Switched Ignition Power To ECM — Cummins 182

POINTS SPEC.
1. Off Check 15A circuit breaker B3 < 1 ohm. Go to next Locate cause of
B3 for open condition. step. overload condition,
then repair. Replace
fuse.
2. On Measure voltage to ground B3, 16E 12 ± 1.5 Go to next Locate cause of no or
at circuit breaker B3 and to gnd. volts. step. low voltage in circuit
circuit 16E. 13H, 16A, connector
(102), circuit 16A, or
circuit 16E from ignition
relay (462)/R1, then
repair. Refer to POWER
AND DISTRIBUTION
GROUND SYSTEM
Section.
3. Off/On Disconnect engine harness (309), A 12 ± 1.5 Go to next Locate cause of low or
21-pin ECM connector to gnd. volts. step. no voltage in circuit 16D
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(309) from Cummins between circuit breaker
harness. Turn key on, and connector (309),
measure voltage to gnd. at then repair.
connector (309) terminal A
(circuit 16D).
4. Off Switched ignition voltage
circuit to ECM checks
good.
3.11. SERVICE BRAKE AND CLUTCH SWITCHES — CUMMINS

This test would be performed if the Electronic Service Tool (EST) displayed an incorrect switch position or
Cummins diagnostic codes indicate a problem may be present.
Testing Clutch Switch — Cummins
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Table 38 Testing Clutch Switch — Cummins 184

POINTS SPEC.
1. Off Disconnect clutch switch Clutch switch < 2 Go to Step Check switch
connector (55) from cab across pigtail ohms. 3. adjustment. Go
harness. With clutch terminals to next step.
pedal released, measure (55).
resistance between the
pigtail terminals.
2. Off With clutch pedal Replace Adjust clutch switch.
depressed to the bottom and adjust Go to Step 1.
of the free travel position clutch
(approx. 1.7 inches or switch. Go
43 mm from pedal stop to Step 1.
plate), the u-bolt plate
should touch the switch
actuator arm. The switch
should actuate (to closed
position) with an audible
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click when the clutch
pedal returns to the stop.
Is clutch switch adjusted
properly?
3. Off Depress clutch pedal Clutch switch > 100K Go to next If switch is not
and measure resistance across pigtail ohms. step. properly adjusted,
between clutch switch terminals adjust and retest. If
pigtail connector (55) (55). switch was properly
terminals. adjusted, replace the
switch.
4. Off Check clutch switch for Clutch switch > 100K Clutch Replace the clutch
short to ground. With each pigtail ohms. switch switch, then adjust.
switch disconnected, to gnd. checks
measure resistance to good.
ground at each switch Perform
terminal. Testing
Clutch
Switch
Circuits
Table 38 Testing Clutch Switch — Cummins (cont.)
POINTS SPEC.
for "Open
and Short"
Condition
—
Cummins.
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185
Testing Clutch Switch Circuits for “Open and Short” Condition — Cummins
Perform Testing Clutch Switch — Cummins before performing this test.
CAUTION – When testing at ECM connector (263), do not use probes or leads other than Cummins
test leads , Part No. 3822758. The connector will be damaged. The leads must fit snug without
expanding the connector terminal.
Table 39 Testing Clutch Switch Circuits for "Open and Short" Condition — Cummins
POINTS SPEC.
1. Off With clutch switch Go to next Replace harness
disconnected, remove step. connector terminals
ECM connector (263) if damaged. If ECM
from the ECM. Refer pins are damaged,
to Inspecting Navistar have Cummins dealer
Connector (263) — to Accelerator/ ECM
Cummins to inspect Calibration — Cummins
connector. ECM harness to recalibrate ECM/
connector or ECM pins accelerator pedal.
OK?
2. Off Turn all CELECT cab (263), 4 > 100K Go to next Locate short to ground
switches to off or neutral and 10 ohms. step. in circuit where
position and set service to gnd. resistance at terminal
brake using trailer hand was less than 100K
valve. Use test leads ohms, then repair.
and measure resistance
to ground at connector
(263) terminal 4 and 10
(circuit 97AH and 97-G).
3. Off With CELECT cab (263), 4 > 100K Go to next Locate short between
switches still in off or to 10 and ohms. step. circuit where resistance
neutral position and all other between terminals is
service brake set, use term. less than 100K ohms,
test leads and measure then repair.
resistance between
terminals 4 and 10
(circuit 97AH and 97-G)
and all other terminals in
connector (263).
4. On At connector (263), (263) 4 < or = 1.5 The clutch Locate short to
use test leads and and 10 volts. switch unwanted voltage
measure voltage to gnd. to gnd. circuits source in circuit with
at terminals 4 and 10 are free more than 1.5 volts,
(circuit 97AH and 97-G). of short then repair. Refer
circuits. to Accelerator/ ECM
Perform Calibration — Cummins
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Table 39 Testing Clutch Switch Circuits for "Open and Short" Condition — Cummins (cont.)
POINTS SPEC.
Testing to recalibrate ECM/
Clutch accelerator pedal.
Switch
Circuits for
Continuity
—
Cummins.
Testing Clutch Switch Circuits For Continuity — Cummins
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Table 40 Testing Clutch Switch Circuits For Continuity — Cummins 188

POINTS SPEC.
1. Off At ECM connector (263) (55), < 5 ohms Go to next Locate open or
use test lead to jumper 97AH to step. poor connection in
terminal 4 (circuit 97AH) to gnd. circuit 97AH between
ground. At clutch switch connectors (263) and
connector (55) measure (55), then repair.
resistance of 97AH to Refer to Accelerator/
ground. ECM Calibration —
Cummins to recalibrate
ECM/ accelerator
pedal.
2. Off At ECM connector (263) (55), < 5 Go to next Locate open or poor
use test lead to jumper 97AH to ohms. step. connection in circuit
terminal 4 to 10 (circuit 97-G. 97-G, 97-GA or 97-GH
97AH to 97-G). At clutch between connectors
switch connector (55) (263) and (55), then
measure resistance repair. Accelerator/
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between circuits 97AH ECM Calibration —
and 97-G. Cummins to recalibrate
ECM/ accelerator
pedal.
3. Off The clutch switch circuits
and switch check good.
Refer to Accelerator/ECM
Calibration —
ECM/accelerator pedal.
Testing Service Brake Switch (5) — Cummins
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Table 41 Testing Service Brake Switch (5) — Cummins 190

POINTS SPEC. SPEC.
1. Off Remove connector (5) Pressure < 2 Go to next Replace the brake
from brake switch. With switch ohms. step. switch.
brakes released, measure across
resistance across switch terminals.
terminals. Switch should
be closed.
2. Off Apply service brakes Pressure > 100K Go to next Replace the brake
and measure resistance switch ohms. step. switch.
across the brake pressure across
switch. Switch should be terminals.
open. NOTE: Sufficient
air pressure must be
present to apply service
brakes for this test step.
3. Off Measure resistance to Pressure > 100K Reconnect Replace the brake
ground at both brake switch both ohms. (5) to brake switch.
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switch terminals with terminals to switch.
service brakes applied, gnd. Perform
and with brakes released. Testing
Both should be isolated Service
from ground at all times. Brake
Switch
Circuits
for "Open
and Short"
Condition —
Cummins.
Testing Service Brake Switch Circuits for "Open and Short" Condition — Cummins
Perform Testing Service Brake Switch (5) — Cummins before performing this test.
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Table 42 Testing Service Brake Switch Circuits for "Open and Short" Condition — Cummins 192

POINTS SPEC.
1. Off With connector (5) Go to next Replace harness
disconnected from brake step. connector terminals
switch, remove connector if damaged. If ECM
(263) from the ECM. Refer pins damaged, have
to Inspecting Navistar Cummins dealer
Connector (263)- Cummins to Accelerator/
to inspect connector. ECM ECM Calibration —
connector and ECM pins Cummins to recalibrate
OK? ECM/ accelerator
pedal.
2. Off Turn all CELECT cab (263), 13 > 100K Go to next Locate short to ground
switches to off or neutral and 10 to ohms. step. in circuit where
position and disconnect gnd. resistance at terminal
clutch switch. Use test was less than 100K
leads and measure ohms, then repair.
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resistance to ground at
connector (263) terminals
13 and 10 (circuits 97AL
and 97-G).
3. Off Use test leads and (263), 13 > 100K Go to next Locate short between
measure resistance to 10 and ohms. step. any circuit where
between terminals 13 all other resistance between
and 10 (circuits 97AL term. terminals is less than
and 97-G) and all other 100K ohms, then
terminals in connector repair.

(263).
4. On At connector (263), use test (263), 13 < or = The brake Locate short to
leads and measure voltage and 10 to 1.5 volts. switch unwanted voltage
to ground at terminals 13 gnd. circuits source in circuit
and 10 (circuits 97AL and are free with more than
97-G). of short 1.5 volts, then
circuits. repair. Accelerator/
Perform ECM Calibration —
Testing Cummins to recalibrate
Table 42 Testing Service Brake Switch Circuits for "Open and Short" Condition — Cummins (cont.)
POINTS SPEC.
Service ECM/ accelerator
Brake pedal.
Switch
Circuits for
Continuity
—
Cummins.
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193
Testing Service Brake Switch Circuits for Continuity — Cummins
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Table 43 Testing Service Brake Switch Circuits for Continuity — Cummins
POINTS SPEC.
1. Off At ECM connector (263) (5), < 5 ohms Go to next Locate open or
use test lead to jumper 97AL to step. poor connection
terminal 13 to ground gnd. in circuit 97AL
(cir. 97AL to ground). At between connectors
brake switch connector (5) (263) and (5), then
measure resistance to gnd. repair. Accelerator/
at circuit 97AL. ECM Calibration —
ECM/ accelerator
pedal.
2. Off At ECM connector (263) (5), < 5 ohms. Go to next Locate open or
use test lead to jumper 97AL to step. poor connection in
terminal 13 to terminal 10 97-GF. circuit 97-G, 97-GA,
(circuits 97AL to 97-G). or 97-GF between
At brake switch connector connectors (263)
(5) measure resistance and (5), then repair.
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between circuits 97AL and Refer to Accelerator/
97-GF. ECM Calibration —
ECM/ accelerator
pedal.
3. Off The service brake switch
circuits and switch
check good. Refer

to Accelerator/ECM
Calibration —
ECM/accelerator pedal.
195
3.12. ENGINE BRAKE — CUMMINS

In the event the engine brake fails to operate, the following test chart provides a systematic series of steps to
check the switches and circuits that are installed by Navistar.
Testing Engine Brake Components and Circuits — Cummins
Table 44 Testing Engine Brake Components and Circuits — Cummins

POINTS SPEC.
1. Off Disconnect engine (412), < 1 ohm. Go to next Locate open or poor
brake on/off switch from 24-G to step. connection in circuit
connector (412). Measure gnd. 24-G, 97-GA or
resistance to ground at 97-G, then repair.
connector (412), circuit
24-G.
2. Off With on/off switch Go to next Replace the switch.
disconnected, refer to step.
Testing Engine Brake
Switches— Cummins and
use ohmmeter to check
switch. Switch good?
3. Off Remove connector (411) 24AD < 1 ohm. Go to next Locate open or
from selector switch. between step. poor connection in
Measure resistance of (412) and circuit 24AD between
circuit 24AD between (411). connectors (412) and
connectors (412) and (411), then repair.
(411).
4. Off Refer to Testing Engine Go to next Replace the switch.
Brake Switches — step.
Cummins and test the
selector switch. Switch
good?
5. Off Reconnect engine brake Go to next
on/off switch conn. (412) step.
and place in on position.
Reconnect engine brake
switch conn. (411) and
place in position 3.
Disconnect 28-way conn.
(263) from engine harness.
6. On At connector (263) and (263), 5 < 5 ohms. Engine Locate open or
circuits going to switch, and 28 to brake poor connection in
measure resistance from gnd. circuits and circuit 24AE or 24AF
pin 5 and 28 to ground. components between connectors
check (411) and (263), then
good. repair.
Testing Engine Brake Switches — Cummins
1. Testing Engine Brake On/Off Switch.
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a. With switch in on position, resistance between terminals 5 and 6 and between 2 and 3 should be
less than 2 ohms.
b. With switch in off position, resistance should be 100K ohms or more.
c. To test the LED in the switch, connect a test lead at battery voltage (B+) to terminal 7 and ground
terminal 8. LEDs should illuminate.
2. Testing Engine Brake Selector Switch.

a. With switch in position 3, resistance between terminals 2 and 3, and 2 and 6 should be less than 2
ohms.
b. With switch in position 1, resistance between terminals 2 and 3 should be less than 5 ohms.
c. With switch in position 2, resistance between terminals 2 and 6 should be less than 5 ohms.
d. To test the LED in the switch, connect a test lead at battery voltage (B+) to terminal 7 and ground to
terminal 8. LEDs should illuminate.
3.13. ATA DATA LINK CONNECTOR (220) AND SPEEDOMETER/TACHOMETER INPUT

CIRCUITS — CUMMINS
This following series of tests provide charts for testing: [1] The Data Link circuits between the ECM, connector
(263), ATA Data Link connector (220), and the speedometer/tachometer connector (595). [2] The power and
ground circuits to the Data Link connector (220).
Testing Diagnostic Connector Power and Ground Circuits— Cummins
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Table 45 Testing Diagnostic Connector Power and Ground Circuits — Cummins 198

POINTS SPEC.
1. Off At connector (220) (220), 12 ± 1.5 Go to Locate cause of low
measure voltage to ground term. C volts. next or no voltage in circuit
at terminal C (circuit 97DL). to gnd. step. 97DL from 5A fuse
F6–A, then repair.
2. Off At connector (220) (220), 12 ± 1.5 Go to Locate open or poor
measure voltage between between volts. next connection in circuit
terminals C and E (circuits term. C step. 11–GR between
97DL and 11–GR). and E. connector (220) and
G5 ground adapter
(533), then repair.
3. Off The power and ground
circuits to the ATA data
link connector (220) check
good.
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Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit —
Cummins
test leads, Part No. 3822758. The connector will be damaged. The leads must fit snug without
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Table 46 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit — Cummins 200

POINTS SPEC.
1. Off Disconnect ECM connector Go to next Replace harness
(263) from the ECM. Refer step. connector terminals
to Inspecting Navistar if damaged. If ECM
Engine Harness ECM pins are damaged,
Connector (263) — have Cummins
Cummins and inspect dealer replace
connector. ECM harness ECM. Refer to
connector OK? Accelerator/ECM
Calibration —
Cummins to
recalibrate ECM/
accelerator pedal.
2. Off Disconnect connector (263), > 100K Go to next Locate short circuit
(595) from speedometer/ term. 8 ohms. step. to ground in circuit
tachometer unit and and 27 to where resistance
if additional devices gnd. is less than 100K
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have been connected to ohms, then repair.
(514) and (515) data link
connectors, they must
be disconnected. At
connector (263), using test
leads, measure resistance
to ground at terminals 8
and 27 [circuit 98B(-) and
98(+)].
3. On At connector (263) use (263), > 100K Go to next Locate short

test leads and measure between ohms. step. between circuits
resistance between term. 8 where resistance
terminals 8 and 27 [circuit and 27 and between terminals
98B(-) and 98(+)] and all other is less than 100K
all other terminals in term. ohms, then repair.
connector.
Table 46 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit — Cummins (cont.)
POINTS SPEC.
4. On At connector (263) use test (263), < or = 1.5 Go to next Locate short to
leads and measure voltage term. 8 volts step. unwanted voltage
to ground at terminals 8 and 27 to source in circuit
and 27 [circuits 97B(-) and gnd. where more than 1.5
98(+)]. volts is present at
terminal, then repair.
5. Off At connector (263) use test (220), B to < 5 ohms. Go to next Locate open or
lead to jumper terminal gnd. step. poor connection in
8 [circuit 98B(-)] to circuit 98B(-)/ 98C(-)
ground. At connector between connectors
(220) measure resistance (263) and (220),
to ground at terminal B then repair.
[circuit 98C(-)].
6. Off With connector (263) (595), 47/ < 5 ohms. Go to next Locate open or poor
terminal 8 still jumpered to 48(-) to step. connection in circuit
ground, at connector (595) gnd. 47/48(-) between
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measure resistance to connectors (515)
ground at circuit 47/48(-). and (595), then
repair.
7. Off At connector (263) use test (220), A to < 5 ohms. Go to next Locate open or
lead to jumper terminal 27 gnd. step. poor connection in
[circuit 98(+)] to ground. At circuit 98(+)/(98A+)
connector (220) measure between connectors

resistance from terminal A (263) and (220),
[circuit 98A(+)] to ground. then repair.
201
Table 46 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit — Cummins (cont.)
202

POINTS SPEC.
8. Off With connector (263) (595), 47/ < 5 ohms. Go to next Locate open or poor
terminal 27 still jumpered to 48(+) to step. connection in circuit
ground, at connector (595) gnd. 47/48(+) between
ground at circuit 47/48(+). and (595), then
repair.
9. Off The data link circuits
between ECM connector
(263), diagnostic connector
(220) and speedometer/
tachometer connector
(595) test good.
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3.14. DIAGNOSTIC SWITCHES — CUMMINS

The diagnostic On/Off and Idle/Diagnostic switches can be checked with an electronic service tool in the switch
monitoring mode. If the switches do not operate properly, perform the following test.
Testing Diagnostic On/Off Switch and Circuit — Cummins
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Table 47 Testing Diagnostic On/Off Switch and Circuit — Cummins 204

POINTS SPEC.
1. Off Remove connector (234) Sw., < 5 ohms. Go to next Replace the switch.
from On/Off switch. With across step.
switch in on position, term. 5
measure resistance and 6.
between terminals 5 and 6.
2. Off With switch in off position, Switch > 100K Go to next Replace the switch.
measure resistance across ohms. step.
between terminals 5 and 6. term. 5
and 6.
3. Off To test the LED in the Go to next Replace the switch.
switch, connect 12V to step.
terminal 7 and connect
terminal 8 to ground. Does
LED illuminate?
4. Off Remove ECM connector Go to next Replace harness
(263) from the ECM. Refer step. connector terminals
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to Inspecting Navistar if damaged. If
Engine harness ECM ECM pins are
Connector (263) — damaged, have
Cummins and inspect Cummins dealer
connector. ECM harness replace ECM. Refer
connector and ECM pins to Accelerator/
OK? ECM Calibration
— Cummins to
recalibrate ECM/
accelerator pedal.
5. Off At connector (309) (309), > 100K Go to next Locate short to
measure resistance from V to ohms. step. ground in circuit
terminal V (circuit. 97AM) gnd. and with less then 100K
to ground, and at connector (263), 10 ohms, then repair.
(263), measure resistance to gnd.
from terminal 10 (circuit
97–G) to ground.
Table 47 Testing Diagnostic On/Off Switch and Circuit — Cummins (cont.)
POINTS SPEC.
6. Off With all CELECT switches (309) V to > 100K Go to next Locate short
in off or neutral position, all other ohms. step. between circuits
service brakes set using terminals. where resistance
trailer hand control between terminals
valve, and clutch switch is less than 100K
disconnected, measure ohms, then repair.
resistance between
terminal V (circuit 97AM)
(309).
7. Off At connector (309), use test (234), < 5 ohms. Go to next Locate open or poor
lead and jumper terminal V 97AM to step. connection in circuit
(circuit 97AM) to ground. At gnd. 97AM between
connector (234) measure connectors (234)
resistance to ground at and (309), then
circuit 97AM. repair.
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8. Off At connector (263), use test (234) , < 5 ohms. Go to next Locate open or
lead and jumper terminal 10 97-GE to step. poor connection
(circuit 97-G) to ground. At gnd. in circuit 97-GE,
connector (234) measure 97-GA or 97-G
resistance to ground at between connectors
circuit 97-GE. (234) and (263),
then repair.
9. Off The diagnostic On/Off

switch and circuits check
good.
205
Testing Idle/Diagnostic Switch (265) and Circuits — Cummins
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Table 48 Testing Idle/Diagnostic Switch (265) and Circuits — Cummins
POINTS SPEC.
1. Off Remove connector (265) Switch, < 5 Go to Replace the switch.
from idle/ diagnostic switch across term. ohms. next step.
and test the switch. With 2 and 3.
switch in INC position
measure resistance
2. Off With switch in neutral Switch > 100K Go to Replace the switch.
position measure across term. ohms. next step.
resistance between 1, 2, and 3.
terminals 1, 2 and 3.
3. Off With switch in DEC position Switch < 5 Go to Replace the switch.
measure resistance across term. ohms. next step.
between terminals 1 and 2. 1 and 2.
4. Off To test the LED in the Go to Replace the switch.
switch, connect 12V to next step.
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LED illuminate?
5. Off Disconnect ECM connector Go to Replace harness
(263) from the ECM and next step. connector terminals
inspect. Refer to Inspecting if damaged. If
Navistar Engine Harness ECM pins are
ECM Connector (263) — damaged, have

Cummins. ECM harness Cummins dealer
connector or ECM pins OK? replace ECM. Refer
to Accelerator/
ECM Calibration
— Cummins to
recalibrate ECM/
accelerator pedal.
207
Table 48 Testing Idle/Diagnostic Switch (265) and Circuits — Cummins (cont.)
208

POINTS SPEC.
6. Off At connector (263) use (263), term. >100K Go to Locate short to
test leads and measure 10, 14, and ohms. next step. ground in circuit
resistance to ground at 23 to gnd. where terminal
terminals 10, 14, and 23 resistance is less
(circuits 97-G, 97AV and than 100K ohms,
97AU). then repair.
7. Off At connector (263) measure (263), 14 > 100K Go to Locate short circuit
resistance between and 23 to all ohms. next step. between any circuit
terminals 14 and 23 other term. where resistance
(circuits 97AV and 97AU) between terminals
and all other terminals in is less than 100K
connector. ohms, then repair.
8. On At connector (263) measure (263), 14 < or = 1.5 Go to Locate short to
voltage to ground at and 23 to volts. next step. unwanted voltage
terminals 14 and 23 gnd. source in circuit
(circuits 97AV and 97AU). where more than
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1.5 volts is present,
then repair.
9. Off At connector (263) use test (265), 97AV < 5 Go to Locate open or poor
lead to jumper terminal 14 to gnd. ohms. next step. connection in circuit
(circuit 97AV) to ground. At 97AV between
resistance to gnd. at circuit and (263), then
97AV. repair.
10. Off At connector (263) use test (265), 97AU < 5 Go to Locate open or poor
lead to jumper terminal 23 to gnd. ohms. next step. connection in circuit
(circuit 97AU) to ground. At 97AU between
resistance to ground at and (263), then
circuit 97AU. repair.
Table 48 Testing Idle/Diagnostic Switch (265) and Circuits — Cummins (cont.)
POINTS SPEC.
11. Off At connector (263) use test (265), < 5 Go to Locate open or poor
lead to jumper terminal 10 97-GD to ohms. next step. connection in circuit
(circuit 97-G) to ground. At gnd. 97-GD, 97-GA,
connector (265) measure or 97-G between
resistance to ground at connectors (265)
circuit 97-GD. and (263), then
repair.
12. Off The idle/diagnostic switch
and circuits check good.
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209
3.15. CRUISE CONTROL — CUMMINS

When monitoring switches with an Electronic Service Tool, the cruise On/Off switch will indicate On or Off.
The Set/Resume switch will indicate either Set or Resume, depending on the switch position. If the switch is
not operable, the screen will be blank.
Testing Cruise Control On/Off Switch and Circuits — Cummins
Table 49 Testing Cruise Control On/Off Switch and Circuits — Cummins

POINTS SPEC.
1. Off Remove connector (419) Switch < 5 ohms. Go to Replace the switch.
from cruise On/Off switch. (419), next step.
With switch in on position, across
measure resistance term. 5 and
6.
2. Off With switch (419) in Switch > 100K Go to Replace the switch.
off position, measure (419), ohms. next step.
resistance between across
terminals 5 and 6. term. 5 and
6.
LED illuminate?
4. Off Remove ECM connector Go to Replace harness
(263) from the ECM and next step. connector terminals
inspect (refer to Inspecting if damaged. If ECM
Navistar Engine Harness pins are damaged,
ECM Connector (263) — have Cummins
Cummins). ECM harness dealer replace
connector and ECM pins ECM. Refer to
OK? Accelerator/ECM
Calibration —
Cummins to
recalibrate ECM/
accelerator pedal.
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Table 49 Testing Cruise Control On/Off Switch and Circuits — Cummins (cont.)
POINTS SPEC.
5. Off At ECM connector (263) (263), term. > 100K Go to Locate short to
use test leads and 2 and 10 to ohms. next step. ground in circuit
measure resistance to gnd. with less than 100K
ground at terminals 2 and ohms, then repair.
10 (circuits 97AE and
97-G).
6. Off At connector (263) (263), term. > 100K Go to Locate short between
measure resistance 2 to all ohms. next step. circuit 97AE and
between terminal 2 (circuit others. any circuit where
97AE) and all other resistance between
terminals in connector. terminals is less than
100K ohms, then
repair.
7. On At connector (263) (263), term. < or = 1.5 Go to Locate short between
measure voltage from 2 to gnd. volts. next step. circuit 97AE and
terminal 2 (circuit 97AE) to unwanted voltage
ground. source, then repair.
8. Off At connector (263) use test (419), < 5 ohms. Go to Locate open or
lead to jumper terminal 2 97AE to next step. poor connection in
(circuit 97AE) to ground. At gnd. circuit 97AE between
connector (419) measure connectors (263) and
resistance to ground at (419), then repair.
circuit 97AE.
9. Off At connector (263) use test (419), < 5 ohms. Go to Locate open or poor
lead to jumper terminal 10 97-GC to next step. connection in circuit
(circuit 97-G) to ground. At gnd. 97-GC, 97-GA or
connector (419) measure 97-G, then repair.
circuit 97-GC.
10. Off The cruise on/off switch
Testing Cruise Set/Resume Switch and Circuits — Cummins
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Table 50 Testing Cruise Set/Resume Switch and Circuits — Cummins

POINTS SPEC.
1. Off Remove connector (418) Switch (418), < 5 Go to Replace the switch.
from cruise set/resume across term. ohms. next step.
switch. With switch in 2 and 3.
set position, measure
resistance between
terminals 2 and 3.
2. Off With switch in neutral Switch (418), > 100K Go to Replace the switch.
position, measure between ohms. next step.
resistance between term. 1, 2
terminals 1, 2 and 3. and 3.
3. Off With switch in resume Switch (418), < 5 Go to Replace the switch.
position, measure between ohms. next step.
resistance between term. 1 and
terminals 1 and 2. 2.
terminal 8 to ground.
Does LED illuminate?
(263) from the ECM next step. connector terminals
and inspect. Refer if damaged. If ECM
to Inspecting Navistar pins are damaged,
Engine Harness ECM have Cummins
Connector (263). — dealer replace
Cummins ECM harness ECM. Refer to
connector and ECM pins Accelerator/ECM
OK? Calibration —
Cummins to
recalibrate ECM/
accelerator pedal.
6. Off At ECM connector (263) (263), term. > 100K Go to Locate short to
use test leads and 12, 22, and ohms. next step. ground in circuit
measure resistance to 10 to gnd. with less than 100K
ground at terminals 12, ohms, then repair.
22 and 10 (circuits 97AB,
97AA and 97-G).
7. Off At connector (263) (263), > 100K Go to Locate short between
measure resistance between ohms. next step. any circuits where
between terminal 12 term. 12 and resistance between
and 22 (circuits 97AB 22, and all terminals is less than
and 97AA), and all other others. 100K ohms, then
terminals in the connector. repair.
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Table 50 Testing Cruise Set/Resume Switch and Circuits — Cummins (cont.)

POINTS SPEC.
8. On At connector (263) (263), term. < or = Go to Locate short to
measure voltage to 12 and 22 to 1.5 volts. next step. unwanted voltage
ground at terminals 12 gnd. source in circuit
and 22 (circuits 97AB and 97AA or 97AB, then
97AA). repair.
9. Off At connector (263) use (418), 97AB < 5 Go to Locate open or
test lead to jumper to gnd. ohms. next step. poor connection in
terminal 12 (circuit 97AB) circuit 97AB between
to ground. At connector connectors (263) and
(418) measure resistance (418), then repair.
to ground at circuit 97AB.
10. Off At connector (263) use (418), 97-GB < 5 Go to Locate open or poor
test lead to jumper to gnd. ohms. next step. connection in circuits
terminal 10 (circuit 97-G) 97-GB, 97-GA or
to ground. At connector 97-G, then repair.
(418) measure resistance
to ground at circuit 97-GB.
11. Off At connector (263) use (418), 97AA < 5 Go to Locate open or poor
test lead to jumper to gnd. ohms. next step. connection in circuit
terminal 22 (circuit 97AA) 97AA, then repair.
to ground. At connector
(418) measure resistance
to ground at circuit 97AA.
12. Off The cruise set/resume
good.
3.16. VEHICLE SPEED SENSOR — CUMMINS

When monitoring engine functions with an electronic service tool, if the vehicle is moving, the miles-per-hour
will display as MPH=XXX (actual vehicle speed if operating properly). To test the sensor and circuits to
the ECM, use the following test charts.
Inspecting and Adjusting the Vehicle Speed Sensor (VSS) — Cummins
1. Disconnect engine harness connector (225) from the sensor. Loosen the locknut and remove the sensor.
The harness connector and sensor should be free of damage or corrosion. Remove any metal shavings or
debris from the sensor.
2. To install the sensor, turn in until the sensor contacts the transmission speedometer gear, then back out
one full turn. Tighten locknut to 15 ft-lbs. (20.3 N•m). This assures that the sensor is adjusted properly
for the next test.
Testing Vehicle Speed Sensor — Cummins
Construct test leads using terminals (Navistar Part No. 1680205C1), short length of 16 gauge wire and
alligator clips.
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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.
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Table 51 Testing Vehicle Speed Sensor — Cummins

POINTS SPEC.
1. Off Inspect VSS for damage Go to next
and proper adjustment step.
before performing this
test. Refer to Inspecting
and Adjusting the Vehicle
Speed Sensor (VSS) —
Cummins above.
2. Off Disconnect engine harness VSS, 600 to Go to next Replace the vehicle
(225) from VSS and use term. 1 800 step. speed sensor (VSS).
test leads to measure to 2. ohms.
resistance between
terminal 1 and 2 of sensor
connector.
3. Off Measure resistance to VSS, > 100K Go to next Replace the vehicle
ground at both sensor term. 1 ohms. step. speed sensor (VSS).
terminals. and 2 to
gnd.
4. Off Block front wheels and Go to next
place rear axles on floor step.
stands.
5. Off CAUTION: Use AC Go to next
voltmeter with sufficient step.
length leads to avoid
personal contact with
rotating vehicle wheels
during test. Connect
meter leads to test leads.
6. On Run engine at idle speed, VSS, >2.0 volts VSS Replace the VSS
with transmission in high across AC. checks (refer to Inspecting
gear. Measure voltage term. good. And Adjusting the
across the two sensor Vehicle Speed
terminals. Sensor — Cummins
above). NOTE:
Improper sensor
adjustment will
cause low, erratic or
no output.
Testing Vehicle Speed Sensor Circuits To ECM — Cummins
To check circuits between the ECM and the speedometer/tachometer unit, refer to ATA Data Link Connector
(220) and Speedometer/Tachometer Input Circuits — Cummins.
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Table 52 Testing Vehicle Speed Sensor Circuits To ECM — Cummins
POINTS SPEC.
1. Off Remove connector (225) Go to next Replace harness
from vehicle speed sensor. step. connector terminals
Remove ECM connector if damaged. If ECM
(263) from the ECM and pins are damaged,
inspect (refer to Inspecting have Cummins
Navistar Engine Harness dealer replace
ECM Connector (263) — ECM. Refer to
Cummins. ECM harness Accelerator/ECM
connector and ECM pins Calibration —
OK? Cummins to
recalibrate ECM/
accelerator pedal.
2. Off At connector (263), use (263), 3 > 100K Go to next Locate short to
test leads and measure and 7 to ohms. step. ground in circuit
resistance to gnd. at gnd. with less than 100K
terminals 3 and 7 (circuit ohms, then repair.
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97AJ and 97AK).
3. Off At connector (263), (263), 3 > 100K Go to next Locate short circuit
measure resistance and 7 and ohms step. between circuits
between terminals 3 and 7 all others. where resistance
(circuits 97AJ and 97AK), between terminals is
and all other terminals in less than 100K ohms,
connector. then repair.
4. On At connector (263), (263), 3 < or = 1.5 Go to next Locate short to

measure voltage at and 7 to volts. step. unwanted voltage
terminals 3 and 7 (circuits gnd. source in circuit
97AJ and 97AK) to ground. where voltage at
terminal is more than
1.5 volts, then repair.
217
Table 52 Testing Vehicle Speed Sensor Circuits To ECM — Cummins (cont.)
218

POINTS SPEC.
5. Off At connector (263) use (225), < 5 ohms. Go to next Locate open or
test leads and jumper 97AJ to step. poor connection in
terminal 3 (circuit 97AJ) gnd. circuit 97AJ between
to ground at circuit 97AJ.
6. Off At connector (263) use (225), < 5 ohms. Go to next Locate open or
test leads and jumper 97AK to step. poor connection in
terminal 7 (circuit 97AK) gnd. circuit 97AK between
to ground at circuit 97AK.
7. Off The vehicle speed sensor
circuits between the sensor
and ECM check good.
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B3 Circuit Breaker/Fuse Resetting. . . . . . . . . . . . . . . . . .. . . . . . Under mag switch cover near battery box
F1–F5 Fuseblock (462). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
F9–F13 Fuseblock (464). . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
G4 Ground Adapter (457). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind left gauge cluster
G5 Ground Adapter (533). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, center
I1 Ignition Adapter (518). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument cluster, right
L1 LED Panel Lt. Feed Adapt (504). . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
L3 LED Panel Lt. Ground Adapt (505). . . . . . . . . . . . . .. . . . . . Behind switch cluster
(B2) Battery Stud/Deep Cycle Stud. . . . . . . . . . . . . . . . .. . . . . . At power distribution panel
(5) Cruise Brake Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At left side of steering column and pedal support
bracket
(55) Clutch Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind left instrument panel
(72) Right Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At back of right gauge cluster
(102) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor, right front.
(136) Ether Start Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At rear of cab, at bottle
(220) Data Link Connector. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Under left side of instrument panel
(225) Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On top of transmission
(234) Diagnostic On/Off Switch. . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(262) Cab Floor Electronic Connector. . . . . . . . . . . . . .. . . . . . On cab floor, front right
(263) Eng. Control Module W/Celect. . . . . . . . . . . . . . .. . . . . . On left side of engine, at rear of ECM
(265) Diagnostics Inc./Dec. Switch. . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(306) TPS/Idle Validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Under instrument panel, left
(307) Low Coolant Level Switch. . . . . . . . . . . . . . . . . . . . .. . . . . . On surge tank, rear of engine
(309) Cummins Engine Connector. . . . . . . . . . . . . . . . . .. . . . . . Between engine harnesses, near ECM
(310) ECM Power Connector. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Near starting motor
(411) Engine Brake Selector Switch. . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(412) Engine Brake On/Off Switch. . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(418) Cruise Set/Resume Switch. . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(419) Cruise On/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(437) Left Door Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, left corner
(451) Ether Start On/Off Switch. . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(452) Key Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At base of dash, right wing panel
(462–R1) Ignition Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(504) LED Panel Lt. Feed Adapt L1. . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(505) LED Panel Lt. Ground Adapt L3. . . . . . . . . . . . . .. . . . . . Behind switch cluster
(514) Positive Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind right gauge cluster
(515) Negative Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind right gauge cluster
(518) Ignition Adapter I1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, center
(533) Ground Adapter G5. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, center
(595) Data Link Connector. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, lt. side, near (55)
(657) J1922 Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor, front right
(676) ECM 5–Way Power Connector. . . . . . . . . . . . . . .. . . . . . On left side of engine, at ECM
Refer to Figure 6, Figure 7, Figure 8, Figure 9, Figure 10, Figure 11, Figure 12, Figure 13, Figure 14, Figure
15, Figure 16, Figure 17, Figure 18, Figure 19, Figure 20, Figure 21, Figure 22, Figure 23, Figure 24, Figure
25, Figure 26, Figure 27, Figure 28, and Figure 29.
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Figure 70 Cab Wiring
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Figure 73 Cummins M11 Celect Engine Wiring — 9800
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Figure 78 Cummins M11 Celect Engine Wiring, Transmission Effects — 9800
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Figure 79 Cummins M11 Engine Wiring, Alternator Connections — 9800
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Figure 82 Cummins M11 Celect Engine Wiring, Starter Effects — 9800
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Figure 84 Cummins N14 Celect Engine Wiring — 9800

1. SEE FIGURE 21
2. ENGINE HARNESS
3. CIRCUIT 2 TO (B)
4. (780) CIRCUIT 14
5. CIRCUIT 2–G
6. GROUND CABLE ASSEMBLY TO (G)
7. ALTERNATOR
8. (775) CIRCUIT 11–GX
9. TO RADIATOR GROUND CIRCUIT 11–GAP
10. CAB HARNESS
11. (102) ENGINE HARNESS TO CAB HARNESS
12. (262) ENGINE HARNESS TO CAB HARNESS
13. ENGINE HARNESS
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1. ENGINE HARNESS
2. SEE FIGURE 26
3. TEMPERATURE SENSOR (244) CIRCUIT 29A, 29–G
4. CIRCUIT 2–G
5. ALTERNATOR, SEE FIGURE 27
6. GROUND CABLE ASSEMBLY
7. (775)
8. (780)
9. CIRCUIT 14
10. SEE FIGURE 20
11. SEE FIGURE 25
12. ENGINE HARNESS
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Figure 89 Cummins N14 Celect Engine Wiring, Transmission Effects — 9800
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Figure 91 Cummins N14 Celect Engine Wiring, Alternator Effects — 9800
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Figure 92 Cummins N14 Celect Engine Wiring, Starter Effects — 9800
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7 CUMMINS ISM ENGINE 245
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
2.1. ECM CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
2.2. ECM POWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
2.3. ATA DATA LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
2.4. DIAGNOSTIC SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
2.6. COOLANT LEVEL SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
2.7. CUMMINS ISM CRUISE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
2.8. DIAGNOSTIC ON/OFF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
2.9. BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
2.10. CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
2.11. VEHICLE SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
2.12. ENGINE BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
2.13. J1939 DATA LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
2.14. GAUGES AND WARNING LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
3.1. ONBOARD DIAGNOSTICS WITH ENGINE RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
3.2. PERFORMING A DIAGNOSTIC CHECK WITH THE ENGINE OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
3.3. CUMMINS ELECTRONIC SERVICE TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
3.4. EZ-TECH OR PRO-LINK ELECTRONIC SERVICE TOOL (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
3.5. RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
3.6. TESTING RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
3.7. ACCELERATOR PEDAL TPS/IVS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
Testing Throttle Position Sensor (TPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
Testing Idle Validation Switch (IVS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
Testing Accelerator Pedal (TPS/IVS) System for “Short or Open” Circuits. . . . . . . . . . . . . .257
Testing TPS/IVS Circuits for Continuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
Accelerator/ECM Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
3.8. LOW COOLANT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Testing Low Coolant Level Switch And Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
3.9. POWER SUPPLY CIRCUITS TO ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
Testing Unswitched Battery Power Circuits And ECM Ground Circuit. . . . . . . . . . . . . . . . . . .261
Testing Switched Ignition Power To ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
3.10. SERVICE BRAKE AND CLUTCH SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Testing Clutch Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Testing Clutch Switch Circuits for "Open and Short" Condition. . . . . . . . . . . . . . . . . . . . . . . . . . .264
Testing Clutch Switch Circuits For Continuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
Testing Service Brake Switch (5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
Testing Service Brake Switch Circuits for "Open and Short" Condition. . . . . . . . . . . . . . . . . .267
Testing Service Brake Switch Circuits for Continuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
3.11. ENGINE BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
Testing Engine Brake Components And Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
Testing Engine Brake Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
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246 7 CUMMINS ISM ENGINE

CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
Testing Diagnostic Connector Power and Ground Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
Testing Data Link Circuits Between Diagnostic Connector, ECM and
Speedometer/Tachometer Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
3.13. DIAGNOSTIC ON/OFF SWITCH AND CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
Testing Diagnostic On/Off Switch And Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
3.14. CRUISE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
Testing Cruise Control On/Off Switch and Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
Testing Cruise Set/Resume Switch and Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
3.15. VEHICLE SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Inspecting And Adjusting the Vehicle Speed Sensor (VSS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Testing Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
Testing Vehicle Speed Sensor Circuits To ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
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Model: 9800
1. DESCRIPTION
The CM570 engine controller provides many engine/vehicle functions including:
• Tachometer/Speedometer Input To Gauges
• Idle Shutdown
• Adjustable Low Idle Speed (In-Cab)
• Engine Cooling Fan Control
• Self Diagnostics
• J1939 Datalink (Used for Diagnostics and to Interface With Transmission and ABS).
Refer to the Cummins Engine Manual furnished with the vehicle for additional feature information.
Since each engine control system is electronically programmable to individual owner specifications, the
shift schedules, governor type (automotive type or variable speed), idle RPM, full engine shutdown as part
of the engine protection system and many others.
The electronic control module (ECM) is the control center of the system. The ECM receives input from
Cummins and International sensors and switches, processes the information, then uses electrical signals
to control engine and vehicle functions.
The ECM receives inputs from International installed components including:

• Idle Validation Switch (IVS)
• Clutch Switch
• Low Coolant Level Switch
• ABS/Traction Control Controller
• Cab Switches.
The ECM receives inputs from the sensors and switches, then outputs signals to the injectors, engine brake
relay, and other system components.
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2. OPERATION
2.1. ECM CONNECTIONS
Refer to circuit diagram CUMMINS ISM - ENGINE CONTROLS in CTS-5254W.
The ECM is connected to the International electrical system at two points:
1. International engine harness 50-way ECM connector (955) connects to ECM port C-1. This connector
links several International sensors, switched power, unswitched power ground, switches, diagnostic
connector to the ECM and the 1939 data link. The J1939 data link will interface with the transmission
and ABS as required.
2. International 31-way connector (957) connects to the Cummins sensor harness. This connector links the
vehicle speed sensor, low coolant switch, air conditioner power switch and engine fan controls to the ECM.
2.2. ECM POWER

Power is supplied at all times to the ECM directly from the battery. Circuits 14A and 14B run from the positive
battery post to 15 amp fuses. Circuits 14C and 14D run from the fuses to connector (675). Circuits 14C and
14D. 14C and 14D are split into circuits 14CJ, 14CK, 14CH, 14CG and 14CF to 50-way ECM connector (955).
The ECM is grounded from the battery on circuit 11G which is split into circuits 11GCF, 11GCB, 11GCK,
11GCJ, and 11GCH for input to 50-way ECM connector (955).
Turning the key switch to the ignition or start position energizes the ignition relay. The relay then applies power
to circuits 16A and 16E, 15A fuse B3, and circuit 16D to 50-way ECM connector (955).
2.3. ATA DATA LINK

between the ECM and the speedo/tachometer cluster. Thus, the ECM provides vehicle and engine information
• Circuit 98A(+) is the positive data link connection and it is fed by the positive data link connector (514), the
• Circuit 98C(-) is the negative data link connection and it is fed by the negative data link connector (515), the
jumper bus bar, circuit 98B(-), connector (262) and circuit 98B(-) coming from the ECM connector (955).
• Circuit 97DL is a 12 volt circuit and is fed from B1 battery stud to circuit 14K and 14L, through 5A fuse
• Circuit 11–GR is connected to G5 ground adapter (533) and provides a ground for the electronic service
tool.
2.4. DIAGNOSTIC SWITCH

A lighted diagnostic on/off switch is provided for on-board diagnostics. The switch is connected to the ECM
common/ground connection by way of ECM connector (955), circuit 97-GA, connector (262), and circuits
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97-GA and 97-GE. Moving the switch to the on position, closing the switch, applies the ground to circuit 97AM,
connector (262), and circuit 97AM to the Cummins engine connector (955). This tells the ECM that the
diagnostic on/off switch has been turned on. Thus the ECM will switch modes to display fault codes or the
absence of codes by flashing the engine warning light and the stop engine light.

The CM570 ECM utilizes an electronic accelerator pedal assembly that includes an integrated throttle position
sensor (TPS) and idle validation switch (IVS). The accelerator pedal assembly is serviceable, to the extent that
the IVS switch is replaceable without replacing the whole assembly.
The TPS is attached to the accelerator pedal and acts like a potentiometer. Movement of the pedal results in
a variable signal being sent to the ECM that is proportional to pedal position. A 5 volt signal from the ECM
connector (955) is applied to circuit 99A, connector (262), circuit 99A and the TPS/IVS (306). The variable
wiper signal (varies with pedal position) from TPS/IVS (306) is returned to the ECM over circuit 99, connector
(262), circuit 99 and ECM connector (955). This variable signal tells the ECM the position of the accelerator
pedal. The TPS (306) is grounded through circuit 99–G, connector (262) and circuit 99–G to the ECM (955).
NOTE – Any time the accelerator pedal sensor (TPS) is disconnected from the ECM with the key switch
on, the TPS and ECM must be recalibrated.
The IVS is used to indicate when accelerator pedal is in the low idle position and when the pedal is not in
the low idle position. A ground path from the ECM connector (955), circuit 97–GA, connector (262), circuit
99–GA is applied to the TPS/IVS (306).
When the accelerator is in the low idle position, the IVS (306) applies a ground signal to circuit 99B, connector
(262) and circuit 99B to the ECM (955). When the accelerator is not in the idle position, the IVS (306) applies a
ground signal to circuit 99C, connector (262) and circuit 99C to the ECM (955).
The ECM analyzes the signals received from the TPS and IVS to make certain that the signals fall within
certain parameters. For example: if the IVS signal indicates that the accelerator pedal is in the idle position,
the ECM expects to see a TPS signal that indicates that no throttle is applied. If it does not see a logical
response from both, a fault code may be logged.
The ECM and accelerator pedal must be calibrated to one another for proper engine response. Therefore,
the ECM and accelerator pedal must be calibrated when the accelerator pedal is initially installed, when an
accelerator pedal is replaced, when a new calibration is downloaded to the ECM, or when the accelerator
pedal wiring is disconnected at the pedal, the cab floor, or the ECM connector. To recalibrate the ECM and the
accelerator pedal, move the key switch to ignition position, slowly move the accelerator pedal from idle position
to fully depressed position and then release. Repeat this cycle two more times to assure proper calibration.
2.6. COOLANT LEVEL SENSOR

The coolant level switch is a fluid level actuated switch that sends two signals to the ECM, thus providing a
warning when coolant is being lost. It is mounted in the coolant surge tank. The coolant level switch is an
electronic switch that operates on the electrostatic or capacitance principle and cannot be tested with a
multimeter. The probe extends into the coolant and produces a change in capacitance when coolant displaces
air immediately surrounding the probe. This change is converted in the switch to an on/off solid state switch
closure indicating the absence or presence of coolant. The switch is electrically insulated providing a slick,
non-fouling surface as well as good electrical characteristics to prevent current flow into the coolant. The low
coolant level switch connects to the engine harness at connector (307). Four circuits from connector (307)
connect the low coolant switch to the ECM through the 31–way ECM connector (957).
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The coolant level switch (307) receives a 5 volt signal on circuit 34B(5V) from the ECM (957). When the
coolant level is above the probe, the switch sends a high signal (3.5 volts minimum) on circuit 34A and a low
signal (0.5 volt maximum) on circuit 34 to the ECM (957).
When the coolant level is below the probe, the switch sends a low signal (0.5 volt maximum) on circuit 34A and
a high signal (3.5 volts minimum) on circuit 34 to ECM (251).
The low coolant level switch is grounded through circuit 34–G to ECM (957).
NOTE – The low coolant level switch cannot be tested with a multimeter in the ohmmeter mode. This is
because the switch is an electronic switch and not a mechanical switch.
2.7. CUMMINS ISM CRUISE CONTROL

The cruise control switches are used as PTO controls when the vehicle road speed is not present (this is a
customer selected parameter). Refer to the operators manual furnished with the vehicle for specific cruise
control operating instructions.
The cruise control system has three modes of operation: off, standby and active. The off position of the on/off
switch turns cruise control off. The standby mode occurs when the driver switches the cruise control on/off
switch to the on position. The driver can then achieve the active mode by toggling the set/resume switch
after reaching the desired road speed.
Once the system is active, the driver can accelerate beyond the set speed by depressing the accelerator
pedal. When the pedal is released, cruise control is reactivated when the vehicle speed reaches the previously
set speed.
Cruise is deactivated, and returns to the standby mode in several ways: the brake or clutch pedal is depressed,
the engine speed (rpm) drops below 1000 rpm, or the vehicle speed (mph) drops below 30 mph.
The resume switch can be used to reactivate cruise at the previous set speed, or the set switch can be used
to establish a new set speed.
While in the active mode, the coast feature is used to decrease vehicle speed and establish a new lower set
speed. By holding select switch in the coast position, vehicle speed decreases until the switch is released;
the speed at release becomes the new set speed.
While in the active mode, the accelerate feature is used to increase the vehicle speed and establish a new
higher speed. By holding the select switch in the accel position, vehicle speed increases until the switch is
released; the speed at release becomes the new set speed.
The lighted cruise control on/off switch (419) receives a ground signal on circuits 97-GC and 97-GA, through
connector (262) on circuit 97-GA from (955). In the on position, a ground signal is sent from the switch on
circuit 97AE, connector (262), and circuit 97AE to ECM connector (955) terminal 23. This indicates to the
ECM that the cruise control switch is in the on position. In the off position, circuit 97AE returns to its 12 volt
value, indicating to the ECM that the switch is off.
The lighted cruise set/resume switch (418) is a momentary switch. This switch receives a ground signal on
circuits 97-GB, through connector (262) on circuit 97-GA from (955). The cruise selector switch sends a
ground signal from the switch on circuit 97AB, connector (262), and circuit 97AB to the ECM connector (955)
terminal 14 while in the set/accel position. In the resume/coast position, the switch sends a ground signal by
way of circuit 97AA, connector (262), and circuit 97AA to the ECM connector (955) terminal 24.
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The cruise set/resume switch also adjusts the low engine idle speed, PTO settings and is used during on-board
diagnostics (when the diagnostic switch is in the on position) to move through the diagnostic fault code list.
The engine idle speed can be adjusted by the switch in increments of 25 rpm by toggling the switch. Maximum
idle speed is 800 rpm and minimum idle speed is 550 rpm. When the idle has been changed and the key
turned off, the new setting is saved in memory. This feature is owner selected and can be turned off with an
electronic service tool.
2.8. DIAGNOSTIC ON/OFF SWITCH

The lighted diagnostic on/off switch is used during on-board diagnostics to move through the diagnostic
fault code list.
The switch is connected to the ECM common/ground connection by way of ECM connector (955), circuit
97-GA, connector (262), and circuits 97-GA and 97-GE. Placing the switch in the on position applies ground
to circuit 97AM, connector (262), and circuit 97AM to the ECM (955).
2.9. BRAKE SWITCH

The brake switch (5) receives a ground signal on circuits 97-GF, through connector (262) on circuit 97-GA
from (955). While the brake pedal is released, the switch is closed supplying a ground on circuit 97AL through
connector (262) to ECM connector (955).
When the brake is applied the ground will be removed signaling the ECM that the brake has been applied.
2.10. CLUTCH SWITCH

The clutch switch (55) is a N.O. momentary switch, and its contacts are held closed when the clutch pedal
is released.
The switch is provided a ground path over circuits 97-GH, through connector (262) on circuit 97-GA from (955).
The clutch switch (294) sends a ground signal by way of circuit 97AH, connector (262), and circuit 97AH to
the ECM connector (955) terminal 2 while the clutch pedal is released.

The vehicle speed sensor (962) feeds a VSS signal to the ECM (955) by way of circuits 97AJ and 97AK
through connector (262).
2.12. ENGINE BRAKE

The lighted engine brake on/off switch (412) receives a ground signal on circuits 24-G, through connector
(262) on circuit 97-GA from (955). In the on position, a ground signal is sent from the switch on circuit 24AD
to engine brake selector switch (411).
When switch (411) is placed in the first position, a ground is applied to circuit 24AE, connector (262), and
circuit 24AE to the ECM (955). This tells the ECM to enable the brake solenoid for the front three cylinders
when braking is called for.
When switch (411) is placed in the second position, a ground is applied to circuit 24AF, connector (262), and
circuit 24AF to the ECM (955). This tells the ECM to enable the brake solenoid for the rear three cylinders
when braking is called for.
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2.13. J1939 DATA LINK

The CM570 ECM uses a J1939 data link to communicate with the antilock brake system and some types
of transmissions.
A. Circuit 98YL(+) is the positive data link connection. It originates from ECM connector (955),
terminal 46. The circuit is connected to J1939 terminating resistor connector (958), terminal
A, J1939 backbone connector (960), terminal A, and J1939 cap diagnostic connector (959),
terminal A.
B. Circuit 98GN(-) is the negative data link connection. It originates from ECM connector (955),
terminal 37. The circuit is connected to J1939 terminating resistor connector (958), terminal
C, J1939 backbone connector (960), terminal C, and J1939 cap diagnostic connector (959),
terminal B.
2.14. GAUGES AND WARNING LIGHTS

Refer to separate gauge and warning lights sections in GROUP 08 - ELECTRICAL in the CTS-5000 Master
Service Manual for information on speedometer, tachometer, gauges, and warning lights.
3. TROUBLESHOOTING
This section includes troubleshooting charts for International installed circuits and components that are part of
the CM570 Electronic Control system. To begin the troubleshooting process, refer to the appropriate Cummins
manual and follow their directions. If the Cummins diagnostics (fault codes) indicate that the suspect circuits
are International circuits or components, then use the charts in this section.
The EZ-Tech or PRO-LINK 9000 EST can also be used to determine if the International switches and
components are working properly. If they are not, use a Fluke digital multimeter (DMM) to troubleshoot
the circuits.
If the Cummins diagnostic (fault codes) or the EZ-Tech or the PRO-LINK indicate a problem with International
installed circuits, the diagnostic tables in this chapter provide step-by-step test procedures.
relay, or solenoid.
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3.1. ONBOARD DIAGNOSTICS WITH ENGINE RUNNING

All CM570 vehicles have a yellow Engine Warning light and a red Engine Stop light located in the instrument
cluster. Every time the key is turned to the ignition position, the lights come on for several seconds as a
system self-test and then turn off.
If the warning lights remain on, it is an indication that the ECM has detected a problem. The CM570 system
can show and record certain problems. The problems are shown as fault codes. The fault codes are recorded
in the ECM.
If a fault is detected (becomes active) during vehicle operation, the driver is alerted by the illumination of
either the yellow Engine Warning Light or the red Stop Engine Light. The yellow Service/Check Engine
light may also be illuminated.
The yellow Engine Warning light turns on to warn the driver of an active component or system fault that should
be serviced as soon as possible to solve the problem, but the situation is not considered an emergency.
The red Stop Engine light turns on to warn the driver that there is a major system problem and the vehicle
should be stopped and engine shut down as soon as is safely possible.
The yellow Service/Check Engine Light (engine protection system) turns on to warn the driver that:
A. Coolant temperature is out of range.

B. Oil temperature is out of range.
C. Oil pressure is out of range.
D. Intake manifold temperature is out of range.
E. Engine coolant level is below the acceptable level.
3.2. PERFORMING A DIAGNOSTIC CHECK WITH THE ENGINE OFF

A diagnostic check may be performed using the Diagnostic On/Off switch and Cruise Set/Resume. Any
error codes will be flashed through the red Engine Stop Light and yellow Engine Warning Light. If no errors
are found, both lights will stay on while the diagnostics switch is on. Consult the Cummins Operation and
Maintenance Manual furnished with the vehicle for exact procedures and fault code information.
To determine the fault codes use the following procedure:
1. Begin the procedure with the engine off.
2. Place the switch key in the off position.
3. Turn the diagnostic On/Off switch to the on position.
4. Turn the key switch to run position (not crank).
NOTE – Cummins CM570 engine diagnostics must be run with the engine NOT RUNNING.
If BOTH the yellow Engine Warning and red Engine Stop lights come on momentarily and then go out, it is an
indication that engine faults are present.
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If BOTH the yellow Engine Warning and red Engine Stop lights come on and stay on, it is an indication that
no engine faults are present.
5. Yellow Engine Warning light will flash once.
6. There will be a one to two second pause.
7. Red Engine Stop will flash code with one or two seconds between digits.
8. Yellow Engine Warning light will flash indicating the end of that fault code, and then start over and
repeat the same fault code.
9. To go to the second fault code, move the Set/Resume switch to the Inc position and then release it. The
process will then repeat itself as indicated in Steps 5 through 8.
10. To move back to the last or previous fault code, move the Set/Resume switch to the Dec position and then
release it. The process will then repeat itself as indicated in Steps 5 through 8.
11. To stop the diagnostics procedure, correct the faults or move the diagnostic On/Off switch to the off,
and turn the vehicle key switch to the off position.
3.3. CUMMINS ELECTRONIC SERVICE TOOL

CM570 vehicles have a data link connected to the ATA data link connector (137). The Cummins electronic
service tool can be used to program owner-specified information into the engine, monitor the system, and aid
in troubleshooting the engine. Consult the Cummins ISM Troubleshooting and Repair Manuals. The Cummins
electronic service tool may be available at the nearest Cummins Authorized Service Center.
3.4. EZ-TECH OR PRO-LINK ELECTRONIC SERVICE TOOL (EST)

The EZ-Tech or Pro-Link 9000 EST with the appropriate software program can also be used with the
International data link to read active and inactive fault codes through the data link. The use of the EST or
specific codes are not discussed in this manual as the information is part of the EZ-Tech or Pro-Link 9000
documentation.
The EZ-Tech or Pro-Link 9000 can also be used to monitor operation of various switches and controls and
perform other diagnostic tasks. The specific capabilities and operating instructions are included in the EZ-Tech
or Pro-Link 9000 documentation.
3.5. RELAYS
Navistar circuits use suppressed relays for controlling power to load devices. The suppression feature (a
resistor circuit parallel to the relay coil) prevents voltage spikes from damaging electronic components in the
vehicle. These relays must be replaced with the correct International part.
Relays used in exposed areas such as the engine compartment are sealed relays and are a different part
number than those in the cab. The part number is embossed on the relay. There is also a circuit diagram of the
relay located on the relay body. The terminals are numbered on the relay in the same manner as in the circuit
diagrams. To test the relay, refer toTesting Relay below.
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3.6. TESTING RELAYS

Table 53 Testing Relays
POINTS SPEC.
1. Off With relay removed, Relay, 30 > 100K Go to next Replace the relay.
measure resistance to 87. ohms. step.
between terminals 30
and 87.
2. Off Measure resistance Relay, 30 < 2 ohms. Go to next Replace the relay.
between terminals 30 to 87A. step.
and 87A.
3. Off Connect 12V lead to Go to next Replace the relay.
terminal 85 and ground step.
lead to terminal 86. Does
relay energize with audible
click?
4. Off With relay energized (Step Energized < 2 ohms. Relay Replace the relay.
3), measure resistance Relay, 30 tests
between terminals 30 and to 87. good.
87.
3.7. ACCELERATOR PEDAL TPS/IVS

The following four tests check the throttle position sensor (TPS), the idle validation switch (IVS) and the related
International cab and engine harness circuits connected to the ECM.
NOTE – The following four tests must be performed in sequence.
The tests should be performed if a Cummins fault code indicates a problem in the circuits or if the EST
indicates that the TPS/IVS is not working properly while monitoring switches. If a fault is present while
monitoring Percent Of Throttle, the percent displayed does not indicate actual throttle position.
NOTE – The following two tests, Testing Throttle Position Sensor (TPS) and Testing Idle Validation Switch
(IVS), check operation of the TPS and IVS, but do not check the timing between the two functions.
Testing Throttle Position Sensor (TPS)
This test checks the TPS circuits in the accelerator pedal assembly. This test will help identify if the resistances
are within specifications and if there are any opens or shorts in the TPS, but will not verify the correct
switching of the IVS and TPS.
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Table 54 Testing Throttle Position Sensor (TPS)

POINTS SPEC.
1. Off Disconnect accelerator TPS, A to 2000 to Go to Replace the TPS/IVS
pedal from cab harness at C 3000 ohms. next switch, then
connector (306). At pedal step. recalibrate (refer to
side of (306) measure Accelerator/ECM
resistance between Calibration).
terminals A and C with
the pedal in the idle
position, then with the
pedal fully depressed.
2. Off With the pedal in the TPS, B to 1500 to Go to Replace the TPS/IVS
idle position, at pedal, C. 3000 ohms. next switch, then
measure resistance step. recalibrate (refer to
C. Calibration).
3. Off With the pedal in the TPS, B to 250 to Go to Replace the TPS/IVS
full throttle position, at C. 1500 ohms, next switch, then
pedal, measure resistance and <idle step. recalibrate (refer to
between terminals B and position Accelerator/ECM
C. Is reading 1000 ohms reading Calibration).
less than reading at idle -1000
position and between 250 ohms.
and 1500 ohms?
4. Off At the accelerator pedal, TPS, A, >100K Go to Replace the TPS/IVS
measure resistance B, C, D, ohms. next switch, then
between ground (metal and E to step. recalibrate (refer to
part of pedal) and gnd. Accelerator/ECM
terminals A, B, C, D, Calibration).
and E.
Testing Idle Validation Switch (IVS)
This test checks the IVS circuits in the accelerator pedal assembly.
Perform Testing Throttle Position Sensor (TPS) before performing this test.
Table 55 Testing Idle Validation Switch (IVS)

POINTS SPEC.
1. Off Disconnect accelerator TPS/IVS, F >125 Go to Replace the TPS/IVS
pedal from cab harness at to E. ohms. next switch, then
connector (306). At pedal step. recalibrate (refer
side of (306) measure to Accelerator/ECM
resistance between Calibrations).
terminals F and E with
pedal in idle position. Is it
<125 ohms?
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Table 55 Testing Idle Validation Switch (IVS) (cont.)

POINTS SPEC.
2. Off At pedal measure TPS/IVS, F >100K Go to Replace the TPS/IVS
resistance between to E. ohms. next switch, then
terminals F and E while step. recalibrate (refer
slowly depressing the to Accelerator/ECM
pedal (idle to full throttle). Calibrations).
After approximately 10
degrees of travel, is the
resistance 100K ohms or
more?
3. Off At pedal measure TPS/IVS, F >100K Go to Replace the TPS/IVS
resistance between to D. ohms. next switch, then
terminals F and D while the step. recalibrate (refer
pedal is at idle position. to Accelerator/ECM
Calibrations).
4. Off At pedal measure TPS/ IVS F <125 Go to Replace the TPS/IVS
resistance between to D. ohms. next switch, then
terminals F and D while step. recalibrate (refer
slowly depressing the to Accelerator/ECM
pedal (idle to full throttle). Calibrations).
After approximately 10
degrees of travel the
resistance should be less
than 125 ohms.
5. Off At pedal measure TPS/ IVS, >100K Go to Replace the TPS/IVS
resistance between metal metal to D, ohms. next switch, then
part of accelerator pedal E, and F. step. recalibrate (refer
and terminals D, E and F. to Accelerator/ECM
Calibrations).
6. Off The TPS/IVS pedal
assembly checks good.
Note that this test is not
able to check the timing
between TPS and IVS
functions.
Testing Accelerator Pedal (TPS/IVS) System for “Short or Open” Circuits
This test checks the cab and engine harness TPS/IVS circuits for opens, shorts to ground, shorts to “hot”
circuits and shorts to other circuits in the harness.
Perform the preceding 2 tests before performing this test.
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Table 56 Testing Accelerator Pedal (TPS/IVS) System for “Short or Open” Circuits
POINTS SPEC.
1. Off With (306) disconnected, Go to next Replace connector
disconnect connector step. terminals if damaged.
(955) from ECM and If ECM pins are
inspect ECM connector. damaged, have
Connector and ECM pins Cummins dealer
OK? replace ECM. Refer to
Accelerator/ECM
Calibration to
recalibrate the ECM to
TPS/IVS.
2. Off At connector (955) use (955), >100K Go to next Locate short to ground
test leads and measure 99B, 99C, ohms. step. in circuit where
resistance to ground at 97-GA, terminal resistance
terminals 3, 13, 49, 47, 99, 99A is less than 100K
48 and 10 (circuits 99B, and 99–G ohms, then repair.
99C, 97-GA, 99, 99A and to gnd.
99-G).
3. Off At connector (955) use (955), >100K Go to next Locate short between
test leads and measure between ohms. step. any circuits where
resistance between 99B, 99C, resistance between
terminals 3, 13, 49, 47, 48 97-GA, terminals is less than
and 10 (circuits 99B, 99C, 99, 99A, 100K ohms, then
97-GA, 99, 99A and 99-G) and 99-G repair.
and all other terminals in and all
(955). other cir.
in conn.
4. On At connector (955) use (955), <1.5 Go to Locate short to
test leads and measure 99B, 99C, volts. Testing unwanted voltage
voltage to ground at 97-GA, TPS/ IVS source in any circuit
terminals 3, 13, 49, 47, 99, 99A Circuits for where more than
48 and 10 (circuits 98B, and 99-G Continuity. 1.5 volts is present,
99C, 97-GA, 99, 99A and to gnd. then repair. Go to
99-G). Accelerator/ECM
Calibration
to recalibrate
ECM/accelerator
pedal.
Testing TPS/IVS Circuits for Continuity
This test checks the individual TPS and IVS circuits (cab and engine harness) for correct resistance while
disconnected from the accelerator pedal assembly and ECM. Perform the preceding three tests before
performing this test.
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Table 57 Testing TPS/IVS Circuits for Continuity

POINTS SPEC.
1. Off At ECM connector (955) (306), 99 < 5 ohms. Go to next Locate cause of
use test lead to jumper to 99A. step. out-of- specification
terminal 47 to 48 (circuit resistance in either
99 to 99A). At connector circuit 99 or 99A(5V),
(306) measure resistance then repair. Refer to
C (circuit 99 to 99A). Calibration to
recalibrate ECM/
accelerator pedal.
2. Off At connector (955) use test (306), < 5 ohms. Go to next Locate cause of
lead to jumper terminal 99-G to step. out-of- specification
47 to 49 (circuit 99 to 99. resistance in
99-G). At connector circuit 99-G, then
(306) measure resistance repair. Refer to
between terminals A and Accelerator/ECM
B (circuit 99-G to 99). Calibration to
recalibrate ECM/
accelerator pedal.
3. Off At connector (955) use test (306), 99 < 5 ohms. Go to next Locate cause of
lead to jumper terminal to 99C. step. out-of- specification
47 to 3 (circuit 99 to resistance in
99C). At connector (306) circuit 99C, then
measure resistance repair. Refer to
D (circuit 99 to 99C). Calibration to
recalibrate ECM/
accelerator pedal.
lead to jumper terminal to 99B. step. out-of- specification
47 to 13 (circuit 99 to resistance in circuit
99B). At connector (306) 99B, then repair. Refer
measure resistance to Accelerator/ECM
between terminals B and Recalibration to
E (circuit 99 to 99B). recalibrate ECM/
accelerator pedal.
lead to jumper terminal to 99-GA. step. out-of- specification
47 to 10 (circuit. 99 resistance in circuit
to 97-G). At connector 99–GA or 97–G,
(306) measure resistance then repair. Refer to
F (circuit 99 to 99-GA). Calibration to
recalibrate ECM/
accelerator pedal.
6. Off If these four tests have
been performed and
defects were not noted,
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Table 57 Testing TPS/IVS Circuits for Continuity (cont.)

POINTS SPEC.
the TPS and IVS circuits
check good. If the problem
is still present, replace the
accelerator pedal. If
this does not correct the
problem, have Cummins
dealer diagnose the ECM
operation.
Accelerator/ECM Calibration
The electronic accelerator pedal assembly and the ECM must be calibrated when:
A. The pedal assembly is initially installed.

B. The pedal assembly or sensor is replaced.
C. The accelerator pedal is disconnected (at any point in the circuitry) and the key switch is placed in
the on position.
To recalibrate the accelerator pedal and ECM:
A. The vehicle key must be in the on position.

B. Depress the accelerator pedal slowly through the complete range of movement, then release.
Slowly depress and release, three times in this manner. This completes the calibration process.
3.8. LOW COOLANT SWITCH

First check for proper coolant levels. If coolant levels are not low, this test would be performed if Cummins
diagnostic codes were logged indicating a low coolant condition or other circuit fault.
This test procedure requires a VOM to check the Navistar harness for opens, shorts to ground, or shorts to
other circuits in the Navistar harness. The low coolant sensor has complex circuits and a VOM should not
be used to test the sensor as it may damage the circuits.
Testing Low Coolant Level Switch And Circuits
Table 58 Testing Low Coolant Level Switch And Circuits

POINTS SPEC.
1. Off Disconnect 31-way (957), > 100K Go to Locate short between
connector (957) from between ohms. next any circuits where
Cummins connector. 34B(5V), step. resistance between
Disconnect (307) from 34-G, 34A terminals is less than
low coolant switch. At and 34 and 100K ohms, then repair.
connector (957) measure all other
terminals 7, 19, 5 and 8
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Table 58 Testing Low Coolant Level Switch And Circuits (cont.)

POINTS SPEC.
(circuits 34B[5V], 34-G,
34A and 34) and all other
terminals in (957).
2. Off At (957) measure (957), > 100K Go to Locate short to ground
resistance to ground 34B[5V], ohms. next in any circuit(s) where
at terminals 7, 19, 5 and 34-G, 34A step. resistance is less than
8 (circuits 34B[5V], 34-G, and 34 to 100K ohms, then repair.
34A and 34). gnd.
3. On At (957) measure voltage (957), 34B < 1.5 Go to Locate short to
to ground at terminals (5V), 34-G, volts. next unwanted voltage
7, 19, 5 and 8 (circuits 34A and 34 step. source in any circuit(s)
34B[5V], 34-G, 34A and to gnd. where voltage is more
34). than 1.5V, then repair.
4. Off Measure resistance of 34, 34A, < 5 ohms. Go to Locate open or poor
circuits 34, 34A, 34-G 34-G, and next connection in circuit(s),
and 34B(5V) between 34B(5V) step. if resistance is more
connectors (307) and between than 5 ohms, then
(957). (307) and repair.
(957).
5. Off The low coolant switch
circuits check good. If
problem is still present,
replace low coolant
switch. If problem
persists, have Cummins
dealer diagnose ECM
operation.
3.9. POWER SUPPLY CIRCUITS TO ECM

This test checks the unswitched battery power feed to the ECM and the ECM ground circuit that is part of the
Battery Feed Harness. Check the two 15A Cummins fuses before performing this test.
NOTE – Batteries must be fully charged before performing this test.
Testing Unswitched Battery Power Circuits And ECM Ground Circuit
Table 59 Testing Unswitched Battery Power Circuits And ECM Ground Circuit
POINTS SPEC.
1. Off Check ECM power Good Go to Correct poor
harness connector at connections. next connections.
starter (circuits 14A, step.
14B and 11-G) and at
connector (675) for clean,
tight connections.
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Table 59 Testing Unswitched Battery Power Circuits And ECM Ground Circuit (cont.)
POINTS SPEC.
2. Off Check the two 15 amp ECM fuses. < 5 ohms. Go to Locate cause of
fuses located in the next overload condition,
engine harness for open step. then correct. Replace
condition. with correct rated
fuse.
3. Off Disconnect ECM power (955), 12 ± 1.5 Go to Locate cause of low
connector (955) from 14CH, volts. next or no voltage in circuit
Cummins engine harness. 14CG, step. 14CH, 14CG, 14CF,
Measure voltage to 14CF, 14CJ 14CJ or 14CK from
ground at circuits 14CH, and 14CK batteries, then repair.
14CG, 14CF, 14CJ and to gnd.
14CK. Battery voltage
present?
4. Off At connector (955) (955), 12 ± 1.5 Go to Locate open or high
measure voltage between 14CH to volts. next resistance in circuit
circuits 14CH and 11-G. 11-G. step. 11-G between (955)
Battery voltage present? and batteries, then
repair.
5. On At connector (955) (955), > 7 volts. Go to Locate cause of
measure voltage between 14CH to next excess voltage drop
circuits 14CH and 11-G 11-G while step. in cranking circuit,
while cranking engine. cranking. then repair.
6. Off Unswitched battery power
circuits and ECM ground
circuit at connector (955)
checks good.
Testing Switched Ignition Power To ECM
Table 60 Testing Switched Ignition Power To ECM

POINTS SPEC.
1. Off Check 15A fuse B3 for B3 < 1 ohm. Go to next Locate cause of
open condition. step. overload condition,
fuse.
2. On Measure voltage to 16A and 12 ± 1.5 Go to next Locate cause of no
ground at input circuit 16E to gnd. volts. step. or low voltage in 16A
(16A and 16E to fuse B3). and 16E from ignition
relay (462–R1),
then correct. Refer
to POWER AND
DISTRIBUTION
GROUND SYSTEM
Section.
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Table 60 Testing Switched Ignition Power To ECM (cont.)

POINTS SPEC.
3. Off/ Disconnect engine (955), 38 to 12 ± 1.5 Go to next Locate open in circuit
On harness 50-pin ECM gnd. volts. step. 13D between fuse
connector (955) from and connector (955),
Cummins harness. Turn then repair.
key on, measure voltage
to ground at connector
(955) terminal 38 (circuit
16D).
4. Off Measure voltage between (955), 38 12 ± 1.5 Switched Locate open in
terminal 38, circuit 13D to each volts. ignition circuit between
and each terminal (29, terminal voltage engine ground and
30, 50, 40 and 39) (29, 30, 50, circuit connector (955),
(circuits 11-GCF, 11-GCB, 40 and 39). to ECM then repair.
11-GCK, 11-GCJ and checks
11-GCH). good.
3.10. SERVICE BRAKE AND CLUTCH SWITCHES

This test would be performed if the Electronic Service Tool (EST) displayed an incorrect switch position or
Cummins diagnostic codes indicate a problem may be present.
Testing Clutch Switch
Table 61 Testing Clutch Switch

POINTS SPEC. SPEC.
1. Off Disconnect clutch switch Clutch < 2 ohms. Go to Step 3. Check switch
connector (55) from cab switch adjustment. Go
harness. With clutch across to next step.
pedal released, measure pigtail
resistance between the terminals
pigtail terminals. (55).
2. Off With clutch pedal Replace and Adjust clutch
depressed to the bottom adjust clutch switch. Go to
of the free travel position switch. Go to Step 1.
(approx. 1.7 inches or 43 Step 1.
mm from pedal stop plate),
the u-bolt plate should
touch the switch actuator
arm. When the clutch
pedal returns to the stop,
the switch should actuate
(to closed position) with
an audible click. Is clutch
switch adjusted properly?
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Table 61 Testing Clutch Switch (cont.)

POINTS SPEC. SPEC.
3. Off Depress clutch pedal Clutch > 100K Go to next If switch is
and measure resistance switch ohms. step. not properly
between clutch switch across adjusted,
pigtail connector (55) pigtail adjust and
terminals. terminals retest. If switch
(55). was properly
adjusted, replace
the switch.
4. Off Check clutch switch for Clutch > 100K Clutch switch Replace the
short to ground. With switch each ohms. checks good. clutch switch,
switch disconnected, pigtail to Perform then adjust.
measure resistance to gnd. Testing
ground at each switch Clutch Switch
terminal. Circuits
for "Open
and Short"
Condition.
Testing Clutch Switch Circuits for "Open and Short" Condition
Perform Testing Clutch Switch before performing this test.
Table 62 Testing Clutch Switch Circuits for "Open And Short" Condition
POINTS SPEC.
1. Off With clutch switch Go to next Replace damaged
disconnected, remove step. harness connector
ECM connector (955) terminals. If ECM
from the ECM. ECM pins are damaged,
harness connector or have Cummins
ECM pins OK? dealer replace
ECM. Refer to
Accelerator/ECM
Calibration to
recalibrate ECM/
accelerator pedal.
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Table 62 Testing Clutch Switch Circuits for "Open And Short" Condition (cont.)
POINTS SPEC.
2. Off Set service brake using (955), > 100K Go to next Locate short to
trailer hand valve. 97AH and ohms. step. ground in circuit
Disconnect clutch switch 97-GA to where resistance at
(55). Use test leads and gnd. terminal was less
measure resistance to than 100K ohms,
ground at connector (955) then repair.
terminal 2 and 10 (cir.
97AH and 97-GA).
3. Off With cab switches still in (955), >100K Go to next Locate short
off or neutral position and 97AH and ohms. step. between circuits,
service brake set, use 97-GA and then repair.
test leads and measure all other
terminals 2 and 10 (cir.
97AH and 97-GA) and
all other terminals in
connector (955).
4. On At connector (955), use (955), < 1.5 The clutch Locate short to
test leads and measure 97AH and volts. switch unwanted voltage
voltage to ground at 97-GA to circuits source in circuit with
terminals 2 and 10 (cir. gnd. are free more than 1.5 volts,
97AH and 97-GA). of short then repair.
circuits.
Perform
Testing
Clutch
Switch
Circuits for
Continuity.
Testing Clutch Switch Circuits For Continuity
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Table 63 Testing Clutch Switch Circuits For Continuity

POINTS SPEC.
1. Off At ECM connector (955) (55), < 5 Go to Locate open or
use test lead to jumper 97AH to ohms. next step. poor connection in
terminal 2 (circuit 97AH) to gnd. circuit 97AH between
ground. At clutch switch connectors (955) and
resistance of 97AH to
ground.
2. Off At ECM connector (955) (55), < 5 Go to Locate open or poor
use test lead to jumper 97AH to ohms. next step. connection in circuit
terminal 2 to 10 (circuit 97-GH. 97-GH or 97-GA
97AH to 97-GA) . At between connectors
clutch switch connector (955) and (55), then
(55) measure resistance repair.
between circuits 97AH and
97-GH.
3. Off The clutch switch circuits
and switch check good.
Testing Service Brake Switch (5)
Table 64 Testing Service Brake Switch (5)

POINTS SPEC. SPEC.
1. Off Remove connector Brake < 2 Go to next Replace the brake
(5) from brake switch. pressure ohms. step. switch.
With brakes released, switch
measure resistance across
across switch terminals. terminals.
Switch should be closed.
2. Off Apply service brakes Brake > 100K Go to next Replace the brake
and measure resistance pressure ohms. step. switch.
across the brake pressure switch
switch. Switch should be across
open. NOTE: Sufficient terminals.
air pressure must be
present to apply service
brakes for this test step.
3. Off Measure resistance to Brake > 100K Reconnect Replace the brake
ground at both brake pressure ohms. (5) to brake switch.
switch terminals with switch both switch.
service brakes applied, terminals to Perform
and with brakes released. gnd. Testing
Both should be isolated Service
from ground at all times. Brake Switch
Circuits
for "Open
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Table 64 Testing Service Brake Switch (5) (cont.)

POINTS SPEC. SPEC.
and Short"
Condition.
Testing Service Brake Switch Circuits for "Open and Short" Condition
Perform Testing Service Brake Switch (5) before performing this test.
Table 65 Testing Service Brake Switch Circuits for "Open and Short" Condition
POINTS SPEC.
1. Off With connector (5) Go to next Replace harness
disconnected from step. connector terminals
brake switch. Remove if damaged. If ECM
connector (955) from the pins are damaged,
ECM. ECM connector have Cummins
and ECM pins OK? dealer replace ECM.
2. Off Turn all cab switches (955), > 100K Go to next Locate short to
to off or neutral position 97AL and ohms. step. ground in circuit
and disconnect clutch 97-GA to where resistance at
switch. Use test leads gnd. terminal was less
and measure resistance than 100K ohms,
to ground at connector then repair.
(955) terminals 1 and
10 (circuits 97AL and
97–GA.
3. Off Use test leads and (955), > 100K Go to next Locate short between
measure resistance 97AL to ohms. step. any circuit where
between terminal 1 and 97-G A and resistance between
10 (circuit 97AL and all other terminals is less than
97-GA) and all other circuits. 100K ohms, then
terminals in connector repair.
(955).
4. On At connector (955), (955), < 1.5 The brake Locate short to
use test leads and 97AL and volts. switch unwanted voltage
measure voltage to 97-GA to circuits are source in circuit with
ground at terminals 1 gnd. free of short more than 1.5 volts,
and 10 (circuits 97AL circuits. then repair.
and 97-GA). Perform
Testing
Service
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Table 65 Testing Service Brake Switch Circuits for "Open and Short" Condition (cont.)
POINTS SPEC.
Brake
Switch
Circuits for
Continuity.
Testing Service Brake Switch Circuits for Continuity
Table 66 Testing Service Brake Switch Circuits for Continuity

POINTS SPEC.
1. Off At ECM connector (955) (5), 97AL to < 5 Go to Locate open or
use test lead to jumper gnd. ohms. next poor connection in
terminal 1 (circuit 97AL) to step. circuit 97AL between
ground. At brake switch connectors (955) and
circuit 97AL.
2. Off At ECM connector (955) (5), 97AL to < 5 Go to Locate open or poor
use test lead to jumper 97-GF. ohms. next connection in circuit
terminal 1 to terminal 10 step. 97-GF or 97-GA
(circuit 97AL to 97-GA). between connectors
At brake switch connector (955) and (5), then
(5) measure resistance repair.
between circuits 97AL and
97-GF.
3. Off The service brake switch
circuits and switch check
good.
3.11. ENGINE BRAKE

In the event the engine brake fails to operate, the following chart provides a systematic series of steps to check
the switches and circuits that are installed by International.
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Testing Engine Brake Components And Circuits
Table 67 Testing Engine Brake Components And Circuits

POINTS SPEC.
1. Off Remove engine brake (412), < 1 ohm. Go to next Locate open or poor
on/off switch from 24-G to step. connection in circuit
connector (412). Measure gnd. 24-G or 97-GA, then
resistance to gnd. at repair.
connector (412), circuit
24-G.
2. Off With on/off switch Go to next Replace the switch.
removed, refer to Testing step.
Engine Brake Switches
and use ohmmeter to
check switch. Switch
good?
3. Off Remove connector (411) 24AD < 5 ohms. Go to next Locate open or
from selector switch. between step. poor connection in
Measure resistance of (412) and circuit 24AD between
circuit 24AD between (411). connectors (412) and
connectors (412) and (411), then repair.
(411).
4. Off Refer to Testing Engine Go to next Replace the switch.
Brake Switches and step.
test the selector switch.
Switch good?
5. Off Re-install conn. (412) to Go to next
engine brake on/off switch step.
and place in on position.
Re-install conn. (411)
to engine brake switch
and place in position
3. Disconnect 50-way
conn. (955) from engine
harness.
6. on At connector (955) (955), < 1 ohm. Go to next Locate open or
measure resistance from 24AE and step. poor connection in
pin 22 and 31 to ground 24AF to circuit 24AE, or 24AF
(circuit 24AE and 24AF to gnd. between connectors
ground). (411) and (955), then
repair.
Testing Engine Brake Switches
1. Testing Engine Brake On/Off Switch

a. With switch in on position, resistance between terminals 5 and 6, and between 2 and 3 should be
less than 5 ohms.
b. With switch in off position, resistance should be 100K ohms or more.
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c. To test the LED in the switch, connect B+ test lead to terminal 7 and ground terminal 8. LEDs should
illuminate.
2. Testing Engine Brake Selector Switch

a. With switch in 3 position, resistance between terminals 2 and 3 and 6 should be less than 5 ohms.
b. With switch in 1 position, resistance between terminals 2 and 3 should be less than 5 ohms.
c. With switch in 2 position, resistance between terminals 2 and 6 should be less then 5 ohms.
d. To test the LED in the switch, connect B+ test lead to terminal 7 and ground terminal 8. LEDs should
illuminate.

CIRCUITS
This series of tests provide charts for testing: (1) The Data Link circuits between the ECM and ATA Data
Link connector (220) and the speedometer/tachometer connector (421). (2) The power and ground circuits
to the ATA Data Link connector (220).
Testing Diagnostic Connector Power and Ground Circuits
Table 68 Testing Diagnostic Connector Power and Ground Circuits

POINTS SPEC.
1. Off Remove and check 5A F6–A. < 1 ohm. Go to next Locate cause of
fuse F6–A for open step. overload condition,
condition. then repair. Replace
5A fuse.
2. On Re-install fuse. At (220), 12 ± 1.5 Go to next Locate cause of no or
connector (220) measure 97DL to volts. step. low voltage in circuit
voltage at terminal C gnd. 97DL from fuse F9-C,
(circuit 97DL) to ground. then repair.
3. On At connector (220) (220), 12 ± 1.5 Go to next Locate open or poor
measure voltage between 97DL to volts. step. connection in circuit
terminals C and E (circuits 11-GR. 11-GR between
97DL and 11-GR). connector (220) and
G5 ground adapter
(533), then repair.
4. On The power and ground
circuits to the ATA data
link connector (220) check
good.
Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer Unit
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Table 69 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer
Unit
POINTS SPEC.
1. Off Disconnect ECM Harness Go to Replace harness
connector (955) from the conn. OK. next conn. terminals if
ECM. Inspect connector. step. damaged. If ECM
ECM harness connector pins are damaged,
OK? have Cummins
dealer replace ECM.
Refer to Accelerator/
ECM Calibration to
recalibrate ECM/
accelerator pedal.
2. Off Disconnect connector (955), >100K Go to Locate short circuit
(421) from speedometer/ 98B(-) and ohms. next to ground in circuit
tachometer unit and 98(+) to step. where resistance is
if additional devices gnd. less than 100K ohms,
have been connected to then repair.
(514) and (515) data link
connectors, they must
be disconnected. At
connector (955), using test
leads, measure resistance
to ground at terminals 26
and 27 [circuit 98B(+) and
98(-)].
3. On At connector (955) use (955), > 100K Go to Locate short between
test leads and measure 98B(-) and ohms. next circuits where
resistance between 98(+) and step. resistance between
terminal 26 and terminal 27 all other terminals is less than
[circuits 98B(+) and 98(-)] circuits in 100K ohms, then
and all other terminals in conn. repair.
connector.
4. On At connector (955) use test (955), <1.5 volts. Go to Locate short to
leads and measure voltage 98B(-) and next unwanted voltage
to ground at terminals 26 98(+) to step. source in circuit where
and 27 [circuits 98B(+) and gnd. more than 1.5 volts
98(-)]. is present at terminal,
then repair.
lead to jumper terminal 27 98C(-) to next connection in circuit
[circuit 98B(-)] to ground. gnd. step. 98B(-) or (98C(-)
At Data Link connector between connectors
(220) measure resistance (955) and (220), then
to ground at terminal B repair.
[circuit 98C(-)].
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Table 69 Testing Data Link Circuits Between Diagnostic Connector, ECM and Speedometer/Tachometer
Unit (cont.)
POINTS SPEC.
6. Off With connector (955) (421), 47/ < 5 ohms. Go to Locate open or poor
terminal 27 [circuit 98B(-)] 48(-) to next connection in circuit
still jumpered to ground, at gnd. step. 47/48(-) between
speedometer/ tachometer connectors (515) and
circuit 47/48(-).
lead to jumper terminal 26 98A(+) to next connection in circuit
[circuit 98(+)] to ground. At gnd. step. 98(+)/98A(+) between
resistance at terminal A (220), then repair.
[circuit 98A(+)] to ground.
8. Off With connector (955) (421), 47/ < 5 ohms. Go to Locate open or poor
terminal 26 [circuit 98(+)] 48(+) to next connection in circuit
still jumpered to ground, at gnd. step. 47/48(+) between
resistance to ground at (421), then repair.
circuit 47/48(+).
between ECM connector
(955), diagnostic
connector (220) and
speedometer/ tachometer
connector (421) test good.
3.13. DIAGNOSTIC ON/OFF SWITCH AND CIRCUITS

The diagnostic On/Off switch can be checked with EZ-Tech or Pro-Link 9000 EST in the switch monitoring
mode. If the switches do not operate properly, perform the following test.
Testing Diagnostic On/Off Switch And Circuits
Table 70 Testing Diagnostic On/Off Switch And Circuits

POINTS SPEC.
1. Off Remove connector (234) Across < 5 ohms. Go to Replace the switch.
from on/off switch. With switch next
switch in on position, terminals 5 step.
measure resistance and 6.
between terminals 5 and
6.
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Table 70 Testing Diagnostic On/Off Switch And Circuits (cont.)

POINTS SPEC.
2. Off With switch in off position, Across > 100K Go to Replace the switch.
measure resistance switch ohms. next
between terminals 5 and terminals 5 step.
6. and 6.
switch, connect B+ test next
lead to terminal 7 and step.
connect terminal 8 to
ground. Does LED
illuminate?
(955) from the ECM. next connector terminals
Inspect connector. ECM step. if damaged. If ECM
harness connector and pins are damaged,
ECM pins OK? have Cummins
dealer replace
ECM. Refer to
Accelerator/ECM
Calibration to
recalibrate ECM/
accelerator pedal.
5. Off Disconnect connector (955), 97AM > 100K Go to Locate short to
(955) and measure to gnd. ohms. next ground in circuit
resistance to gnd. at step. 97AM, then repair.
terminal 44 (circuit 97AM)
to ground.
6. Off At connector (955) (955), 97-GA > 100K Go to Locate short to
measure resistance to gnd. ohms. next ground in circuit
from terminal 10 (circuit step. 97-GA, then repair.
97-GA) to ground.
7. Off Set service brakes using (955), 97AM > 100K Go to Locate short between
trailer hand control to all other ohms. next circuits where
valve, with clutch switch circuits. step. resistance between
disconnected, measure terminals is less than
resistance between 100K ohms, then
terminal 44 (circuit 97AM) repair.
(955).
8. Off At connector (955), (234), 97AM < 5 ohms. Go to Locate open or poor
use test lead to jumper to gnd. next connection in circuit
terminal 44 (circuit 97AM) step. 97AM between
to ground at circuit 97AM.
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Table 70 Testing Diagnostic On/Off Switch And Circuits (cont.)

POINTS SPEC.
9. Off At connector (955), use (234), 97-GE < 5 ohms. Go to Locate open or
test lead and jumper to gnd. next poor connection in
terminal 10 (circuit 97-G) step. circuit 97-GE, 97-GA
to ground. At connector or 97-G between
(234) measure resistance connectors (234) and
to ground at circuit 97-GE. (955), then repair.
9. Off The diagnostic on/off
good.
3.14. CRUISE CONTROL

When monitoring switches with an Electronic Service Tool, the cruise On/Off switch will indicate on or off.
The Set/Resume switch will indicate either Set or Res, depending on the switch position. If the switch is
not operable, the screen will be blank.
Testing Cruise Control On/Off Switch and Circuits
Table 71 Testing Cruise Control On/Off Switch and Circuits

POINTS SPEC.
1. Off Remove connector (419) Across < 5 ohms. Go to Replace the switch.
from cruise On/Off switch. terminals next
With switch in on position, 5 and 6. step.
measure resistance
6.
2. Off With switch in off position, Across > 100K Go to Replace the switch.
measure resistance terminals ohms. next
between terminals 5 and 5 and 6. step.
6.
ground. Does LED
illuminate?
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Table 71 Testing Cruise Control On/Off Switch and Circuits (cont.)

POINTS SPEC.
4. Off Remove ECM connector ECM Go to Replace harness
(955) from the ECM and harness next connector terminals
inspect. ECM harness connector step. if damaged. If ECM
connector and ECM pins and ECM pins are damaged,
OK? pins OK. have Cummins
dealer replace ECM.
Refer to Accelerator/
ECM Calibration to
recalibrate ECM/
accelerator pedal.
5. Off At ECM connector (955) (955), > 100K Go to Locate short to ground
use test leads and 97AE and ohms. next in circuit with less
measure resistance to 97-G to step. than 100K ohms, then
ground at terminals 23 gnd. repair.
and 10 (circuit 97AE and
97-G).
6. Off At connector (955) (955), > 100K Go to Locate short between
measure resistance 23 to ohms. next circuit 97AE and
between terminal 23 and all other step. any circuit where
all other terminals in terminals. resistance between
connector. terminals is less than
100K ohms, then
repair.
7. On At connector (955) (955), < 1.5 volts. Go to Locate short between
measure voltage from 97AE to next circuit 97AE and
terminal 23 (circuit 97AE) gnd. step. unwanted voltage
to ground. source, then repair.
8. Off At connector (955) use (419), < 5 ohms. Go to Locate open or
test lead to jumper 97AE to next poor connection in
terminal 23 (circuit 97AE) gnd. step. circuit 97AE between
to ground at circuit 97AE.
9. Off Measure the resistance Between < 5 ohms. Go to Locate open or poor
between connector (955), (955), next connection in circuit
terminal 10 (circuit 97-G) terminal step. 97-GC, 97-GA or 97-G,
and connector (419), 10 and then repair.
circuit 97-GC. (419),
97-GC.
10. Off The cruise On/Off switch
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Testing Cruise Set/Resume Switch and Circuits
Table 72 Testing Cruise Set/Resume Switch and Circuits

POINTS SPEC.
1. Off Remove connector (418) Between < 5 ohms. Go to Replace the switch.
from cruise set/resume switch term. next
switch. With switch in 2 and 3. step.
resistance between
terminals 2 and 3.
2. Off With switch in neutral Between > 100K Go to Replace the switch.
position, measure switch term. ohms. next
resistance between 1, 2 and 3. step.
terminals 1, 2 and 3.
3. Off With switch in resume Between < 5 ohms. Go to Replace the switch.
position, measure switch term. next
resistance between 1 and 2. step.
terminals 1 and 2.
ground. Does LED
illuminate?
5. Off Remove ECM connector ECM Go to Replace harness
(955) from the ECM and harness next connector terminals
inspect. ECM harness conn. and step. if damaged. If ECM
connector and ECM pins ECM pins pins are damaged,
OK? OK. have Cummins
dealer replace
ECM. Refer to
Accelerator/ECM
Calibration to
recalibrate ECM/
accelerator pedal.
6. Off At ECM connector (955) (955), 97AB > 100K Go to Locate short to
use test leads and to 97AA to ohms. next ground in circuit
measure resistance to gnd. step. with less than 100K
ground at terminals 24 ohms, then repair.
and 14 (circuit 97AB and
97AA).
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Table 72 Testing Cruise Set/Resume Switch and Circuits (cont.)

POINTS SPEC.
7. Off At connector (955) (955) > 100K Go to Locate short
measure resistance between ohms. next between any circuits
between terminal 24 97AB and step. where resistance
and 14 (circuits 97AB 97AA, and between terminals
and 97AA), and all other all others. is less than 100K
terminals in the connector. ohms, then repair.
8. On At connector (955) (955), 97AB < 1.5 volts. Go to Locate short to
measure voltage to and 97AA next unwanted voltage
ground at terminals 24 to gnd. step. source in circuit
and 14 (circuits 97AB and 97AA or 97AB, then
97AA). repair.
9. Off At connector (955) use (418), 97AB < 5 ohms. Go to Locate open or
test lead to jumper to gnd. next poor connection in
terminal 24 (circuit 97AB) step. circuit 97AB between
to ground at circuit 97AB.
10. Off Measure the resistance Between < 5 ohms. Go to Locate open or poor
between connector (955), (955), next connection in circuit
terminal 10 (circuit 97-G) term. 10 step. 97-GC, 97-GA or
and connector (418), and (418), 97-G, then repair.
circuit 97-GB. 97-GB.
11. Off At connector (955) use (418), 97AA < 5 ohms. Go to Locate open or
test lead to jumper to gnd. next poor connection in
terminal 24 (circuit 97AA) step. circuit 97AA between
to ground at circuit 97AA.
12. Off The cruise set/resume
good.

When monitoring engine functions with an EST, if the vehicle is moving the miles-per-hour will display as
MPH=XXX (actual vehicle speed if operating properly). To test the sensor and circuits to the ECM, use the
following charts.
Inspecting And Adjusting the Vehicle Speed Sensor (VSS)
one full turn. Tighten lock nut to 15 ft-lbs. (20.3 N•m). This assures that the sensor is adjusted properly
for the next test.
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Testing Vehicle Speed Sensor
Construct test leads using terminals (Navistar Part No. 1680205C1), short length of 16 gauge wire and
alligator clips.
Table 73 Testing Vehicle Speed Sensor

POINTS SPEC.
1. Off Inspect VSS for damage Go to
and proper adjustment next
before performing this step.
test. Refer to Inspecting
and Adjusting the Vehicle
Speed Sensor (VSS)
above.
2. Off Disconnect engine VSS, 600 to Go to Replace the vehicle
harness (962) from VSS terminal 1 800 next speed sensor (VSS).
and use test leads to to 2. ohms. step.
measure resistance
between terminal 1 and 2
of sensor connector.
3. Off Measure resistance to VSS, term. > 100K Go to Replace the vehicle
ground at both sensor 1 and 2 to ohms. next speed sensor (VSS).
terminals. gnd. step.
4. Off Block front wheels and Go to
place rear axles on floor next
stands. step.
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Table 73 Testing Vehicle Speed Sensor (cont.)

POINTS SPEC.
5. Off Use AC voltmeter with Go to
sufficient length leads to next
avoid personal contact step.
with rotating vehicle
wheels during test.
Connect meter leads
to test leads.
6. Off Run engine at idle speed, VSS, >2.0 volts VSS Replace the VSS
with transmission in high across AC checks (refer to Inspecting
gear. Measure voltage terminals. good. And Adjusting The
across the two sensor Vehicle Speed Sensor
terminals. (above). Note:
Improper sensor
adjustment will
cause low, erratic
or no output.
Testing Vehicle Speed Sensor Circuits To ECM
To check circuits between the ECM and the speedometer/tachometer unit, refer to ATA Data Link Connector
(220) and Speedometer/Tachometer Input Circuits.
Table 74 Testing Vehicle Speed Sensor Circuits To ECM

POINTS SPEC.
1. Off Remove connector (962) Go to Replace harness
from vehicle speed sensor. next connector terminals
Remove ECM connector step. if damaged. If ECM
(957) from the ECM and pins are damaged,
inspect. ECM harness have Cummins
connector and ECM pins dealer replace ECM.
OK? Refer to Accelerator/
ECM Calibration to
recalibrate ECM/
accelerator pedal.
2. Off At connector (957), use (957), 97AJ > 100K Go to Locate short to ground
test leads and measure and 97AK ohms. next in circuit with less
resistance to ground to gnd. step. than 100K ohms, then
at terminals 21 and 22 repair.
(circuits 97AJ and 97AK).
3. Off At connector (957), (957), 97AJ > 100K Go to Locate short circuit
measure resistance and 97AK ohms. next between circuits where
between terminals 21 and all step. resistance between
and 22 (circuits 97AJ others. terminals is less than
and 97AK) and all other 100K ohms, then
terminals in connector. repair.
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Table 74 Testing Vehicle Speed Sensor Circuits To ECM (cont.)

POINTS SPEC.
4. On At connector (957), (957), 97AJ < 1.5 Go to Locate short to
measure voltage at and 97AK volts. next unwanted voltage
terminals 21 and 22 to gnd. step. source in circuit where
(circuits 97AJ and 97AK) voltage at terminal is
to ground. more than 1.5 volts,
then repair.
5. Off At connector (957) use (962), 97AJ < 5 ohms. Go to Locate open or
test leads and jumper to gnd. next poor connection in
terminal 21 (circuit 97AJ) step. circuit 97AJ between
to ground at circuit 97AJ.
6. Off At connector (957) use (962), < 5 ohms. Go to Locate open or
test leads and jumper 97AK to next poor connection in
terminal 22 (circuit 97AK) gnd. step. circuit 97AK between
to ground at circuit 97AK.
7. Off The vehicle speed sensor
circuits between the
sensor and ECM check
good.
B3 Circuit Breaker/Fuse/Resetting. . . . . . . . . . . . . . . . . .. . . . . . Under mag. switch cover near battery box
F9–F13 Fuseblock (464). . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
L1 LED Panel Lt Feed Adapt (504). . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
L3 LED Panel Lt Ground Adapt (505). . . . . . . . . . . . . . .. . . . . . Behind switch cluster
bracket
(102) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor, ft. rt.
(234) Diagnostic On/Off Switch. . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(263) Eng. Control Module W/Celect. . . . . . . . . . . . . . .. . . . . . On left side of engine, at rear of ECM
(307) Low Coolant Level Switch. . . . . . . . . . . . . . . . . . . . .. . . . . . On surge tank, rear of engine
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(595) Data Link Connector. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, lt. side, near (55)
(955) ECM 50–Way Connector. . . . . . . . . . . . . . . . . . . . . .. . . . . . At ECM
(957) ECM Interface 31–Way Connector. . . . . . . . . . .. . . . . . At engine harness near ECM
(958) J1939 Term. Resistor. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Located by engine ECM
(959) J1939 Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Located by engine ECM
(960) J1939 Backbone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Located near cab floor, front right
(962) Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On transmission
See Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8, Figure 9, Figure 10, Figure
11, and Figure 12.
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Figure 97 Cummins ISM Engine Wiring
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Figure 103 Cummins ISM Engine Wiring — Alternator Connections
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Figure 105 Cummins ISM Engine Wiring — Starter Effects
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8 DETROIT DIESEL SERIES 60 ENGINE 295
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
2.1. ENGINE SHUTDOWN OVERRIDE/DIAGNOSTIC SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
2.2. ATA DATA LINK CONNECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
2.3. IDLE SHUTDOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
2.4. COOLANT SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
2.6. CRUISE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
2.7. VEHICLE SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
2.8. CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
2.9. BRAKE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
2.10. IDLE TIMER/PARK BRAKE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
2.11. ENGINE BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
2.12. OPTIMIZED IDLE™ (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
Engine Start Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
Blower Disable Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
Thermostat Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
Alarm and Indicator Light Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
3.1. DETERMINING FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Diagnostic On/Off/Shutdown Override Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
EZ-Tech and PRO-LINK 9000 Electronic Service Tools (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
3.2. INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
Before Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
Testing Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
3.3. ACCELERATOR PEDAL (TPS/IVS) — DETROIT DIESEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
Testing Throttle Position Sensor (TPS) — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
Testing Idle Validation Switch (IVS) — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
Testing Accelerator Pedal (TPS/IVS) Circuits — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
3.4. DIAGNOSTIC CONNECTOR (220) AND DATA LINK CIRCUITS INCLUDING
SPEEDOMETER/TACHOMETER INPUT CIRCUITS — DETROIT DIESEL. . . . . . . . . . . . . . . . . . . . . . .308
Testing Diagnostic Connector Power and Ground Circuits — Detroit Diesel. . . . . . . . . . . .308
Testing ATA Data Link Circuits — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309
3.5. CRUISE/PTO CONTROL SYSTEM AND RELATED COMPONENTS — DETROIT DIESEL. . .310
Testing Clutch Switch — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
Testing Service Brake Switch And Circuits — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
Testing Cruise On/Off Switch — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313
Testing Cruise Set/Resume Switch And Circuits — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . .315
3.6. VEHICLE SPEED SENSOR (VSS) — DETROIT DIESEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316
Inspecting And Adjusting the Vehicle Speed Sensor (VSS) — Detroit Diesel. . . . . . . . . . .316
Testing Vehicle Speed Sensor (VSS) — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
Testing Vehicle Speed Sensor (VSS) Circuits To ECM — Detroit Diesel. . . . . . . . . . . . . . . . . .318
3.7. ENGINE BRAKE SYSTEM — DETROIT DIESEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
Testing Engine Brake Switches and Circuits — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
3.8. DIAGNOSTIC ON/OFF/SHUTDOWN OVERRIDE SWITCH (332) — DETROIT DIESEL. . . . . . .321
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296 8 DETROIT DIESEL SERIES 60 ENGINE
Testing Diagnostic On/Off/Shutdown Override Switch — Detroit Diesel. . . . . . . . . . . . . . . . .321

3.9. PARK BRAKE (IDLE TIMER) SWITCH (328) — DETROIT DIESEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
Testing Park Brake Switch (328) and Circuits — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . .323
3.10. ECM POWER SUPPLY (SWITCHED AND UNSWITCHED) — DETROIT DIESEL. . . . . . . . . . . . .324
Testing Unswitched Battery Power To ECM At Connector (N/L) — Detroit Diesel. . . . . .324
Testing Switched Battery Power To ECM — Detroit Diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326
3.11. OPTIMIZED IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328
Testing Optimized Idle Safety Loop Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328
Testing Ignition and Idle Relay Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331
Testing Heater Blower Disable Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334
Testing Optimized Idle Thermostat Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
Testing Optimized Idle Active Indicator Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
Testing Optimized Idle Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
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Model: 9800
1. DESCRIPTION
The Detroit Diesel Electronic Control system (DDEC III) provides an electronic fuel control system, electronic
engine protection and other operational controls.
DDEC III is standard on Series 60 engines and provides many engine/vehicle functions including:
• Automatic Idle Shutdown Timer (3–100 Minutes)
• Engine Diagnostics
• Engine Cooling System
• Speedometer/Tachometer Input Signals
• ABS/Traction Control Interface
Refer to Detroit Diesel manual furnished with the vehicle for additional feature information.
Since each Series 60 DDEC III system is electronically programmable to individual owner specifications, the
maximum road speed settings and many others.
The “brain” of the DDEC III system is the Electronic Control Module (ECM), located on the left side of the
engine. The ECM receives inputs from the following Navistar components:

• Park Brake Switch
• Clutch Switch
• Low Coolant Level Sensor
• Cab Switches.
The ECM receives inputs from sensors and switches, then outputs signals to the injectors, engine brake relay
and other system components.
2. OPERATION
2.1. ENGINE SHUTDOWN OVERRIDE/DIAGNOSTIC SWITCH
The lighted two-position momentary engine shutdown override/diagnostic switch is a dual function switch. The
switch overrides the engine shutdown and enables the on-board diagnostics.
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The switch is connected to the negative battery terminal by way of circuits 97-GD, and 97-GA, connector (262),
circuits 97-GA and 97-G, connector (N/L), circuits 97-G and 11-G, connector (N/L), and circuit 11-G to the
negative battery terminal. The switch is connected to the ECM by way of circuit 97AU, connector (262), and
circuit 97AU to ECM (341). Closing the switch causes the voltage state of circuit 97AU to change to ground,
indicating to the ECM that the switch has been toggled to the on position. Thus the ECM will switch modes to
display fault codes or the absence of codes by flashing the engine warning light and the stop engine light. The
red stop engine light will flash the active codes and the yellow engine warning light will flash the inactive codes.
2.2. ATA DATA LINK CONNECTOR

between the ECM and the speedo/tachometer cluster. Thus the ECM provides vehicle and engine information
• Circuit 98A(+) is the positive data link connection and it is fed by the positive data link connector (514), the
• Circuit 98C(-) is the negative data link connection and it is fed by the negative data link connector (515), the
jumper bus bar, circuit 98B(-), connector (262), and circuit 98B(-) coming from the ECM connector (341).
• Circuit 97DL is a 12 volt circuit and is fed from B1 Battery Stud to circuits 14K and 14AL, through 5A fuse
• Circuit 11–GR is connected to the G5 ground adapter (533), and provides a ground for the electronic
service tool.
2.3. IDLE SHUTDOWN

The customer selectable idle shutdown feature shuts down the engine (does not shut down power to the cab)
after a customer selected (programmed) length of time between 3 and 100 minutes. The timer (an ECM
function) begins counting when the parking brake is set [which closes the park brake/idle timer switch (328)],
the engine temperature is above 104°F/40°C, the engine speed is at idle rpm, and the ECM does not see any
clutch or brake pedal operation. Switch (328) is grounded through circuits 97-GE, 97-GA, connector (262),
circuits 97-GA, 97-G and 11-G to the battery ground. The switch then applies a ground signal by way of circuit
97AV, connector (262) and circuit 97AV to the ECM (341).
If these conditions are present, the ECM counts down the customer selected length of time until 90 seconds
before the scheduled engine shutdown is to occur. At this time the yellow engine warning light begins to flash
rapidly. The idle timer can be disabled by depressing the accelerator pedal. This will allow the idle timer to be
overridden if longer idle time is wanted. The shutdown timing sequence can be re-started by releasing and
re-applying the parking brake.
If the idle timer shuts the engine down, fueling is stopped, but ignition voltage is still present to the ECM on
circuit 16D at connector (341).
NOTE – The key switch must be cycled to off and back to on before the engine will start.
NOTE – The engine is shut down, but power to the cab is not turned off.
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2.4. COOLANT SENSOR

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

DDEC engines use an electronic accelerator pedal assembly that includes a throttle position sensor (TPS)
and idle validation switch (IVS) function. The TPS/IVS sensor assembly is not serviceable, and if defective,
must be replaced.
The TPS acts like a potentiometer, and movement of the pedal results in a variable signal being sent to the
ECM. This signal is proportional to the pedal position. A five volt signal from the ECM (341) is sent through
circuit 99A, connector (262), and circuit 99A to the potentiometer of TPS/IVS (306). The variable potentiometer
signal is returned from the TPS/IVS (306) over circuit 99, connector (262), and circuit 99 to the ECM (341).
This signal varies with pedal position and tells the ECM the position of the accelerator pedal. The TPS/IVS
(306) potentiometer is grounded through circuit 99-R, connector (262), and circuit 99-R to the ECM (341).
The IVS is used to verify when the accelerator pedal is in the idle position. One side of the idle validation
switch (306) is connected to circuit 99B, connector (262), and circuit 99B to the ECM (341). The ECM sets
this input at 5 volts, and when the throttle is at idle, a ground is applied to this input by the idle validation
switch (306). This ground pulls the input voltage down to nearly zero, telling the ECM that the accelerator
pedal is in the idle position. The ground path that is applied by the IVS (306) is through circuits 99-GA and
97-GA, connector (262), circuits 97-GA and 97-G, connector (N/L), circuits 97-G and 11-G, connector (N/L),
and circuit 11-G to the negative battery terminal.
The ECM analyzes the signals received from the TPS/IVS, making certain that the signals fall within certain
parameters. For example, if the IVS signal indicates that the pedal is in the idle position, the ECM expects to
see a TPS signal that indicates no throttle (or very little) is being applied. If the ECM does not see a logical
response from both, a fault code will be logged. The TPS/IVS timing cannot be checked using a multimeter.
2.6. CRUISE CONTROL

The cruise control operates when vehicle speed is greater than 20 mph and engine speed is greater than 1100
rpm. The vehicle speed signal used by the ECM to control the cruise system comes from the Navistar installed
vehicle speed sensor. The PTO mode is activated when vehicle speed is zero and the park brake is set [park
brake switch (268) contacts open]. Releasing the park brake disables the PTO controls.
The cruise control and PTO systems share the same components, which include a cruise on/off switch (419),
cruise set/resume switch (418), service brake switch (5), idle timer/park brake switch (328), clutch pedal switch
(55), and vehicle speed sensor (225).
The lighted cruise on/off switch (419) is connected by circuit 97AE, connector (262), and circuit 97AE to the
ECM (341). The other side of switch (419) is connected through circuits 97-GC, 97-GA, connector (262),
circuits 97-GA and 97-G, connector (N/L), circuits 97-G and 11-G, connector (N/L), and circuit 11-G to negative
battery stud. With the switch in the on position, the voltage state at the ECM input changes to ground, telling
the ECM that the switch is in the on position.
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The lighted set/resume switch (418) is connected by circuit 97AB, connector (262), and circuit 97AB to the
ECM (341). The switch is also connected by circuit 97AA, connector (262), and circuit 97AA to the ECM (341).
The switch (418) is connected by circuits 62-GK and 11-GJ to the L3 panel lights ground adapter (505).
With the switch held in the set position, circuit 97AB is switched to ground, signaling the ECM. With the switch
held in the resume position, circuit 97AA is switched to ground, signaling the ECM.

The vehicle speed sensor (225) feeds a VSS signal to the ECM (341) by way of circuits 97AJ and 97AK.
2.8. CLUTCH SWITCH

The clutch switch (55) is a normally open (N.O.) switch that is adjusted so that its contacts are closed when the
clutch pedal is in the released position. Depressing the clutch pedal causes the switch contacts to open.
The clutch switch is connected by circuit 97AH, connector (262), and circuit 97AH to the ECM (341). The other
side of the switch is connected through circuits 97-GH, 97-GA, connector (262), circuits 97-GA and 97-G,
connector (N/L), circuits 97-G and 11-G, connector (N/L), and circuit 11-G to negative battery stud.
2.9. BRAKE SWITCH

The service brake switch (5) is a normally closed (N.C) air operated switch. Its contacts are closed when the
brakes are not applied, and its contacts open up when the brakes are applied. One terminal of the service
brake switch (5) is connected to circuit 97AL, connector (262), circuit 97AL and the ECM (341). The other
terminal of the switch is connected to ground by way of circuits 97-GF and 97-GA, connector (262), circuits
97-GA and 97-G, connector (N/L), circuits 97-G and 11-G, connector (N/L), and circuit 11-G to the negative
terminal of the batteries.
2.10. IDLE TIMER/PARK BRAKE SWITCH

The customer selectable idle shutdown feature shuts down the engine [does not shut down power to the
cab] after a customer selected [programmed] length of time between 3 and 100 minutes. The timer [an
ECM function] begins counting when the parking brake is set [which closes the park brake switch (268)], the
engine temperature is above 104°F/40°C, the engine speed is at idle rpm, and the ECM does not see any
clutch or brake pedal operation.
If these conditions are present, the ECM counts down the customer selected length of time until 90 seconds
before the scheduled engine shutdown is to occur. At this time the yellow engine warning light begins to
flash rapidly.
The idle timer can be disabled by depressing the accelerator pedal. This will allow the idle timer to be
overridden if longer idle time is wanted. The shutdown timing sequence can be re-started by releasing and
re-applying the parking brake.
If the idle timer shuts the engine down, fueling is stopped, but ignition voltage is still present to the ECM on
circuit 13D at connector (341).
NOTE – The key switch must be cycled to off and back to on before the engine will start.
NOTE – The engine is shut down, but power to the cab is not turned off.
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The idle timer/park brake switch (328) is an air operated normally closed (N.C.) switch. Its contacts are closed
when the parking brakes are applied, and its contacts open up when the brakes are released. One terminal
of the idle timer switch (328) is connected to circuit 97AV, connector (262), circuit 97AV and the ECM (341).
The other terminal of the switch is connected to ground by way of circuits 97-GE and 97-GA, connector
(262), circuits 97-GA and 97-G, connector (N/L), circuits 97-G and 11-G, connector (N/L), and circuit 11-G to
the negative terminal of the batteries.
2.11. ENGINE BRAKE

The driver controls the engine brake on/off and selector switches, but the ECM enables or disables the system
by way of a relay in response to the engine throttle position. The ECM enables the relay whenever the engine
speed is 150 rpm greater than idle rpm, and the throttle is in the idle position.
The engine brake can provide braking when the vehicle is in the cruise control mode. For example, if the
vehicle is in the cruise control mode, going down hill, and the engine brake is selected, the ECM will control the
engine brake with respect to the cruise control set speed. The amount of braking will not exceed the number
of cylinders selected at the brake selector switch.
If the vehicle is equipped with antilock brakes, the ECM will share information with ABS controller module
(627) over circuit 98Z(+), connector (657), and a pink wire. Information is also shared over circuit 98Y(-),
connector (657), and a light blue wire.
The lighted two position engine brake on/off switch (412) receives a ground signal on circuits 24-GA and
97-GA, connector (262), circuits 97-GA and 97-G, connector (N/L), circuits 97-G and 11-G, connector (N/L),
and circuit 11-G to the negative terminal of the batteries. In the on position, a ground is applied by the switch
on circuit 24AJ to the engine brake selector switch (411).
When switch (411) is placed in the center position, position 1, a ground is applied to circuit 24AF, connector
(262), and circuit 24AF to the ECM (341). This tells the ECM to enable the brake solenoid for two of the
cylinders.
When switch (411) is placed in position 2, a ground is applied to circuit 24AE, connector (262), and circuit
24AE to the ECM (341). This tells the ECM to enable the brake solenoids for four of the cylinders.
When switch (411) is placed in position 3, a ground is applied to circuit 24AE, connector (262), and circuit
24AE to the ECM (341), and circuit 24AF, connector (262), and circuit 24AF to the ECM (341). This tells the
ECM to enable the brake solenoids for all six of the cylinders.
2.12. OPTIMIZED IDLE™ (OPTIONAL)

Refer to Detroit Diesel manual furnished with the vehicle for additional feature information.
The Detroit Optimized Idle is a system that automatically starts and stops the engine to maintain oil temperature
and battery voltage. The system will disable all heater blowers to conserve battery voltage as required.
The Optimized Idle system can also be used to automatically start and stop the engine to maintain sleeper
temperature. A thermostat in the sleeper compartment is utilized to maintain cab temperature. The inside
thermostat is set for a desired temperature and a range is selected. The engine is then started and stopped as
required to maintain inside temperature. The system is controlled by the ECM.
The system is initiated when the ignition is on, the engine is idling, the transmission is in neutral, the cab is
lowered, the idle shutdown timer in the ECM must be enabled, and the cruise control must be cycled from off to
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on. An indicator lamp on the dash will be illuminated when the Optimized Idle is active. An alarm in the engine
compartment will sound for 5 seconds with an additional 2 second delay prior to engine startup.
The Optimized Idle system utilizes three switches to prevent unwanted starts. A transmission neutral safety
switch, park brake switch and cab tilt switch are wired in series and help prevent a driverless launch of the
vehicle. If any of the switches are open the system will not function. If any of the switches are shorted to ground
during normal operation a fault will be logged and the system will be disabled until the problem is corrected. If
the switches go to ground during engine operation the speed and toque drop to normal idle operation.
The ECM also senses the vehicle speed and engine speed. If the engine speed fails to reach 200 RPM within
2 seconds during cranking the start is aborted. If the vehicle speed sensors record two counts during cranking
the start will be aborted. If two starts are aborted the system is disabled. While running in the Optimized Idle
mode, if the vehicle speed sensor detects two counts or the required torque exceeds 25% of the available
torque, the engine is shut down. This provides additional protection against driverless launches.
Engine Start Circuits
The Idle Timer Switch supplies a ground on circuit 97AV, to connector (262), terminal R. The ground continues
on circuit 97BD through the Neutral Position Switch (918) to circuit 97BB and connector (102/338). Circuit
97BB goes to connector (920) and the Hood Closure Switch. Circuit 97BH comes from (920) and is split into
circuit 97BF, to Idle Relay (482) and into circuit 97BA, through (102/308) to circuit 97AV, to ECM connector
(341) terminal H2.
The ground on circuit 97BH at Idle Relay (482) will energize the relay. 12 Volts to the relay coil comes from
I2 Ignition adapter (607-C) on circuit 13BA, through fuse F10-A, to circuits 17C, 17E, 17F. 12 Volts on
circuit 17T will be applied through the relay contacts to circuits 17P. Circuit 17P supplies 12 volts to the coil
of Ignition Relay (483).
Ignition Relay (483) will be energized by a ground from the ECM connector (913), terminal B through connector
(262) on circuit 17H. The energized relay applies 12 volts to Start Feed Adapter (509-B) from circuit 17E. This
will engage the engine starter.
The 10K resistor (782) provides a current path to the Ignition Relay (483) to allow the ECM to monitor the coil
for an open condition.
Blower Disable Circuits
12 volts is supplied to Heater Relay (463-R5) from Ignition Relay (462-R1) on circuits 13H and 13T through
Heater Control Diode (783) to circuit 13TA. The relay is energized when a ground is supplied from ECM
connector (341) terminal F3, circuit 75BB. This ground also controls Sleeper Medium Speed Relay (480),
Sleeper High Speed Relay (481) and Bunk blower Relay (441).
Thermostat Circuits
12 volts is supplied to Thermostat (910), terminal 5 from I3 Ignition Adapter (496-G) on circuit 13BN through
fuse F10-B to circuit 75BD, connector (911) and (909). Ground on (910) terminal 6 comes from G2 Gnd.
Adapter (455-C) on circuit 75-GE through connector (911) and (909). Thermostat (910) terminal 4 is the
input to the ECM (913) on circuit 75BC. Thermostat (910) terminals 1 and 3 are connector to a thermistor
which senses the sleeper temperature.
Alarm and Indicator Light Circuits
12 volts from I2 Ignition Adapter (607-C) on circuit 13BA through fuse F10-A to circuit 17C. 17C is split into
circuit 17K, which connects to Indicator Light (912), and circuit 17M, which connects to Alarm (916).
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The Indicator Light is turned on by a ground supplied from ECM connector (914) terminal B on circuits 17LA
and 17L through connector (262) to the Indicator Light (912).
The Alarm is turned on by a ground supplied from ECM connector (913) terminal A on circuit 17N through
connector (915) to Alarm connector (916).
3. TROUBLESHOOTING
C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires,
etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in the GROUP 08 —
relay, or solenoid.
3.1. DETERMINING FAULT CODES

The ECM continuously monitors itself and other system components, including sensors, injectors, connectors
and associated wiring.
The yellow Engine Warning Light is turned on if a minor fault occurs. A fault code is also logged. This
indicates the problem should be diagnosed as soon as possible.
The ECM turns on the yellow Engine Warning Light and the red Stop Engine Light and stores a fault code
if a major fault is detected. If this occurs, the vehicle should be brought to a safe stop and the engine shut down.
A diagnostic check may be performed using the diagnostic on/off switch, the EZ-Tech or Pro-Link 9000 EST.
Diagnostic On/Off/Shutdown Override Switch
The diagnostic on/off switch is used to signal the ECM to flash the yellow Engine Warning light and the red
Stop Engine light with flash codes. The red Stop Engine light will flash the ACTIVE codes and the yellow
Engine Warning light will flash the INACTIVE codes.
If no fault codes are logged, the code "25" will be flashed out on the yellow Engine Warning Light. For example,
the yellow Engine Warning light blinks out: FLASH, FLASH. The first digit is a 2, then a half-second pause:
FLASH, FLASH, FLASH, FLASH, FLASH. The second digit is a 5. Code 25 is System OK.
The diagnostic on/off switch is used to flash codes in the following circumstances:
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A. When the engine is not running and the ignition switch is on, toggling and releasing the diagnostic
on/off switch will flash out the engine codes. Toggling then releasing the diagnostic on/off switch a
second time will stop the ECM from flashing the codes.
B. When the engine is idling and not in an "engine protection condition," toggling and releasing the
diagnostic on/off switch will flash out the engine codes. Toggling then releasing the diagnostic
on/off switch a second time will stop the ECM from flashing the codes.
NOTE – All Series 60 fault codes are 2 digits.
The Detroit Diesel Troubleshooting Manual contains flash code descriptions and diagnostic procedures.
If the fault code(s) or symptoms indicate a need to troubleshoot a Navistar installed circuit or component,
procedures are included in this chapter or other CTS-5000 Master Service Manual sections.
EZ-Tech and PRO-LINK 9000 Electronic Service Tools (EST)
The EZ-Tech or the PRO-LINK 9000 electronic service tools (EST) with a Series 60 program can be used to
read logged fault codes and monitor many of the system switches and operating parameters. Refer to the
EZ-Tech and PRO-LINK 9000 manuals for information on using the EST.
Navistar vehicles include an 6-way diagnostic connector used to access the system with an EST.
The diagnostic tables in this section are not designed for specific symptoms, but designed to test those circuits
and components installed by Navistar. Use DDEC III diagnostics procedures to identify the suspect circuit or
system, then use the procedures included in this section to troubleshoot the specific Navistar circuit.
3.2. INSPECTION
NO TESTS in this section require testing "into" the DDEC ECM.
Before Troubleshooting
A. Before troubleshooting, make sure that the vehicle batteries are fully charged!Check battery
cables and grounds for clean, tight connections free of damage and corrosion. Many of the voltage
tests included in the procedures will give misleading readings if the batteries are not fully charged.
B. Before troubleshooting a particular circuit, inspect connectors for pushed back, loose or damaged
(spread or bent), or corroded terminals, or wires with cut strands, etc. The wires and connections
must be free of damage or corrosion. When some connectors corrode, a light white residue will
be present that must be removed.
C. Before troubleshooting, inspect the suspect circuit grounds for clean, tight connections free of
damage or corrosion.
Testing Relays
International circuits use suppressed relays for controlling power to load devices (Figure 1). The suppression
feature (a resistor circuit parallel to the relay coil) prevents voltage spikes from damaging electronic
components in the vehicle. These relays must be replaced with approved International parts.
Figure 106 Typical Relay
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The part number and relay circuit diagram are embossed on the relay body. The terminals are numbered on
the relay in the same manner as in the circuit diagrams.
Relay Test Procedure

1. With relay removed, measure resistance between terminals 30 and 87A. If resistance is less than 5
ohms, go to step 2; otherwise replace the relay.
2. Measure resistance between terminals 30 and 87. If resistance is 100K ohms or more, go to step 3;
otherwise replace the relay.
3. Using 12V battery source and test leads, connect (+) lead to terminal 85 and (-) lead to terminal 86. If relay
energizes with an audible click sound, go to step 4; otherwise replace the relay.
4. While relay is energized, measure resistance between terminals 30 and 87. If resistance is less than 5
ohms, go to step 5; otherwise replace the relay.
5. While relay is energized, measure resistance between terminals 30 and 87A. If resistance is 100K ohms or
more, the relay is good; otherwise replace relay.
3.3. ACCELERATOR PEDAL (TPS/IVS) — DETROIT DIESEL

Review the circuit diagram and inspect the TPS circuits and connectors as outlined in Before Troubleshooting.
The following 3 tests, Testing Throttle Position Sensor (TPS) — Detroit Diesel, Testing Idle Validation Switch
(IVS) — Detroit Diesel and Testing Accelerator Pedal (TPS/IVS) Circuits — Detroit Diesel, check the TPS/IVS
connection and related International cab and engine harness connections leading to the ECM.
NOTE – The following 3 tests must be performed in sequence.
Testing Throttle Position Sensor (TPS) — Detroit Diesel
This test checks the TPS circuits in the accelerator pedal assembly. This test will identify if the resistance of
the pedal circuits is within specifications.
Table 75 Testing Throttle Position Sensor (TPS) — Detroit Diesel

STEP KEY ACTION TEST POINTS SPEC. YES-IN NO-OUT OF
SPEC. SPEC.
1. Off Disconnect the accelerator At accelerator 2000 to Go to next Replace
pedal from cab harness pedal (306), A 3000 step. TPS/IVS
connector (306). At the to C. ohms. sensor.
pedal side of (306) measure
resistance between
terminals A and C with the
pedal in the idle position,
then with the pedal fully
depressed. Resistance
should be 2000 to 3000
ohms in all positions.
2. Off With the pedal at idle, at At accelerator 1500 to Go to next Replace
connector (306) measure pedal (306), B 3000 step. TPS/IVS
resistance between to C. ohms. sensor.
terminals B and C.
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Table 75 Testing Throttle Position Sensor (TPS) — Detroit Diesel (cont.)

SPEC. SPEC.
3. Off With pedal at full throttle At accelerator 250 to Go to next Replace
position, at connector pedal (306), B 1500 step. TPS/IVS
(306) measure resistance to C. ohms, and sensor.
between terminals B and C. 1000 less
Resistance must be 1000 than idle
ohms less than reading at position
idle position and must be reading.
250 to 1500 ohms.
4. Off At accelerator pedal, Accelerator > 100K TPS Replace
measure resistance to pedal (306), ohms. sensor TPS/IVS
the metal part of pedal metal to checks sensor.
assembly and terminals A, terminals. good. Go
B, C, D and E. to Testing
Idle
Validation
Switch
(IVS)-
Detroit
Diesel.
Testing Idle Validation Switch (IVS) — Detroit Diesel
Perform preceding test before performing this test. This test checks the IVS circuits in the accelerator
pedal assembly.
Table 76 Testing Idle Validation Switch (IVS) — Detroit Diesel

SPEC. SPEC.
1. Off With accelerator pedal still At accelerator < 125 Go to next Replace
disconnected at connector pedal (306) , F ohms. step. TPS/IVS sensor.
(306) and the pedal at to E.
idle, measure resistance
between terminal F and E
on the accelerator pedal.
2. Off At connector (306), At accelerator > or = Go to next Replace
measure resistance pedal (306), E 100K step. TPS/IVS sensor.
between terminals E to F, after 10° of ohms.
and F while slowly travel.
depressing the pedal
(idle to full throttle). After
approximately 10° of
travel the resistance
should be 100K ohms or
more.
3. Off The TPS and IVS Go to
functions check good. Testing
NOTE: This test is not Accelerator
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Table 76 Testing Idle Validation Switch (IVS) — Detroit Diesel (cont.)

SPEC. SPEC.
able to check the timing Pedal
function between the (TPS/IVS)
two functions. Circuits
— Detroit
Diesel
following.
Testing Accelerator Pedal (TPS/IVS) Circuits — Detroit Diesel
Inspect TPS/IVS circuits and connectors as outlined in Before Troubleshooting. This test checks the cab and
engine harness TPS/IVS circuits for opens, shorts to ground, shorts to "hot" circuits and shorts to other circuits
in the harness and checks the circuits for continuity.
Perform the two preceding tests before performing this test.
Table 77 Testing Accelerator Pedal (TPS/IVS) Circuits — Detroit Diesel

POINTS SPEC.
1. Off With accelerator pedal (341), > 100K Go to next Locate short to
disconnected from the term. E1, ohms. step. ground in circuit
cab harness at (306), C3, D2 and where resistance at
disconnect connector A3 to gnd. terminal is less than
(341) from the ECM. 100K ohms, then
At International ECM repair.
connector (341), measure
terminals E1, C3, D2 and
A3 [circuits 99B, 99–R, 99
and 99A(5V)].
2. Off At connector (341) (341), > 100K Go to next Locate short
measure resistance term. E1, ohms. step. between circuits
between terminals E1, C3, D2 and where resistance
C3, D2, A3 [circuits 99B, A3, and all between terminals
99–R, 99 and 99A(5V)] other term. is less than 100K
and all other terminals in ohms, then repair.
connector (341).
3. Off At connector (341) (341), < 1 volt. Go to next Locate short to
measure voltage to term. E1, step. unwanted voltage
ground at terminals E1, C3, D2 and source in circuit with
C3, D2, A3 [circuits 99B, A3 to gnd. more than 1V, then
99–R, 99 and 99A(5V)]. repair.
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Table 77 Testing Accelerator Pedal (TPS/IVS) Circuits — Detroit Diesel (cont.)

POINTS SPEC.
4. Off At connector (306) (306), F to < 5 ohms. Go to next Locate open or poor
measure resistance to gnd. step. connection in circuit
ground at terminal F 99–GA, 97–GA,
(circuit 99-GA). 97–G, or 11–G to
negative battery
5. Off At connector (341) use (306), E to < 5 ohms. Go to next Locate open or
test lead to jumper F. step. poor connection in
terminal E1 (circuit 99B) circuit 99B between
to ground. At connector connectors (341)
(306) measure resistance and (306), then
between terminals E repair.
and F (circuits 99B and
99–GA).
6. Off At connector (341) use (306), A to < 5 ohms. Go to next Locate open or poor
test lead to jumper F. step. connection in circuit
terminal C3 (circuit 99–R) 99–R between
between terminals A and repair.
F (cir. 99R and 99-GA).
7. Off At connector (341) use (306), B to < 5 ohms. Go to next Locate open or
test lead to jumper F. step. poor connection in
terminal D2 (cir. 99) circuit 99 between
between terminals B and repair.
F (cir. 99 and 99-GA).
8. Off At connector (341) use (306), C to < 5 ohms. TPS/ IVS Locate open or
test lead to jumper F. circuits poor connection in
terminal A3 [cir. 99A(5V)] between circuit 99A between
to ground. At connector (341) and connectors (341)
(306) measure resistance (306) check and (306), then
between terminals C good. repair.
and F [cir. 99A(5V) and
99-GA].
3.4. DIAGNOSTIC CONNECTOR (220) AND DATA LINK CIRCUITS INCLUDING

SPEEDOMETER/TACHOMETER INPUT CIRCUITS — DETROIT DIESEL
Make sure batteries are fully charged and inspect circuits and connectors as outlined in Before Troubleshooting.
Testing Diagnostic Connector Power and Ground Circuits — Detroit Diesel
This test checks the power and ground circuits to the diagnostic connector (220).
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Table 78 Testing Diagnostic Connector Power and Ground Circuits — Detroit Diesel
POINTS SPEC.
1. Off At diagnostic connector (220), C to 10 to 12 Go to Locate cause of no or
(220) measure voltage to gnd. volts. next low voltage in circuit
ground at terminal C (circuit step. 97DL from 5A fuse
97DL). F6–A, then repair.
2. Off At connector (220) measure (220), C to 10 to 12 Go to Locate open or poor
voltage between terminals E. volts. next connection in ground
C and E (circuit 97DL and step. circuit between
11–GR). connector (220) and
G5 ground adapter
(533), then repair.
3. Off The power and ground
circuits to diagnostic
connector (220) check
good. Proceed to following
test.
Testing ATA Data Link Circuits — Detroit Diesel
This test checks the data link circuits between ECM connector (341) and the diagnostic connector (220)
and the speedometer/tachometer connector (595).
Table 79 Testing ATA Data Link Circuits — Detroit Diesel

POINTS SPEC.
1. Off Disconnect ECM Go to
connector (341) next
from ECM and (595) step.
from speedometer/
tachometer unit. If
any other devices are
connected to the data
link connectors (515) and
(514), disconnect these
devices.
2. Off At connector (220) (220), A to > 100K Go to Locate short to ground
measure resistance to gnd. ohms. next in circuit, then repair.
gnd. at terminal A, [circuit step.
98A(+)].
3. Off At connector (220) (220), B to > 100K Go to Locate short to ground
measure resistance to gnd. ohms. next in circuit, then repair.
ground at terminal B, step.
[circuit 98C(-)].
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Table 79 Testing ATA Data Link Circuits — Detroit Diesel (cont.)

POINTS SPEC.
4. Off At connector (220) (220), A to > 100K Go to Locate short between
measure resistance B. ohms. next the positive data
between terminals A and step. link circuit and the
B [circuits 98A(+) and negative data link
98C(-)]. circuit, then repair.
5. Off Measure voltage to (220), A to < or = 1 Go to Locate short to
ground at connector B. volt. next unwanted voltage
(220) terminals A and step. source in circuit where
B [circuits 98A(+) and voltage is more than 1
98C(-)]. volt, then repair.
6. Off At ECM connector (220), B to < 5 ohms. Go to Locate open or poor
(341) use test lead to gnd. next connection in circuit
jumper terminal C1 step. 98B(-) or 98C(-)
[circuit 98B(-)] to gnd. At between connectors
connector (220) measure (341) and (220), then
resistance to ground repair.
at terminal B, [circuit
98C(-)].
7. Off At connector (595) (595), 47/ < 5 ohms. Go to Locate open or poor
measure resistance to 48(-) to gnd. next connection in circuit
ground at circuit 47/48(-). step. 47/48(-) between
connectors (515) and
(595), then repair.
8. Off At ECM connector (220), A to < 5 ohms. Go to Locate open or
(341) use test lead to B. next poor connection in
jumper terminal C1 to C2 step. circuit 98A(+) or 98(+)
[circuit 98B(-) to 98]. At between connectors
connector (220) measure (341) and (220), then
resistance between repair.
terminals A and B [circuit
98A(+) to 98C(-)].
9. Off At connector (595) (595), < 5 ohms. Go to Locate open or poor
measure resistance 47/48(+) to next connection in circuit
to ground at circuit gnd. step. 47/48(+) between
47/48(+). connectors (514) and
(595), then repair.
between connectors
(341), (220) and (595)
check good.
3.5. CRUISE/PTO CONTROL SYSTEM AND RELATED COMPONENTS — DETROIT

DIESEL
Inspect TPS/IVS circuits and connectors as outlined in Before Troubleshooting.
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IMPORTANT – The following cruise control test procedures must be performed in the sequence that they
appear in this manual. Each test relies on information from the previous test procedure.
NOTE – The clutch switch is a normally open switch, adjusted to be closed when the pedal is in the
released (foot off) position.
NOTE – Use the EST to check clutch switch operation. If the EST indicates the clutch switch is not
operating properly, perform this procedure.
Testing Clutch Switch — Detroit Diesel
Table 80 Testing Clutch Switch — Detroit Diesel

POINTS SPEC.
1. Off Visually check clutch Go to next Adjust clutch switch.
switch adjustment. The step.
switch should be adjusted
to open with an audible
click when the pedal is
depressed 0.5 inch (13
mm). Is clutch switch
adjusted properly?
2. Off Disconnect clutch switch Clutch < 5 Go to next If switch is properly
pigtail from cab harness switch (55), ohms. step. adjusted, replace the
at connector (55). With across switch.
pedal released, measure terminals.
resistance across pigtail
connector terminals.
3. Off Depress clutch pedal Clutch > 100K Go to next If switch is properly
and measure resistance switch, ohms. step. adjusted, replace the
across pigtail connector across switch.
(55) terminals. terminals.
4. Off At cab side of connector (55), 97-GH < 5 Go to next Locate open or
(55), measure resistance to gnd. ohms. step. poor connection in
of 97-GH to ground. gnd. path for circuit
97-GH, 97–GA, 97–G,
or 11–G between
connector (55) and
negative battery
5. Off Disconnect ECM (55), 97AH < 5 The clutch Locate open or
connector (341) from to gnd. ohms. switch and poor connection in
ECM. Use test lead to circuits circuit 97AH between
jumper terminal J2 (circuit check connectors (341) and
97AH) to ground. At good. (55), then repair.
connector (55) measure
circuit 97AH.
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Testing Service Brake Switch And Circuits — Detroit Diesel
Inspect circuits and connectors as outlined in Before Troubleshooting.
NOTE – Use the EST to check service brake switch operation. If the EST indicates the service brake
switch is not operating properly, perform this procedure.
NOTE – Vehicle air brake system must be fully charged for this test.
Table 81 Testing Service Brake Switch And Circuits — Detroit Diesel

POINTS SPEC. SPEC.
1. Off Remove harness Switch (5), > 100K Go to next Replace service
connector (5) from term. to gnd. ohms. step. brake switch.
service brake switch.
Measure resistance to
ground at both service
brake switch terminals.
2. Off At service brake switch Switch (5), < 2 Go to next Replace service
(5), measure resistance across term. ohms. step. brake switch.
between the two
terminals with brakes
released.
3. Off At service brake switch Switch (5), > 100K Go to next Replace service
(5), measure resistance across term. ohms. step. brake switch.
between the two
terminals with brakes
applied.
4. Off At service brake switch (5), 97-GF to < 5 Go to next Locate open or
harness connector (5), gnd. ohms. step. poor connection
measure resistance to in ground path
ground at circuit 97-GF. for circuit 97-GF,
97–GA, 97–G, or
11–G between
connector (5) and
negative battery
terminal, then
repair.
5. Off Remove ECM connector (341), G2 to > 100K Go to next Locate short to
(341) from the ECM. gnd. ohms. step. ground in circuit
At connector (341) 97AL between
ground at terminal G2 and (5), then
(circuit 97AL). repair.
6. Off Use test lead to jumper (5), 97AL to < 5 The service Locate open or
terminal G2 (circuit gnd. ohms. brake switch poor connection
97AL) to ground at and circuits in circuit
(341). At connector (5) check good. 97AL between
connectors (341)
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Table 81 Testing Service Brake Switch And Circuits — Detroit Diesel (cont.)
POINTS SPEC. SPEC.
measure resistance to and (5), then
ground at circuit 97AL. repair.
Testing Cruise On/Off Switch — Detroit Diesel
NOTE – Use EST to check cruise on/off switch operation. If the EST indicates the cruise on/off switch is
not operating properly, perform this procedure.
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Table 82 Testing Cruise On/Off Switch — Detroit Diesel 314

POINTS SPEC.
1. Off Remove connector (419) Switch < 2 Go to Replace cruise on/off
from on/off switch. With (419), 5 and ohms. next step. switch.
switch in on position, 6.
measure resistance
6.
2. Off With switch (419) in Switch > 100K Go to Replace cruise on/off
off position, measure (419), 5 to ohms. next step. switch.
resistance between 6.
terminals 5 and 6.
3. Off To test switch light Go to Replace cruise on/off
function, connect 12V next step. switch.
lead to terminal 7 and
ground terminal 8. Does
light turn on?
4. Off Disconnect ECM (341), F2 to > 100K Go to Locate short to
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connector (341) from gnd. ohms. next step. ground in circuit
the ECM. At connector 97AE between
(341) measure resistance connectors (341) and
from terminal F2, (circuit (419), then repair.
97AE) to ground.
5. Off At connector (419), (419), < 5 Go to Locate open or poor
measure resistance to 97-GC to ohms. next step. connection in circuit
ground at circuit 97-GC. gnd. 97–GC, 97–GA,
8 DETROIT DIESEL SERIES 60 ENGINE
97–G or 11–G to
negative battery
6. Off Connect (419) to cruise (341), F2 to < 5 Switch Locate open or
on/off switch and turn gnd. ohms. (419) and poor connection in
switch to on position. At circuits circuit 97AE between
connector (341) measure check connectors (341) and
resistance of F2 to good. (419), then repair.
ground.
Testing Cruise Set/Resume Switch And Circuits — Detroit Diesel
NOTE – Use the EST to check set/resume switch operation. If the EST indicates the set/resume switch
is not operating properly, perform this procedure.
Table 83 Testing Cruise Set/Resume Switch And Circuits — Detroit Diesel

POINTS SPEC. SPEC.
1. Off Remove connector (418) Switch < 5 ohms. Go to next Replace cruise
from cruise set/resume (418), 2 to step. set/resume switch.
switch. With switch in 3.
resistance between
terminals 2 and 3.
2. Off With switch (418) Switch > 100K Go to next Replace cruise
in neutral position, (418), ohms. step. set/resume switch.
measure resistance between 1, 2
between terminals 1, 2, and 3.
and 3.
3. Off With switch (418) Switch < 5 ohms. Go to next Replace cruise
in resume position, (418), step. set/resume switch.
measure resistance between 1
between terminals 1 and and 2.
2.
4. Off To test switch light Go to next Replace cruise
function, connect 12V step. set/resume switch.
lead to terminal 7 and
ground to terminal 8.
Does LED light turn on?
5. Off At connector (418) (418), < 5 ohms. Go to next Locate open or
measure resistance to 97-GB to step. poor connection
ground at circuit 97-GB. gnd. in circuit 97-GB,
97–GA, 97–G, or
11–G to negative
battery terminal,
then repair.
6. Off Disconnect ECM (341), G3 to >100K Go to next Locate short to
connector (341). gnd. ohms. step. ground in circuit
Measure resistance 97AA, then repair.
from terminal G3 to
ground.
7. Off Disconnect ECM (341), J1 to > 100K Go to next Locate short to
connector (341). gnd. ohms. step. ground in circuit
Measure resistance 97AB, then repair.
from terminal J1 (circuit
97AB) to ground.
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Table 83 Testing Cruise Set/Resume Switch And Circuits — Detroit Diesel (cont.)
POINTS SPEC. SPEC.
8. Off With set/resume (341), G3 to > 100K Go to next Locate short
switch disconnected, J1. ohms. step. between circuits
at connector (341) 97AA and 97AB,
measure resistance then repair.
between terminal G3
and J1 (circuit 97AA to
97AB).
9. On At connector (341), (341), J1 to < 1 volt. Go to next Locate short to
measure voltage from J1 gnd. step. unwanted voltage
(circuit 97AB) to ground. source, then repair.
10. On At connector (341), (341), G3 to < 1 volt. Go to next Locate short to
measure voltage from gnd. step. unwanted voltage
G3 (circuit 97AA) to source, then repair.
ground.
11. Off At connector (341) use (418), 97AA < 5 ohms. Go to next Locate open or
test lead to jumper to 97-GB. step. poor connection
terminal G3 (circuit in circuit
97AA) to ground. 97AA between
At connector (418) connectors (418)
measure resistance and (341), then
between circuits 97AA repair.
and 97-GB.
12. Off At connector (341) use (418), 97AB < 5 ohms. The cruise Locate open or
test lead to jumper to 97-GB. set/ resume poor connection
terminal J1 (circuit switch and in circuit
97AB) to ground. circuits 97AB between
At connector (418) check good. connectors (418)
measure resistance and (341), then
between circuits 97AB repair.
and 97-GB.
3.6. VEHICLE SPEED SENSOR (VSS) — DETROIT DIESEL

Inspect circuits and connectors as outlined in Before Troubleshooting. When monitoring engine functions using
an EST, if the vehicle is moving, the EST will display vehicle speed if the system is working properly.
Inspecting And Adjusting the Vehicle Speed Sensor (VSS) — Detroit Diesel
one full turn. Tighten locknut to 15 ft-lbs. (20.3 N•m). This assures that the sensor is adjusted properly
for the next test.
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Testing Vehicle Speed Sensor (VSS) — Detroit Diesel
To perform this test construct two test leads using terminals (1680205C1) and suitable length of 16GA wire.
Table 84 Testing Vehicle Speed Sensor (VSS)

POINTS SPEC.
1. Off With VSS (225) VSS (225), > 100K Go to next Replace VSS. (Refer
disconnected, use term. to gnd. ohms. step. to Inspecting and
test lead to measure Adjusting the Vehicle
resistance to ground at Speed Sensor (VSS)
both sensor terminals. — Detroit Diesel,
above).
2. Off Use test leads and Across term. 600 to Go to next Replace VSS (refer
measure resistance of VSS (225). 900 step. to Inspecting and
between VSS (225) ohms. Adjusting the Vehicle
sensor terminals. Speed Sensor (VSS)
— Detroit Diesel).
3. Off Block front wheels and Go to next
place rear axles on floor step.
stands.
4. Off CAUTION: Use AC Go to next
voltmeter with sufficient step.
length leads to avoid
personal contact with
rotating vehicle wheels
during this test. Connect
meter leads to test leads.
5. Off Run engine at idle speed, Across term. >2.0 VSS Replace VSS (refer
with transmission in high of VSS (225). volts AC. checks to Inspecting and
gear. Measure voltage good. Adjusting the Vehicle
across the two VSS (225) Speed Sensor (VSS)
sensor terminals. — Detroit Diesel).
NOTE: Improper
adjustment will
cause low, erratic,
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Table 84 Testing Vehicle Speed Sensor (VSS) (cont.)

POINTS SPEC.
or no sensor
output.
Testing Vehicle Speed Sensor (VSS) Circuits To ECM — Detroit Diesel
Table 85 Testing Vehicle Speed Sensor (VSS) Circuits To ECM — Detroit Diesel
POINTS SPEC.
1. Off With VSS sensor (225) (341), E2 >100K Go to next Locate short to
disconnected, remove to gnd. ohms. step. ground, then repair.
ECM connector (341). At
resistance to ground
at terminal E2, (circuit
97AJ).
2. Off At connector (341) (341), E3 >100K Go to next Locate short to
measure resistance to gnd. ohms. step. ground, then repair.
to ground at terminal E3
(circuit 97AK).
3. Off At connector (341) (341), E2 >100K Go to next Locate short
measure resistance to E3. ohms. step. between circuits
between terminals E2 97AJ and 97AK,
and E3 (circuits 97AJ and then repair.
97AK).
4. Off At connector (341) (341), E2 <1 volt. Go to next Locate short in circuit
measure voltage from to gnd. step. 97AJ to unwanted
E2 (circuit 97AJ) to voltage source, then
ground. repair.
5. Off At connector (341) (341), E3 <1 volt. Go to next Locate short in circuit
measure voltage from to gnd. step. 97AK to unwanted
E3 (circuit 97AK) to voltage source, then
ground. repair.
6. Off At connector (225), use (341), E2 < 5 ohms. Go to next Locate open or
test leads to connect to gnd. step. poor connection in
circuit 97AJ to ground. At circuit 97AJ between
resistance from E2 (circuit and (341), then
97AJ) to ground. repair.
7. Off At connector (225), use (341), E3 < 5 ohms. The VSS Locate open or poor
test leads to connect to gnd. circuits connection in circuit
circuit 97AK to ground. At between 97AK between
connector (341) measure connectors connectors (225)
resistance from E3 (circuit (341) and and (341), then
97AK) to ground. (225) check repair.
good.
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3.7. ENGINE BRAKE SYSTEM — DETROIT DIESEL

Testing Engine Brake Switches and Circuits — Detroit Diesel
Table 86 Testing Engine Brake Switches and Circuits — Detroit Diesel

POINTS SPEC.
1. Off Remove connector (412) Switch (412), < 2 Go to next Replace the (412)
from on/off switch. With 5 to 6. ohms. step. switch.
switch in on position
measure resistance
6.
2. Off With switch (412) in Switch (412), > 100K Go to next Replace the (412)
off position, measure 5 to 6. ohms. step. switch.
resistance between
terminals 5 and 6.
3. Off To test switch light Go to next Replace the switch.
function, connect 12V step.
lead to terminal 7, and
4. Off At connector (412) (412), 24-GA < 1 ohm. Go to next Locate open or poor
measure resistance to to gnd. step. connection in circuit
ground at circuit 24-GA. 24-GA, 97–GA,
97–G or 11–G, then
repair.
5. Off Reconnect on/off switch (411), 24AJ to < 5 Go to next Locate open or poor
to connector (412) and gnd. ohms. step. connection in circuit
place in on position. 24AJ between
Remove connector connectors (412)
(411) from engine brake and (411), then
selector switch. At (411) repair.
24AJ to ground.
6. Off With engine brake Switch (411), < 2 Go to next Replace the (411)
selector switch (411) 2 to 6. ohms. step. switch.
in position 3, measure
resistance between
terminals 2 and 6.
resistance between
terminals 2 and 3.
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Table 86 Testing Engine Brake Switches and Circuits — Detroit Diesel (cont.)
POINTS SPEC.
resistance between
terminals 2 and 3.
resistance between
terminals 2 and 6.
10. Off To test the LED in the Go to next Replace the switch.
switch, connect 12V to step.
terminal 7, and connect
terminal 8 to ground.
11. Off Remove connector (341), K2 to > 100K Go to next Locate short to
(341) from the ECM. At gnd. ohms. step. ground in circuit,
connector (341) measure then repair.
resistance to ground
at terminal K2 (circuit
24AE).
12. Off At connector (341) (341), K3 to > 100K Go to next Locate short to
measure resistance to gnd. ohms. step. ground in circuit,
ground at terminal K3 then repair.
(circuit 24AF).
13. Off At connector (341) (341), K2 to > 100K Go to next Locate short
measure resistance K3. ohms. step. between circuits
between terminals K2 24AF and 24AE,
and K3 (circuits 24AE then repair.
and 24AF).
14. On At connector (341) (341), K2 to <1 volt. Go to next Locate short to
measure voltage at gnd. step. unwanted voltage
terminal K2 (circuit source, then repair.
24AE) to ground.
15. On At connector (341) (341), K3 to <1 volt. Go to next Locate short to
measure voltage at gnd. step. unwanted voltage
terminal K3 (circuit 24AF) source, then repair.
to ground.
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Table 86 Testing Engine Brake Switches and Circuits — Detroit Diesel (cont.)
POINTS SPEC.
16. Off At connector (341) use (411), 24AE < 1 ohm. Go to next Locate open or poor
test lead to jumper K2 to gnd. step. connection in circuit
(circuit 24AE) to ground. 24AE between
At connector (411) connectors (341)
measure resistance to and (411), then
ground at circuit 24AE. repair.
17. Off At connector (341) use (411), 24AF to < 1 ohm. The engine Locate open or poor
test lead to jumper K3 gnd. brake connection in circuit
(circuit 24AF) to ground. switches 24AF between
At connector (411) and circuits connectors (341)
measure resistance to check and (411), then
ground at circuit 24AF. good. repair.
3.8. DIAGNOSTIC ON/OFF/SHUTDOWN OVERRIDE SWITCH (332) — DETROIT DIESEL

Testing Diagnostic On/Off/Shutdown Override Switch — Detroit Diesel
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Table 87 Testing Diagnostic On/Off - Shutdown Override Switch — Detroit Diesel 322
STEP KEY ACTION TEST SPEC. YES-IN SPEC. NO-OUT OF

POINTS SPEC.
1. Off Remove connector (332) Switch (332), < 5 ohms. Go to next Replace the
from the on/off shutdown 5 to 6. step. (332) switch.
override switch. With
switch in on position,
measure resistance
6.
2. Off With switch in off Switch (332), > 100K Go to next Replace the
position, measure 5 to 6. ohms. step. (332) switch.
resistance between
terminals 5 and 6.
3. Off To test the LED in the Go to next Replace the
switch, connect 12V to step. (332) switch.
terminal 7, and terminal
8 to ground. Does LED
light turn on?
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4. Off At connector (332) (332), 97-GD < 5 ohms. Go to next Locate open or
measure resistance of to gnd. step. poor connection
circuit 97-GD to ground. in circuit 97-GD,
97–GA, 97–G,
or 11–G, then
repair.
5. Off Remove connector (341) (332), 97AU < 5 ohms. The shutdown Locate open or
from ECM. At (341) to gnd. override/ poor connection
use test lead to jumper diagnostic in circuit

terminal G1 to ground. switch and 97AU between
At connector (332) circuits check connectors (341)
measure resistance from good. and (332), then
circuit 97AU to ground. repair.
3.9. PARK BRAKE (IDLE TIMER) SWITCH (328) — DETROIT DIESEL

Testing Park Brake Switch (328) and Circuits — Detroit Diesel
NOTE – Vehicle air system must be fully charged for this test.
Table 88 Testing Park Brake Switch (328) and Circuits — Detroit Diesel
POINTS SPEC. SPEC.
1. Off Remove connector (328) Switch < 5 Go to next Replace the (328)
from the park brake switch. (328), across ohms. step. switch.
With park brake applied, terminals.
measure resistance across
switch terminals.
2. Off With park brake applied, Switch (328), > 100K Go to next Replace the switch.
measure resistance to term. to gnd. ohms. step.
ground at both switch
terminals.
3. Off Release park brake Switch (328), > 100K Go to next Replace the switch.
and measure resistance across term. ohms. step.
between switch terminals.
4. Off At connector (328) (328), 97-GE < 5 Go to next Locate open or
measure resistance from to gnd. ohms. step. poor connection
97-GE to ground. in circuit 97-GE,
97–GA, 97–G or
11–G to negative
battery terminal,
then repair.
5. Off Remove connector (341) (341), H2 to > 100K Go to next Locate short to
from ECM. At connector gnd. ohms. step. ground in circuit
(341) measure resistance 97AV between
from H2 (circuit 97AV) to connectors (341)
ground. and (328), then
repair.
6. On At connector (341) terminal (341), H2 to < 1 volt. Go to next Locate short to
H2 (circuit 97AV) , measure gnd. step. unwanted voltage
voltage to ground. source in circuit
97AV, then repair.
7. Off Connect (328) to park (341), H2 to < 5 Park brake Locate open or poor
brake switch, and apply gnd. ohms. (idle timer) connection in circuit
park brake. At connector switch 97AV between
(341) measure resistance (328) and connectors (341)
to ground at terminal H2 circuits and (328), then
(circuit 97AV). check repair.
good.
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3.10. ECM POWER SUPPLY (SWITCHED AND UNSWITCHED) — DETROIT DIESEL

Inspect ECM power and ground circuits and connectors as outlined in Before Troubleshooting.
Testing Unswitched Battery Power To ECM At Connector (N/L) — Detroit Diesel
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Table 89 Testing Unswitched Battery Power To ECM At Connector (N/L) — Detroit Diesel
POINTS SPEC.
1. Off Check the two 15A Fuses near < 1 ohm. Go to next Locate cause of
power fuses located batteries. step. overload condition,
near batteries for open then repair.
condition. Replace fuse(s).
2. Off Disconnect ECM (676), A to 10 to 12 Go to next Locate cause of no
connector (676) and gnd. volts. step. or low voltage in
measure voltage to circuit 14B, 14C,
ground at terminal A. conn. (675), or
circuit 14C from
battery, then repair.
3. Off At connector (676) (676), C to 10 to 12 Go to next Locate cause of no
measure voltage to gnd. volts. step. or low voltage in
ground at terminal C. circuit 14A, 14D,
conn. (675), or
circuit 14D from
battery, then repair.
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4. Off At connector (676) (676), C to 10 to 12 ECM power At terminal (B, D,
measure voltage between B, D, and E. volts. connector or E) where less
terminal C and terminals circuits test than battery voltage
B, D, and E. good. is present, locate
open in circuit
between connector
(676) and negative

battery terminal,
then repair.
325
Testing Switched Battery Power To ECM — Detroit Diesel
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Table 90 Testing Switched Battery Power To ECM — Detroit Diesel
STEP KEY ACTION TEST SPEC. YES-IN SPEC. NO-OUT OF
POINTS SPEC.
1. Off Check fuses F2–C and F2–C, < 1 ohm. Go to next Locate cause
F7–A, and circuit breaker F7–A, step. of overload
B3 for open condition. circuit condition, then
breaker B3. repair. Replace
fuse(s).
2. Off/ Remove connector (341) (341), B3 to 12 ± 1.5 Switched Go to next step.
On from ECM. Turn key on, gnd. volts voltage circuit
and at (341) terminal B3 to ECM
(circuit 16D) measure connector
voltage to ground. (341) is good.
3. On At circuit breaker B3/ Circuit 12 ± 1.5 Locate open Locate cause of
circuit 16E, measure beaker B3/ volts. in circuit 16D, no or low voltage
voltage to ground. 16E to gnd. then repair. in circuit 16E to
circuit breaker
B3, then repair.
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3.11. OPTIMIZED IDLE

Inspect ECM power and ground circuits and connectors as outlined in Before Troubleshooting.
Testing Optimized Idle Safety Loop Circuit
Insure all Safety switches are closed by setting the idle timer switch to on. Shifting the transmission to neutral,
insure the cab is fully lowered. Also, insure the Idle Timer switch is closed.
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Table 91 Testing Optimized Idle Safety Loop Circuit
POINTS SPEC.
1. Off. Remove ECM connector (341) term. < 1 ohm. Go to Step Go to next step.
(341). Measure H2 to gnd. 10.
resistance from harness
connector, terminal H2,
circuit 97AV to chassis
ground.
2. Off Remove Cab Tilt Switch < 1 ohm. Go to next Replace defective
Switch connector (920). term. step. switch.
Measure resistance
across switch terminals
with cab lowered.
3. Off Measure resistance (341), term. < 1 ohm. Go to next Locate open in
between harness H2 to (920), step. circuits 97AV, 97BA
connector (341), terminal term. A. or 97BH, then
H2, circuit 97AV to (920), repair.
terminal A, circuit 97BH.
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4. Off Remove neutral position Switch < 1 ohm. Go to next Replace defective
switch connector (918). term. step. switch.
Measure resistance
with transmission in
neutral.
between Cab Tilt Switch B to (918), step. circuit 97BB, then
connector (920), terminal term. A. repair.
B, circuit 97BB to (918),
terminal A, circuit 97BB.
6. Off Remove Idle Timer Switch < 1 ohm. Go to next Replace defective
Switch connector (328). term. step. switch.
Measure resistance
with switch closed.
329
Table 91 Testing Optimized Idle Safety Loop Circuit (cont.)
330

POINTS SPEC.
7. Off Measure resistance (918), term. <1 ohm. Go to next Locate open in
between connector (918), B to (328), step. circuit 97AV or
terminal B, circuit 97BD to term. C. 97BD, then repair.
(328), terminal C, circuit
97AV.
between connector (328), A to gnd. step. circuit 97–GE,
terminal A, circuit 97–GE 97–GA, 97–G or
to chassis ground. 11–G, then repair.
9. Off Reconnect all connectors (482), < 1.5 Go to next Locate short to
except ECM connector cavity 2 to volts. step. unwanted voltage in
(341). Remove Idle gnd. safety circuits, then
Relay (482). Measure the repair.
voltage between cavity 2
and ground.
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10. Off Reconnect all
connectors. Optimized
Idle safety circuits check
good.
Testing Ignition and Idle Relay Circuits
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Table 92 Testing Ignition and Idle Relay Circuits 332

POINTS SPEC.
1. Off Check fuse F10–A for F-10A. < 1 ohm. Go to Locate cause of
open condition. next overload condition,
step. then repair. Replace
defective fuse or circuit
breaker.
2. Off Remove Ignition Relay Relay Go to Replace defective
(483). Bench test relay tests next relay.
as outlined in Testing good. step.
Relays.
3. Off Remove Ignition Relay Relay Go to Replace defective
(482). Bench test relay tests next relay.
as outlined in Testing good. step.
Relays.
4. Off/ Turn key on. Measure (483), cavity 12 ± 1.5 Go to Locate cause of no or
On voltage to ground at (483) 1 to gnd. volts. next low voltage in circuit
cavity 1, circuit 17E. step. 17E or 17C to F-10.
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5. On Measure voltage to (483), cavity 12 ± 1.5 Go to Locate cause of no or
ground at (482) cavity 5, 5 to gnd. volts. next low voltage in circuit
circuit 17F. step. 17F.
6. On Measure voltage to (483), cavity 12 ± 1.5 Go to Locate cause of no or
ground at (482) cavity 4, 4 to gnd. volts. next low voltage circuit in
circuit 17T. step. circuit 17T.
7. Off Remove 10K resistor Across 10K Go to Replace defective
connector (782). resistor ohms. next resistor.

Measure the resistance term. step.
across the resistor
terminals.
8. Off Measure voltage to (782), cavity 12 ± 1.5 Go to Locate cause of no or
ground at (782) cavity B, B to gnd. volts. next low voltage in circuit
circuit 17S. step. 17S, then repair.
Table 92 Testing Ignition and Idle Relay Circuits (cont.)
POINTS SPEC.
9. Off Measure resistance (782), cavity < 1 ohm. Go to Locate open in circuit
between resistor A to (483), next 17P or 17R, then
connector (782), cavity cavity 5. step. repair.
A, circuit 17R to Ignition
Relay Connector (483),
cavity 5, circuit 17P.
10. Off Remove ECM connector (913), term. < 1 ohm. Go to Locate open in circuit
(913). Measure B and (483) next 17H, then repair.
resistance between cavity 2. step.
(913), terminal B, circuit
17H and Ignition Relay
connector (483), cavity 2.
11. On Measure the voltage (913), cavity < 1.5 Go to Locate short to
between (913), cavity B B to gnd. volts. next unwanted voltage in
and ground. step. circuit 17H, then repair.
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12. Off Reconnect all connectors.
Ignition and Idle Relay
333
Testing Heater Blower Disable Circuits
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Table 93 Testing Heater Blower Disable Circuits
POINTS SPEC.
1. Off Remove Heater Control Diode Go to Replace defective
Diode assembly checks next step. diode assembly.
connector (783). Bench good.
check the diode.
2. On Measure the voltage (783), term. 12 ± 1.5 Go to Locate cause of no
between connector (783), A and gnd. volts. next step. or low voltage in
terminal A, circuit 13T circuit 13T or 13H
and ground. to the Ignition Relay
(462–R1).
3. Off Remove Heater Relay Relay Go to Replace defective
(463–R5). Bench test tests next step. relay.
relay as outlined in good.
Testing Relays.
4. Off Measure resistance (783), term. < 1 ohm. Go to Locate open in circuit
between (783), terminal B, and next step. 13TA.
B, circuit 13TA and (463–R5),
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(463–R5), terminal 5, term. 5.
circuit 13TA.
5. Off Remove engine ECM (341), cavity < 1 ohm. Go to Locate open in circuit
connector (341). F3, and next step. 75BB, then repair.
Measure the resistance (463–R5),
between (341), cavity term. 4.
F3, circuit 75BB and

(463–R5), terminal 4,
circuit 75BB.
6. Off Measure the resistance (341), cavity > 100K Go to Locate short to
between (341), cavity F3, F3, and gnd. ohms. next step. ground in circuit
circuit 75BB and ground. 75BB, then repair.
Heater blower disable
335
Testing Optimized Idle Thermostat Circuits
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Table 94 Testing Optimized Idle Thermostat Circuits
POINTS SPEC.
1. Off Check fuse F10–B for F10–B < 1 ohm. Go to Locate cause of
defective fuse.
2. Off/ Remove Thermostat (910) term. 12 ± 1.5 Go to Locate cause of
On connector (910). Turn 5, circuit volts. next no or low voltage
key on. Measure 75BD and step. in circuit 75BD or
voltage between (910) gnd. 13BN, then repair.
terminal 5, circuit 75BD
and ground.
3. Off Measure resistance (910) term. < 1 ohm. Go to Locate open in
between (910) terminal 6 and gnd. next circuit 75–GE to
6, circuit 75–GE and step. G2 ground adapter
ground. (455–C), and repair.
4. Off Remove engine ECM (910), term. < 1 ohm. Go to Locate open in
connector (913). 4 and (913), next circuit 75BC, and
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Measure resistance term. D. step. repair.
4, circuit 75BC and
(913), terminal D, circuit
75BC.
5. Off Measure resistance (910), term. Varying Go to Replace defective
between (910) terminal 1 and 3. resistance next thermistor.

1 and 3. with change step.
in temp.
6. Off Reconnect all
connectors. Thermostat
337
Testing Optimized Idle Active Indicator Light
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Table 95 Testing Optimized Idle Active Indicator Light
POINTS SPEC. SPEC.
1. Off Check fuse F10–A for F10–A. < 1 ohm. Go to Locate cause of
open condition. next step. overload condition,
then repair.
Replace defective
fuse.
2. Off/ Remove connector (912) Indicator Light Go to Replace light.
On from the indicator light. light. illuminates. next step.
Bench check the light.
3. Off/ Turn key on, and at (912), term. 12 ± 1.5 Go to Locate cause of no
On (912) terminal A, (circuit A to gnd. volts. next step. or low voltage in
17K) measure voltage to circuit 17K or 17C,
connector (914). B and (912), next step. circuits 17K or
Measure resistance term. B. 17C, then repair.
between (914), terminal
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B, circuit 17LA and (912),
terminal B, circuit 17L.
5. Off Measure resistance (914), term. >100K Go to Locate short to
between (914), terminal B and gnd. ohms. next step. ground in circuits
B, circuit 17LA and 17LA or 17L, then
ground. repair.

Indicator light circuits
check good.
339
Testing Optimized Idle Alarm
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Table 96 Testing Optimized Idle Alarm
POINTS SPEC.
1. Off Check fuse F10–A for F10–A < 1 ohm. Go to Locate cause of
defective fuse.
2. Off/ Remove connector (916) Alarm. Alarm Go to Replace alarm.
On from the alarm. Bench sounds. next
check the alarm. step.
3. Off/ Turn key on, and at (912), term. 12 ± 1.5 Go to Locate cause of no
On (916), terminal B, (circuit B to gnd. volts. next or low voltage in
17M) measure voltage to step. circuit 17M or 17C,
connector (913). A and (916), next circuit 17N, then
Measure resistance term. A. step. repair.
between (913), terminal
A, circuit 17N and (916),
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terminal A, circuit 17N.
5. Off Measure resistance (913), term. >100K Go to Locate short to
between (913), terminal A and gnd. ohms. next ground in circuit
A, circuit 17N and ground. step. 17N, then repair.
Alarm circuits check

good.
341
F1–F5 Fuse Block (462). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
F6–F8 fuse Block (463). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
F9–F13 Fuse Block (464). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
L1 LED Panel Lt. Feed Adapt (504). . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
L3 LED Panel Lt. Ground Adapt (505). . . . . . . . . . . . . .. . . . . . Behind switch cluster
bracket
(225) Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On top of transmission
(278) Low Coolant Probe W/Detroit. . . . . . . . . . . . . . . . .. . . . . . On surge tank at rear of engine
(328) Idle Timer W/Series 60. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind dash control valve
(332) Eng. Override Switch W/Ser 60. . . . . . . . . . . . . .. . . . . . Behind switch cluster
(338) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor front right
(341) ECM Connector W/Series 60. . . . . . . . . . . . . . . . .. . . . . . On left side of engine, at rear of ECM
(347) ECM Communications Connector. . . . . . . . . . . .. . . . . . On left side of engine, at rear of ECM
(482) Optimum Idle Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(483) Start Enable Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(595) Data Link Connector. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, Lt. side, near (55)
(676) ECM 5–Way Power Conn.. . . . . . . . . . . . . . . . . . . .. . . . . . On left side of engine, at ECM
(782) Resistor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel
(783) Heater Control Diode. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel
(909) Optimized Idle Thermo. Conn.. . . . . . . . . . . . . . . .. . . . . . At roof above left B pillar
(910) Optimized Idle Thermo. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In left C pillar
(911) Optimized Idle Thermo. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Below left A pillar
(912) Optimized Idle Active Light. . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel
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(913) Optimized Idle ECM Sensor Harness

Conn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . By engine ECM
(914) Optimized Idle ECM Output. . . . . . . . . . . . . . . . . . .. . . . . . By engine ECM
(915) Optimized Idle Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Along left rail in front of battery box
(916) Optimized Idle Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Along left rail in front of battery box
(918) Neutral Position Switch. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On transmission
(919) Optimized Idle Interconnect. . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel
(920) Cab Tilt Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Right cowl side of inner panel
Refer to Figure 2, Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8, Figure 9, Figure 10, Figure
11Figure 12, Figure 13, Figure 14, Figure 15, Figure 16, Figure 17and Figure 18.
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Figure 110 Engine Wiring, Detroit Diesel Series 60 Engines
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Figure 115 Engine Wiring, Detroit Diesel Series 60 Engines — Transmission Effects
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Figure 116 Engine Wiring, Detroit Diesel Series 60 Engines — Alternator Wiring
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Figure 119 Optimized Idle Cab Wiring
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Figure 120 Optimized Idle Engine Wiring
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Figure 121 Optimized Idle Sleeper Wiring
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Figure 122 Optimized Idle Sleeper Wiring
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Figure 123 Optimized Idle Transmission Wiring
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9 CHASSIS ACCESSORIES 361
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
1.1. HEATED AIR DRYER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
1.2. HEATED FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
1.3. TRAILER SOCKET WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
Without Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
With Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
2.1. HEATED AIR DRYER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
Without Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364
With Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364
3.1. HEATED AIR DRYER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .366
Without Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
With Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373
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362 9 CHASSIS ACCESSORIES
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Model: 9800
1. DESCRIPTION
1.1. HEATED AIR DRYER
The air dryer collects and removes moisture and contaminants from the compressed air in the vehicle’s system
before the air reaches the first air reservoir. The heater and thermal switch assembly, located in the air dryer,
prevents “freeze-up” in the purge drain valve during cold weather operation.
1.2. HEATED FUEL FILTER

The fuel filter collects and removes moisture and contamination from the fuel in the vehicle’s system before
the fuel reaches the engine. The heater and thermal switch assembly, located in the fuel filter, prevents
“gel-up" in the filter during cold weather operation.
1.3. TRAILER SOCKET WIRING

Without Sleeper
The 7-way trailer socket (577) connects the tractor and trailer wiring for operation of stop, tail, turn and hazard,
and clearance lights. Additionally, the trailer socket includes a circuit that provides power for the trailer ABS
system. Each circuit is fed by a dedicated relay.
With Sleeper
The 7-way trailer socket (577) connects the tractor and trailer wiring for operation of stop, tail, turn and hazard,
and clearance lights. Additionally, the trailer socket includes a circuit that provides power for the trailer ABS
system. Each circuit is fed by a dedicated relay.
2. OPERATION
Moving the key switch (452) to ignition position energizes the ignition relay (462-R1) and thus supplies power
to circuits 13H and 16A, connector (102), circuits 16A and 16B, 15A resetting fuse B4, and circuit 31 to the air
dryer connector (N/L). The ground path for the air dryer is through the air dryer connector (N/L) and circuit
31-G to the starter magnetic switch mounting bolt (J5). This causes the heating element in the air dryer to
warm the air if its temperature falls below the thermostat’s value of 50°F (10°C).

Moving the key switch (452) to ignition position energizes the ignition relay (462-R1) and thus supplies power
to circuits 13H and 16A, connector (102), circuits 16A and 16B, 15A resetting fuse B4, and circuit 31A to the
fuel heater relay. This energizes the relay and allows power to flow from the mag switch through circuit 14B,
20A resetting fuse B7, a black wire, the relay N.O. contacts, and a red wire to the heated fuel filter (60). The
ground path for the air dryer is a brown wire to the starter magnetic switch mounting bolt ground (J5). This
keeps the fuel in the filter warm to prevent fuel “gel-up."
s08270

Without Sleeper
When the tractor brakes are applied, the vehicle stop light switch (421) supplies power through circuit 70B
to energize the trailer stop light relay (464-R10). With the stop light relay energized, power from the (B1)
battery stud, circuits 14BH and 14F, 30A fuse F-7D and circuit 70E is sent through the N.O. contacts of relay
(464-R10) on circuit 70C to the trailer socket harness connector (114)/(575). From connector (114)/(575) the
stop light power flows through circuit 70C to the trailer socket connector (577).
With the left turn signal selected or the hazard switch on, power flows from the (B1) battery stud through circuits
14K and 14J, 20A fuse F2-D, circuit 55, flasher (501), and circuit 55A, to the black wire of turn signal switch (36).
Power flows out of the orange wire of switch (36) through circuit 56A to energize the left turn relay (464-R11)
which is grounded through circuits 56-G, 11-GZ, and 11-GI to the left cab ground (429). With the relay
energized, power flows from the (B1) battery stud through circuits 14BH and 14L, 15A fuse F7-B, circuit 56,
relay (464-R11) N.O. contacts and circuit 56D to the trailer socket harness (116)/(576). From connector
(116)/(576) the left turn signal power flows through circuit 56D to the trailer socket connector (577).
With the right turn signal selected or hazard switch on, power flows from the (B1) battery stud through circuits
14K and 14J, 20A fuse F2-D, circuit 55, flasher (501) and circuit 55A, to the black wire of the turn signal switch
(36). Power flows out of the blue wire of the turn signal switch (36) through circuit 57A to energize the right turn
relay (464-R12) which is grounded through circuits 11-GZ and 11-GI to the left cab ground (429). With the
relay energized, power flows from the (B1) battery stud through circuits 14BH and 14L, 15A fuse F7-C, circuit
57, relay (464-R12) N.O. contacts and circuit 57D to the trailer socket harness (116)/(576). From connector
(116)/(576) the right signal power flows through circuit 57D to the trailer socket connector (577).
Power from (B1) battery stud, circuit 94AH, 30A fuse F10-A (location may vary), and circuit 94AG is applied to
trailer ABS relay (483). When the key switch (452) is placed in the ignition position, ignition relay (462-R1)
is energized and power is applied to circuit 13H, circuit 13F, I1 ignition adapter (518), and circuit 94AJ to
trailer ABS relay (483.) This energizes the relay which is grounded through circuit 94-GD to G5 ground
adapter (533.) Thus power flows through the N.O. relay contacts, circuit 94AF, connector (114)/(575), and
circuit 94AF to the trailer socket (577).
Power from the (B2) battery stud, circuits 14W and 14B, 30A fuse F3-C, and circuit 68 is applied to trailer tail
light relay (464-R9). When trailer lights switch (409) is moved to the on position, power from the headlight
switch (410) and circuit 58E is supplied through switch (409) to circuit 58P and the coil of trailer tail light relay
(464-R9). This energizes the relay and provides power to circuits 68E and 68A, to the trailer socket harness
connector (114)/(575). From connector (114)/(575) tail light power flows through circuit 68A to the trailer socket
connector (577). The trailer tail light relay (464-R9) coil is grounded through circuit 58-G, circuit 70-G, circuit
56-G, and circuits 11-GZ and 11-GI to left cab ground (429).
Power from (B2) battery stud circuits 14H and 14E, 20A fuse F3-A, and circuit 58D is applied to trailer marker
relay (463-R8). When trailer lights switch (409) is moved to the on position, power from the headlight switch
(410) and circuit 58E is supplied through switch (409) to circuit 58C and the coil of trailer marker relay (463-R8).
This energizes the relay and provides power to circuit 58A, connector (116)/(576), and circuit 58A to the trailer
socket connector (577). The trailer marker relay (463-R8) coil is grounded through circuit 58-GA, circuit 58-G,
circuit 70-G, circuit 56-G, and circuits 11-GZ and 11-GI to left cab ground (429).
With Sleeper
When the tractor brakes are applied, the vehicle stop light switch (421) supplies power through circuit 70B to
energize the trailer stop light relay (464-R10).
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With the stop light relay energized, power from the (B1) battery stud, circuits 14BH and 14F, 30A fuse F-7D
and circuit 70E is sent through the N.O. contacts of relay (464-R10) on circuit 70C to the trailer socket harness
connector (114). From connector (114) the stop light power flows through circuit 70C to the trailer socket
harness connector (575), circuit 70C, and the trailer socket connector (577).
With the left turn signal selected or the hazard switch on, power flows from the (B1) battery stud through
circuits 14K and 14J, 20A fuse F2-D, circuit 55, flasher (501) and circuit 55A to the black wire of turn signal
switch (36). Power flows out of the orange wire of switch (36) through circuit 56A to energize the left turn relay
(464-R11) which is grounded through circuits 56-G, 11-GZ, and 11-GI to the left cab ground (429). With the
relay energized, power flows from the (B1) battery stud through circuits 14BH and 14L, 15A fuse F7-B, circuit
56, relay (464-R11) N.O. contacts and circuit 56D to the trailer socket harness (116). From connector (116)
the left turn signal power flows through circuit 56D to the trailer socket harness connector (576), circuit 56D,
and the trailer socket connector (577).
With the right turn signal selected or hazard switch on, power flows from the (B1) battery stud through circuits
14K and 14J, 20A fuse F2-D, circuit 55, flasher (501) and circuit 55A to the black wire of the turn signal
switch (36). Power flows out of the blue wire of the turn signal switch (36) through circuit 57A to energize the
right turn relay (464-R12), which is grounded through circuits 11-GZ and 11-GI to the left cab ground (429).
With the relay energized, power flows from the (B1) battery stud through circuits 14BH and 14L, 15A fuse
F7-C, circuit 57, relay (464-R12) N.O. contacts and circuit 57D to the trailer socket harness (116). From
connector (116) the right signal power flows through circuit 57D to the trailer socket harness connector (576),
circuit 57D, and the trailer socket (577).
Power from (B1) battery stud, circuit 97AH, 30A fuse F10-A (location may vary), and circuit 94AG is applied to
trailer ABS relay (483). When the key switch (452) is placed in the ignition position, ignition relay (462-R1)
is energized and power is applied to circuit 13H, circuit 13F, I1 ignition adapter (518), and circuit 94AJ to
trailer ABS relay (483). This energizes the relay which is grounded through circuit 94-GD to G5 ground
adapter (533). Thus power flows through the N.O. relay contacts and circuit 94AF to the trailer socket harness
connector (114). From (114), ABS power flows through circuit 94AF, connector (575), and circuit 94AF to
trailer socket connector (577).
Power from the (B2) battery stud, circuits 14W and 14B, 30A fuse F3-C, and circuit 68 is applied to trailer tail
light relay (464-R9). When trailer lights switch (409) is moved to the on position, power from the headlight
switch (410) and circuit 58E is supplied through switch (409) to circuit 58P and the coil of trailer tail light relay
(464-R9). This energizes the relay and provides power to circuits 68E and 68A to the trailer socket harness
connector (114). From connector (114) tail light power flows through circuit 68A, connector (575), and circuit
68A to trailer socket connector (577). The trailer tail light relay (464-R9) coil is grounded through circuits 58-G,
70-G and 56-G, the relay, and circuits 11-GZ and 11-GI to left cab ground (429).
Power from (B2) battery stud circuits 14H and 14E, 20A fuse F3-A, and circuit 58D is applied to trailer marker
relay (463-R8). When trailer lights switch (409) is moved to the on position, power from the headlight switch
(410) and circuit 58E is supplied through switch (409) to circuit 58C and the coil of trailer marker relay
(463-R8). This energizes the relay and provides power to circuit 58A and connector (116). From connector
(116) power is applied to circuit 58A, connector (576), circuit 58A, and trailer socket connector (577). The
trailer marker relay (463-R8) coil is grounded through circuit 58-GA, circuit 58-G, circuit 70-G, circuit 56-G, and
circuits 11-GZ and 11-GI to left cab ground (429).
3. TROUBLESHOOTING
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relay, or solenoid.

Table 97 Heated Air Dryer
POINTS SPEC.
1. Off/ On Disconnect connector (102), 16A 12 ± 1.5 Go to Locate cause of low
(102), move key switch to gnd. volts. next step. or no voltage in circuit
to ignition position and at 16A or 13H, ignition
connector (102), circuit relay (462–R1), circuit
16A, measure voltage to 14S, fuse F2–C, or
ground. circuit 14R or 14K
from battery stud (B1),
then repair.
2. Off/ On Reconnect connector B4, 16B to 12 ± 1.5 Go to Locate cause of low
(102), remove circuit gnd. volts. next step. or no voltage in circuit
breaker B4, move 16B, 16A, or connector
key switch to ignition (102), then repair.
position, and at circuit
16B, measure voltage to
ground.
3. Off/ On Disconnect air dryer (N/L), 31 to 12 ± 1.5 Go to Locate cause of low
circuit 31 [connector gnd. volts. next step. or no voltage in circuit
(N/L)], and re-install 31, then repair.
circuit breaker B4. Move
position and at circuit
31, measure voltage to
ground.
4. On With ignition on, at (N/L), 31 to 12 ± 1.5 Go to Locate open or poor
connect (N/L), measure 31–G. volts. next step. connection in ground
voltage from circuit 31 to circuit 31–G to (J5)
31–G. mag. switch ground,
then repair.
s08270
Table 97 Heated Air Dryer (cont.)

POINTS SPEC.
5. Off With air dryer cooled Air dryer < 10 ohms. Go to Repair or replace
to below 50° F (10° C), term. to next step. defective heater
check for continuity of housing. element or thermal
air dryer element and switch.
thermal switch.
6. Off Circuits and dryer check
good. Reconnect circuit
31.

Table 98 Heated Fuel Filter
POINTS SPEC.
1. Off/ On Disconnect connector (102), 16A 12 ± 1.5 Go to Locate cause of low
to ignition position, and 16A or 13H, ignition
at connector (102) circuit relay (462–R1), circuit
16A, measure voltage to 14S, fuse F2–C, or
ground. circuit 14R or 14K
from battery stud (B1),
then repair.
2. Off/ On Reconnect connector B4, 16B to 12 ± 1.5 Go to Locate cause of low
(102), remove circuit gnd. volts. next step. or no voltage in circuit
breaker B4, move 16B, circuit 16A, or
key switch to ignition connector (102), then
position, and at circuit repair.
16B measure voltage to
ground.
3. Off/ On Remove fuel heater At relay 12 ± 1.5 Go to Locate cause of low
relay and re-install circuit socket, volts. next step. or no voltage in circuit
breaker B4. Move 31A to gnd. 31, then repair.
position and at circuit
31A, measure voltage to
ground.
4. On With ignition on, at relay At relay 12 ± 1.5 Go to Locate open or poor
socket, measure voltage socket, volts. next step. connection in black
from circuit 31A to black 31A to wire to (J5) mag.
wire [going to (J5)]. black wire. switch ground, then
repair.
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Table 98 Heated Fuel Filter (cont.)

POINTS SPEC.
5. On With ignition on, at relay At relay 12 ± 1.5 Go to Locate cause of low
socket, measure voltage socket, volts. next step. or no voltage in black
from black wire (coming black wire wire from resetting
from B7) to black wire to black fuse B7 and circuit
[going to (J5)]. wire. 14B, then repair.
6. Off Bench test fuel heater Relay, < 1 ohm. Go to Replace defective fuel
relay by measuring term. 30 next step. heater relay.
resistance from terminal to 87A.
30 to 87A.
7. Off Bench test fuel heater Energized < 1 ohm. Go to Replace defective fuel
relay by applying +12 relay, term. next step. heater relay.
volts to terminal 86, 30 to 87.
ground to terminal
85, and measuring
30 to 87.
8. Off/ On Re-install fuel heater (60), red to 12 ± 1.5 Go to Locate cause of low or
relay, disconnect gnd. volts. next step. no voltage in red wire,
connector (60), and then repair.
move key switch to
ignition position. At (60)
red wire to ground.
9. On At connector (60), (60), red to 12 ± 1.5 Go to Locate open or poor
measure voltage from brown. volts. next step. connection in brown
red wire to brown wire. wire to (J5) magnetic
switch mounting bolt
ground.
10. Off Circuits to heated fuel
filter check good. If filter
fails to warm fuel, repair
or replace.

Without Sleeper
Table 99 Without Sleeper

POINTS SPEC.
1. Off At trailer socket (577) (577), 11P < 1 ohm. Go to Locate open or poor
and circuit 11P, measure to gnd. next step. connection in circuit
resistance to ground. 11P, then repair.
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Table 99 Without Sleeper (cont.)

POINTS SPEC.
2. Off Remove trailer stop light (464– 12 ± 1.5 Go to Locate cause of low
relay (464-R10) and at R10), 70B volts. next step. or no voltage in circuit
circuit 70B, measure to gnd. 70B from stop light
voltage to ground while switch (421), then
an assistant applies repair.
service brakes.
3. Off At relay socket (464– 12 ± 1.5 Go to Locate cause of low
(464–R10) and circuit R10), 70C volts. next step. or no voltage in circuit
70C, measure voltage to to gnd. 70C from 30A fuse
ground. F3–B, then repair.
4. Off At relay socket (464– < 1 ohm. Go to Locate open or poor
(464–R10) and circuit R10), next step. connection in circuit
70–G, measure 70–G to 70–G, 56–G, 11–GZ,
resistance to ground. gnd. or 11–GI to left cab
ground (429), then
repair.
5. Off Bench test trailer stop Relay < 1 ohm. Go to Replace defective
light relay (464–R10) by (464– next step. trailer stop light relay
measuring resistance R10), term. (464–R10).
from terminal 30 to 87A. 30 to 87A.
6. Off Bench test trailer stop Energized < 1 ohm. Go to Replace defective
light relay (464–R10) by relay (464– next step. trailer stop light relay
applying +12V to terminal R10), term. (464–R10).
86, ground to terminal 30 to 87.
85, and measuring
30 to 87.
7. Off Re-install trailer stop (577), 70C 12 ± 1.5 Go to Locate cause of
light relay and at trailer to gnd. volts. next step. low or no voltage in
socket (577) and circuit circuit 70C, connector
70C, measure voltage (114)/(575), or circuit
to ground while an 70C, then repair.
assistant applies the
service brake.
8. Off Remove left turn relay (464– 12 ± 1.5 Go to Locate cause of low or
(464–R11), and at circuit R11), 56 volts. next step. no voltage in circuit 56
56, measure voltage to to gnd. from 15A fuse F7–B,
9. Off Move turn signal switch (464– Pulsating Go to Locate cause of low
to left turn position and at R11), 56A 12 ± 1.5 next step. or no voltage in circuit
relay socket (464–R11) to gnd. volts. 56A, then repair.
voltage to ground.
s08270

POINTS SPEC.
10. Off Bench test left turn relay Relay < 1 ohm. Go to Replace defective
(464–R11) by measuring (464– next step. relay.
resistance from terminal R11), term.
30 to 87A. 30 to 87A.
11. Off Bench test left turn relay Energized 12 ± 1.5 Go to Replace defective
(464–R11) by applying relay (464– volts. next step. relay.
+12V to terminal 86, R11), term.
ground to terminal 30 to 87.
85, and measuring
30 to 87.
12. Off Re-install left turn relay (577), 56D Pulsating Go to Locate cause of
(464–R11), place turn to gnd. 12 ± 1.5 next step. low or no voltage in
signal switch in left turn volts. circuit 56D, connector
position, and at trailer (116)/(576), or circuit
socket (577) and circuit 56D, then repair.
56D, measure voltage to
ground.
13. Off Remove right turn relay (464– 12 ± 1.5 Go to Locate cause of low or
57, measure voltage to to gnd. from 15A fuse F7–C,
to right turn position R12), 57A 12 ± 1.5 next step. or no voltage in circuit
and at relay socket to gnd. volts. 57A, then repair.
(464–R12) circuit 57A,
measure voltage to
ground.
15. Off Bench test right turn relay Relay < 1 ohm. Go to Replace defective
30 to 87A. 30 to 87A.
16. Off Bench test right turn relay Energized < 1 ohm. Go to Replace defective
(464–R12) by applying relay (464– next step. relay.
85, and measuring
30 to 87.
s08270

POINTS SPEC.
17. Off Re-install right turn relay (577), 57D Pulsating Go to Locate cause of
(464–R12), place turn to gnd. 12 ± 1.5 next step. low or no voltage in
signal switch in right turn volts. circuit 57D, connector
position, and at trailer (116)/(576), or circuit
socket (577) and circuit 57D, then repair.
57D, measure voltage to
ground.
18. Off Remove trailer ABS fuse Fuse < 1 ohm. Re-install Locate cause of
F10–A (location may F10–A. fuse. Go overload condition,
vary), and check for to next then repair. Replace
open condition. step. fuse.
19. Off At ABS fuse F10–A F10–A, 12 ± 1.5 Go to Locate cause of low
(location may vary) and 94AH to volts. next step. or no voltage in circuit
circuit 94AH, measure gnd. 94AH from (B1)
voltage to ground. battery stud (779),
then repair.
20. Off Remove trailer ABS relay (483) 94AJ 12 ± 1.5 Go to Locate cause of low
to ignition position, and 94AJ from I1 ignition
at circuit 94AJ measure adapter (518), then
21. On At (483) measure voltage (483), 12 ± 1.5 Go to Locate open or poor
from circuit 97AJ to 94AJ to volts. next step. connection in circuit
94–GD. 94–GD. 94–GD, then repair.
22. Off Bench test trailer ABS Relay < 1 ohm. Go to Replace defective
relay (483) by measuring (483), next step. relay.
resistance from terminal term. 30
30 to 87A. to 87A.
23. Off Bench test trailer ABS Energized < 1 ohm. Go to Replace defective
relay (483) by applying relay (483), next step. relay.
+12V to terminal 86, term. 30 to
85, and measuring
30 to 87.
24. Off/ On Re-install ABS relay (577), 12 ± 1.5 Go to Locate cause of low
(483), and move key 94AF to volts. next step. or no voltage in circuit
switch to ignition position. gnd. 94AF, connector
At (577) circuit 94AF, (114)/(575), or circuit
measure voltage to 94AF, then repair.
ground.
25. Off Remove trailer tail light (464– R9), 12 ± 1.5 Go to Locate cause of low or
relay (464–R9), and 68 to gnd. volts. next step. no voltage in circuit 68
at circuit 68, measure from 30A fuse F3–C,
s08270

POINTS SPEC.
26. Off At relay socket (464–R9), (464– 12 ± 1.5 Go to Locate open or poor
measure voltage from R9), 68 to volts. next step. connection in circuit
circuit 68 to 58–G. 58–G. 58–G, 70–G, 56–G,
11–GZ, or 11–GI to
left cab ground (429),
then repair.
27. Off Move headlight switch to (464– R9), Pulsating Go to Locate cause of low
park light position and at 58P to gnd. 12 ± 1.5 next step. or no voltage in circuit
relay socket (464–R9) volts. 58P from trailer lights
circuit 58P, measure switch (409), then
28. Off Bench test trailer tail Relay < 1 ohm. Go to Replace defective
light relay (464–R9) by (464– R9), next step. relay.
measuring resistance term. 30 to
from terminal 30 to 87A. 87A.
29. Off Bench test trailer tail Energized < 1 ohm. Go to Replace defective
light relay (464–R9) by relay (464– next step. relay.
applying +12V to terminal R9), term.
85, and measuring
30 to 87.
30. Off Re-install trailer tail light (577), 68A Pulsating Go to Locate cause of low
relay (464–R9), place to gnd. 12 ± 1.5 next step. or no voltage in circuit
turn signal switch in left volts. 68E, 68A, connector
turn position, and at (114)/(575), or circuit
trailer socket (577) and 68A, then repair.
voltage to ground.
31. Off Remove trailer marker (463– R8), 12 ± 1.5 Go to Locate cause of low
relay (463–R8), and at 58D to gnd. volts. next step. or no voltage in circuit
circuit 58D, measure 58D from 20A fuse
voltage to ground. F3–A, then repair.
32. Off At relay socket (463–R8), (463– R8), 12 ± 1.5 Go to Locate open or poor
measure voltage from 58D to volts. next step. connection in circuit
circuit 58D to 58–GA. 58–GA. 58–GA, 58–G, 70–G,
56–G, 11–GZ, or
11–GI to left cab
ground (429), then
repair.
park light position and at 58C to gnd. 12 ± 1.5 next step. or no voltage in circuit
relay socket (463–R8) volts. 58C, then repair.
voltage to ground.
s08270

POINTS SPEC.
34. Off Bench test trailer marker Relay < 1 ohm. Go to Replace defective
relay (463–R8) by (463– R8), next step. relay.
35. Off Bench test trailer marker Energized < 1 ohm. Go to Replace defective
relay (463–R8) by relay (463– next step. relay.
85, and measuring
30 to 87.
36. Off Re-install trailer marker (577), 58A Pulsating Trailer Locate cause of
relay (463–R8), place to gnd. 12 ± 1.5 socket low or no voltage in
headlight switch in park volts. circuits circuit 58A, connector
lights position, and at check (116)/(576), or circuit
trailer socket (577) and good. 58A, then repair.
voltage to ground.
With Sleeper
Table 100 With Sleeper

POINTS SPEC.
1. Off At trailer socket (577) (577), 11P < 1 ohm. Go to Locate open or poor
and circuit 11P, measure to gnd. next step. connection in circuit
resistance to ground. 11P, then repair.
2. Off Remove trailer stop light (464– 12 ± 1.5 Go to Locate cause of low
relay (464–R10) and R10), 70B volts. next step. or no voltage in circuit
at circuit 70B, measure to gnd. 70B from stop light
voltage to ground while switch (421), then
an assistant applies repair.
service brakes.
3. Off At relay socket (464– 12 ± 1.5 Go to Locate cause of low
(464–R10) and circuit R10), 70C volts. next step. or no voltage in circuit
70C, measure voltage to to gnd. 70C from 30A fuse
ground. F3–B, then repair.
4. Off At relay socket (464– < 1 ohm. Go to Locate open or poor
(464–R10) and circuit R10), next step. connection in circuit
70–G, measure 70–G to 70–G, 56–G, 11–GZ,
resistance to ground. gnd. or 11–GI to left cab
ground (429), then
repair.
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Table 100 With Sleeper (cont.)

POINTS SPEC.
5. Off Bench test trailer stop Relay < 1 ohm. Go to Replace defective
light relay (464–R10) by (464– next step. trailer stop light relay
measuring resistance R10), term. (464–R10).
from terminal 30 to 87A. 30 to 87A.
6. Off Bench test trailer stop Energized < 1 ohm. Go to Replace defective
light relay (464–R10) by relay (464– next step. trailer stop light relay
applying +12V to terminal R10), term. (464–R10).
85, and measuring
30 to 87.
7. Off Re-install trailer stop (577), 70C 12 ± 1.5 Go to Locate cause of
light relay and at trailer to gnd. volts. next step. low or no voltage in
socket (577) and circuit circuit 70C, connector
70C, measure voltage (114), or circuit 70C,
to ground while an connector (575) or
assistant applies the circuit 70C, then
service brake. repair.
8. Off Remove left turn relay (464– 12 ± 1.5 Go to Locate cause of low or
56, measure voltage to to gnd. from 15A fuse F7–B,
to left turn position and at R11), 56A 12 ± 1.5 next step. or no voltage in circuit
relay socket (464–R11) to gnd. volts. 56A, then repair.
voltage to ground.
10. Off Bench test left turn relay Relay < 1 ohm. Go to Replace defective
30 to 87A. 30 to 87A.
11. Off Bench test left turn relay Energized < 1 ohm. Go to Replace defective
85, and measuring
30 to 87.
12. Off Re-install left turn relay (577), 56D Pulsating Go to Locate cause of low
(464–R11), place turn to gnd. 12 ± 1.5 next step. or no voltage in circuit
signal switch in left turn volts. 56D, connector (116)
position, and at trailer circuit 56D, connector
socket (577) and circuit (576) or, circuit 56D,
56D, measure voltage to then repair.
ground.
s08270

POINTS SPEC.
13. Off Remove right turn relay (464– 12 ± 1.5 Go to Locate cause of low or
57, measure voltage to to gnd. from 15A fuse F7–C,
to right turn position R12), 57A 12 ± 1.5 next step. or no voltage in circuit
and at relay socket to gnd. volts. 57A, then repair.
(464–R12) circuit 57A,
measure voltage to
ground.
15. Off Bench test right turn relay Relay < 1 ohm. Go to Replace defective
30 to 87A. 30 to 87A.
16. Off Bench test right turn relay Energized < 1 ohm. Go to Replace defective
85, and measuring
30 to 87.
17. Off Re-install right turn relay (577), 57D Pulsating Go to Locate cause of low
(464–R12), place turn to gnd. 12 ± 1.5 next step. or no voltage in circuit
signal switch in right turn volts. 57D, connector (116),
position, and at trailer circuit 57D, connector
socket (577) and circuit (576) or circuit 57D,
57D, measure voltage to then repair.
ground.
18. Off Remove trailer ABS fuse F10–A. < 1 ohm. Re-install Locate cause of
F10–A (location may fuse. Go overload condition,
vary), and check for to next then repair. Replace
open condition. step. fuse.
19. Off At ABS fuse F10–A F10–A, 12 ± 1.5 Go to Locate cause of low
(location may vary) and 94AH to volts. next step. or no voltage in circuit
circuit 94AH, measure gnd. 94AH from (B1)
voltage to ground. battery stud (779),
then repair.
20. Off Remove trailer ABS relay (483) 94AJ 12±1.5 Go to Locate cause of low
(483), move key switch to gnd. volts next step. or no voltage in circuit
to ignition position, and 94AJ from I1 ignition
at circuit 94AJ measure adapter (518), then
21. On At (483) measure voltage (483), 12 ± 1.5 Go to Locate open or poor
from circuit 97AJ to 94AJ to volts. next step. connection in circuit
94–GD. 94–GD. 94–GD, then repair.
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POINTS SPEC.
22. Off Bench test trailer ABS Relay < 1 ohm. Go to Replace defective
relay (483) by measuring (483), next step. relay.
30 to 87A. to 87A.
23. Off Bench test trailer ABS Energized < 1 ohm. Go to Replace defective
relay (483) by applying relay (483), next step. relay.
+12V to terminal 86, term. 30 to
85, and measuring
30 to 87.
24. Off/ On Re-install ABS relay (577), 12 ± 1.5 Go to Locate cause of low
(483), and move key 94AF to volts. next step. or no voltage in circuit
switch to ignition position. gnd. 94AF, connector (114),
At (577) circuit 94AF, circuit 94AF, connector
measure voltage to (575), or circuit 94AF,
25. Off Remove trailer tail light (464– R9), 12 ± 1.5 Go to Locate cause of low or
relay (464–R9), and 68 to gnd. volts. next step. no voltage in circuit 68
at circuit 68, measure from 30A fuse F3–C,
26. Off At relay socket (464–R9), (464– 12 ± 1.5 Go to Locate open or poor
measure voltage from R9), 68 to volts. next step. connection in circuit
circuit 68 to 58–G. 58–G. 58–G, 70–G, 56–G,
11–GZ, or 11–GI to
left cab ground (429),
then repair.
park light position and at 58P to gnd. 12 ± 1.5 next step. or no voltage in circuit
relay socket (464–R9) volts. 58P from trailer lights
circuit 58P, measure switch (409), then
28. Off Bench test trailer tail Relay < 1 ohm. Go to Replace defective
light relay (464–R9) by (464– R9), next step. relay.
29. Off Bench test trailer tail Energized 12 ± 1.5 Go to Replace defective
light relay (464–R9) by relay (464– volts. next step. relay.
85, and measuring
30 to 87.
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POINTS SPEC.
30. Off Re-install trailer tail light (577), 68A Pulsating Go to Locate cause of low
relay (464–R9), place to gnd. 12 ± 1.5 next step. or no voltage in circuit
turn signal switch in left volts. 68E, 68A, connector
turn position, and at (114), circuit 68A,
trailer socket (577) and connector (575),
circuit 68A, measure or circuit 68A, then
31. Off Remove trailer marker (463– R8), 12 ± 1.5 Go to Locate cause of low
relay (463–R8), and at 58D to gnd. volts. next step. or no voltage in circuit
circuit 58D, measure 58D from 20A fuse
voltage to ground. F3–A, then repair.
32. Off At relay socket (463–R8), (463– R8), 12 ± 1.5 Go to Locate open or poor
measure voltage from 58D to volts. next step. connection in circuit
circuit 58D to 58–GA. 58–GA. 58–GA, 58–G, 70–G,
56–G, 11–GZ, or
11–GI to left cab
ground (429), then
repair.
park light position and at 58C to gnd. 12 ± 1.5 next step. or no voltage in circuit
relay socket (463–R8) volts. 58C, then repair.
voltage to ground.
34. Off Bench test trailer marker Relay < 1 ohm. Go to Replace defective
relay (463–R8) by (463–R8), next step. relay.
35. Off Bench test trailer marker Energized < 1 ohm. Go to Replace defective
relay (463–R8) by relay (463– next step. relay.
85, and measuring
30 to 87.
36. Off Re-install trailer marker (577), 58A Pulsating Trailer Locate cause of low
relay (463–R8), place to gnd. 12 ± 1.5 socket or no voltage in circuit
headlight switch in park volts. circuits 58A, connector (116),
lights position, and at check circuit 58A, connector
trailer socket (577) and good. (576), or circuit 58A,
circuit 58A, measure then repair.
voltage to ground.
A1 Accessory Adapter (516). . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, center
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(B1) Battery Stud (779). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On top of power distribution center

F1 — F5 Fusebock (462). . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
F6 — F8 Fuseblock (463). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
F9 — F13 Fuseblock (464). . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
G5 Ground Adapter (533). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind center instrument panel
I1 Ignition Adapter (518). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind center instrument panel
(J5) Mag. Switch Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At mag. switch mntg. bolt, left side of battery box
(J7) Cab Ground Junction. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At left luggage compartment on tunnel
(36) Turn Signal Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel at left
(60) Heated Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At filter, left rear of cab
(102) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor, frt rt, 1/2 replace by (338) W/Ser 60
(114) Trailer Socket #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind driver’s seat
(116) Trailer Socket #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind driver’s seat
(125) Chassis Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor, front right
(409) Trailer Lights Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(410) Headlight Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(421) Stop Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At dash panel inside cab
(429) Left Cab Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left hand cowl inner panel
(452) Key Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At base of wing panel (right instrument panel)
(462) Ignition Relay R1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(463) Trailer Marker Relay R8. . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(464) Trailer Tail Lights Relay R9. . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(464) Stop Light Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(464) Lt. Turn Relay R11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(464) Rt. Turn Relay R12. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(483) Trailer ABS Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(501) Flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(518) Ignition Adapter (I1). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind center instrument panel
(533) Ground Adapter G5. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind center instrument panel
(575) Sleeper Trailer Socket #1. . . . . . . . . . . . . . . . . . . . . .. . . . . . At pigtail of trailer socket
(576) Sleeper Trailer Socket #2. . . . . . . . . . . . . . . . . . . . . .. . . . . . At pigtail of trailer socket
(577) Trailer Socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At rear of cab or sleeper
(779) Battery Stud (B1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At top of power distribution center
See Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, and Figure 8.
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Figure 124 Air Dryer Wiring — 9800 SFA 63 Inch BBC
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Figure 125 Air Dryer Wiring — 9800 SFA 110 Inch BBC
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Figure 126 Air Dryer Wiring — 9800 SBA
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Figure 127 Air Dryer Wiring — 9800
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Figure 128 Trailer Socket Wiring for Cab Mounted Location — 9800 With 63 Inch Cab
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Figure 129 Trailer Socket Wiring for Cab Mounted Location — 9800 With 89 or 110 Inch Cab
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Figure 130 Trailer Socket Wiring for Sleeper Mounted Location — 9800 With 89 Inch Cab
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Figure 131 Trailer Socket Wiring for Sleeper Mounted Location — 9800 With 110 Inch Cab
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10 LIGHT SYSTEMS 387
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
1.1. BACK-UP LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
1.2. CAB CLEARANCE/ID LIGHTS (FLAT ROOF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
1.3. CAB DOME, READING, AND COURTESY LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
1.4. STOP, TAIL, TURN AND HAZARD LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
1.5. FOG LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
1.6. FRONT PARK, TURN AND MARKER LIGHTS — 9800 SFA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
1.7. FRONT PARK, TURN AND MARKER, AND SIDE TURN AND MARKER — 9800 SBA. . . . . . .389
1.8. HEADLIGHTS — 9800 SFA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
1.9. HEADLIGHTS — 9800 SBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
1.10. DAYTIME RUNNING LIGHTS (DRL) — CANADA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
1.11. DAYTIME RUNNING LIGHTS (DRL) — USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
1.12. LUGGAGE COMPARTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
1.13. PANEL LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
1.14. SPOT, BUNK FLUORESCENT AND READING LIGHTS, AND CIGAR LIGHTER (NON-RAISED
ROOF CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
1.15. BUNK FLUORESCENT AND READING LIGHTS (WITH RAISED ROOF CAB). . . . . . . . . . . . . . .390
1.16. TRAILER WORK OR HOOK-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
2.1. BACK-UP LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
2.2. CAB CLEARANCE/ID LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
Flat Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
Raised Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
2.3. CAB, DOME, READING, COURTESY LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
2.4. STOP, TAIL, TURN AND HAZARD LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392
2.5. FOG LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .393
2.6. FRONT PARK, TURN AND MARKER LIGHTS — 9800 SFA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .393
2.7. FRONT PARK, TURN AND MARKER, AND SIDE TURN AND MARKER LIGHTS — 9800
SBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .393
2.8. HEADLIGHTS — 9800 SFA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394
2.9. HEADLIGHTS — 9800 SBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395
2.13. PANEL LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .396
ROOF CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397
3.1. BACK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399
3.2. CAB CLEARANCE/ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
Flat Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
Raised Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402
3.3. CAB DOME, READING, COURTESY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403
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388 10 LIGHT SYSTEMS
3.4. STOP, TAIL, TURN AND HAZARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406

3.5. FOG LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410
3.6. FRONT PARK, TURN, AND MARKER — 9800 SFA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412
3.7. FRONT PARK, TURN AND MARKER, AND SIDE TURN AND MARKER — 9800 SBA. . . . . . .414
3.8. HEADLIGHTS — 9800 SFA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .417
3.9. HEADLIGHTS — 9800 SBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
3.13. PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .429
ROOF CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436
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Model: 9800
1. DESCRIPTION
1.1. BACK-UP LIGHTS
The vehicle back-up lights are a set of lamps that come on when the vehicle transmission is shifted into reverse.
1.2. CAB CLEARANCE/ID LIGHTS (FLAT ROOF)

Cab identification lights (three lights located in the center of the cab roof) function to provide quick visual
identification of trucks and tractors in the dark. They are required on trucks and tractors wider than 80" to
distinguish them from automobiles. Clearance lights are located at the widest points of the cab roof to identify
the width of the vehicle.
1.3. CAB DOME, READING, AND COURTESY LIGHTS

The left and right dome and courtesy lights provide light when they are switched on at the dome light switch, or
when the cab doors are opened and the dome light switch is set for automatic operation. Thus the driver is
able to fill out log books, etc., and enter and exit the cab safely after dark. The left and right reading lights
are controlled individually by a switch at each lamp.
1.4. STOP, TAIL, TURN AND HAZARD LIGHTS

This set of circuits contains the turn signal switch, stop light switch, flasher unit (turn signal/hazard), right and
left turn relays, stop light relay, and right and left stop, turn, and tail light assemblies for the rear of the vehicle.
The turn indicators located in the instrument cluster are also included.
1.5. FOG LIGHTS

Fog lights are a set of lights that are mounted low on the front of the truck and operate only when the
headlights are on and in the low beam mode. (Many state laws prohibit operation of fog lights with the high
beam headlights on.) Since they are mounted low, they are useful in foggy conditions.
NOTE – Fog lights will only function if headlight switch is in the on position, dimmer switch is in low
beam position, and the fog light switch is in the on position.
1.6. FRONT PARK, TURN AND MARKER LIGHTS — 9800 SFA

This set of circuits consists of left front and right front combination park, turn and marker light units.
1.7. FRONT PARK, TURN AND MARKER, AND SIDE TURN AND MARKER — 9800 SBA
This set of circuits consists of left and right side combination turn and marker lights, and left front and right front
combination park, turn, and marker lights.
1.8. HEADLIGHTS — 9800 SFA

The 9800 model truck uses a two headlamp system. Each lamp contains a low beam element and a high
beam element. The headlight switch and circuits function to turn the headlights on and off, and when on or in
parking light position, allow parking and clearance lights to function if they are selected. The dimmer switch is
used to switch between low beam (dim) elements and high beam (bright) elements.
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1.9. HEADLIGHTS — 9800 SBA

The 9800 model truck uses a two headlamp system. Each lamp contains a low beam element and a high
beam element. The headlight switch and circuits function to turn the headlights on and off, and when on or
in parking light position, allow parking and clearance lights to function. The dimmer switch is used to switch
between low beam (dim) elements and high beam (bright) elements.
1.10. DAYTIME RUNNING LIGHTS (DRL) — CANADA

The Canadian DRL system utilizes a relay to feed power to the headlights, in electrical series, causing them
to illuminate at about 50% of the normal brightness, thus providing better daytime visibility. This relay and
a park brake switch shut off the DRL when the tractor is parked. A DRL night relay is provided to turn
off the DRL circuitry when the standard headlight system is turned on, and to enable fog light operation
with standard headlights only.
1.11. DAYTIME RUNNING LIGHTS (DRL) — USA

The USA DRL system utilizes an electronic module to drive the low beam headlight elements at approximately
50% of their normal brightness, thus providing better daytime visibility. The module and a park brake switch
shut off the DRL circuitry when the tractor is parked. The module also shuts off the DRL system when the
standard headlight system is turned on, and requires the headlights to be on and low beams selected for
the fog lights to operate.
1.12. LUGGAGE COMPARTMENT

Switches and compartment lights are provided in both the left and right luggage compartments, thus
illuminating the compartments when the doors are opened.
1.13. PANEL LIGHTS

Panel lights are low wattage bulbs that illuminate gauges and other miscellaneous items. The panel light
switch dims/brightens panel lights for the right and left gauge cluster, speedo/tach module, cigar lighter, heater
control, push button start, key switch, and fresh air control.
1.14. SPOT, BUNK FLUORESCENT AND READING LIGHTS, AND CIGAR LIGHTER
(NON-RAISED ROOF CAB)
The bunk fluorescent light is a fluorescent light and switch assembly mounted at the headliner to provide the
main source of illumination in the sleeper. An additional light switch is located in the control panel where it is
more accessible. The reading light is located at the control panel for the sleeper bunk to provide illumination
for reading when the fluorescent light is off, or when additional light is needed. The cigar lighter is located in
the control panel to be used for lighting cigars or powering accessories. Single or dual spotlights are also
available, have on/off switches mounted on their handles, and are controlled from inside the sleeper.
1.15. BUNK FLUORESCENT AND READING LIGHTS (WITH RAISED ROOF CAB)
The bunk fluorescent light is a fluorescent light and switch assembly mounted at the headliner to provide the
main source of illumination in the sleeper. An additional light switch is located in the control panel where it
is more accessible. The reading light is also located at the control panel for the sleeper bunk to provide
illumination for reading when the fluorescent light is off, or when additional light is needed. The cigar lighter is
located in the control panel to be used for lighting cigars or powering accessories.
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1.16. TRAILER WORK OR HOOK-UP

The work light circuit consists of a work light, a work light switch, and an indicator light located in the instrument
cluster. The work light, located on the back of the sleeper, provides light for the operator when the trailer air
and electrical lines are being connected or disconnected from the trailer.
2. OPERATION
2.1. BACK-UP LIGHTS
When the ignition key switch (452) is in the ignition position, the ignition relay (462-R1) becomes energized.
With the relay energized, power is supplied to circuits 13H and 13J, 20A fuse F4-C, circuit 16A, connector
(102), circuits 16A and 16C, connector (N/L), 15A circuit breaker B2, connector (N/L), circuit 71A, connector
(189), and a white wire to the back-up switch (12). When the transmission is placed in reverse, the switch
contacts close and power flows through the blue wire, connector (189), circuit 71, connector (102), circuit 71,
connector (125), a blue wire, and connector (4) of the left back-up light, causing it to illuminate. The left light is
grounded through connector (4), and a white wire to frame ground. Power also flows from the left light through
connector (4A), the blue wire, and connector (3) of the right back-up light, causing it to illuminate. The right light
is grounded through connector (3), the white wire, connectors (4A) and (4), and a white wire to frame ground.
2.2. CAB CLEARANCE/ID LIGHTS

Flat Roof
When headlight switch (410) is in the park light or headlight position, and trailer lights switch (409) is on, trailer
tail light relay (464-R9) will be energized. With the relay energized, power is applied to circuits 68E and 68B,
15A fuse F8-C, circuits 68C and 58AF, connector (22), and circuit 58AF to a splice. From the splice power is
supplied to lamp (766) by circuit 58H, lamp (767) by circuit 58J, lamp (768) by circuit 58K, lamp (769) by circuit
58L, and lamp (770) by circuit 58M, thus causing the lamps to illuminate. A ground path is provided by roof
strainer ground (J3), and circuit 58-GB to a splice. From the splice lamp (766) is grounded through circuit
58-GH, lamp (767) through circuit 58-GJ, lamp (768) through circuit 58-GK, lamp (769) through circuit 58-GL,
and lamp (770) through circuit 58-GM.
Raised Roof
When the headlight switch (410) is in the park light or headlight position, and the trailer lights switch (409) is
on, the trailer tail light relay (464-R9) will be energized. With the relay energized, power is applied to circuits
68E and 68B, 15A fuse F8-C, circuits 68C and 58AF, connector (22), circuit 58AF, connector (7), and circuit
58AF to connector (775). From connector (775) power is applied to lamp (58) by circuit 58A, lamp (59) by
circuit 58B, lamp (61) by circuit 58C, lamp (62) by circuit 58D, and lamp (66) by circuit 58E, thus causing the
lamps to illuminate. Lamp (66) is grounded through circuit 58-GD to lamp (62). Lamp (62) is grounded through
circuit 58-GC to lamp (61). Lamp (61) is grounded through circuit 58-GB to lamp (59). Lamp (59) is grounded
through circuit 58-GA to lamp (58). Lamp (58) is grounded through circuit 58-G to connector (775). A ground
path is provided by the right cab ground stud (404), circuits 11-GBB, 11-GAN, conn. (81), circuits 11-GAN and
11-GAH, conn. (557), and circuits 11-GAH and 58-G to conn. (775).
2.3. CAB, DOME, READING, COURTESY LIGHTS

Power from the (B2) battery stud is applied to circuits 14W and 14T, 10A fuse F2-B, circuit 63AC, connector
(19), circuits 63C and 63S, connector (559), and circuit 63 to a splice. From the splice power is applied to
circuit 63C and the left dome light connector (571), and circuit 63A and the right dome light connector (570).
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When the dome light switch (439) is moved to the on position, a ground path is provided by the L4 panel
ground adapter (587), circuits 11-GLB and 63-G, dome light switch (439), circuit 63AD, connector (19), circuit
63D, connector (559), and circuit 63B to a splice. From the splice, the left dome light (571) is grounded through
circuit 63D, and the right dome light (570) is grounded through circuit 63E, thus causing them to illuminate.
Power from the (B2) battery stud is also applied to circuits 14W and 14T, 10A fuse F2-B, circuit 63AC,
connector (19), and circuit 63C to a splice. From the splice power is applied to circuit 63R and the left reading
light connector (569), and circuit 63T and the right reading light connector (568).
When the switch on a reading light is moved to the on position, the light will illuminate. The ground path
for the left reading light is through connector (569), and circuits 63GR and 11-GAA to roof strainer ground
(J3). The ground for the right reading light is through connector (568), and circuits 63-GT and 11-GAA to
roof strainer ground (J3).
Likewise power from the (B2) battery stud is applied to circuits 14W and 14T, 10A fuse F2-B, circuit 63AC,
connector (19), circuit 63C, connector (437), and circuit 63V to the left courtesy light (207). Power from
10A fuse F2-B is also applied to circuit 63V, connector (403), and circuit 63V to the right courtesy light
(207). When the dome light switch (439) is moved to the on position, a ground path is provided by the L4
panel ground adapter (587), circuits 11-GLB and 63-G, dome light switch (439), circuit 63AD, connector (19),
circuit 63D, connector (437), and circuit 63H to the left courtesy light (207). A ground path is also provided
by switch (439) to circuit 63H, connector (403), and circuit 63H to the right courtesy light (207), thus causing
the courtesy lights to illuminate.
When the dome light switch (439) is set in the automatic position, the dome lights and courtesy lights will be
automatically turned on when either the left or right door is opened. This is accomplished by the left door
switch and circuit 63J, or the right door switch and circuit 63K, in conjunction with the ground circuits leading
from the dome light switch to the lights.
2.4. STOP, TAIL, TURN AND HAZARD LIGHTS

(B2) battery stud supplies power to circuits 14H and 14E, 20A fuse F3-B, circuits 70 and 70F, and stop light
switch (421). When the service brakes are applied, the contacts of switch (421) close and power flows through
circuit 70B to the trailer stop light relay (464-R10) and circuit 70A to the turn signal switch connector (36). Thus
with the turn signal switch in its neutral position, power flows through the red wire, switch contacts, yellow
wire, circuit 56B, connector (125), and circuit 56B to left rear tractor stop lamp. The left lamp is grounded
through connector (4) and a white wire to frame ground. Thus with the turn signal switch in its neutral
position, power also flows through the green wire, circuit 57B, connector (125), circuit 57B, connector (4),
internal jumper, connector (4A), a green wire, and connector (3) to right rear tractor stop lamp. The right
lamp is grounded through connector (3), a white wire, connector (4A), an internal jumper, connector (4) and
a white wire to frame ground.
When the headlight switch (410) is in the headlight or park light position, power is fed by circuit 58E to the N.C.
contacts of trailer lights switch (409), to circuit 58P, and the coil of trailer tail light relay (464-R9). This energizes
the relay which is grounded through circuits 58-G, 70-G, 56-G, 11-GZ, and 11-GI to left cab ground (429). With
the relay energized, power flows from battery stud (B2) through circuits 14W and 14B, 30A fuse F3-C, circuit
68, N.O. relay contacts, circuits 68E and 68B, 15A fuse F8-C, circuits 68C and 68D, connector (125), and
circuit 68D to the left tractor tail light, and connector (4A), the brown wire and right tractor tail light connector
(3). The left tail light is grounded through connector (4) and the white wire to frame ground. The right tail light
is grounded through connector (3), the white wire, connectors (4A) and (4), and the white wire to frame ground.
With turn signal switch (36) in the left turn position, power flows from battery stud (B1) through circuits 14K and
14R, 20A fuse F2-D, circuit 55, flasher (501), and circuit 55A to the turn signal switch (36) black wire. Power
will flow through the closed contacts and orange wire of switch (36), and circuit 56A to the left turn relay, and
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through switch (36) and circuit 56E to the left front turn lights. Power will also flow through the yellow wire of
switch (36), and circuit 56B, connector (125), and circuit 56B to the left rear tractor turn light. With turn signal
switch (36) in the right turn position, power will flow through the closed contacts and the blue wire of switch
(36), and circuit 57A to the right turn relay, and through switch (36) and circuit 57E to the right front turn lights.
Power will also flow through the green wire of switch (36), and circuit 57B, connector (125), circuit 57B to the
left rear tractor light connectors (4) and (4A), and a green wire to the right rear tractor turn light (3).
The hazard lights system functions by the turn signal switch selecting both the left and right turn signal circuits
at the same time.
2.5. FOG LIGHTS

When the headlights are on and in the low beam position, power is fed to the fog lights switch (414) by way
of circuit 64B. When the fog lights switch (414) is moved to the on position, power is applied to circuit 64A
and the coil of the fog light relay (440).
This energizes the relay, which is grounded through circuit 64-GA, connector (78), circuits 64-GB and 64-GC to
G3 ground adapter (456) on vehicles without Canadian DRL. On vehicles with Canadian DRL, the fog light
relay is grounded through circuit 64-GA, connector (78), circuit 64-GA, DRL night relay (474), and circuits
66-GC, 66-GB and 66-GA to G6 ground adapter (616). With the relay energized, power flows from A3
accessories adapter (593) through circuit 12P, 20A fuse F10-A, circuit 64, N.O. relay contacts, circuit 64D,
connector (125), circuit 64P, connector (155), and circuit 64P to a splice. From the splice power flows through
circuit 64E, left fog light connector (156), and a black wire to the left fog light and through circuit 64H, right fog
light connector (157), and a black wire to the right fog light.
The left fog light is grounded through a white wire, the left fog light connector (156), circuits 11BX and
11BW, connector (155), and circuit 11-GW to frame ground (J11). The right fog light is grounded through a
white wire, the right fog light connector (157), circuits 11BY and 11BW, connector (155), and circuit 11-GW
to frame ground (J11).
2.6. FRONT PARK, TURN AND MARKER LIGHTS — 9800 SFA

The front park lights receive power through the trailer tail light relay (464-R9), circuits 68E and 68B, fuse F8-C,
circuits 68C and 54, and connector (N/L). From connector (N/L), power flows through circuit 54, connector
(N/L), a black wire, connector (N/L), and a brown wire to the left front park light. From connector (N/L), power
flows through circuit 54A, connector (N/L), a black wire, connector (N/L), and a brown wire to the right front
park light. The lights are grounded through their mounting hardware.
The left front turn light receives power through the turn signal switch (36), circuit 56E, connector (N/L), circuit
56E, a black wire, connector (N/L), and a red wire. The light is grounded through its mounting hardware.
The right front turn light receives power through the turn signal switch (36), circuit 57E, connector (N/L), circuit
57E, a black wire, connector (N/L), and a red wire. The light is grounded through its mounting hardware.
2.7. FRONT PARK, TURN AND MARKER, AND SIDE TURN AND MARKER LIGHTS
— 9800 SBA
The front park lights receive power through the trailer tail light relay (464-R9), circuits 68E and 68B, fuse F8-C,
circuits 68C and 54, and connector (N/L). From connector (N/L), power flows through circuit 54, connector
(N/L), and circuit 54 to a splice.
From the splice, power flows through a brown wire, the left front park light connector (242), and a brown wire to
the park light. Power also flows from the splice, through a brown wire, the left side marker light connector
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(241), and a black wire to the marker light. The left front park light is grounded through a dark blue wire,
connector (242), and a blue wire to a splice. The left side marker light is grounded through a white wire,
connector (241), and a blue wire to a splice. From the splice, a ground is provided through circuit 11-GL,
connector (498)/(423), circuit 11-GL, connector (490), and circuits 11-GM and 11-GF to left cab ground (429)
without Canadian daytime running lights. With Canadian DRL, the left front park light is grounded through a
dark blue wire, connector (242), a blue wire, a splice, circuit 11-GAG, connector (580), and circuit 11-GAG to
G6 ground adapter (616). As previously stated, the front park lights receive power through the trailer tail light
relay (464-R9), circuits 68E and 68B, fuse F8-C, circuits 68C and 54, and connector (N/L). From connector
(N/L), power flows through circuit 54A, connector (N/L), and circuit 54A to a splice.
From the splice, power flows through a brown wire, the right front park light connector (242), and a brown
wire to the marker light. Power also flows from the splice, through a brown wire, the right side marker light
connector (241), and a black wire to the marker light. The right front park light is grounded through a dark blue
wire, connector (242), and a blue wire to a splice. The right side marker light is grounded through a white
wire, connector (241), and a blue wire to a splice. From the splice, a ground is provided through circuit 11-GK,
connector (498)/(400), circuits 11-GK and 11-G to right cab ground (404).
The turn signal switch, when in left turn position, provides power to circuit 56E, connector (N/L), and circuit
56E to a splice. From the splice, power flows through a red wire, the left front turn light connector (242), and
a red wire to the left turn light. Power also flows from the splice, through a red wire, the left side turn light
connector (241), and a red wire to the left side turn light. The left front turn light is grounded through a dark
blue wire, connector (242), and a blue wire, to a splice. The left side turn light is grounded through a white wire,
connector (241), and a blue wire to a splice. From the splice, the lights on vehicles with Canadian DRL are
grounded through circuit 11-GAG, connector (580), and circuit 11-GAG to G6 ground adapter (616). From the
splice, the lights on vehicles without Canadian DRL are grounded through circuit 11-GL, connector (498)/(423),
circuit 11-GL, connector (490), and circuits 11-GM and 11-GF to left cab ground (429).
The turn signal switch, when in right turn position, provides power to circuit 57E, connector (N/L), and circuit
57E to a splice. From the splice, power flows through a red wire, the right front turn light connector (242), and
a red wire to the right turn light. Power also flows from the splice, through a red wire, the right side turn light
connector (241), and a red wire to the right side turn light. The right front turn light is grounded through a dark
blue wire, connector (242), and a blue wire to a splice. The right side turn light is grounded through a white
wire, connector (241), and a blue wire to a splice. From the splice, the lights are grounded through circuit
11-GK, connector (498)/(400), circuits 11-GK and 11-G, and right cab ground.
When the headlight switch is in the park lights position, the trailer tail light relay is energized, and power flows
through 15A fuse F8-C, circuits 68C and 54, and connector (N/L). From connector (N/L), power flows through
circuit 54, connector (N/L), and circuit 54 to a splice. From the splice power flows through a brown wire,
connector (242), and a brown wire to the left front marker light. From the splice power also flows through a
brown wire, connector (241), and a black wire to the left side marker light. From connector (N/L), power also
flows through circuit 54A, connector (N/L), and circuit 54A to a splice. From the splice power flows through a
brown wire, connector (242), and a brown wire to the right front marker light. From the splice power also flows
through a brown wire, connector (241), and a black wire to the right side marker light. Refer to the turn light
grounding above for a description of the marker light ground circuits.

When the headlight switch (410) is moved to the headlight on position, power from battery stud (B2) flows
through circuit 14D, 10A circuit breaker F6-C, circuit 50A, the contacts of switch (410), and circuit 50B to the
headlight relay (462-R4). This energizes the relay that is grounded through circuits 50-GB, 75-GC, 75-GB,
11-GN, and 11-GB to right cab ground stud (404). With the relay energized, power flows from battery stud
(B2) through circuit 14D, 20A circuit breaker F6-D, circuit 51, N.O. contacts of (462-R4), and circuit 51A
to dimmer switch (70).
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With switch (70) in low beam position, power flows through the switch contacts, circuit 53B, connector
(423)/(498), and circuit 53B, to the left headlight (2) low beam element, thus causing low beam illumination. On
vehicles without Canadian DRL, the left headlight is grounded through circuit 11-GL, connector (498)/(423),
circuit 11-GL, connector (N/L), and circuits 11-GM and 11-GF to left cab ground (429). On vehicles with
Canadian DRL, the left headlight is grounded through circuit 11-GL, connector (498)/(423), circuit 11-GL,
connector (N/L), circuit 66J, N.C. contacts of DRL day relay (475) and circuit 66-GA to G6 ground adapter
(616). Power also flows through the switch contacts, circuits 53 and 53A, connector (400)/(498), and circuit
53A to the right headlight (2) low beam element, thus causing low beam illumination. The right headlight is
grounded through circuits 11-GK and 11-G to right cab ground (404).
With switch (70) in high beam position, power flows through the switch contacts, circuit 52C, connector
(423)/(498), and circuit 52C to the left headlight (2) high beam element, thus causing high beam illumination.
Power also flows through the switch contacts, circuits 52 and 52B, connector (400)/(498), and circuit 52B to
the right headlight (2) high beam element, thus causing high beam illumination. See low beam illumination
operation above for description of ground circuits.

When the headlight switch (410) is moved to the headlight on position, power from battery stud (B2) flows
through circuit 14D, 10A circuit breaker F6-C, circuit 50A, the contacts of switch (410), and circuit 50B to the
headlight relay (462-R4). This energizes the relay that is grounded through circuits 50-GB, 75-GC, 75-GB,
11-GN, and 11-GB to right cab ground stud (404). With the relay energized, power flows from battery stud
(B2) through circuit 14D, 20A circuit breaker F6-D, circuit 51, N.O. contacts of (462-R4), and circuit 51A
to dimmer switch (70).
With switch (70) in low beam position, power flows through the switch contacts, circuit 53B, connector
(423)/(498), circuit 53B, and circuit (243) to the left headlight (2) low beam element, thus causing low beam
illumination. On vehicles without Canadian DRL, the left headlight is grounded through a blue wire, connector
(243), circuits 50-G and 11-GL, connector (498)/(423), circuit 11-GL, connector (N/L), and circuits 11-GM and
11-GF to left cab ground (429). On vehicles with Canadian DRL, the left headlight is grounded through a blue
wire, connector (243), circuit 66J, connector (498)/(423), circuit 11-GL, connector (N/L), circuit 66J, N.C.
contacts of DRL day relay (475) and circuit 66-GA to G6 ground adapter (616). Power also flows through
the switch contacts, circuits 53 and 53A, connector (400)/(498), circuit 53A, connector (243), and a red
wire to the right headlight (2) low beam element, thus causing low beam illumination. The right headlight is
grounded through a blue wire, connector (243), circuits 50-GA and 11-GK, connector (498)/(400), and circuits
11-GK and 11-G to right cab ground (404).
With switch (70) in high beam position, power flows through the switch contacts, circuit 52C, connector
(423)/(498), circuit 52C, connector (243), and a brown wire to the left headlight (2) high beam element, thus
causing high beam illumination. Power also flows through the switch contacts, circuits 52 and 52B, connector
(400)/(498), circuit 52B, connector (243), and a brown wire to the right headlight (2) high beam element, thus
causing high beam illumination. See low beam illumination operation above for description of ground circuits.

Power from the A3 accessories adapter (593) is applied to circuit 12R, 10A fuse F10-A, and circuit 66A to
DRL day relay (475) N.O. contacts. Circuit 66B applies this power also to the relay coil. When the park brake
is released, the contacts of the park brake switch (293) close. If the headlight switch is in the off position, a
ground path is applied to the DRL day relay (475), causing it to become energized. The ground path is
circuit 66D, the closed contacts of switch (293), circuit 66E, the N.C. contacts of relay (474), circuits 66-GC,
66-GB, and 66-GA to G6 ground adapter (616). With the DRL day relay (475) energized, the power that is
applied to the relay’s N.O. contacts will flow through the relay’s contacts, circuit 66J, connector (490), circuit
11-GL, connector (423)/(498), and circuit 11-GL to the common side of the left headlight elements. Since the
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headlights are then connected in series, the voltage will be divided in half, causing the 6 volts at each high
beam element to illuminate at approximately 50% of its brightness.
The DRL night relay (474) is grounded through circuits 66-GB and 66-GA to G6 ground adapter (616). Thus
when the headlight switch (410) is placed in the on position, power is applied to circuits 50B and 66H,
connector (N/L), and circuit 66H to the DRL relay (474). This energizes the relay which opens up the ground
circuit for the DRL day relay (475), and enables the ground to the fog light circuitry, thus de-energizing the
relay and causing the headlights to be connected in parallel and to illuminate at normal low beam brightness.

The DRL module (633) receives power from the B1 battery adapter (517), circuit 14BL, 15A fuse F10-B,
and circuit 66A. The module is grounded through circuit 66-GA to G6 ground adapter (616). When the key
switch is moved to the ignition position, power is applied to I2 ignition adapter (607), circuit 13AJ, 10A fuse
F10-A, and circuit 66D to the DRL module (633).
When the parking brakes are released, the DRL park brake switch (293) opens up. Thus the ground path
through circuit 66E, N.C. park brake switch contacts, and circuit 66-GB to G6 ground adapter (616) is removed.
This tells the module to power the low beam elements of the headlights at 50% of normal low beam brightness,
which is 75% to 84% of battery voltage. The power output to the headlights will continue, but be overridden by
power from the headlight switch, when the switch is moved to the on position.
Power is fed to fog light switch (414) by the DRL module over circuit 64D, connector (N/L), and circuit 64B.
Per federal law, this power is removed whenever high beam headlights are selected. The module knows to
remove the power to the fog lights when it senses that the high beams are on via circuit 66F, connector
(N/L), and circuit 66F.

Power is supplied by the (B2) battery stud to circuits 14W and 14T, 15A fuse F2-A, circuits 63E and 63F to the
black wire of the left luggage compartment light (101). The ground path for the left luggage light is completed
when the compartment door is opened and the contacts of the light switch close. The ground path consists of a
black wire, connector (169), the light switch, connector (169), and a white wire to a ground screw.
As with the left luggage compartment light, power is supplied by the (B2) battery stud to circuits 14W and 14T,
15A fuse F2-A, and circuit 63E to the black wire of the right luggage compartment light (101). The ground
path for the right luggage light is completed when the compartment door is opened and the contacts of the
light switch close. The ground path consists of a black wire, connector (171), the light switch, connector
(171), and a white wire to a ground screw.
2.13. PANEL LIGHTS

When the headlight switch (410) is in the parking lights or headlights on position, power is fed through the
trailer lights switch (409) to energize the trailer tail light relay (464–R9). With the relay energized, power flows
from battery stud (B2) through circuits 14W and 14B, 30A fuse F3–C,. circuit 68, the NO contacts relay
(464–R9), circuits 68E and 68B, 15A fuse F8–C, circuits 68C and 62 to panel light switch (416). The panel
light switch, which is grounded through circuits 11–GS and 11–GLC to L3 ground adapter (505), contains an
integrated circuit for variable voltage output. This adjustable voltage is applied to circuits 62A, 62S, and 62AE
to the L1 panel lights adapter (504). The adjustable voltage is also applied to circuits 62A and 62W going to
the panel light in the panel lights switch and to circuits 62A, 62S, and 62M to the L2 panel lights adapter (586).
Power from adapter (504) is applied to circuit 62BW and a splice. From the splice power is applied to circuit
62T, connector (N/L), and the black wire of the cigar lighter panel light. Power from the splice is applied to
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circuit 62B and the right gauge cluster panel lights connector (72), to circuit 62C and the left gauge cluster
panel lights (73), to circuit 62D and tachometer panel light (64), to circuit 62E and tachometer panel light (63),
to circuit 62F and speedometer panel light (68), and to circuit 62G and speedometer panel light (67).
The right gauge cluster panel lights (72) are grounded through circuits 11–GW and 11–GD to the left cab
ground stud (429). The left gauge cluster panel lights (73) are grounded through circuits 11–GV and 11–GF to
the left cab ground stud (429). Tachometer panel light (64) is grounded through circuits 62–GD and 11–GAC to
the left cab ground stud (429). Tachometer panel light (63) is grounded through circuits 62–GE and 11–GAC to
the left cab ground stud (429). Speedometer panel light (68) is grounded through circuits 62–GF and 11–GAC
to the left cab ground stud (429). Speedometer panel light (67) is grounded through circuits 62–GG and
11–GAC to the left cab ground stud (429).
Power from L2 panel lights adapter (586) is applied to circuit 62AD and a splice. From the splice power is
applied to circuit 62AT and the key switch panel light (495). From the splice power is also applied to circuit 62P,
the heater control panel lamp (84), circuit 62AU, and the fresh air panel light (494).
The key switch light (495) is grounded through circuits 62–GAT and 11-GLB, and L4 panel ground adapter
(587). The heater control light (84) is grounded through circuits 62–GP and 11–G, and the right cab ground
(404). The fresh air control panel light (494) is grounded through circuits 62–GAU, 62–GP, and 11–G, and the
right cab ground (404).
Power from the L1 panel lights feed adapter (504) is applied to circuit 62AX and the push button start light
(541). This light is grounded through circuit 62GAX and the L3 panel lights ground adapter (505).
Power is applied by battery stud (B2) to circuits 14H and 14AP, 25A fuse F8–D, circuit 14AE, connector (22)
and circuit 14AE to a splice.
From the splice, power is applied to circuit 14AY, connect (N/L), and a back wire to the left spot light. From
the splice, power is also applied to circuit 14BA, connector (N/L), and a black wire to the right spot light. The
spot lights are grounded through their mounting brackets, and illuminate when their switches are moved
to the on position.
From the splice power is applied to circuit 14AZ, connector (N/L), circuit 14AE to a second splice. From the
second splice, power is applied to circuit 84A and the cigar lighter. The cigar lighter is grounded through
circuits 84–GA and 11–GAH to sleeper ground (J13), and heats up when the element is pushed into the socket.
From the second splice, power also flows through circuit 63P to the bunk reading light connector (564). The
bunk reading light is grounded through circuits 63–GP and 11–GAH to sleeper ground (J13), and illuminates
when its switch is moved to the on position.
From the second splice, power also flows through circuit 14BA to the bunk fluorescent light (562). The ground
circuit consists of two circuits and three switches. Thus the bunk fluorescent light will illuminate when the
switch on the light fixture, at the bunk switch panel, or at the dash switch panel is moved to its other position.
One ground path is through connector (562), circuit 63–GB, connector (557), circuit 63–GB, switch (563),
circuit 63–GD, connector (557), circuit 63–GD, connector (11), circuit 63–GD, connector (19), circuit 63–GD,
switch (589), circuit 63–GE, and 11–GLC to L3 panel ground adapter (505). The other ground path is through
connector (562), circuit 63–GA, connector (557), circuit 63–GA, switch (563), circuit 63–GC, connector (557),
circuit 63–GC, connector (11), circuit 63–GC, connector (19), circuit 63–GC, switch (589), circuit 63–GE, and
11–GLC to L3 panel ground adapter (505).
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Power is applied by battery stud (B2) to circuits 14H and 14AP, 25A fuse F8–D, circuit 14AE, connector (22),
and circuit 14AE to a splice.
From the splice, power is applied to circuit 63M and the bunk reading light (564). The reading light is grounded
through circuits 63–GM, 11–GAH, and 11–GAN, connector (81), and circuits 11–GAN and 11–GBB to the right
cab ground (404), and illuminates when its switch is moved to the on position.
From the splice, power also flows through circuit 63L to the fluorescent light connector (562). The ground
circuit consists of two circuits and three switches. Thus the bunk fluorescent light will illuminate when the
switch on the light fixture, at the bunk switch panel, or at the dash switch panel is moved to its other position.
One ground path is through the light connector (562), circuit 63–GB, connector (557), circuit 63–GB, switch
(563), circuit 63–GD, connector (557), circuit 63–GD, connector (11), circuit 63–GD, connector (19), circuit
63–GD, switch (589), and circuits 63–GE and 11–GLC to L3 panel ground adapter (505). The other ground
path is through the light connector (562), circuit 63–GA, connector (557), circuit 63–GA, switch (563), circuit
63–GC, connector (557), circuit 63–GC, connector (11), circuit 63–GC, connector (19), circuit 63–GC, switch
(589), and circuits 63–GE and 11–GLC to L3 panel ground adapter (505).

Power from the (B1) battery stud is applied to circuits 14K and 14AN, 10A fuse F1–D, circuit 85, and work light
switch (25). When the switch is moved to the on position, power is applied to circuit 65, connector (23), a black
wire, connector (N/L), and an orange wire to the work light. The work light is grounded through a white wire,
connector (N/L), and circuit 11 to the J7 cab ground.
3. TROUBLESHOOTING
relay, or solenoid.
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3.1. BACK-UP
Table 101 Back-Up
STEP KEY ACTION TEST SPEC. YES - IN NO - OUT OF SPEC.
POINTS SPEC.
1. On Move key switch to F4–C, 16A 12 ± 1.5 Go to Locate cause of
ignition position and at to gnd. volts. next step. low or no voltage
20A fuse F4–C and circuit in circuit 13H, 13J,
16A, measure voltage to or 16A from ignition
ground. relay (462–R1), then
repair.
2. Off/ On Remove 15A circuit Fuse block 12 ± 1.5 Go to Locate cause of low
breaker B2, move key B2, 16C to volts. next step. or no voltage in 20A
switch to ignition position gnd. fuse F4–C, circuit
and at circuit 16C, 16A, conn. (102),
measure voltage to circuit 16A, or circuit
ground. 16C, then repair.
3. On Disconnect back-up light (12), white 12 ± 1.5 Go to Locate cause of
switch (12), re-install 15A wire to gnd. volts. next step. low or no voltage in
circuit breaker B2, and at 15A circuit breaker
connector (12) and white B2, circuit 71A,
wire, measure voltage to connector (189),
ground. or white wire, then
repair.
4. On With transmission in Across < 1 ohm. Go to Replace defective
reverse, measure back- up next step. back-up light switch.
resistance across the light sw.
terminals to back-up light (12).
switch (12).
5. On Disconnect left back-up (4), blue 12 ± 1.5 Go to Locate cause of low
light switch connector (4), wire to gnd. volts. next step. or no voltage in the
reconnect back-up light black wire, connector
switch connector (12), (189), circuit 71,
and at connector (4) and connector (102),
a blue wire, measure circuit 71, connector
voltage to ground. (125), or the blue
wire, then repair.
6. On At connector (4), (4), blue 12 ± 1.5 Go to Locate open or poor
measure voltage from wire to volts. next step. connection in the
blue wire to white wire. white wire. white wire to frame
ground, then repair.
7. On Reconnect connector Go to Replace defective
(40). Does left back-up next step. light bulb or socket.
light illuminate?
8. On Does right back-up light Go to Go to next step.
illuminate? Step 11.
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Table 101 Back-Up (cont.)

POINTS SPEC.
9. On Disconnect connector (3), (3), blue 12 ± 1.5 Go to Locate cause of low
and at blue wire, measure wire to gnd. volts. next step. or no voltage in the
voltage to ground. blue wire, then repair.
10. On At connector (3), (3), blue 12 ± 1.5 Go to Locate open or poor
measure voltage from wire to volts. next step. connection in the
blue wire to white wire. white wire. white wire, then
repair.
11. On Reconnect connector (3). Go to Replace defective
Does right back-up light next step. light bulb or socket.
illuminate?
12. Off Back-up light circuits
check good. Move key
switch to off position,
and place transmission in
neutral.
3.2. CAB CLEARANCE/ID

Flat Roof
Table 102 Flat Roof

STEP KEY ACTION TEST SPEC. YES - IN NO - OUT OF
POINTS SPEC. SPEC.
1. Off Move headlight switch to F8–C, 68B to 12 ± 1.5 Go to next Locate cause of
park light position and at gnd. volts. step. low or no voltage in
15A fuse F8–C and circuit circuit 63B or 68E
68B, measure voltage to from trailer tail light
ground. relay (464–R9),
then repair.
2. Off Disconnect connector (22), 58AF to 12 ± 1.5 Go to next Locate cause of
(22), move headlight gnd. volts. step. low or no voltage
switch to park light in circuit 58AF, 68C
position, and at circuit or 15A fuse F8–C,
58AF, measure voltage to then repair.
ground.
3. Off Disconnect connector (766), 58H 12 ± 1.5 Go to next Locate cause of
(766) and reconnect to gnd. volts. step. low or no voltage in
connector (22). At (766) circuit 58AF or 58H,
circuit 58H, measure then repair.
voltage to ground.
4. Off At connector (766), (766), 58H to 12 ± 1.5 Go to next Locate open or poor
measure voltage from 58–GH. volts. step. connection in circuit
circuit 58H to 58–GH. 58–GH or 58–GB
to ground stud (J3),
then repair.
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Table 102 Flat Roof (cont.)

POINTS SPEC. SPEC.
5. Off Reconnect conn. (766). Go to next Replace defective
Does lamp illuminate? step. lamp or socket.
6. Off Disconnect connector (767), 58J to 12 ± 1.5 Go to next Locate cause of
(767) and at circuit 58J, gnd. volts. step. low or no voltage
measure voltage to in circuit 58J, then
ground. repair.
7. Off At connector (767), (767), 58J to 12 ± 1.5 Go to next Locate open or poor
measure voltage from 58–GJ. volts. step. connection in circuit
circuit 58J to 58–GJ. 58–GJ, then repair.
8. Off Reconnect connector Go to next Replace defective
(767). Does lamp step. lamp or socket.
illuminate?
9. Off Disconnect connector (768), 58K 12 ± 1.5 Go to next Locate cause of
(768) and at circuit 58K, to gnd. volts. step. low or no voltage
measure voltage to in circuit 58K, then
ground. repair.
10. Off At connector (768), (768), 58K to 12 ± 1.5 Go to next Locate open or poor
measure voltage from 58–GK. volts. step. connection in circuit
circuit 58K to 58–GK. 58–GK, then repair.
illuminate?
12. Off Disconnect connector (769), 58L 12 ± 1.5 Go to next Locate cause of
(769) and at circuit 58L, to gnd. volts. step. low or no voltage
measure voltage to in circuit 58L, then
ground. repair.
13. Off At connector (769), (769), 58L to 12 ± 1.5 Go to next Locate open or poor
measure voltage from 58–GL volts. step. connection in circuit
circuit 58L to 58–GL. 58–GL, then repair.
illuminate?
15. Off Disconnect connector (770), 58M to 12 ± 1.5 Go to next Locate cause of
(770) and at circuit 58M, gnd. volts. step. low or no voltage
measure voltage to in circuit 58M, then
ground. repair.
16. Off At connector (770), (770), 58M to 12 ± 1.5 Go to next Locate open or poor
measure voltage from 58–GM. volts. step. connection in circuit
circuit 58M to 58–GM. 58–GM, then repair.
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POINTS SPEC. SPEC.
illuminate?
18. Off Clearance and
identification lights check
good. Move headlight
switch to off position.
Raised Roof
Table 103 Raised Roof

POINTS SPEC.
1. Off Move headlight switch to F8–C, 68B 12 ± 1.5 Go to next Locate cause of
park light position and at to gnd. volts. step. low or no voltage in
15A fuse F8–C and circuit circuit 63B or 68E
68B, measure voltage to from trailer tail light
ground. relay (464–R9), then
repair.
2. Off Disconnect connector (22), 58AF 12 ± 1.5 Go to next Locate cause of
(22), move headlight to gnd. volts. step. low or no voltage in
switch to park light circuit 58AF, 68C or
position, and at circuit 15A fuse F8–C, then
58AF, measure voltage to repair.
ground.
3. Off Remove clearance light (58), 58A 12 ± 1.5 Go to next Locate cause of low
bulb at socket (58) and to gnd. volts. step. or no voltage in circuit
reconnect connector (22). 58AF, connector (7),
At socket (58) and circuit circuit 58AF, conn.
58A, measure voltage to (775) or circuit 58A,
4. Off At socket (58), measure (580), 58A 12 ± 1.5 Go to next Locate open or
voltage form circuit 58A to 58–G. volts. step. poor connection
to 58–G. in cir. 58–G, conn.
(775), cir. 58–G
or 11–GAH, conn.
(557), cir. 11–GAH
or 11–GAN, conn.
(81), cir. 11–GAN
or 11–GBB to right
cab gnd. (404), then
repair.
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Table 103 Raised Roof (cont.)

POINTS SPEC.
5. Off Remove clearance light (66), 58E 12 ± 1.5 Go to next Locate cause of low
bulb at socket (66) and to gnd. volts. step. or no voltage in cir.
at circuit 58E, measure 58B, 58C, 58D, or
voltage to ground. 58E, then repair.
6. Off At socket (66), measure (66), 58E 12 ± 1.5 Cir. to Locate open or poor
voltage from circuit 58E to 58–GD. volts. clearance connection in circuit
to 58–GD. and ID 58–GD, 58–GC,
lights check 58–GB, or 58–GA,
good. If a then repair.
light fails
to function,
replace
bulb or
socket if
necessary.
3.3. CAB DOME, READING, COURTESY

Table 104 Cab Dome, Reading, Courtesy
POINTS SPEC.
1. Off At 10A fuse F2–B and F2–B, 14T 12 ± 1.5 Go to next Locate cause of low
circuit 14T, measure to gnd. volts. step. or no voltage in circuit
voltage to ground. 14W or 14T from (B2)
battery stud, then
repair.
2. Off Disconnect connector (559), 63S 12 ± 1.5 Go to next Locate cause of low
(559) and at circuit 63S, to gnd. volts step. or no voltage in 10A
measure voltage to fuse F2–B, circuit
ground. 63AC, conn. (19), cir.
63C, or cir. 63S, then
repair.
3. Off Disconnect dome light (439), < 1 ohm. Go to next Locate open or poor
switch conn. (439), and 63–G to step. connection in circuit
at cir. 63–G, measure gnd. 63–G or 11–GLB to L4
resistance to ground. panel ground adapter
(587), then repair.
4. Off At connector (439) and (439), 63J < 1 ohm. Go to next Locate open or poor
circuit 63J, measure to gnd. step. connection in circuit
resistance to ground with 63J or left door switch,
left cab door open. then repair.
5. Off At connector (439) and (439), 63K < 1 ohm. Go to next Locate open or poor
circuit 63K, measure to gnd. step. connection in circuit
resistance to ground with 63K or right door
right cab door open. switch, then repair.
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Table 104 Cab Dome, Reading, Courtesy (cont.)

POINTS SPEC.
6. Off Test dome light switch Switch < 1 ohm. Go to next Replace defective
(439) by placing it in (439), step. dome light switch
the normal/ automatic term. 1 (439).
position and measuring to 2.
1 to 2.
7. Off Test dome light switch Sw. (439), < 1 ohm. Go to next Replace defective
(439) by placing it in on term. 2 to step. dome light switch
position and measuring 3. (439).
2 to 3.
8. Off Reconnect dome light (559), 63S 12 ± 1.5 Go to next Locate open or poor
switch (439), place to 63D. volts step. connection in circuit
in on position, and 63D, connector (19),
at connector (559), or circuit 63AD to
measure voltage from dome light switch
circuit 63S to 63D. (439), then repair.
9. Off Reconnect connector (571), 12 ± 1.5 Go to next Locate cause of low
(559) and disconnect 63C to volts step. or no voltage in circuit
connector (571). With gnd. 63 or 63C, then repair.
dome light switch in the
on position, at (571) and
voltage to ground.
10. Off With switch still on, (571), 12 ± 1.5 Go to next Locate open or
at connector (571), 63C to volts step. poor connection in
measure voltage from 63D. circuit 63D, 63B, or
circuit 63C to 63D. connector (559), then
repair.
11. Off Reconnect left dome Go to next Replace defective
light (571). With switch step. lamp or socket.
still on, does left dome
light illuminate?
12. Off Disconnect connector (570), 63A 12 ± 1.5 Go to next Locate cause of low
(570). With dome light to gnd. volts step. or no voltage in circuit
switch in the on position, 63A, then repair.
at (57) and circuit 63A,
measure voltage to
ground.
13. Off With switch still on, (570), 63A 12 ± 1.5 Go to next Locate open or poor
at connector (570), to 63E. volts step. connection in circuit
measure voltage from 63E, then repair.
circuit 63A to 63E.
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POINTS SPEC.
14. Off Reconnect right dome Dome Replace defective
light (570). With switch light cir. lamp or socket.
still on, does right dome check
light illuminate? good. Go
to next
step.
15. Off Disconnect left courtesy (207), 63V 12 ± 1.5 Go to next Locate cause of low
light connector (207) and to gnd. volts step. or no voltage in circuit
at circuit 63V, measure 63V, conn. (437),
voltage to ground. or circuit 63C, then
repair.
16. Off With dome light switch (207), 63V 12 ± 1.5 Go to next Locate open or poor
in the on position, at left to 63H. volts step. connection in circuit
courtesy light connector 63H, connector (437),
(207), measure voltage or circuit 63D, then
from circuit 63V to 63H. repair.
17. Off Reconnect left courtesy Go to next Replace defective
light (207). Does left step. lamp or socket.
courtesy light illuminate?
18. Off Disconnect right courtesy (207), 63V 12 ± 1.5 Go to next Locate cause of low
at circuit 63V, measure 63V, conn. (403),
voltage to ground. or circuit 63V, then
repair.
19. Off With dome light switch in (207), 63V 12 ± 1.5 Go to next Locate open or poor
the on position, at right to 63H. volts step. connection in circuit
courtesy light connector 63H, conn. (403),
(207), measure voltage or circuit 63H, then
from circuit 63V to 63H. repair.
20. Off Reconnect right courtesy Go to next Replace defective
light (207). Does right step. lamp or socket.
courtesy light illuminate?
21. Off Disconnect left reading (569), 12 ± 1.5 Go to next Locate cause of low
light connector (569) and 63R to volts step. or no voltage in circuit
at circuit 63R, measure gnd. 63R, then repair.
voltage to ground.
22. Off With dome light switch (569), 12 ± 1.5 Go to next Locate open or poor
in the on position, at left 63R to volts step. connection in circuit
reading light connector 63–GR. 63–GR or 11–GAA to
(569), measure voltage ground stud (J3), then
from circuit 63R to repair.
63–GR.
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POINTS SPEC.
23. Off Reconnect left reading Go to next Replace defective
light (569) and place step. lamp or switch and
its switch in the on socket assembly.
position. Does reading
light illuminate?
24. Off Disconnect right reading (568), 63T 12 ± 1.5 Go to next Locate cause of low
at circuit 63T, measure 63T, then repair.
voltage to ground.
25. Off With dome light switch (568), 63T 12 ± 1.5 Go to next Locate open or poor
in on position, at right to 63–GT. volts step. connection in circuit
reading light connector 63–GT, then repair.
from circuit 63T to
63–GT.
26. Off Reconnect right reading Cab dome Replace defective
light (568) and place its reading lamp or switch and
switch in on position. and socket assembly.
Does reading light courtesy
illuminate? light cir.
check
good.
3.4. STOP, TAIL, TURN AND HAZARD

Table 105 Stop, Tail, Turn and Hazard
POINTS SPEC.
1. Off Do brake lights function Go to Go to next step.
properly? Step 14.
2. Off At 20A fuse F3–B and F3–B, 14E 12 ± 1.5 Go to Locate cause of low
circuit 14E, measure to gnd. volts. next step. or no voltage in circuit
voltage to ground. 14H or 14E from (B2)
battery stud, then
repair.
3. Off Disconnect stop light switch (421), 70F 12 ± 1.5 Go to Locate cause of low or
(421) and at circuit 70F, to gnd. volts. next step. no voltage in 20A fuse
measure voltage to ground. F3–B, circuit 70 or 70F,
then repair.
4. Off Test stop light switch (421) Across sw. < 1 ohm. Go to Replace defective stop
by applying service brakes (421) next step. light switch.
across switch terminals.
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Table 105 Stop, Tail, Turn and Hazard (cont.)

POINTS SPEC.
5. Off Reconnect stop light switch (36), 70A 12 ± 1.5 Go to Locate cause of low
(421) and disconnect turn to gnd. volts. next step. or no voltage in circuit
signal switch (36). At (36) 70B or 70A, then
and circuit 70A, measure repair.
voltage to ground while
service brakes are applied.
6. Off Test turn signal switch (36) Sw. (36), < 1 ohm. Go to Replace defective
by measuring resistance red wire next step. switch.
from red wire to yellow to yellow
wire with switch in center wire.
position.
7. Off Test turn signal switch (36) Sw. (36), < 1 ohm. Go to Replace defective
by measuring resistance red wire to next step. switch.
from red wire to green green wire.
wire with switch in center
position.
8. Off Disconnect left rear stop (4), yellow 12 ± 1.5 Go to Locate cause of low
and turn light connector (4), wire to volts. next step. or no voltage in circuit
and at yellow wire, measure gnd. 56B, connector (125),
voltage to ground while an or yellow wire, then
assistant places turn signal repair.
switch in center position
and applies service brakes.
9. Off At connector (4), measure (4), yellow 12 ± 1.5 Go to Locate open or poor
voltage from yellow wire wire to volts. next step. connection in white
to white wire while an white wire. wire to frame ground,
assistant places turn signal then repair.
switch in center position
10. Off At connector (4) measure (4), green 12 ± 1.5 Go to Locate cause of low
voltage from green wire wire to volts. next step. or no voltage in circuit
to white wire while an white wire. 57B, connector (125),
assistant places turn signal or green wire, then
switch in center position repair.
11. Off Reconnect connector Go to Replace defective
(4). Does left brake light next step. lamp or socket.
illuminate when service
brakes are applied?
12. Off Disconnect connector (3) (3), green 12 ± 1.5 Go to Locate cause of low or
and at green wire, measure wire to volts. next step. no voltage in connector
voltage to ground while as gnd. (4A) or green wire,
assistant applies service then repair.
brakes.
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POINTS SPEC.
13. Off At connector (3), measure (3), green 12 ± 1.5 Go to Locate open or
voltage from green wire wire to volts. next step. poor connection in
to white wire while an white wire. connector (4A) or
assistant applies service white wire, then repair.
brakes.
14. Off Stop light circuits check Go to
good. next step.
15. Off Does left rear turn signal Go to Go to next step.
function properly? Step 22.
16. Off At 20A fuse F2–D and F2–D, 14R 12 ± 1.5 Go to Locate cause of low
circuit 14R, measure to gnd. volts. next step. or no voltage in circuit
voltage to ground. 14K or 14R from (B1)
battery stud, then
repair.
17. Off Disconnect flasher (501) (501), 55 12 ± 1.5 Go to Locate cause of low
and at circuit 55, measure to gnd. volts. next step. or no voltage in 20A
voltage to ground. fuse F2–D or circuit
55, then repair.
18. Off Disconnect connector (36), (36), 55A 12 ± 1.5 Go to Locate cause of low
install a jumper wire at to gnd. volts. next step. or no voltage in circuit
conn. (501) from circuit 55 55A, then repair.
to 55A, and at (36) circuit
55A, measure voltage to
ground.
19. Off Test turn signal switch (36), black < 1 ohm. Go to Replace defective turn
(36) by placing in left turn wire to next step. signal switch.
position and measuring yellow
resistance from black wire wire.
to yellow wire.
20. Off Test turn signal switch (36), black < 1 ohm. Go to Replace defective turn
(36) by placing in left turn wire to next step. signal switch.
position and measuring orange
resistance from black wire wire.
to orange wire.
21. Off At (501) remove jumper Left rear Replace defective
wire, and reconnect flasher turn flasher.
and turn signal switch (36). signal
Move turn signal switch to cir. test
left turn position. Does left good. Go
rear turn signal flash on to next
and off? step.
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POINTS SPEC.
22. Refer to Front Park, Turn, Go to
and Marker — 9800 SFA next step.
and Front Park, Turn and
Marker, and Side Turn
and Marker — 9800 SBA
sections for testing of left
front turn signal lamp.
23. Off Does right rear turn signal Go to Go to next step.
24. Off Test turn signal switch (36) (36), black < 1 ohm. Go to Replace defective turn
by placing in right turn wire to next step. signal switch.
position and measuring green wire.
resistance from black wire
to green wire.
25. Off Test turn signal switch (36) (36), black < 1 ohm. Go to Replace defective turn
by placing in right turn wire to next step. signal switch.
position and measuring blue wire.
resistance from black wire
to blue wire.
26. Reconnect turn signal Go to
switch (36). Right rear turn next step.
signal circuits test good.
27. Off Refer to Front Park, Turn, Go to
and Marker — 9800 SFA next step.
and Front Park, Turn and
Marker, and Side Turn
and Marker — 9800 SBA
sections for testing of right
front turn signal lamp.
28. Off Turn signal circuits check Test Go to next step.
good. Do tail lights function complete.
properly?
29. Off Move headlight switch to F8–C, 68B 12 ± 1.5 Go to Locate cause of low
park light position, and at to gnd. volts. next step. or no voltage in circuit
15A fuse F8–C and circuit 68B from trailer tail
68B, measure voltage to light relay (464–R9),
30. Off Disconnect connector (4) (4), brown 12 ± 1.5 Go to Locate cause of low
and with headlight switch wire to volts. next step. or no voltage in 15A
still set, measure voltage gnd. fuse F8–C, circuit 68C,
from brown wire to ground. 68D, conn. (125), or
a brown wire, then
repair.
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POINTS SPEC.
(4). Does left tail light next step. lamp or socket
illuminate? assembly.
32. Off Disconnect connector (3) (3), brown 12 ± 1.5 Go to Locate cause of low
and with headlight switch wire to volts. next step. or no voltage in brown
still set, measure voltage gnd. wire, then repair.
from brown wire to ground.
33. Off Reconnect connector Tail light Replace defective
(3). Does right tail light cir. test lamp or socket
illuminate? good. assembly.
3.5. FOG LIGHTS

Table 106 Fog Lights
POINTS SPEC.
1. Off Disconnect fog light (414), 64B to 12 ± 1.5 Go to Locate cause of
switch connector (414), gnd. volts. next step. low or no voltage
move headlight switch in circuit 64D or
to on position, and set 64B with USA DRL
dimmer switch to low module, or cir. 53
beam position. At (414) or 64B from dimmer
circuit 64B, measure switch with Canadian
voltage to ground. DRL, then repair.
2. Off Test fog light switch Sw. (414), < 1 ohm Go to Replace defective
(414) by placing in on term. 5 to 6. next step. fog light switch.
position and measuring
5 to 6.
3. Off At 20A fuse F10–A F10–A, 12P 12 ± 1.5 Go to Locate cause of
(location may vary) and to gnd. volts next step. low or no voltage in
circuit 12P, measure circuit 12P from A3
voltage to ground. accessories adapter
(593), then repair.
4. Off Remove fog light relay (440), 64 to 12 ± 1.5 Go to Locate cause of low
(440) and at circuit 64, gnd. volts. next step. or no voltage in 20A
measure voltage to fuse F10–A (location
ground. may vary) or circuit
64, then repair.
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Table 106 Fog Lights (cont.)

POINTS SPEC.
5. Off At relay socket (440), (440), 64 to 12 ± 1.5 Go to Locate open or
measure voltage from 64–GA volts. next step. poor connection in
circuit 64 to 64–GA. cir. 64–GA, conn.
(78), cir. 64–GB or
64–GC to G3 ground
adapter (456) [conn.
(78) and cir. 64–GA
to DRL relay (474)
with Canadian DRL],
then repair.
6. Off With headlight switch (440), 64A to 12 ± 1.5 Go to Locate cause of
on, dimmer switch in low gnd. volts. next step. low or no voltage
beam position, and fog in circuit 64A, then
light switch on, at (440) repair.
and circuit 64A, measure
voltage to ground.
7. Off Bench test fog light Relay (440), < 1 ohm. Go to Replace defective
relay (440) by measuring term. 30 to next step. fog light relay (440).
resistance from terminal 87A.
30 to 87A.
8. Off Bench test fog light Energized < 1 ohm. Go to Replace defective
relay (440) by applying relay (440), next step. fog light relay (440).
+12 volts to terminal term. 30 to
86, ground to terminal 87.
85, and measuring
30 to 87.
9. Off Re-install fog light relay (156), 64E to 12 ± 1.5 Go to Locate cause of
(440), disconnect left fog gnd. volts. next step. low or no voltage in
light connector (156), circuit 64D, conn.
move headlight switch (125), circuit 64P,
to on position, dimmer conn. (155), circuit
switch to low beam 64P or 64E, then
position, and fog light sw. repair.
to on position. At (156)
and circuit 64E, measure
voltage to ground.
10. Off/ With switches still set, (156), 64E to 12 ± 1.5 Go to Locate open or
On at connector. (156), 11BX. volts. next step. poor connection in
measure voltage from circuit 11BX, 11BW,
circuit 64E to 11BX. connector (155), or
circuit 11–GW to
frame ground (J11),
then repair.
s08270
Table 106 Fog Lights (cont.)

POINTS SPEC.
(156). Does fog light next step. lamp or socket.
illuminate?
12. Off Disconnect right fog light (157), 64H 12 ± 1.5 Go to Locate cause of
connector (157) and to gnd. volts next step. low or no voltage
with switches still set, in circuit 64H, then
at circuit 64H, measure repair.
voltage to ground.
13. Off/ With switches still set, (157), 64H to 12 ± 1.5 Go to Locate open or poor
On at connector (157), 11BY. volts. next step. connection in circuit
measure voltage from 11BY, then repair.
circuit 64H to 11BY.
(157). Does fog light next step. lamp or socket.
illuminate?
15. Off Fog light circuits check
good. Shut off all
switches.
3.6. FRONT PARK, TURN, AND MARKER — 9800 SFA

Table 107 Front Park, Turn, and Marker — 9800 SFA
POINTS SPEC.
1. Off Refer to Stop, Tail, Turn Go to
and Hazard Table for next
troubleshooting of turn step.
signal switch and power
circuits.
2. Off At left front turn light, Black wire Pulsating Go to Locate cause of low
disconnect red wire, move to gnd. 12 ± 1.5 next or no voltage in circuit
turn signal switch to left volts. step. 56E, connector (N/L),
turn position and measure circuit 56E, conn.
voltage to ground in black (N/L), a black wire,
wire that was connected or conn. (N/L), then
to red wire. repair.
3. Off Reconnect red wire at left Go to Replace defective
front turn light. Does light next lamp or socket
illuminate? step. assembly.
s08270
Table 107 Front Park, Turn, and Marker — 9800 SFA (cont.)
POINTS SPEC.
4. Off At right front turn light, Black wire Pulsating Go to Locate cause of low
disconnect red wire, to gnd. 12 ± 1.5 next or no voltage in circuit
move turn signal switch volts. step. 57E, conn. (N/L),
to right turn position, circuit 57E, conn.
and measure voltage to (N/L), a black wire,
ground at black wire that or conn. (N/L), then
was connected to red repair.
wire.
5. Off Reconnect red wire at Go to Replace defective
right front turn light. Does next lamp or socket
light illuminate? step. assembly.
6. Off Move turn signal switch Black wire 12 ± 1.5 Go to Locate cause of low
to center/off position, and to gnd. volts. next or no voltage in circuit
place headlight switch in step. 68C, 54, conn. (N/L),
park light position. At left circuit 54, conn. (N/L),
marker light, disconnect a black wire, or conn.
brown wire, and measure (N/L) from 15A fuse
voltage to ground at black F8–C, then repair.
wire that was connected
to brown wire.
7. Off Reconnect brown wire of Go to Replace defective
left front park light. Does next lamp or socket
light illuminate? step. assembly.
8. Off With switches still set, Black wire 12 ± 1.5 Go to Locate cause of
at right marker light, to gnd. volts. next low or no voltage in
disconnect brown wire, step. connector (N/L), circuit
and measure voltage to 54A, conn. (N/L), a
ground at black wire that black wire, or conn.
was connected to brown (N/L), then repair.
wire.
9. Off Reconnect brown wire of Park, Replace defective
right front park light. Does turn and lamp or socket
light illuminate? marker assembly.
light cir.
check
good.
s08270
3.7. FRONT PARK, TURN AND MARKER, AND SIDE TURN AND MARKER — 9800 SBA
Table 108 Front Park, Turn and Marker, and Side Turn and Marker — 9800 SBA
POINTS SPEC.
1. Off Refer to Stop, Tail, Turn Go to next
and Hazard Table for step.
troubleshooting of turn
signal switch and power
circuits.
2. Off Does left front turn light Go to Step Go to next step.
3. Off Disconnect left front turn (242), red Pulsating Go to next Locate cause of low
signal connector (242), supply 12 ± 1.5 step. or no voltage in circuit
move turn signal switch wire to volts. 56E, conn. (N/L),
to left turn position, gnd. circuit 56E, or red wire,
and measure voltage then repair.
to ground at red supply
wire.
4. Off With switch still set, (242), red Pulsating Go to next Locate open or poor
at connector (242), supply 12 ± 1.5 step. connection in blue
measure voltage from wire to volts. wire, cir. 11–GL,
red supply wire to blue blue gnd. conn. (498)/(423),
ground wire. wire. cir. 11–GL, conn.
(490), cir. 11–GM,
11–GF, or left cab gnd.
(429) [blue wire, cir.
11–GAG, conn. (580),
cir. 11–GAG, or G6
gnd. adapter (616)
with Canadian DRL],
then repair.
5. Off With switch still set, Go to next Replace defective
reconnect connector step. lamp or socket
(242). Does light assembly.
illuminate?
6. Off Does left side turn light Go to Step Go to next step.
7. Off With turn signal switch (241), red Pulsating Go to next Locate cause of low or
in left turn position, supply 12 ± 1.5 step. no voltage in red wire,
disconnect left side turn wire to volts. then repair.
light connector (241), gnd.
and measure voltage
wire.
s08270
Table 108 Front Park, Turn and Marker, and Side Turn and Marker — 9800 SBA (cont.)
POINTS SPEC.
measure voltage from wire to volts. wire, then repair.
red supply wire to blue blue gnd.
ground wire. wire.
(241). does light assembly.
illuminate?
10. Off Does right front turn light Go to Step Go to next step.
11. Off Disconnect right front (242), red Pulsating Go to next Locate cause of low
turn signal conn. (242), supply 12 ± 1.5 step. or no voltage in circuit
move turn signal switch wire to volts. 57E, conn. (N/L),
to right turn position, gnd. circuit 57E, or red wire,
and measure voltage then repair.
wire.
measure voltage from wire to volts. wire, cir. 11–GK,
red supply wire to blue blue gnd. conn. (498)/(400), cir.
ground wire. wire. 11–GK, 11–G, or right
cab ground (404), then
repair.
illuminate?
14. Off Does right side turn light Go to Step Go to next step.
15. Off With turn signal switch (241), red Pulsating Go to next Locate cause of low or
in right turn position, supply 12 ± 1.5 step. no voltage in red wire,
disconnect right side wire to volts. then repair.
turn light connector gnd.
(241), and measure
voltage to ground at red
supply wire.
measure voltage from wire to volts. wire, then repair.
red supply wire to blue blue gnd
ground wire. wire.
s08270
POINTS SPEC.
illuminate?
18. Off Does left front park light Go to Step Go to next step.
19. Off Move headlight switch to F8–C, 68B 12 ± 1.5 Go to next Locate cause of low
park light position, and to gnd. volts. step. or no voltage in circuit
at 15A fuse F8–C and 68E or 68B from
circuit 68B, measure trailer tail light relay
voltage to ground. (464–R9), then repair.
20. Off Disconnect left front turn (242), 12 ± 1.5 Go to next Locate cause of low or
light connector (242) brown wire volts. step. no voltage in 15A fuse
and with switch still to gnd. F8–C, circuits 68C and
set, measure voltage in 54, conn. (N/L), circuit
brown wire, coming from 54, conn. (N/L), circuit
source, to ground. 54, or brown wire, then
repair.
reconnect conn. (242). step. lamp or socket
Does light illuminate? assembly.
22. Off Does left side marker Go to Step Go to next step.
light function properly? 25.
23. Off Disconnect left side (241), 12 ± 1.5 Go to next Locate cause of low
marker light conn. (241), brown wire volts. step. or no voltage in brown
move headlight switch to gnd. wire, then repair.
to park light position,
and measure voltage in
brown wire, coming from
source, to ground.
illuminate?
25. Off Does right front park Go to Step Go to next step.
26. Off Disconnect right front (242), 12 ± 1.5 Go to next Locate cause of low
turn light connector brown wire volts. step. or no voltage in circuit
(242) and with switch to gnd. 54A, conn. (N/L), cir.
still set, measure voltage 54A, conn. (N/L), cir.
in brown wire, coming 54, or brown wire, then
from source, to ground. repair.
s08270
POINTS SPEC.
reconnect conn. (242). step. lamp or socket
Does light illuminate? assembly
28. Off Does right side marker Go to Step Go to next step.
29. Off Disconnect right side (241), 12 ± 1.5 Go to next Locate cause of low
marker light conn. (241), brown wire volts. step. or no voltage in brown
move headlight switch to gnd. wire, then repair.
to park light position,
and measure voltage in
brown wire, coming from
source, to ground.
illuminate?
31. Off Park, turn, and marker
lights check good. Move
headlight switch to off
position.

Table 109 Headlights — 9800 SFA
POINTS SPEC.
1. Off Does either headlight Go to Step Go to next step.
illuminate when headlight 9.
switch is moved to on
position and the dimmer
switch is placed in low
beam or high beam
position?
2. Off Remove 10A circuit F6–C, 12 ± 1.5 Go to next Locate cause of low
breaker F6–C, and at 14D to volts. step. or no voltage in circuit
circuit 14D, measure gnd. 14D from (B2) battery
voltage to ground. stud, then repair.
3. Off Disconnect headlight (410), 50A 12 ± 1.5 Go to next Locate cause of low
switch (410), re-install to gnd. volts. step. or no voltage in circuit
circuit breaker F6–C, and breaker F6–C or circuit
at circuit 50A, measure 50A, then repair.
voltage to ground.
s08270
Table 109 Headlights — 9800 SFA (cont.)

POINTS SPEC.
4. Off Test headlight switch (410), < 1 ohm. Go to next Replace defective
(410) by placing switch term. 5 step. switch.
in headlight position and to 6.
5. Off Remove headlight relay (462– R4), 12 ± 1.5 Go to next Locate cause of low
(462–R4) and reconnect 50B to volts. step. or no voltage in circuit
headlight switch (410). gnd. 50B, then repair.
Move headlight switch to
headlight position, and
at relay socket (462–R4)
and circuit 50B, measure
voltage to ground.
6. Off At relay socket (462–R4) (462– R4), 12 ± 1.5 Go to next Locate cause of low
and circuit 51, measure 51 to gnd. volts. step. or no voltage in 20A
voltage to ground. circuit breaker or circuit
51, then repair.
7. Off At relay socket (462–R4), (462– 12 ± 1.5 Go to next Locate open or poor
measure voltage from R4), 51 to volts. step. connection in circuit
circuit 51 to 50–GB. 50–GB. 50–GB, 75–GC,
75–GB, 11–GN, or
11–GB to right cab
ground stud (404),
then repair.
8. Off Bench test headlight Relay < 1 ohm. Go to next Replace defective
relay (462–R4) by (462– R4), step. headlight relay.
measuring resistance term. 30
from terminal 30 to 87A. to 87A.
9. Off Bench test headlight Energized < 1 ohm. Re- install Replace defective
relay (462–R4) by relay headlight headlight relay.
applying +12 volts to (462– R4), relay
terminal 86, ground term. 30 (462–R4).
to terminal 85, and to 87. Go to next
measuring resistance step.
10. Off Disconnect dimmer (70), 51A 12 ± 1.5 Go to next Locate cause of low
switch (70). Move to gnd. volts. step. or no voltage in circuit
headlight switch to on 51A, then repair.
position and at connector
measure voltage to
ground.
s08270

POINTS SPEC.
11. Off Test dimmer switch (70) Sw. (70), <1 ohm. Go to next Replace defective
by placing it in low beam term. B to step. switch.
position and measuring C.
B to C.
12. Off Test dimmer switch (70) Sw. (70), < 1 ohm. Go to next Replace defective
by placing it in high beam term. B to step. switch.
position and measuring A.
B to A.
13. Off Disconnect right (2), 53A to 12 ± 1.5 Go to next Locate cause of
headlight conn. (2), gnd. volts. step. low or no voltage in
move headlight switch to circuit 53, 53A, conn.
on position, and dimmer (400)/(498), or circuit
switch to low beam 53A, then repair.
position. At conn. (2)
and circuit 53A, measure
voltage to ground.
14. Off With switches still set, (2), 53A to 12 ± 1.5 Go to next Locate open or
at conn. (2), measure 11–GK. volts. step. poor connection in
voltage from circuit 53A cir. 11–GK, conn.
to 11–GK. (400)/(498), cir. 11–GK
or 11–G to right cab
ground stud (404),
then repair.
15. Off With switches still set, Go to next Replace defective
reconnect conn. (2). step. lamp.
Does right headlight
illuminate?
16. Off Disconnect left headlight (2), 53B to 12 ± 1.5 Go to next Locate cause of
conn. (2), move gnd. volts. step. low or no voltage
headlight switch to in circuit 53B, conn.
switch to low beam 53B, then repair.
voltage to ground.
s08270

POINTS SPEC.
17. Off With switches still set, at (2), 53B to 12 ± 1.5 Go to next Locate open or
connector (2), measure 11–GL. volts. step. poor connection in
voltage from circuit 53B cir. 11–GL, conn.
to 11–GL. (423)/(498), cir.
11–GL, conn. (490),
circuit 11–GM or
11–GF to left cab
ground stud (429), then
repair. [With Canadian
DRL, ground path from
conn. (490) is through
cir. 66J, relay (475)
N.C. contacts, and
circuit 66–GA to G6
ground adapter (616)].
reconnect conn. (2). step. lamp.
Does left headlight
illuminate?
19. Off Disconnect right (2), 52B to 12 ± 1.5 Go to next Locate cause of low
headlight conn. (2), gnd. volts. step. or no voltage in circuit
move headlight switch to 52 or 52B, conn.
switch to high beam 52B, then repair.
voltage to ground.
reconnect connector step. lamp.
(2). Does right headlight
illuminate?
21. Off Disconnect left headlight (2), 52C to 12 ± 1.5 Go to next Locate cause of
conn. (2), move gnd. volts. step. low or no voltage in
headlight switch to circuit 52C, conn.
on position and dimmer (423)/(498), or circuit
switch to high beam 52C, then repair.
and circuit 52C, measure
voltage to ground.
22. Off With switches still set, Headlight Replace defective
reconnect conn. (2). cir. check lamp.
Does left headlight good.
illuminate?
s08270

Table 110 Headlights — 9800 SBA
POINTS SPEC.
1. Off Does either headlight Go to Step Go to next step.
illuminate when headlight 10.
switch is moved to on
position and the dimmer
switch is placed in low beam
or high beam position?
2. Off Remove 10A circuit breaker F6–C, 14D 12 ± 1.5 Go to next Locate cause of low
F6–C, and at circuit 14D, to gnd. volts. step. or no voltage in circuit
measure voltage to ground. 14D from (B2) battery
stud, then repair.
3. Off Disconnect headlight (410), 50A 12 ± 1.5 Go to next Locate cause of
switch (410), re-install to gnd. volts. step. low or no voltage in
circuit breaker F6–C, and circuit breaker F6–C
at circuit 50A, measure or circuit 50A, then
4. Off Test headlight switch (410), < 1 ohm. Go to next Replace defective
(410) by placing switch term. 5 to step. switch
in headlight position and 6
measuring resistance from
terminal 5 to 6.
5. Off Remove headlight relay (462– R4), 12 ± 1.5 Go to next Locate cause of low
(462–R4) and reconnect 50B to volts. step. or no voltage in circuit
headlight switch (410). gnd. 50B, then repair.
Move headlight switch to
headlight position, and
at relay socket (462–R4)
voltage to ground.
6. Off At relay socket (462–R4) (462– R4), 12 ± 1.5 Go to next Locate cause of
and circuit 51, measure 51 to gnd. volts. step. low or no voltage in
voltage to ground. 20A circuit breaker or
circuit 51, then repair.
7. Off At relay socket (462–R4), (462– 12 ± 1.5 Go to next Locate open or poor
measure voltage from R4), 51 to volts. step. connection in cir.
circuit 51 to 50–GB. 50–GB. 50–GB, 75–GC,
75–GB, 11–GN, or
11–GB to right cab
ground stud (404),
then repair.
8. Off Bench test headlight relay Relay < 1 ohm. Go to next Replace defective
(462–R4) by measuring (462– R4), step. headlight relay.
resistance from terminal 30 term. 30 to
to 87A. 87A.
s08270
Table 110 Headlights — 9800 SBA (cont.)

POINTS SPEC.
9. Off Bench test headlight relay Energized < 1 ohm. Go to next Replace defective
(462–R4) by applying relay (462– step. headlight relay.
+12 volts to terminal 86, R4), term.
ground to terminal 85, and 30 to 87.
terminal 30 to 87.
10. Off Disconnect dimmer switch (70), 51A 12 ± 1.5 Go to next Locate cause of low
(70) and re-install headlight to gnd. volts. step. or no voltage in circuit
relay (462–R4). Move 51A, then repair.
headlight switch to on
position and at connector
measure voltage to ground.
by placing it in low beam term. B to step. switch.
position and measuring C.
resistance from terminal B
to C.
by placing it in high beam term. B to step. switch.
position and measuring A.
resistance from terminal B
to A.
13. Off Disconnect right headlight (2), red 12 ± 1.5 Go to next Locate cause of
connector (2), move wire to volts. step. low or no voltage in
headlight switch to on gnd. circuit 53, 53A, conn.
position, and dimmer switch (400)/(498), cir. 53A,
to low beam position. At conn. (243), or red
conn. (2) and red wire, wire, then repair.
14. Off With switches still set, at (2), red 12 ± 1.5 Go to next Locate open or poor
connector (2), measure wire to volts. step. connection in blue
voltage from red wire to blue wire. wire, conn. (243),
blue wire. cir. 50–GA, 11–GK,
conn. (400)/(498),
cir. 11–GK or 11–G to
right cab ground stud
(404), then repair.
illuminate?
s08270

POINTS SPEC.
16. Off Disconnect left headlight (2), red 12 ± 1.5 Go to next Locate cause of
connector (2), move wire to volts. step. low or no voltage in
headlight switch to on gnd. circuit 53B, conn.
position, and dimmer switch (423)/(498), cir. 53B,
to low beam position. At conn. (243), or red
connector (2) and red wire, wire, then repair.
17. Off With switches still set, at (2), red 12 ± 1.5 Go to next Locate open or poor
connector (2), measure wire to volts. step. connection in blue
voltage from red wire to blue wire. wire, conn. (243),
blue wire. cir. 50–G, 11–GL,
conn. (423)/(498),
cir. 11–GL, conn.
(490), cir. 11–GM
or 11–GF to left
cab ground stud
(429), then repair.
[With Canadian
DRL ground path
from conn. (490)
is through cir. 66J,
relay (475) N.C.
contacts, and cir.
66–GA to G6 gnd.
adapter (616)]
(2). Does left headlight
illuminate?
19. Off Disconnect right headlight (2), brown 12 ± 1.5 Go to next Locate cause of
connector (2), move wire to volts. step. low or no voltage
headlight switch to on gnd. in circuit 52 or 52B,
position, and dimmer switch conn. (400)/(498),
to high beam position. At cir. 52B, conn. (243),
conn. (2) and brown wire, or brown wire, then
measure voltage to ground. repair.
illuminate?
s08270

POINTS SPEC.
21. Off Disconnect left headlight (2), brown 12 ± 1.5 Go to next Locate cause of
connector (2), move wire to volts. step. low or no voltage
headlight switch to on gnd. in cir. 52C, conn.
position, and dimmer switch (423)/(498), cir. 52C,
to high beam position. At conn. (243), or brown
connector (2) and brown wire, then repair.
wire, measure voltage to
ground.
22. Off With switches still set, Head- Replace defective
reconnect conn. (2). Does light cir. lamp.
left headlight illuminate? check
good.

Table 111 Daytime Running Lights (DRL) — Canada
POINTS SPEC.
1. On Move key switch to F10–A, 12 ± 1.5 Go to next Locate cause of
accessories position and 12R to volts. step. low or no voltage in
at 10A fuse F10–A and gnd. circuit 12R from A3
circuit 12R, measure accessories adapter
voltage to ground. (593), then repair.
2. Off/ Remove DRL day relay (475), 66A 12 ± 1.5 Go to next Locate cause of low
On (475), move key sw. to to gnd. volts. step. or no voltage in 10A
accessories position, and fuse F10–A or circuit
at circuit 66A, measure 66A, then repair.
voltage to ground.
3. On At relay socket (475), (475), 66A 12 ± 1.5 Go to next Locate open or poor
measure voltage from to 66–GA. volts. step. connection in circuit
circuit 66A to 66–GA. 66–GA or G6 gnd.
adapter, then repair.
4. On At relay socket (475), (475), 66B 12 ± 1.5 Go to next Locate cause of low
measure voltage from to gnd. volts. step. or no voltage in circuit
circuit 66B to ground. 66B, then repair.
5. Off Remove DRL night relay (474), 66H 12 ± 1.5 Go to next Locate cause of low
(474), move headlight to gnd. volts. step. or no voltage in circuit
switch to on position, and 66H from headlight
measure voltage from relay (462–R4), then
circuit 66H to ground. repair.
6. Off With headlight switch on, (474), 66H 12 ± 1.5 Go to next Locate open or poor
at relay socket (474), to 66–GB. volts. step. connection in circuit
measure voltage from 66–GB, then repair.
circuit 66H to 66–GB.
s08270
Table 111 Daytime Running Lights (DRL) — Canada (cont.)

POINTS SPEC.
7. Off With headlight switch still (474), 66H 12 ± 1.5 Go to next Locate open or poor
on, at (474), measure to 66–GC. volts. step. connection in circuit
voltage from circuit 66H to 66–GC, then repair.
66–GC.
8. Off Disconnect park brake Across sw. > 100K Go to next Replace defective
switch connector (293), (293). ohms. step. switch.
and with parking brakes
applied, measure
resistance across switch.
9. Off With wheels chocked, Across sw. < 1 ohm. Go to next Replace defective
release parking brakes (293). step. switch.
across switch (293).
10. Off With wheels still chocked (474), 66E < 1 ohm. Go to next Locate open or poor
and parking brake still to (475), step. connection in circuit
released, reconnect 66D. 66E or 66D, then
conn. (293). Measure repair.
resistance from relay
socket (474) circuit 66E to
relay socket (475) circuit
66D.
11. Off Bench test DRL night Relay < 1 ohm. Go to next Replace defective
relay (474) by measuring (474), step. DRL relay.
30 to 87A. to 87A.
12. Off Bench test DRL night Energized < 1 ohm. Go to next Replace defective
relay (474) by applying relay step. DRL relay.
+12 volts to terminal 86, (474),
ground to terminal 85, term. 30
and measuring resistance to 87.
13. Off Bench test DRL day Relay < 1 ohm. Go to next Replace defective
relay (475) by measuring (475), step. DRL relay.
30 to 87A. to 87A.
s08270
Table 111 Daytime Running Lights (DRL) — Canada (cont.)

POINTS SPEC.
14. Off Bench test DRL day Energized < 1 ohm. Go to next Replace defective
relay (475) by applying relay step. DRL relay.
+12 volts to terminal 86, (475),
ground to terminal 85, term. 30
and measuring resistance to 87.
15. Off Disconnect connector (490), 66J < 1 ohm. DRL Locate open or poor
(490) going to headlights, to gnd. circuits connection in circuit
and with park brake check 66J going to DRL
applied, measure good. day relay (475), then
resistance from circuit repair.
66J to ground.

Table 112 Daytime Running Lights (DRL) — USA
POINTS SPEC.
1. Off Disconnect DRL module F10–B, 12 ± 1.5 Go to next Locate cause of low
connector (633), and 14BL to volts. step. or no voltage in circuit
at 15A fuse F10–B and gnd. 14BL from B1 battery
circuit 14BL, measure adapter (517), then
2. Off At connector (633) circuit (633), 66A 12 ± 1.5 Go to next Locate cause of low
66A, measure voltage to to gnd. volts. step. or no voltage in 15A
ground. fuse F10–B or circuit
66A, then repair.
3. Off At connector (633), (633), 66A 12 ± 1.5 Go to next Locate open or poor
measure voltage from to 66–GA. volts. step. connection in circuit
circuit 66A to 66–GA. 66–GA or G6 ground
adapter (616), then
repair.
4. Off Move key switch to F10–A, 12 ± 1.5 Go to next Locate cause of low
ignition position and at 13AJ to volts. step. or no voltage in circuit
10A fuse F10–A and gnd. 13AJ from I2 ignition
circuit 13AJ, measure adapter (607), then
5. Off At connector (633) and (633), 66D 12 ± 1.5 Go to next Locate cause of low
circuit 66D, measure to gnd. volts. step. or no voltage in 10A
voltage to ground. fuse F10–A or circuit
66D, then repair.
s08270
Table 112 Daytime Running Lights (DRL) — USA (cont.)

POINTS SPEC.
6. Off Disconnect DRL park (293), < 1 ohm. Go to next Locate open or poor
brake connector (293) 66–GB to step. connection in circuit
and at circuit 66–GB, gnd. 66–GB to G6 ground
measure resistance to adapter (616), then
ground. repair.
7. Off With park brake applied, Across sw. < 1 ohm. Go to next Replace defective
measure resistance (293). step. DRL park brake
across DRL park brake switch.
switch (293).
8. Off Chock wheels, release Across sw. > 100K Go to next Re-apply park brake.
parking brake, and (293). ohms. step. Replace defective
measure resistance DRL park brake
across DRL park brake switch.
switch (293).
9. Off With park brake applied, (633), 66E < 1 ohm. Go to next Locate open or poor
at connector (633), to gnd. step. connection in circuit
measure resistance from 66E, then repair.
circuit 66E to ground.
10. Off Remove fog light switch (414), 64B < 1 ohm. Go to next Locate open or poor
connector (414) and to (633), step. connection in circuit
measure resistance from 64D. 64B or 64D, then
circuit 64B to circuit 64D repair.
of connector (633).
11. Off Move headlight switch (633), 66B 12 ± 1.5 Go to next Locate cause of low
to on and dimmer switch to gnd. volts. step. or no voltage in conn.
to low beam position. (493) or circuit 66B,
Verify that headlights then repair.
are functioning, then
at connector (633) and
circuit 66B, measure
voltage to ground.
12. Off With headlight switch on, (633), 66F 12 ± 1.5 Go to next Locate open or poor
move dimmer switch to to gnd. volts. step. connection in circuit
high beam position, and 66F, then repair.
at conn. (633) circuit
66F, measure voltage to
ground.
13. Off Daytime running light
Reconnect DRL module
(633). If system does not
function properly, replace
DRL module.
s08270

Table 113 Luggage Compartment
POINTS SPEC.
1. Off At 15A fuse F2–A and F2–A, 14T 12 ± 1.5 Go to next Locate cause of low
circuit 14T, measure to gnd. volts. step. or no voltage in (B2)
voltage to ground. battery stud, cir.
14W or 14T, then
repair.
2. Off At right luggage (101), 12 ± 1.5 Go to next Locate cause of low
compartment light socket black wire volts. step. or no voltage in 15A
(101), remove light bulb to gnd. fuse F2–A, cir. 63E,
and measure voltage conn. (N/L) or black
from black wire (coming wire, then repair.
from circuit 63E) to
ground.
3. Off Disconnect connector (171), < 1 ohm. Go to next Locate open or
(171) and at white wire white wire step. poor connection
going to ground, measure to gnd. in white wire
resistance to ground. going to luggage
compartment
4. Off At connector (171), with Sw. (171), < 1 ohm. Go to next Replace defective
compartment door open, black wire step. switch.
measure resistance from to white
white wire of switch to wire.
black wire of switch.
5. Off Reconnect conn. (171) (101), 12 ± 1.5 Go to next Locate open or poor
and at right luggage black wire volts. step. connection in black
compartment light socket to black wire between switch
(101), measure voltage wire. and light socket,
from black wire to black then repair.
wire.
6. Off Re-install right luggage Go to next Replace light bulb.
compartment light bulb. step.
Does light illuminate?
7. Off At left luggage (101), 12 ± 1.5 Go to next Locate cause of
compartment light socket black wire volts. step. low or no voltage
(101), remove light bulb to gnd. in circuit 63F, conn.
and measure voltage (N/L) or black wire,
from black wire (coming then repair.
from circuit 63F) to
ground.
s08270
Table 113 Luggage Compartment (cont.)

POINTS SPEC.
8. Off Disconnect connector (169), < 1 ohm. Go to next Locate open or
(169) and at white wire white wire step. poor connection
going to ground, measure to gnd. in white wire
resistance to ground. going to luggage
compartment
9. Off At connector (169), with Sw. (169), < 1 ohm. Go to next Replace defective
compartment door open, black wire step. switch.
measure resistance from to white
white wire of switch to wire.
black wire of switch.
10. Off Reconnect connector (101), 12 ± 1.5 Go to next Locate open or poor
(169) and at left luggage black wire volts. step. connection in black
compartment light socket to black wire between switch
(101), measure voltage wire. and light socket,
from black wire to black then repair.
wire.
11. Off Re-install left luggage Luggage Replace light bulb.
compartment light bulb. compartment
Does light illuminate? light
circuits
check
good.
3.13. PANEL
Table 114 Panel
POINTS SPEC.
1. Off Move headlight switch to F8–C, 68B 12 ± 1.5 Go to next Locate cause of
park light position, and at to gnd. volts. step. low or no voltage in
15A fuse F8–C and circuit circuit 68E or 68B
68B, measure voltage to from relay (464–R9),
2. Off Disconnect panel light (416), 62 12 ± 1.5 Go to next Locate cause of low
switch connector (416), to gnd. volts. step. or no voltage in 15A
and with headlight switch fuse F8–C, cir. 68C
in park light position, or 62, then repair.
circuit 62 to ground.
s08270
Table 114 Panel (cont.)

POINTS SPEC.
3. Off With headlight switch still (416), 62 12 ± 1.5 Go to next Locate open or poor
set, at connector (416), to 11–GS. volts. step. connection in cir.
measure voltage from 11–GS or 11–GLC to
circuit 62 to 11–GS. L3 panel light gnd.
adapter (505), then
repair.
4. Off With headlight switch still (416), 62 12 ± 1.5 Go to next Locate open or poor
set, at connector (416), to 62–GW. volts. step. connection in circuit
measure voltage from 62–GW, then repair.
circuit 62 to 62–GW.
5. Off At connector (416), (416), 62A < 1 ohm. Go to next Locate open or poor
measure resistance from to 62W. step. connection in circuit
circuit 62A to 62W. 62A or 62W, then
repair.
6. Off Reconnect panel light (416), 62A 0 to 11 ± Go to next Replace defective
switch (416), move to gnd. 1.5 volts. step. panel light switch.
headlight switch to park
light position. Verify
that the output of the
dimmer switch varies in
steps between 0 and
approximately 11 ± 1.5
volts by measuring voltage
from cir. 62A to ground.
Also visually check the
switch’s panel light.
7. Off With headlight switch in (586) to 11 ± 1.5 Go to next Locate cause of low
park light position, slide gnd. volts. step. or no voltage in cir.
dimmer switch to bright 62S or 62M, then
position, and measure repair.
voltage to ground at panel
light adapter (586).
8. Off Does heater control panel Go to Step Go to next step.
9. Off Remove heater panel light (84), 62P 11 ± 1.5 Go to next Locate cause of
bulb, move headlight to gnd. volts. step. low or no voltage in
switch to park light circuit 62AD or 62P,
position, and slide dimmer then repair.
switch to bright position.
At bulb socket (84) and cir.
62P, measure voltage to
ground.
s08270

POINTS SPEC.
10. Off With switches still set, at (84), 62P 11 ± 1.5 Go to next Locate open or poor
bulb socket (84), measure to 62–GP. volts. step. connection in cir.
voltage from circuit 62P to 62–GP or 11–G to
62–GP. right cab ground stud
(404), then repair.
11. Off Heater control panel Go to next
light circuits check good. step.
Replace burned out bulb.
12. Off Does cigar lighter panel Go to Step Go to next step.
13. On Remove cigar lighter Socket, 11 ± 1.5 Go to next Locate cause of
panel light bulb, move black wire volts. step. low or no voltage in
headlight switch to park to gnd. circuit 62AE, 62BW,
light position, and slide 62T, or black wire,
dimmer sw. to bright then repair.
position. At bulb socket
and black wire, measure
voltage to ground.
14. Off With switches still set, Socket, 11 ± 1.5 Go to next Locate open or poor
at bulb socket, measure black wire volts. step. connection in socket
voltage from black wire to to socket. ground, then repair.
socket (ground).
15. Off Cigar lighter panel light Go to next
circuits check good. step.
16. Off Do right gauge cluster Go to Step Go to next step.
panel lights function 20.
properly?
17. Off Disconnect right gauge (72), 62B 11 ± 1.5 Go to next Locate cause of
cluster connector (72), to gnd. volts. step. low or no voltage
move headlight switch in circuit 62B, then
to park light position, repair.
and slide dimmer switch
to bright position. At
conn. (72) and circuit
62B, measure voltage to
ground.
18. Off With switches still set, at (72), 62B 11 ± 1.5 Go to next Locate open or poor
connector (72), measure to 11–GW. volts. step. connection in cir.
voltage from circuit 62B to 11–GW or 11–GD to
11–GW. left cab ground stud
(429), then repair.
s08270

POINTS SPEC.
19. Off Circuits to right gauge Go to next
cluster panel lights check step.
good. Replace defective
lamps or socket assembly.
20. Off Do left gauge cluster panel Go to Step Go to next step.
lights function properly? 24.
21. Off Disconnect left gauge (73), 62C 11 ± 1.5 Go to next Locate cause of low
cluster conn. (73), move to gnd. volts. step. or no voltage in cir.
headlight switch to park 62C, then repair.
light position, and slide
dimmer switch to bright
position. At conn. (73) and
cir. 62C, measure voltage
to ground.
22. Off With switches still set, at (73), 62C 11 ± 1.5 Go to next Locate open or poor
connector (73), measure to 11–GV. volts. step. connection in cir.
voltage from circuit 62C to 11–GV or 11–GF to
11–GV. left cab ground stud
(429), then repair.
23. Off Circuits to left gauge Go to next
cluster panel lights check step.
good. Replace defective
lamps or socket assembly.
24. Off Does tachometer panel Go to Step Go to next step.
light (63) function 28.
properly?
25. Off Remove tachometer (63), 62E 11 ± 1.5 Go to next Locate cause of
panel light bulb, move to gnd. volts. step. low or no voltage
headlight switch to park in circuit 62E, then
light position, and slide repair.
dimmer sw. to bright
(63) and cir. 62E, measure
voltage to ground.
26. Off With switches still set, at (63), 62E 11 ± 1.5 Go to next Locate open or poor
bulb socket (63), measure to 62–GE. volts. step. connection in cir.
voltage from cir. 62E to 62–GE or 11–GAC
62–GE. to left cab ground
stud (429), then
repair.
27. Off Circuits to tachometer Go to next
panel light (63) check step.
good. Replace burned out
bulb.
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POINTS SPEC.
28. Off Does tachometer panel Go to Step Go to next step.
light (64) function 32.
properly?
29. Off Remove tachometer (64), 62D 11 ± 1.5 Go to next Locate cause of
panel light bulb, move to gnd. volts. step. low or no voltage
headlight switch to park in circuit 62D, then
light position, and slide repair.
(64) and cir. 62D, measure
voltage to ground.
30. Off With switches still set, at (64), 62D 11 ± 1.5 Go to next Locate open or poor
bulb socket (64), measure to 62–GD. volts. step. connection in cir.
voltage from cir. 62D to 62–GD, then repair.
62–GD.
31. Off Circuits to tachometer Go to next
bulb.
32. Off Does speedometer Go to Step Go to next step.
panel light (67) function 36.
properly?
33. Off Remove speedometer (67), 62G 11 ± 1.5 Go to next Locate cause of low
panel light bulb, move to gnd. volts. step. or no voltage in cir.
headlight switch to park 62G, then repair.
light position, and slide
(67) and cir. 62G, measure
voltage to ground.
34. Off With switches still set, at (67), 62G 11 ± 1.5 Go to next Locate open or poor
bulb socket (67), measure to 62–GG. volts. step. connection in circuit
voltage from cir. 62G to 62–GG, then repair.
62–GG.
35. Off Circuits to speedometer Go to next
bulb.
36. Off Does speedometer Go to Step Go to next step.
panel light (68) function 40.
properly?
s08270

POINTS SPEC.
37. Off Remove speedometer (68), 62F 11 ± 1.5 Go to next Locate cause of low
panel light bulb, move to gnd. volts. step. or no voltage in cir.
headlight sw. to park light 62F, then repair.
position, and slide dimmer
sw. to bright position. At
bulb socket (68) and cir.
62F, measure voltage to
ground.
38. Off With switches still set, at (68), 62F 11 ± 1.5 Go to next Locate open or poor
bulb socket (68), measure to 62–GF. volts. step. connection in circuit
voltage from cir. 62F to 62–GF, then repair.
62–GF.
39. Off Circuits to speedometer Go to next
bulb.
40. Off Does push button start Go to Step Go to next step.
panel light function 44.
properly?
41. Off Remove push button start (541), 11 ± 1.5 Go to next Locate cause of
panel light bulb, move 62AX to volts. step. low or no voltage in
headlight sw. to park light gnd. circuit 62AX, then
position, and slide dimmer repair.
sw. to bright position.
At bulb socket (541) and
circuit 62AX, measure
voltage to ground.
42. Off With switches still set, Socket, 11 ± 1.5 Go to next Locate open or poor
at bulb socket, measure 62AX to volts. step. connection in cir.
voltage from cir. 62AX to 62–GAX. 62–GAX to L3 panel
62–GAX. light ground adapter
(505), then repair.
43. Off Push button start panel Go to next
44. Off Does fresh air control Go to Step Go to next step.
panel light function 48.
properly?
s08270

POINTS SPEC.
45. Off Remove fresh air control (494), 11 ± 1.5 Go to next Locate cause of
panel light bulb, move 62AU to volts. step. low or no voltage
headlight switch to park gnd. in circuit 62P, conn.
light position, and slide (84), or circuit 62AU,
dimmer sw. to bright then repair.
(494) and cir. 62AU,
measure voltage to
ground.
46. Off With switches still set, (494), 11 ± 1.5 Go to next Locate open or poor
at bulb socket (494), 62AU to volts. step. connection in circuit
measure voltage from 62–GAU. 62–GAU, conn. (84),
circuit 62AU to 62–GAU. cir. 62–GP or 11–G
to right cab gnd. stud
(404), then repair.
47. Off Fresh air control panel Go to next
48. Off Does key switch panel Go to Step Go to next step.
49. Off Remove key sw. light (495), 11 ± 1.5 Go to next Locate cause of
bulb, move headlight sw. 62AT to volts. step. low or no voltage
to park light position, gnd. in circuit 62AT, then
and slide dimmer sw. to repair.
bright position. At bulb
socket (495) and cir.
62AT, measure voltage to
ground.
50. Off With switches still set, (495), 11 ± 1.5 Go to next Locate open or
at bulb socket (495), 62AT to volts. step. poor connection in
measure voltage from cir. 62–GAT circuit 62–GAT or
62AT to 62–GAT. 11–GLB to panel
gnd. adapter (587),
then repair.
51. Off Key switch panel light Go to next
circuits check good. step.
52. Off Panel light circuits check
good. Move headlight
switch to off position.
s08270
Table 115 Spot, Bunk Fluorescent and Reading Lights, and Cigar Lighter (Non-Raised Roof Cab)
POINTS SPEC.
1. Off At 25A fuse F8–D and F8–D, 12± 1.5 Go to Locate cause of
circuit 14AP, measure 14AP to volts. next step. low or no voltage in
voltage to ground. gnd. circuit 14H or 14AP
from (B2) battery
stud, then repair.
2. Off Does left spot light function Go to Go to next step.
properly? Step 5.
3. Off Disconnect left spot light (N/L), 12 ± 1.5 Go to Locate cause of
connector (N/L), and at 14AY to volts. next step. low or no voltage in
circuit 14AY, measure gnd. 25A fuse F8–D, cir.
voltage to ground. 14AE, conn. (22),
cir. 14AE, 14AY, or
conn. (N/L), then
repair.
4. Off Circuits to left spot light Go to Repair or replace
check good. Reconnect next step. spot light bulb,
spot light. Does spot light switch or ground
function properly? connection.
5. Off Does right spot light Go to Go to next step.
6. Off Disconnect right spot light (N/L), 12± 1.5 Go to Locate cause of low
connector (N/L), and at 14BA to volts. next step. or no voltage in cir.
circuit 14BA, measure gnd. 14BA or conn. (N/L),
7. Off Circuits to right spot light Go to Repair or replace
check good. Reconnect next step. spot light bulb,
spot light. Does spot light switch or ground
function properly? connection.
8. Off Does cigar lighter function Go to Go to next step.
properly? Step 12.
9. Off At cigar lighter socket Cigar 12 ± 1.5 Go to Locate cause of low
and circuit 84A, measure socket, volts. next step. or no voltage in cir.
voltage to ground. 84A to 14AZ, conn. (N/L),
gnd. cir. 14AE or 84A,
then repair.
s08270
(cont.)
POINTS SPEC.
10. Off At cigar lighter socket, Cigar 12 ± 1.5 Go to Locate open or poor
measure voltage from socket, volts. next step. connection in cir.
circuit 84A to 84–GA. 84A to 84–GA, 11–GAH,
84–GA. 11–GAN, conn. (81),
cir. 11–GAN or
11–GBB to right cab
gnd. (404), then
repair.
11. Off Circuits to sleeper cigar Go to Replace defective
light socket check good. next step. cigar lighter element.
Does lighter heat up?
12. Off Does bunk reading light Go to Go to next step.
13. Off Disconnect bunk reading (564), 63P 12 ± 1.5 Go to Locate cause of low
light connector (564), and to gnd. volts. next step. or no voltage in cir.
at circuit 63P, measure 63P, then repair.
voltage to ground.
14. Off At connector (564), (564), 63P 12 ± 1.5 Go to Locate open or poor
measure voltage from to 63–GP. volts. next step. connection in circuit
circuit 63P to 63–GP. 63–GP, then repair.
15. Off Circuits to bunk reading Go to Repair or replace
light check good. Does next step. reading light bulb,
reading light function switch, or socket
properly? assembly.
16. Off Does bunk fluorescent light Go to Go to next step.
17. Off Disconnect sleeper dome (589), < 1 ohm. Go to Locate open or poor
light switch (589), and at 63–GE to next step. connection in cir.
circuit 63–GE, measure gnd. 63–GE or 11–GLC
resistance to ground. to L3 panel gnd.
adapter (505), then
repair.
18. Off Test sleeper dome light Sw. (589), < 1 ohm. Go to Replace defective
sw. (589) by measuring term. 1 to next step. dome light switch.
resistance from terminal 1 2.
to 2 with sw. wiper moved
to that position.
19. Off Test sleeper dome light Sw. (589), < 1 ohm. Go to Replace defective
switch (589) by measuring term. 2 to next step. dome light switch.
resistance from terminal 3.
2 to 3 with switch wiper
moved to that position.
s08270
(cont.)
POINTS SPEC.
20. Off Reconnect connector (589) (563), < 1 ohm. Go to Locate open or poor
and disconnect connector 63–GD to next step. connection in cir.
(563). With sleeper dome gnd. 63–GD, conn. (19),
light switch wiper still cir. 63–GD, conn.
in the terminal 2 to 3 (11), or cir. 63–GD
position, at connector (563) from sleeper dome
circuit 63–GD, measure light sw. (589), then
resistance to ground. repair.
21. Off Move sleeper dome (563), < 1 ohm. Go to Locate open or poor
light switch (589) to the 63–GC to next step. connection in circuit
other position (wiper gnd. 63–GC, conn. (19),
between terminals 1 and cir. 63–GC, conn.
2), and at connector (563) (11), or cir. 63–GC
circuit 63–GC, measure from sleeper dome
resistance to ground. light sw. (589), then
repair.
22. Off Test fluorescent light Sw. (563), < 1 ohm. Go to Replace defective
switch (563) by measuring term. 1 to next step. fluorescent light
resistance from term. 1 to 2. switch.
2 with sw. wiper moved to
that position.
23. Off With switch still set as in Sw. (563), < 1 ohm. Go to Replace defective
Step 22, test fluorescent term. 4 to next step. fluorescent light
light switch (563) by 5. switch.
terminal 4 to 5.
24. Off Test fluorescent light Sw. (563), < 1 ohm. Go to Replace defective
switch (563) by moving term. 2 to next step. fluorescent light
sw. to other position and 3. switch.
terminal 2 to 3.
25. Off With switch still set as in Sw. (563), < 1 ohm. Go to Replace defective
Step 24, test fluorescent term. 5 to next step. fluorescent light
terminal 5 to 6.
26. Off Disconnect bunk (562), 63L 12± 1.5 Go to Locate cause of
fluorescent light connector to gnd. volts. next step. low or no voltage
(562), and at circuit 63L, in circuit 63L, then
measure voltage to ground. repair.
s08270
(cont.)
POINTS SPEC.
27. Off With dome light switch (652), 63L 12± 1.5 Go to Locate open or poor
(589) and fluorescent light to 63–GA. volts. next step. connection in cir.
switch (563) still set, as in 63–GA, conn. (557),
Steps 19 and 25, measure or cir. 63–GA, then
voltage from circuit 63L to repair.
63–GA of connector (562).
28. Off Move switch (563) to other (562), 63L 12 ± 1.5 Go to Locate open or poor
position, and at connector to 63–GB. volts. next step. connection in cir.
(562), measure voltage 63–GB, conn. (557),
from circuit 63L to 63–GB. or cir. 63–GB, then
repair.
29. Off Circuits to bunk fluorescent Go to Repair or replace
light check good. next step. bunk fluorescent
Reconnect conn. (562). light assembly.
Does fluorescent light
function properly?
30. Off Spot, bunk fluorescent,
and reading lights, and
cigar lighter circuits check
good.
Table 116 Bunk Fluorescent and Reading Lights (With Raised Roof Cab)
POINTS SPEC.
1. Off At 25A fuse F8–D and F8–D, 12 ± 1.5 Go to next Locate cause of
circuit 14AP, measure 14AP to volts. step. low or no voltage in
voltage to ground. gnd. circuit 14H or 14AP
from (B2) battery
stud, then repair.
2. Off Does bunk reading light Go to Step Go to next step.
3. Off Disconnect bunk reading (564), 63M 12 ± 1.5 Go to next Locate cause of
light connector (564), and to gnd. volts. step. low or no voltage in
at circuit 63M, measure 25A fuse F8–D, cir.
voltage to ground. 14AE, conn. (22), cir.
14AE, conn. (7), cir.
14AE or 63M, then
repair.
s08270
Table 116 Bunk Fluorescent and Reading Lights (With Raised Roof Cab) (cont.)
POINTS SPEC.
4. Off At connector (564) (564), 63M 12 ± 1.5 Go to next Locate open or poor
measure voltage from to 63–GM. volts. step. connection in cir.
circuit 63M to 63–GM. 63–GM, 11–GAH,
11–GAN, conn. (81),
cir. 11–GAN or
ground (404), then
repair.
5. Off Circuits to bunk reading Go to next Repair or replace
light check good. Does step. reading light bulb,
reading light function switch, or socket
properly? assembly.
6. Off Does bunk fluorescent Go to Step Go to next step.
7. Off Disconnect sleeper dome (589), < 1 ohm. Go to next Locate open or poor
light switch (589), and at 63–GE to step. connection in cir.
circuit 63–GE, measure gnd. 63–GE or 11–GLC
resistance to ground. to L3 panel gnd.
adapter (505), then
repair.
8. Off Test sleeper dome Sw. (589), < 1 ohm. Go to next Replace defective
light switch (589) by term. 1 to step. dome light switch.
measuring resistance 2
from terminal 1 to 2 with
switch wiper moved to
that position.
9. Off Test sleeper dome Sw. (589), < 1 ohm. Go to next Replace defective
light switch (589) by term. 2 to step. dome light switch.
measuring resistance 3.
that position.
10. Off Reconnect connector (563), < 1 ohm. Go to next Locate open or poor
(589) and disconnect 63–GD to step. connection in cir.
connector (563). With gnd. 63–GD, conn. (19),
sleeper dome light switch cir. 63–GD, conn.
wiper still in the terminal 2 (11), cir. 63–GD,
to 3 position, at connector conn. (557), or
(563) circuit 63–GD, circuit 63–GD, then
measure resistance to repair.
ground.
s08270
POINTS SPEC.
11. Off Move sleeper dome (563), < 1 ohm. Go to next Locate open or poor
light switch (589) to the 63–GC to step. connection in cir.
other position (wiper gnd. 63–GC, conn. (19),
between terminals 1 and cir. 63–GC, conn.
2), and at connector (563) (11), cir. 63–GC,
circuit 63–GC, measure conn. (557), or cir.
resistance to ground. 63–GC, then repair.
12. Off Test fluorescent light Sw. (563), < 1 ohm. Go to next Replace defective
switch (563) by term. 1 to step. fluorescent light
measuring resistance 2. switch.
that position.
13. Off With switch still set as in Sw. (563), < 1 ohm. Go to next Replace defective
Step 12, test fluorescent term. 4 to step. fluorescent light
14. Off Test fluorescent light Sw. (563), < 1 ohm. Go to next Replace defective
switch (563) by moving term. 2 to step. fluorescent light
switch to other position 3. switch.
and measuring resistance
15. Off With switch. still set as in Sw. (563), < 1 ohm. Go to next Replace defective
Step 14, test fluorescent term. 5 to step. fluorescent light
16. Off Disconnect bunk (562), 63L 12± 1.5 Go to next Locate cause of low
fluorescent light to gnd. volts. step. or no voltage in cir.
connector (562), and 63L, then repair.
at circuit 63L, measure
voltage to ground.
17. Off With dome light switch (562), 63L 12 ± 1.5 Go to next Locate open or poor
(589) and fluorescent light to 63–GA. volts. step. connection in circuit
sw. (563) still set, as in 63–GA, conn. (557),
Steps 9 and 15, measure or cir. 63–GA, then
voltage from cir. 63L to repair.
63–GA of conn. (562).
18. Off Move switch (563) to (562), 63L 12± 1.5 Go to next Locate open or poor
other position, and at to 63–GB. volts. step. connection in cir.
connector (562), measure 63–GB, conn. (557),
voltage from circuit 63L to or cir. 63–GB, then
63–GB. repair.
s08270
POINTS SPEC.
19. Off Circuits to bunk Go to next Repair or replace
fluorescent light check step. bunk fluorescent
good. Reconnect conn. light assembly.
(562). Does fluorescent
light function properly?
20. Off Bunk fluorescent and
reading light circuits
check good.

Table 117 Trailer Work or Hook-Up
POINTS SPEC.
1. Off At 10A fuse F1–D and F1–D, 12 ± 1.5 Go to Locate cause of low
circuit 14AN, measure 14AN to volts. next step. or no voltage in circuit
voltage to ground. gnd. 14K or 14AN from
(B1) battery stud,
then repair.
2. Off Disconnect connector (25) (25), 65 to 12 ± 1.5 Go to Locate cause of low
and at circuit 65, measure gnd. volts. next step. or no voltage in 10A
voltage to ground. fuse F1–D or cir. 65,
then repair.
3. Off With work light switch (25) Sw. (25), > 100K Go to Replace defective
in off position, measure term. 4 to ohms. next step. switch.
resistance from terminal 4 5.
to 5.
4. Off Move work light switch Sw. (25), < 1 ohm. Go to Replace defective
(25) to on position and term. 5 to next step. switch.
measure resistance from 6.
terminal 5 to 6.
5. Off Disconnect trailer work (N/L) 12 ± 1.5 Go to Locate cause of low
light conn. (N/L), and black wire volts. next step. or no voltage in circuit
reconnect work light to gnd. 65A or black wire,
switch (25). At conn. (N/L) then repair.
and black wire, measure
voltage to ground with
switch (25) in the on
position.
6. Off With switch still set, at (N/L), 12 ± 1.5 Go to Locate cause of low
connector (N/L), measure black wire volts. next step. or no voltage in circuit
voltage from black wire to to 11. 11 to (J7) cab ground,
circuit 11. then repair.
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Table 117 Trailer Work or Hook-Up (cont.)

POINTS SPEC.
7. Off Reconnect trailer work Go to Repair or replace
light conn. (N/L). Does next step. defective work light
work light illuminate? lamp or socket.
8. Off Does work light indicator Go to Go to next step.
illuminate? Step 12.
9. Off Disconnect left gauge (73), 65B 12 ± 1.5 Go to Locate cause of low
cluster connector (73), to gnd. volts. next step. or no voltage in circuit
and with work light switch 65B, then repair.
in on position, measure
voltage from circuit 65B to
ground.
10. Off With switch still set, at (73), 65B 12 ± 1.5 Go to Locate open or poor
connector (73), measure to 11–GV. volts. next step. connection in cir.
voltage from circuit 65B to 11–GV or 11–GF to
11–GV. left cab ground stud
(429), then repair.
11. Off Reconnect left gauge Go to Replace defective
cluster connector (73). next step. bulb or socket
Does work light indicator assembly.
light illuminate?
12. Off Trailer work light circuits
check good. Move work
light switch to off position.
F1 Fuseblock (462). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
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F10 Fuseblock (464). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
G3 Ground Adapter (456). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind right gauge cluster
G6 Ground Adapter (616). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument cluster, right
L1 LED Panel Lt Feed Adapter (504). . . . . . . . . . . . . . .. . . . . . Behind switch cluster
L2 LED Panel Lt Feed Adapter (586). . . . . . . . . . . . . . .. . . . . . Behind switch cluster
L3 LED Panel Lt Ground Adapter (505). . . . . . . . . . . .. . . . . . Behind switch cluster
L4 LED Panel Lt Ground Adapter (587). . . . . . . . . . . .. . . . . . Behind switch cluster
(B1) Battery Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At power distribution center
(B2) Battery Stud/ Deep Cycle Stud. . . . . . . . . . . . . . . . .. . . . . . At power distribution center
(J3) Roof Ground Junction. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In roof, strainer
(J7) Cab Ground Junction. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At left luggage compartment on tunnel
(J8) Cranking Motor Ground Junction. . . . . . . . . . . . . . .. . . . . . Ground terminal at engine
(J11) Frame Rail Ground Junction. . . . . . . . . . . . . . . . . . .. . . . . . Right frame rail
(J13) Bunk Ground Junction. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind left side trim panel
(2) Headlight Connector Lt/Rt. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At back of headlights
(3) Rt Stop, Tail, Turn, and Back-up Light. . . . . . . . . .. . . . . . At right tail light (to lt tail light)
(4) Lt Stop, Tail, Turn, and Back-up Light. . . . . . . . . . .. . . . . . At left tail light
(4A) Lt Stop, Tail, Turn, and Back-up Light. . . . . . . . .. . . . . . At left tail light (to rt tail light)
(7) Bunk Roof Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind “B” pillar left roof
(11) Radio Cab Roof Connector. . . . . . . . . . . . . . . . . . . . .. . . . . . Behind trim panel above left door
(12) Back-up Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On top of transmission
(19) Roof Harness #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind left instrument panel
(22) Roof Harness #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At “A” pillar behind lt dash
(23) Work Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In left luggage compartment
(25) Work Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(35) Trailer Socket Connector. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Inside left luggage compartment
(36) Turn Signal Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind left instrument panel
(58) Clearance Light With Raised Cab Roof. . . . . . .. . . . . . At driver’s side clearance light
(59) Clearance Light With Raised Cab Roof. . . . . . .. . . . . . At center clearance/ID light
(61) Clearance Light With Raised Cab Roof. . . . . . .. . . . . . At left clearance/ID light
(62) Clearance Light With Raised Cab Roof. . . . . . .. . . . . . At right clearance/ID light
(63) Tachometer Panel Light. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At back of tachometer/cab harness
(64) Tachometer Panel Light. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At back of tachometer/cab harness
(66) Clearance Light With Raised Cab Roof. . . . . . .. . . . . . At passenger’s side clearance light
(67) Speedometer Panel Light. . . . . . . . . . . . . . . . . . . . . . .. . . . . . At back of speedometer/cab harness
(68) Speedometer Panel Light. . . . . . . . . . . . . . . . . . . . . . .. . . . . . At back of speedometer/cab harness
(69) High Beam Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At back of speedometer/cab harness
(70) Headlight Dimmer Floor Switch. . . . . . . . . . . . . . . .. . . . . . At cab floor left front
(73) Left Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At back of left gauge cluster
(78) Fog Light Relay Feed. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind fuse block
(81) Cab to Sleeper Connector #3. . . . . . . . . . . . . . . . . .. . . . . . Behind driver under floor
(84) Heater Control Panel Light. . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind heater controls/cab harness
(101) Luggage Compartment Light. . . . . . . . . . . . . . . . . .. . . . . . In left and right luggage compartment
(102) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor, ft rt, 1/2 replace by (338) with Series 60
(125) Chassis Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor, front right
(155) Fog Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Under cab, right front side
(156) Left Fog Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Pigtail, behind bumper, left side
(157) Right Fog Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Pigtail, behind bumper, right side
(169) Left Luggage Light Switch. . . . . . . . . . . . . . . . . . . . .. . . . . . On left luggage compartment door
(171) Right Luggage Light Switch. . . . . . . . . . . . . . . . . . .. . . . . . On right luggage compartment door
(189) Back-up Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Inside right sidemember, rear of cab
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(207) Left and Right Courtesy Lights. . . . . . . . . . . . . . . .. . . . . . In door, left and right
(241) Side Turn Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind T/S light assembly, pigtail to headlight harness
(242) Front Turn Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind T/S light assembly
(243) Headlight Connector. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Above headlights
(293) Park Brake Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At parking brake air valve, center of dash panel
(302) Front Turn Signal Lamp Socket. . . . . . . . . . . . . . .. . . . . . Behind light
(400) Right Headlight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor, front right
(403) Right Door Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, left corner
(404) Right Cab Ground Stud. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Right hand cowl inner panel
(409) Trailer Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(410) Headlight Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(414) Fog Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(416) Panel Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(421) Stop Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At dash panel inside cab
(423) Left Headlight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . On cab floor, front left
(429) Left Cab Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left hand cowl inner panel
(439) Dome Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(440) Fog Light Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(462) Ignition Relay R1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(464) Trailer Tail Light Relay R9. . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(464) Trailer Stop Light Relay R10. . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(464) Left Turn Relay R11. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(464) Right Turn Relay R12. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(474) DRL Night Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(475) DRL Day Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(490) Headlight Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Under dash at center, one way inline
(493) Fog Light Accessories Feed. . . . . . . . . . . . . . . . . .. . . . . . Behind fuse block, one way inline
(494) Fresh Air Panel Light. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind heater controls
(495) Key Switch Panel Light. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster, above key switch
(498) Right and Left Headlight Connector. . . . . . . . . .. . . . . . Front of cab floor
(501) Dualtec Flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In power distribution center
(504) LED Panel Lt Feed Adapter L1. . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(505) LED Panel Lt Ground Adapter L3. . . . . . . . . . . .. . . . . . Behind switch cluster
(508) Panel Light Adapter L5. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind right gauge cluster
(517) Battery Adapter B1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, center
(541) Push Button LED Light. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster, above push button start switch
(557) Bunk/Roof Connector #1. . . . . . . . . . . . . . . . . . . . . .. . . . . . At “B” pillar left side with 110 inch, in left luggage area
with 89 inch
(559) Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In header above windshield center
(562) Bunk Fluorescent Light. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Above headliner, center bunk
(563) Fluorescent Light Switch. . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind bunk control panel
(564) Bunk Reading Light. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind headliner, above light
(568) Right Reading Light. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind headliner, above right door
(569) Left Reading Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind headliner, above left door
(570) Right Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Above headliner, right center
(571) Left Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Above headliner, left center
(580) Left Turn Signal Ground. . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind right instrument cluster
(586) LED Panel Lt Feed Adapter L2. . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(587) LED Panel Lt Ground Adapter L4. . . . . . . . . . . .. . . . . . Behind switch cluster
(589) Sleeper Dome Light Switch. . . . . . . . . . . . . . . . . . .. . . . . . Behind switch cluster
(607) Ignition Adapter I2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind speedo/ tach cluster
(633) DRL Module, USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument panel, at key switch breakout
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(616) Ground Adapter G6. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument cluster, right

(766) Cab Roof Clearance and ID Lights. . . . . . . . . . .. . . . . . At pigtail of light
(775) Clearance Connector With Raised Roof. . . . .. . . . . . By “B” pillar
Refer to Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8, Figure 9, Figure 10,
Figure 11, Figure 12, Figure 13, Figure 14, Figure 15, Figure 16, Figure 17, Figure 18, Figure 19, Figure
20, and Figure 21.
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Figure 132 Clearance and Identification Light Wiring
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Figure 133 Clearance and Identification Light Wiring, 110 Inch BBC With Raised Roof Cab
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Figure 134 Turn Signal Switch and Flasher Wiring
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Figure 135 Dimmer Control
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Figure 136 Stop, Tail And Turn Light Wiring
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Figure 137 Stop, Tail, and Turn Light Wiring
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Figure 140 Stop, Tail, and Turn Light Wiring — 9800 With Signal Stat (Federal Mogul Lights)
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Figure 141 Fog Light Wiring
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Figure 142 Fog Light Wiring
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Figure 143 Canadian Daytime Running Light Wiring
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Figure 144 Canadian Daytime Running Light Wiring — 9800 With Detroit Diesel Series 60 Engine
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Figure 145 USA Daytime Running Light Wiring
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Figure 146 USA Daytime Running Light Wiring
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Figure 147 USA Daytime Running Light Wiring — 9800 With Detroit Diesel Series 60 Engine
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Figure 148 Luggage Compartment Light Wiring — 9800 SBA With 89 Inch BBC
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Figure 149 Luggage Compartment Light Wiring — 9800 SBA With 110 Inch BBC
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Figure 150 Bunk Dome Light Wiring — With 89 Inch, 110 Inch BBC Flat Roof Cab and Pro Sleeper
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Figure 151 Bunk Dome Light Wiring — With 89 Inch, 110 Inch BBC Flat Roof Cab and Pro Sleeper
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Figure 152 Trailer Hookup Light Wiring
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11 SLEEPER ACCESSORIES 469
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
1.1. REFRIGERATOR WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
1.2. BUNK SPEAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
Flat Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
Hi-Rise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
1.3. TV/VCR WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
Flat Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
Hi-Rise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
2.2. BUNK SPEAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .472
Flat Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .472
Hi-Rise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .472
2.3. TV/VCR WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473
Flat Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473
Hi-Rise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473
3.2. BUNK SPEAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475
3.3. TV/VCR WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477
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470 11 SLEEPER ACCESSORIES
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Model: 9800
1. DESCRIPTION
1.1. REFRIGERATOR WIRING
A power socket, without an on/off switch, is provided to power a refrigerator in the sleeper. The on/off switch
is located in the sleeper control panel.
1.2. BUNK SPEAKERS

Flat Roof
An optional bunk speaker package is available. It consists of a front (left channel) and rear (right channel)
coaxial speaker in the bunk. A headphone jack and volume control for the rear speakers is located in the bunk.
Hi-Rise
An optional bunk speaker package is available. It consists of a front (left channel) and rear (right channel)
coaxial speaker in the bunk. A headphone jack and volume control for the rear speakers is located in the bunk.
1.3. TV/VCR WIRING

Flat Roof
A receptacle and an on/off switch is provided to supply power to a television and video cassette recorder.
Hi-Rise
A receptacle and an on/off switch is provided to supply power to a television and video cassette recorder.
2. OPERATION
Power is continuously supplied to B2 battery adapter, circuits 14AU and 14BE, 15A fuse F10-A [location
may vary], circuit 86T, connector (80), and circuit 86T to the refrigerator on/off switch (652). With the switch
in the on position, power is applied to circuit 86E, connector (471), and circuit 86T to the refrigerator power
source socket (651).
The ground path for the power socket (651) is circuit 86-GT, connector (471), circuits 86-GT and 11-GAN,
connector (81), and circuits 11-GAN and 11-GBB to the right cab ground stud (404). The refrigerator on/off
switch panel light receives power from the panel light adapter (504), circuit 62BB, connector (80), and circuits
62BB and 62BE.
The ground path is through circuits 62-GBE, 86-GC, 11-GBJ, 11-GAN, connector (81), circuits 11-GAN and
11-GBB to the right cab ground stud (404).
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2.2. BUNK SPEAKERS

Flat Roof
A signal path is provided through a green wire, connector (21), circuit 86CA, connector (738), circuit 86CA,
connector (11), circuit 86CA, connector (557), circuit 86CA, connector (122), and the yellow wire to the left
channel/front bunk speaker volume control. From the volume control the adjusted signal is supplied to a green
wire, a headphone jack, a green wire, connector (122), circuit 86R, connector (558), circuit 86R, connector
(13), circuit 86R, connector (10), and the green wire to the front bunk speaker.
The return path is through a black wire, connector (10), circuit 86P, connector (13), circuit 86CB, connector
(11), circuit 86CB, connector (738), circuit 86CB, connector (21), and the green/black wire to the radio. The
ground path for the volume control is a black wire, connector (122), circuit 86F, connector (558), circuits 86F
and 86CB, connector (11), circuit 86CB, connector (738), circuit 86CB, connector (21), and the green/black
wire to the radio. The headphone jack is grounded through a black wire, a 10 MFD capacitor, a 120 ohm
resistor and a black wire to the volume control ground circuit.
A signal path is provided through a violet wire connector (21), circuit 86CC, connector (738), circuit 86CC,
connector (11), circuit 86CC, connector (557), circuit 86CC, connector (123), and the red wire to the right
channel/rear bunk speaker volume control. From the volume control the adjusted signal is supplied to a green
wire, a headphone jack, a green wire, connector (123), circuit 86S, connector (558), circuit 86S, connector (9),
and the green wire to the rear bunk speaker. The return path is through a black wire, connector (9), circuit
86CD, connector (11), circuit 86CD, connector (738), circuit 86CD, connector (21), and a violet/black wire
to the radio. The ground path for the volume control is a black wire, connector (123), circuit 86H, connector
(558), circuits 86H and 86CD, connector (11), circuit 86CD, connector (738), circuit 86CD, connector (21), and
the green wire to the radio. The headphone jack is grounded through a black wire, a 10 MFD capacitor, a
120 ohm resistor and a black wire to the volume control ground circuit.
Hi-Rise
A signal path is provided through a green wire, connector (21), circuit 86CA, connector (738), circuit 86CA,
connector (11), circuit 86CA, connector (557), circuit 86CA, connector (122), and the yellow wire to the left
channel/front bunk speaker volume control. From the volume control the adjusted signal is supplied to a green
wire, a headphone jack, a green wire, connector (122), circuit 86R, connector (558), circuit 86R, connector
(10), and the green wire to the front bunk speaker. The return path is through a black wire, connector (10),
circuit 86CB, connector (11), circuit 86CB, connector (738), circuit 86CB, connector (21), and the green/black
wire to the radio. The ground path for the volume control is a black wire, connector (122), circuit 86F, connector
(558), circuits 86F and 86CB, connector (11), circuit 86CB, connector (738), circuit 86CB, connector (21), and
the green/black wire to the radio. The headphone jack is grounded through a black wire, a 10 MFD capacitor, a
120 ohm resistor and a black wire to the volume control ground circuit.
A signal path is provided through a violet wire connector (21), circuit 86CC, connector (738), circuit 86CC,
connector (11), circuit 86CC, connector (557), circuit 86CC, connector (123), and the red wire to the right
channel/rear bunk speaker volume control. From the volume control the adjusted signal is supplied to a green
wire, a headphone jack, a green wire, connector (123), circuit 86S, connector (558), circuit 86S, connector
(9), and the green wire to the rear bunk speaker. The return path is through a black wire, connector (9),
circuit 86CD, connector (11), circuit 86CD, connector (738), circuit 86CD, connector (21), and a violet/black
wire to the radio.
The ground path for the volume control is a black wire, connector (123), circuit 86H, connector (558), circuits
86H and 86CD, connector (11), circuit 86CD, connector (738), circuit 86CD, connector (21), and the green wire
to the radio. The headphone jack is grounded through a black wire, a 10 MFD capacitor, a 120 ohm resistor
and a black wire to the volume control ground circuit.
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2.3. TV/VCR WIRING

Flat Roof
Power is continuously applied to the (B2) battery stud, circuits 14AU and 14BE, 15A fuse F10-A [location may
vary], circuit 86U, connector (80), and circuit 86U to the TV/VCR on/off switch (612). When the switch is
moved to the on position, power is applied to circuit 86UA, connector (557), and circuit 86UA to the TV/VCR
receptacle (613). The ground path for (613) is through circuits 86-GS and 11-GAH, connector (557), circuits
11-GAH and 11-GAN, connector (81), circuits 11-GAN and 11-GBB to the right cab ground stud (404).
The TV/VCR switch panel light receives power from L1 panel adapter (504), circuit 68BB, connector (80),
and circuits 62BB and 62BF. The ground path is through circuits 62-GBD, 11-GBJ and 11-GAN, connector
(81), circuits 11-GAN and 11-GBB to the right cab ground stud (404).
Hi-Rise
Power is continuously applied to the (B2) battery stud, circuits 14AU and 14BE, 15A fuse F10-A [location may
vary], circuit 86U, connector (80), and circuit 86U to the TV/VCR on/off switch (612). When the switch is
moved to the on position, power is applied to circuit 86UA, connector (557), and circuit 86UA to the TV/VCR
receptacle (776). Power is also applied by circuit 86UB to TV/VCR receptacle (777). The ground path for (777)
is circuit 86-GB to (776). The ground path for (776) is through circuits 86-GS and 11-GAH, connector (557),
circuits 11-GAH and 11-GAN, connector (81), circuits 11-GAN and 11-GBB to the right cab ground stud (404).
The TV/VCR switch panel light receives power from L1 panel adapter (504), circuit 68BB, connector (80),
and circuits 62BB and 62BF. The ground path is through circuits 62-GBD, 11-GBJ and 11-GAN, connector
(81), circuits 11-GAN and 11-GBB to the right cab ground stud (404).
3. TROUBLESHOOTING
wires, etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in GROUP 08 –
ELECTRICAL in the CTS – 5000 Master Service Manual.
relay, or solenoid.
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Table 118 Refrigerator Wiring
STEP KEY ACTION TEST SPEC. YES – IN NO – OUT OF SPEC.
POINTS SPEC.
1. Off At 15A fuse F10–A and F10–A, 12 ± 1.5 Go to next Locate cause of low
circuit 14BE, measure 14BE to volts. step. or no voltage in circuit
voltage to ground. gnd. 14AU or 14BE from
(B2) battery stud, then
repair.
2. Off Disconnect refrigerator Sw. 86T 12 ± 1.5 Go to next Locate cause of low
on/off switch (652) and to gnd. volts. step. or no voltage in circuit
at circuit 86T, measure 86T, conn. (80), or
voltage to ground. circuit 86T from 15A
fuse F10–A, then
repair.
3. Off Test refrigerator on/off Across < 1 ohm. Go to next Replace defective
switch by placing switch sw. term. step. switch.
in on position and
across terminals that
were connected to
circuits 86T and 86E.
4. Off Reconnect refrigerator (651), 86T 12 ± 1.5 Go to next Locate cause of low
on/off switch and move to gnd. volts. step. or no voltage in circuit
it to the on position. 86E, conn. (471),
At refrigerator power or circuit 86T from
source (651) and circuit the refrigerator on/off
86T, measure voltage to switch, then repair.
ground.
5. Off With switch still on, Power 12 ± 1.5 Go to next Locate open or poor
at refrigerator power source, volts. step. connection in circuit
source, measure voltage 86T to 86–GT, 11–GAN,
from circuit 86T to 86–GT. conn. (81), circuit
86–GT. 11–GAN or 11–GBB to
right cab ground (404),
then repair.
6. Off Refrigerator power
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3.2. BUNK SPEAKERS

Table 119 Flat Roof
POINTS SPEC.
1. Off Do cab radio and Go to next Refer to Radio
speakers function step. and Cab Speaker
properly? Troubleshooting in
CAB ACCESSORIES
section.
2. Off Do bunk speakers Go to Step Go to next step.
3. Off Disconnect volume Across 3.5 to 8 Go to next Replace defective
control connectors speaker ohms. step. rear bunk speaker.
(122) and (123), rear (9).
bunk speaker (9), and
radio connector (21). At
resistance of speaker.
4. Off Reconnect rear bunk (21), 3.5 to 8 Go to next Locate open or
speaker (9). At connector 86CC to ohms. step. poor connection if
(123) install a jumper wire 86CD. resistance is too high,
from circuit 86S to 86CC, or short to ground if
and at connector (21), resistance is too low
measure resistance from in circuit 86CC, 86S,
circuit 86CC to 86CD. or 86CD, then repair.
5. Off Disconnect front bunk Across 3.5 to 8 Go to next Replace defective
speaker (10) and measure speaker ohms. step. front bunk speaker.
resistance of speaker. (10).
6. Off Reconnect front bunk (21) 3.5 to 8 Go to next Locate open or
speaker (10). At 86CA to ohms. step. poor connection if
connector (122) install 86CB. resistance is too high,
a jumper wire from circuit or short to ground if
86R to 86CA, and at resistance is too low
connector (21), measure in circuit 86CA, 86R,
resistance from circuit or 86CB, then repair.
86CA to 86CB.
7. Off At connector (122), move (21), < 1 ohm. Go to next Locate open or poor
jumper wire to between 86CA to step. connection in circuit
circuits 86F and 86CA, 86CB. 86F, then repair.
and at connector (21),
circuit 86CA to 86CB.
8. Off At conn. (123), move (21), < 1 ohm. Go to next Locate open or poor
jumper wire to between 86CC to step. connection in circuit
circuits 86H and 86CC, 86CD. 86H, then repair.
circuit 86CC to 86CD.
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POINTS SPEC.
9. Off Remove jumpers and Go to next Repair or replace
reconnect all connectors. step. defective volume
Do bunk speakers control panel
function properly? assembly.
10. Off Radio and speaker
Table 120 Hi-Rise

POINTS SPEC.
1. Off Do cab radio and Go to next Refer to Radio and
speakers function step. Cab Speaker Trouble-
properly? shooting in the CAB
ACCESSORIES
section.
2. Off Do bunk speakers Go to Step Go to next step.
3. Off Disconnect volume Across 3.5 to 8 Go to next Replace defective
control connectors speaker ohms. step. rear bunk speaker.
(122) and (123), rear (9).
bunk speaker (9), and
radio connector (21). At
resistance of speaker.
4. Off Reconnect rear bunk (21), 3.5 to 8 Go to next Locate open or
speaker (9). At conn. 86CC to ohms. step. poor connection if
(123) install a jumper wire 86CD. resistance is too high,
from circuit 86S to 86CC, or short to ground if
measure resistance from in circuit 86CC, 86S,
circuit 86CC to 86CD. or 86CD, then repair.
5. Off Disconnect front bunk Across 3.5 to 8 Go to next Replace defective
speaker (10) and measure speaker ohms. step. front bunk speaker.
resistance of speaker. (10).
6. Off Reconnect front bunk (21) 86CA 3.5 to 8 Go to next Locate open or
speaker (10). At conn. to 86CB. ohms. step. poor connection if
(122) install a jumper wire resistance is too high,
from circuit 86R to 86CA, or short to ground if
measure resistance from in circuit 86CA, 86R,
circuit 86CA to 86CB. or 86CB, then repair.
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Table 120 Hi-Rise (cont.)

POINTS SPEC.
jumper wire to between 86CA to step. connection in circuit
circuits 86F and 86CA, 86CB. 86F, then repair.
circuit 86CA to 86CB.
jumper wire to between 86CC to step. connection in circuit
circuits 86H and 86CC, 86CD. 86H, then repair.
circuit 86CC to 86CD.
9. Off Remove jumpers and Go to next Repair or replace
reconnect all connectors. step. defective volume
Do bunk speakers control panel
function properly? assembly.
10. Off Radio and speaker
3.3. TV/VCR WIRING

Table 121 Flat Roof
STEP KEY ACTION TEST SPEC. YES – IN NO – OUT OF
POINTS SPEC. SPEC.
1. Off At 15A fuse F10–A and F10–A, 12 ± 1.5 Go to next Locate cause of
circuit 14BE, measure 14BE to volts. step. low or no voltage
voltage to ground. gnd. in circuit 14AU or
14BE from (B2)
battery stud, then
repair.
2. Off/ On Disconnect TV/VCR (612), 86U 12 ± 1.5 Go to next Locate cause of
switch (612). Move key to gnd. volts. step. low or no voltage
switch to accessories in circuit 86U,
position, and at connector (80),
connector (612) and or circuit 86U, then
circuit 86U, measure repair.
voltage to ground.
3. Off Test switch (612) Across < 1 ohm. Go to next Replace defective
by placing in the on switch. step. switch.
resistance across
switch.
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POINTS SPEC. SPEC.
4. Off/ On Reconnect connector (613), 86UA 12 ± 1.5 Go to next Locate cause of
(612) and move key to gnd. volts. step. low or no voltage
switch to accessories in circuit 86UA,
position. With TV/VCR connector (557), or
switch in the on position, circuit 86UA, then
measure voltage at repair.
connector (613) from
circuit 86UA to ground.
5. On With switches still set, (613), 86UA 12 ± 1.5 Go to next Locate open or poor
at connector (613), to 86–GS. volts. step. connection in circuit
measure voltage from 86–GS, 11–GAH,
circuit 86UA to 86–GS. conn. (557), circuit
11–GAH, 11–GAN,
conn. (81), or
circuit 11–GAN or
ground stud (404),
then repair.
6. Off Move switches to off
position. TV/VCR
Table 122 Hi-Rise

POINTS SPEC. SPEC.
1. Off At 15A fuse F10–A and F10–A, 12 ± 1.5 Go to next Locate cause of
circuit 14BE, measure 14BE to volts. step. low or no voltage
voltage to ground. gnd. in circuit 14AU or
14BE from (B2)
battery stud, then
repair.
2. Off/ On Disconnect TV/VCR (612), 86U 12 ± 1.5 Go to next Locate cause of
switch (612). Move key to gnd. volts. step. low or no voltage
switch to accessories in circuit 86U,
position, and at connector (80),
connector (612) and or circuit 86U, then
circuit 86U, measure repair.
voltage to ground.
3. Off Test switch (612) Across < 1 ohm. Go to next Replace defective
by placing in the on switch. step. switch.
resistance across
switch.
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Table 122 Hi-Rise (cont.)

POINTS SPEC. SPEC.
4. Off/ On Reconnect connector Recept. 12 ± 1.5 Go to next Locate cause of
(612) and move key (777), volts. step. low or no voltage
switch to accessories 86UB to in circuit 86UA,
position. With TV/VCR gnd.. connector (557),
switch in the on position, or circuit 86UA, or
measure voltage at circuit 86UB, then
receptacle (777) from repair.
circuit 86UB to ground.
5. On With switches still set, Recept. 12 ± 1.5 Go to next Locate open or
at receptacle (777), (777), volts. step. poor connection
measure voltage from 86UB to in circuit 86–GB,
circuit 86UB to 86–GB. 86–GB. 86–GS, 11–GAH,
conn. (557), circuit
11–GAH, 11–GAN,
conn. (81), circuit
11–GAN or 11–GBB
to right cab ground
stud (404), then
repair.
6. Off If TV-VCR socket (776)
fails to function, replace
defective socket. Move
switches to off position.
TV/VCR circuits check
good.
(B2) Battery Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Top of power distribution center
(I1) Ignition Adapter (518). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument cluster, right
(9) Bunk Rear Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In pigtail behind rear bunk speaker
(10) Bunk Front Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In pigtail behind front bunk speaker
(11) Radio Cab Roof Connector. . . . . . . . . . . . . . . . . . . . .. . . . . . Behind trim panel above left door
(13) Bunk Front Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In pigtail behind trim panel
(21) Radio Connector #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At pigtail of radio
(22) Roof Harness #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At “A” pillar behind lt. dash
(80) Cab To Sleeper #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind driver under floor
(81) Cab To Sleeper #3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind driver under floor
(122) Bunk Speaker Control. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind bunk control panel
(123) Bunk Speaker Control. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind bunk control panel
(404) Right Cab Ground Stud. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Right hand cowl inner panel
(471) Refrigerator Inline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In left luggage area
(504) L1 — LED Panel Light Feed Adapter. . . . . . . .. . . . . . Behind switch cluster
(557) Bunk/Roof Connector #1. . . . . . . . . . . . . . . . . . . . . .. . . . . . pAt “B” pillar left side with 110 inch, and in left luggage
area with 89 inch
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(558) Bunk/Roof Connector #2. . . . . . . . . . . . . . . . . . . . . .. . . . . . At “B” pillar left side with 110 inch, and in left luggage
area with 89 inch
(612) TV/VCR Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind control panel
(613) TV/VCR Receptacle. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind TV/VCR
(651) Refrigerator Power Socket. . . . . . . . . . . . . . . . . . . .. . . . . . In left luggage area
(652) Refrigerator Socket Switch. . . . . . . . . . . . . . . . . . . .. . . . . . Behind bunk control panel
(738) Radio, Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind instrument cluster, left corner
(776) TV/VCR With Hi-Rise. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In TV/VCR cabinet
(777) TV/VCR With Hi-Rise. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . In TV/VCR cabinet
Refer to Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6.
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Figure 153 Refrigerator Wiring — 9800 With 110 Inch Flat Roof Sleeper
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Figure 154 Refrigerator Wiring — 9800 With 110 Inch Flat Roof Sleeper
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Figure 155 Radio/Entertainment Wiring — 9800 SFA and SBA
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Figure 156 Radio/Entertainment Wiring — 9800 SFA and SBA
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Figure 157 TV/VCR Wiring — 9800 With 89 Inch, 110 Inch Low Roof/Flat Roof Sleeper
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Figure 158 TV/VCR Wiring — 9800 With 89 Inch, 110 Inch Low Roof/Flat Roof Sleeper
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12 HEATER AND AIR CONDITIONER (CAB) 487
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489
3.1. CAB HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .491
3.2. CAB AIR CONDITIONER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .496
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488 12 HEATER AND AIR CONDITIONER (CAB)
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Model: 9800
1. DESCRIPTION
The heater/air conditioning system has a blower motor circuit and a compressor control circuit. The
compressor control circuit is tied to the blower motor circuit which can be set to off, low, medium or high
speed to circulate heat or cooling throughout the cab.
2. OPERATION
Power is supplied to (B2) battery stud, circuit 14W, 14Z, fuse F1-C, and circuit 75A to the heater control relay
(463)/R5. When the key switch (452) is moved to the ignition position, power flows through the key switch, and
circuits 13 and 13A to the coil of the ignition relay (462)/R1. The ground path for the ignition relay is circuits
11-GN and 11-GB to right cab ground stud (404). This energizes the ignition relay (462)/R1, and allows power
to flow through the N.O. contacts and circuits 13H and 13T to the coil of the heater control relay (463)/R5. The
ground path for the heater control relay is circuits 13-GT, 50-GB, 75-GC, 75-GB, 11-GN, and 11-GB to right cab
ground stud (404). This energizes the heater control relay (463)/R5, and allows power to flow through the N.O.
contacts and circuit 75B to fan control switch (83).
When the heater-A/C blower switch (83) is moved to the low position, power flows through the switch, circuit
75C, connector (45), circuit 75C, resistor/thermofuse (27), circuit 75T, connector (44), circuit 75T, high speed
relay (462)/R2 N.C. contacts, circuit 75F, connector (44), and circuit 75F to blower motor (39). This causes
the blower motor to run at low speed. The blower motor ground path is through circuit 75-G, connector (44),
circuits 75-G and 11-G to right cab ground stud (404).
When the heater-A/C blower switch (83) is moved to the medium position, power will flow through the switch
as in the low speed setting, and power will also flow through the switch and circuit 75N to the medium speed
relay (462)/R3. This energizes the medium speed relay (462)/R3 and allows power to flow through heater
control relay (463)/R5 N.O. contacts, circuit 75D, medium speed relay (462)/R3 N.O. contacts, circuit 75M,
connector (44), circuit 75M, resistor/thermofuse (27), circuit 75T, connector (44), circuit 75T, high speed relay
(462)/R2 N.C. contacts, circuit 75F, connector (44), and circuit 75F to blower motor (39). This causes the
blower motor to run at medium speed. The blower motor ground path is through circuits 75-G, connector (44),
circuits 75-G and 11-G to right cab ground stud (404). The ground path for the medium speed relay (462)/R3 is
circuits 75-GC, 75-GB, 11-GN and 11-GB to right cab ground stud (404).
When the heater-A/C blower switch (83) is moved to the high position, power will flow through the switch as in
the medium speed setting, and power will also flow through the switch and circuit 75H to the high speed relay
(462)/R2. This energizes the high speed relay (462)/R2 which is grounded through circuits 75-GB, 11-GN, and
11-GB to the right cab ground stud (404). This allows power to flow from (B2) battery stud through circuit 14W,
14X, fuse F1-A, circuit 75, high speed relay (462)/R2 N.O. contacts, circuit 75F, connector (44), and circuit 75F
to blower motor (39). This causes the blower to run at high speed. The blower motor ground path is through
circuit 75-G, connector (44), circuits 75-G and 11-G to right cab ground stud (404).
When the blower switch (83) is in the low, medium or high position, power is supplied by the switch to circuit 77
and the air conditioner switch (30). When switch (30) is moved to the on position, power flows through its
indicator light and ground circuits 77-GK and 11-GI to cab ground (429). This causes the indicator to illuminate.
Power also flows from switch (30) through the blocking diode, circuits 77S and 77K to the A/C control relay
(447)/R16, thus energizing the relay that is grounded through circuits 77-GS, 12-GF, 82-GA, 12-GH, 82-GD
and 11-GD to left cab ground stud (429).
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With the relay energized, power flows from the (B2) battery stud through circuits 14W and 14Z, fuse F1-B,
circuit 77T, A/C control relay (447)/R16 N.O. contacts, circuit 77H, connector (45), and circuit 77B to the
manual temperature control switch.
When the temperature control switch determines that the temperature at the evaporator is above freezing
[34°F - 38°F (1°C - 3°C)] , its contacts will close. This will cause power to flow through the control, circuit 77F,
connector (45), circuit 77F, the air conditioning relay (463)/R6 N.C. contacts, circuit 77A, connector (102),
circuit 77A, connector (N/L), and the black wire to the A/C compressor clutch.
The compressor will then run until the temperature control switch’s contacts open up, or the low or high
pressure safety switch’s contacts close.
With the A/C system switch (30) and the blower control switch (83) turned on, voltage is also applied by A/C
control relay (447)/R16 to circuit 77H, connector (45), and circuits 77C and 77E to the low pressure safety
switch (N/L). Voltage is also applied to circuit 77H, connector (45), circuit 77C, and curcuit 77N to the high
pressure safety switch. If the refrigerant pressure becomes too low, the low pressure safety switch (N/L)
contacts will close and power will flow through circuits 77P and 77R, connector (45), circuits 77R and 77D to
the air conditioning relay (463)/R6. If the refrigerant pressure becomes too high, the high pressure safety
switch (N/L) contacts will close and power will flow through circuits 77J and 77R, connector (45), circuits 77R
and 77D to the air conditioning relay (463)/R6. The power will flow through the air conditioning relay (463)/R6
coil and ground circuits 77-G, 13-GT, 50-GB, 75-GC, 75-GB, 11-GN, and 11-GB to the right cab ground stud
(404), thus energizing the relay.
With the air conditioning relay (463)/R6 energized, power is interrupted to the refrigerant compressor clutch,
and power is applied to circuit 77D going to the air conditioning relay coil. Thus the compressor is shut down
and latched (locked) out by the air conditioning relay, and will not restart until the refrigerant pressure is back
within operating range and the A/C on/off switch or the blower control switch is moved to the off position.
3. TROUBLESHOOTING
relay, or solenoid.
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3.1. CAB HEATER

Table 123 Cab Heater
POINTS SPEC.
1. Off Does the blower run in Go to Step Go to next step.
either the low, medium, 11.
or high speed position?
2. Off/ Remove heater control (463)/ R5, 12 ± 1.5 Go to next Locate cause of
On relay (463)/R5, move 13T to volts. step. low or no voltage in
key switch to ignition gnd. circuit 13T or 13H,
position, and at circuit then repair.
13T measure voltage to
ground.
3. On At relay socket (463)/R5, (463)/ R5, 12 ± 1.5 Go to next Locate open or
measure voltage from 13T to volts. step. poor connection in
circuit 13T to 13–GT. 13–GT circuit 13–GT, 5–GB,
75–GC, 75–GB,
11–GN or 11–GB,
to cab ground, then
repair.
4. Off At (B2) battery stud, (B2) to 12 ± 1.5 Go to next Locate cause of low
measure voltage to gnd. volts. step. or no voltage at (B2)
ground. battery stud, then
repair.
5. Off Remove fuse F1–C and F1–C < 1 ohm. Go to next Locate cause of
check for open condition. step. overload condition,
fuse.
6. Off At F1–C circuit 14Z F1–C, 14Z 12 ± 1.5 Go to next Locate cause of
measure voltage to to gnd. volts. step. low or no voltage in
ground. circuit 14W or 14Z,
then repair.
7. Off Re-install fuse F1–C and Relay 12 ± 1.5 Go to next Locate cause of low
at relay socket (463)/R5, (463)/ R5, volts. step. or no voltage in circuit
measure voltage from 75A to 75A, then repair.
circuit 75A to ground. gnd.
8. Off Bench test heater Relay <1 ohm. Go to next Replace defective
control relay (463)/R5 (463)/ R5, step. heater control relay.
by measuring resistance pin 30 to
from pin 30 to 87A. 87A.
9. Off Bench test heater Energized < 1 ohm. Go to next Replace defective
control relay (463)/R5 (463)/ R5, step. heater control relay.
by applying +12 volts pin 30 to
to pin 86, ground to 87.
pin 85, and measuring
resistance from pin 30 to
87.
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Table 123 Cab Heater (cont.)

POINTS SPEC.
10. Off/ Re-install (463)/R5 and (83), 75B 12 ± 1.5 Go to next Locate cause of low
On disconnect switch (83). to gnd. volts. step. or no voltage in circuit
Move key switch to 75B, then repair.
ignition position and at
(83) circuit 75B, measure
voltage to ground.
11. Off Test blower control switch (83), term. < 1 ohm. Go to next Replace defective
(83) by placing switch B to L and step. blower switch.
in low position, and B to A/C.
from switch terminal B to
L and B to A/C.
12. Off Test blower control switch (83) term. < 1 ohm. Go to next Replace defective
(83) by placing switch B to L, B step. blower switch.
in medium position, and to M and
measuring resistance B to A/C.
L, B to M, and B to A/C.
13. Off Test blower control switch (83), term. < 1 ohm. Go to next Replace defective
(83) by placing switch B to H, B step. blower switch.
in high position, and to M, and
measuring resistance B to A/C.
H, B to M, and B to A/C.
14. Off/ Re-install blower switch Go to Step Go to next step.
On (83). Move key switch to 22.
on position. Does blower
motor run at low speed
when blower switch is set
to low position?
15. Off/ Disconnect conn. (45) (45), 75C 12 ± 1.5 Go to next Locate cause of low
On and with key switch in to gnd. volts. step. or no voltage in circuit
ignition position and 75C, then repair.
blower switch in low
speed position, measure
voltage from circuit 75C
[coming from (83)] to
ground.
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POINTS SPEC.
16. Off/ Reconnect conn. (45) (27) 75C 12 ± 1.5 Go to next Locate cause of low
On and disconnect resistor to gnd. volts. step. or no voltage in circuit
and thermofuse assembly 75C, then repair.
(27). With key switch
in ignition position
and blower switch in
low position, measure
voltage from circuit 75C
to ground.
17. Off At blower resistor and Blower 1.1 to 1.3 Go to next Replace defective
thermofuse assembly resistor ohms. step. blower resistor.
(27), measure resistance (27), pin
from terminal 1 to 2. 1 to 2.
18. Off At blower resistor and Blower .25 to .45 Go to next Replace defective
thermofuse assembly resistor ohm. step. blower resistor.
(27), measure resistance (27), pin
19. Off/ Reconnect blower (44), 75T 12 ± 1.5 Go to next Locate cause of low
On resistor, and disconnect to gnd. volts. step. or no voltage in circuit
conn. (44). With key 75T, then repair.
switch in ignition position
and blower switch in low
speed position, at (44)
circuit 75T [coming from
(27)], measure voltage to
ground.
20. On Reconnect conn. (44) (462)/ R2, 12 ± 1.5 Go to next Locate cause of low
and remove high speed 75T to volts. step. or no voltage in circuit
relay (462)/R2. At circuit gnd. 75T, then repair.
75T, measure voltage to
ground.
21. Off Bench test high speed (462)/ R2, < 1 ohm. Go to next Replace defective
relay (462)/R2 by pin 30 to step. high speed relay
measuring resistance 87A. (462)/R2.
from pin 30 to 87A.
22. Off Bench test high speed Energized < 1 ohm. Go to next Replace defective
relay (462)/R2 by (462)/ R2, step. high speed relay
applying +12 volts to pin 30 to (462)/R2.
pin 86, ground to pin 85, 87.
from pin 30 to 87.
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POINTS SPEC.
23. On Move key switch to (462)/ R2, 12 ± 1.5 Go to next Locate cause of low
ignition position, blower 75H to volts. step. or no voltage in circuit
switch to high speed gnd. 75H, then repair.
position, and at (462)/R2
circuit 75H, measure
volts to ground.
24. On With switches still set, (462)/ R2, 12 ± 1.5 Go to next Locate open or poor
at (462)/R2 measure 75H to volts. step. connection in circuit
voltage from circuit 75H 75–GB. 75–GB, 11–GN or
to 75–GB. 11–GB to right cab
gnd. (404), then
repair.
25. Off At (462)/R2 install a test (44), 75F < 1 ohm. Go to next Locate open or poor
jumper from circuit 75F to to gnd. step. connection in circuit
75–GB. Disconnect conn. 75F, then repair.
(44) and at circuit 75F
[coming from (462)/R2],
measure resistance to
ground.
26. Off At connector (44) (44), < 1 ohm. Go to next Locate open or poor
measure resistance 75–G to step. connection in circuit
from circuit 75–G [going gnd. 75–G or 11–G to
to (404)] to ground. cab gnd. stud, then
repair.
27. Off/ Reconnect (44) and Blower 12 ± 1.5 Go to next Locate cause of low
On disconnect circuit 75F motor volts. step. or no voltage in circuit
from blower motor (39). (39), 75F 75F, then repair.
Move key switch to to gnd.
ignition position and
blower switch to low
position, and at 75F
measure voltage to
ground.
28. On Measure voltage from Blower 12 ± 1.5 Go to next Locate open or poor
circuit 75F to 75–G. motor volts. step. connection in circuit
(39), 75F 75–G, then repair.
to 75–G.
29. Off/ With ignition key in off Go to next Replace defective
On position, reconnect circuit step. blower motor.
75F. Move key switch
to ignition position and
with blower switch in
low speed position, does
blower run?
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POINTS SPEC.
30. Off/ Remove medium speed (462)/ R3, 12 ± 1.5 Go to next Locate cause of low
On relay (462)/R3, move key 75N to volts. step. or no voltage in circuit
switch to ignition position, gnd. 75N, then repair.
and move blower switch
to medium speed. At
circuit 75N, measure
voltage to ground.
31. On With switches still set, (462)/ R3, 12 ± 1.5 Go to next Locate open or poor
at (462)/R3 measure 75N to volts. step. connection in circuit
voltage from circuit 75N 75–GC. 75–GC, 75–GB,
to 75–GC. 11–GN or 11–GB to
right cab gnd. stud
(404), then repair.
32. Off At relay socket (462)/R3 (462)/ R3, 12 ± 1.5 Go to next Locate cause of low
and circuit 75D, measure 75D to volts. step. or no voltage in circuit
voltage to ground. gnd. 75D, then repair.
33. Off Bench test medium (462)/ R3, < 1 ohm. Go to next Replace defective
speed relay (462)/R3 by pin 30 to step. medium speed relay
measuring resistance 87A. (462)/R3.
from pin 30 to 87A.
34. Off Bench test medium Energized < 1 ohm. Go to next Replace defective
speed relay (462)/R3 (462)/ R3, step. medium speed relay
by applying +12V to pin pin 30 to (462)/R3.
86, ground to 85, and 87.
from pin 30 to 87.
35. Off/ Disconnect conn. (44), (44), 75M 12 ± 1.5 Go to next Locate cause of low
On re-install medium speed to gnd. volts. step. or no voltage in circuit
relay (462)/R3, move key 75M, then repair.
switch to ignition position,
and blower switch to
low speed position. At
(44) circuit 75M [coming
from (462)/R3] measure
voltage to ground.
36. On Disconnect connector (27), 75M 12 ± 1.5 Go to next Locate cause of low
(27) and reconnect to gnd. volts. step. or no voltage in circuit
connector (44). At 75N, then repair.
75M, measure voltage to
ground.
37. Off Remove fuse F1–A and F1–A < 1 ohm. Go to next Locate cause of
fuse.
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POINTS SPEC.
38. Off Re-install fuse F1–A, and F1–A, 14X 12 ± 1.5 Go to next Locate cause of low
at circuit 14X, measure to gnd. volts. step. or no voltage in circuit
voltage to ground. 14X, then repair.
39. Off Reconnect (27) and (462)/ R2, 12 ± 1.5 Go to next Locate cause of low
remove high speed relay 75 to gnd. volts. step. or no voltage in circuit
(462)/R2. At (462)/R2 75, then repair.
circuit 75, measure
voltage to ground.
40. Off Re-install high speed
relay (462)/R2. Heater
blower circuits check
good.
3.2. CAB AIR CONDITIONER

Table 124 Cab Air Conditioner
POINTS SPEC. SPEC.
1. Off Does heater — A/C blower Go to next See previous
function properly? step. test for trouble-
shooting of
blower system.
2. Off/ Disconnect A/C switch (30), 77 to 12 ± 1.5 Go to next Locate cause of
On conn. (30), move key switch gnd. volts. step. low or no voltage
to ignition position, and in circuit 77 or
move blower switch to low blower switch,
position. At (30), measure then repair.
voltage from circuit 77 to
ground.
3. On With switches still set, at (30), 77 to 12 ± 1.5 Go to next Locate open or
connector (30), measure 77–GK. volts. step. poor connection
voltage from circuit 77 to in circuit 77–GK
77–GK. or 11–GI to left
cab ground stud
(429), then repair.
4. Off Bench test switch (30) by (30), A to B. < 1 ohm. Go to next Replace defective
measuring resistance from step. switch.
term. A to B with switch in
on position. NOTE: Place
“+” lead on term. A.
5. Off Reconnect switch (30). Go to next Replace defective
Does A/C switch (30) step. switch.
indicator function?
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Table 124 Cab Air Conditioner (cont.)

POINTS SPEC. SPEC.
6. Off/ Remove A/C control relay (447)/R16, 12 ± 1.5 Go to next Locate cause of
On (447)/R16. With key 77K to gnd. volts. step. low or no voltage
switch in ignition position, in circuit 77K or
and blower switch in low 77S, then repair.
position, at (447)/R16 circuit
77K, measure voltage to
ground.
7. On At (447)/R16, with switches (447)/R16, 12 ± 1.5 Go to next Locate open or
still set, measure voltage 77K to volts. step. poor connection
from circuit 77K to 77–GS. 77–GS. in circuits 77–GS,
12–GF, 82–GA,
12–GH, 82–GD
and 11–GD to left
cab ground stud
(429), then repair.
8. On Remove fuse F1–B and F1–B. < 1 ohm. Go to next Locate cause
check for open condition. step. of overload
condition, then
repair. Replace
fuse.
9. On Re-install fuse F1–B and at F1–B, 14Z to 12 ± 1.5 Go to next Locate cause of
circuit 14Z measure voltage gnd. volts. step. low or no voltage
to ground. in circuit 14Z or
14W from (B2),
then repair.
10. On At (447)/R16, circuit 77T, (447)/R16, 12 ± 1.5 Go to next Locate cause of
measure voltage to ground. 77T to gnd. volts. step. low or no voltage
in circuit 77T, then
repair.
11. Off Bench test A/C control relay (447)/R16, < 1 ohm. Go to next Replace defective
(447)/R16 by measuring pin 30 to 87A. step. A/C control relay
resistance from pin 30 to (447)/R16.
87A.
12. Off Bench test A/C control relay Energized < 1 ohm. Go to next Replace defective
(447)/R16 by applying +12V (447)/R16, step. A/C control relay
to pin 86, ground to pin 85, pin 30 to 87. (447)/R16.
from pin 30 to 87.
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POINTS SPEC. SPEC.
13. Off/ Re-install A/C control relay (45), 77H to 12 ± 1.5 Go to next Locate cause of
On (447)/R16 and disconnect gnd. volts. step. low or no voltage
conn. (45). Set A/C switch in circuit 77H,
(30) to on, blower switch then repair.
(83) to low, and key switch
to ignition position. At conn.
(45) circuit 77H, measure
voltage to ground.
14. Off At conn. (45) (going to (45), 77B to < 1 ohm. Go to Go to next step.
heater box), measure 77F. Step 18.
resistance from circuit
77B to 77F [evaporator
temperature must be
greater than 34°F (1°C)].
15. Off Disconnect thermostatic Across < 1 ohm. Go to next Replace defective
switch (N/L), and measure thermo- step. thermostatic
resistance from terminal 1 to static switch switch (N/L).
2 [evaporator temperature (N/L).
must be greater than 34°F
(1°C)].
16. Off At conn. (N/L), removed (45), 77B to < 1 ohm. Go to next Locate open or
from thermostatic switch, gnd. step. poor connection
and circuit 77B, install a in circuit 77B,
jumper wire to ground. At then repair.
conn. (45) circuit 77B,
ground.
17. Off At conn. (N/L), removed (45), 77F to < 1 ohm. Go to next Locate open or
from thermostatic switch, gnd. step. poor connection
and circuit 77F, install a in circuit 77F, then
jumper wire to ground. At repair.
conn. (45) circuit 77F, going
to heater box, measure
18. Off/ With thermostatic switch (463)/R6, 12 ± 1.5 Go to next Locate cause of
On (N/L) and connector (45) 77F to gnd. volts. step. low or no voltage
reconnected, remove A/C in circuit 77F, then
relay (463)/R6. Move key repair.
A/C switch (30) to on, and
blower switch (83) to low.
At (463)/R6 circuit 77F,
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POINTS SPEC. SPEC.
19. On With switches still set, (463)/R6, < 1 ohm. Go to next Locate open or
at relay socket (463)/R6, 77F to 77–G. step. poor connection
measure voltage from circuit in circuit 77–G,
77F to 77–G. 13–GT, 50–GB,
75–GC, 75–GB,
11–GN, or 11–GB
to cab gnd., then
repair.
20. Off At relay socket (463)/R6 (463)/R6, < 1 ohm. Go to next Locate open or
measure resistance of 77D to 77D. step. poor connection
circuit 77D (terminal that in circuit 77D,
relay pin 86 was in, to term. then repair.
that relay pin 87 was in).
21. Off/ At relay socket (463)/R6 Go to Go to next step.
On install jumper wire from Step 25.
circuit 77F to 77A. Set A/C
switch (30) to on, blower
switch (83) to low, and key
switch to ignition position.
Did A/C clutch engage (click
once)?
22. On With switches still set, (102), 77A to 12 ± 1.5 Go to next Locate cause of
disconnect connector (102) gnd. volts. step. low or no voltage
and at circuit 77A [coming in circuit 77A,
from (463)/R6] measure then repair.
voltage to ground.
23. On With switches still set, (N/L), 77A to 12 ± 1.5 Go to next Locate cause of
reconnect conn. (102) and gnd. volts. step. low or no voltage
disconnect compressor in circuit 77A,
conn. (N/L). At (N/L) circuit then repair.
77A measure voltage to
ground.
24. On With switches still set, Go to next Replace defective
reconnect conn. (N/L) at step. A/C compressor
the A/C compressor clutch. clutch.
Does the clutch engage
(click once)?
25. On With switches still set, (N/L), 77E to 12 ± 1.5 Go to next Locate cause of
disconnect low pressure gnd. volts. step. low or no voltage
safety switch (N/L), and in circuit 77C or
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POINTS SPEC. SPEC.
26. On With switches still set, (N/L), 77N to 12 ± 1.5 Go to next Locate cause of
disconnect high pressure gnd. volts. step. low or no voltage
safety switch (N/L), and in circuit 77N,
measure voltage from then repair.
circuit 77N to ground.
27. Off/ At relay socket (463)/R6 (N/L), 77P to 12 ± 1.5 Go to next Locate cause of
On move jumper wire to gnd. volts. step. low or no voltage
between circuit 77F and in circuit 77R or
77R. Move key switch to 77P, then repair.
ignition position, A/C switch
(30) to on, and blower
switch (83) to low. At low
pressure safety switch (N/L)
circuit 77P, measure voltage
to ground.
28. On At high pressure safety (N/L) 77J to 12 ± 1.5 Go to next Locate cause of
switch (N/L) circuit 77J, gnd. volts. step. low or no voltage
measure voltage to ground. in circuit 77J, then
repair.
29. Off Measure resistance of low Across low > 100K Go to next If refrigerant
pressure safety switch pressure ohms. step. charge is within
(N/L). safety switch. limits, replace
defective low
pressure switch.
30. Off Measure resistance of high Across high > 100K Go to next If refrigerant
pressure safety switch pressure ohms. step. charge is within
(N/L). safety switch. limits, replace
defective high
pressure switch.
31. Off Bench test A/C relay A/C relay < 1 ohm. Go to next Replace defective
(463)/R6 by measuring (463)/R6, 30 step. relay.
resistance from terminal 30 to 87A.
to 87A.
32. Off Bench test A/C relay Energized < 1 ohm. Go to next Replace defective
(463)/R6 by applying +12V (463)/R6, 30 step. relay.
to terminal 85 and ground to 87.
to terminal 86. Measure
resistance from terminal 30
to 87.
33. Off Air conditioner circuits
check good. Remove test
jumper, re-install relay, and
reconnect the separated
connectors.
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(B2) Battery Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At power distribution center above engine tunnel
(27) Resistor and Thermofuse Assy.. . . . . . . . . . . . . . . .. . . . . . In heater box
(30) A/C Switch On/Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Inside cab at center of dash
(44) Heater Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Pigtail at right front of cab
(83) Blower Control Switch. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Inside cab at center of dash
(102) Engine Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Right front cab floor
(404) Right Cab Ground Stud. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Right side of cab
(429) Left Cab Ground Stud. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left Side of Cab
(447) Fuse Block/Relay Socket 16. . . . . . . . . . . . . . . . . .. . . . . . At power distribution center above engine tunnel
(452) Key Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Instrument panel to right of steering column
(462) Fuse Block/Relay Socket 1. . . . . . . . . . . . . . . . . . . .. . . . . . At power distribution ctr., above eng. tunnel
(N/L) Low pressure Safety Switch. . . . . . . . . . . . . . . . . . .. . . . . . Under heater box
(N/L) High Pressure Safety Switch. . . . . . . . . . . . . . . . . .. . . . . . Under heater box
(N/L) A/C Compressor Clutch. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . (inline) at black wire to clutch
See Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, and Figure 8.
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Figure 159 Blend-Air HVAC Box Location
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Figure 160 Cab HVAC Controls
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Figure 161 HVAC Unit Exploded View
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Figure 162 HVAC Unit With Cover Removed

1. HEATER CORE MOUNTING NUT
2. HEATER CORE
3. CLIP
4. BUNK BLEND-DOOR ACTUATOR (N/L)
5. BUNK BLEND-DOOR ASSEMBLY
6. EVAPORATOR
7. FILTER
8. CAPILLARY TUBE
9. THERMOSTATIC SWITCH (N/L)
10. BLOWER SPEED RESISTOR (27)
11. BLOWER SPEED RESISTOR HOUSING
12. BLOWER ASSEMBLY
13. CAB BLEND-DOOR ASSEMBLY MOUNTING NUT
14. CAB BLEND-DOOR ASSEMBLY
15. BLOWER ASSEMBLY MOUNTING NUT
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Figure 163 Blend-Air Box Blower Assembly
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Figure 164 Cab Blower Speed Resistor
Figure 165 Thermostatic Switch
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Figure 166 Blend-Air Unit Pressure Switches
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13 HEATER AND AIR CONDITIONER BLOWER WITH STANDARD TEMPERATURE 509
CONTROL (SLEEPER)
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .511
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .511
3.1. HEATER AND AIR CONDITIONER BLOWER (SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512
3.2. AIR CONDITIONER (CAB/SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .517
3.3. STANDARD TEMPERATURE CONTROL (SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .522
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510 13 HEATER AND AIR CONDITIONER BLOWER WITH STANDARD TEMPERATURE CONTROL
(SLEEPER)
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CONTROL (SLEEPER)
Model: 9800
1. DESCRIPTION
The sleeper heater and air conditioner system consists of a blower to provide heat or cooling air from the cab
heater box to the sleeper. The system also includes, at the bunk, a manual temperature control and circuitry
to allow for adjustment to the amount of heat or cooling provided in the sleeper, and a blower control to
allow the blower to be set to off, low, medium or high speed. Note that the A/C must be turned on and off
at the cab switch.
2. OPERATION
When key switch (452) is moved to the ignition position, power is applied to I1 ignition adapter (518), circuit
13AT, and the coil of auxiliary blower relay (441). The ground path for the auxiliary blower relay is circuits
13-GAT, 75-GH, 75-GN, and 11-GBB to right cab ground stud (404). This energizes the auxiliary bunk blower
relay (441) and allows power to flow from (B2) battery stud through circuit 14AU, 15A fuse F10-B [location
may vary], circuit 75AX, aux. bunk relay (441) N.O. contacts, circuit 75AS, connector (80), circuits 75AS and
75AR to bunk heater blower switch (550).
When the bunk heater blower switch (550) is moved to the low speed position, power flows through circuit
75AC, connector (80), circuit 75AC, connector (51), circuit 75AC, resistor and thermofuse assembly, circuit
75AT, connector (48), circuit 75AT, sleeper high speed relay (481) N.C. contacts, circuit 75AF, connector (48),
and circuit 75AF to the sleeper blower motor. This causes the blower motor to run at low speed. The blower
motor ground path is circuit 75-GA, connector (48), circuits 75-GA and 11-GBB to right cab ground stud (404).
When the bunk blower switch (550) is moved to the medium speed position, power flows through circuit 75AN,
connector (80), and circuit 75AN to the sleeper medium speed relay (480). The ground path for the sleeper
medium speed relay (480) is circuits 75-GN and 11-GBB to right cab ground stud (404). This energizes the
sleeper medium speed relay (480) and allows power to flow from (B2) battery stud through circuit 14AU, fuse
F10-A, circuits 75AW and 75AB, sleeper medium speed relay (480) N.O. contacts, circuit 75AM, connector
(48), circuit 75AM, resistor and thermofuse assembly (41), circuit 75AT, connector (48), circuit 75AT, sleeper
high speed relay (481) N.C. contacts, circuit 75AF, connector (48), and circuit 75AF to sleeper blower motor.
This causes the blower motor to run at medium speed. The blower ground path is circuit 75-GA, connector
(48), circuits 75-GA and 11-GBB to right cab ground stud (404).
When the bunk blower switch (550) is moved to the high speed position, power flows through the switch, circuit
75AH, connector (80), and circuit 75AH to the sleeper high speed relay (481). The ground path for the sleeper
high speed relay (481) is circuits 75-GH, 75-GN, and 11-GBB to right cab ground stud (404).
This energizes the sleeper high speed relay (481) and allows power to flow from (B2) battery stud through
circuit 14AU, 30A fuse F10-A [location may vary], circuits 75AW and 75AD, sleeper high speed relay (481)
N.O. contacts, circuit 75AF, connector (48), and circuit 75AF to sleeper blower motor. This causes the blower
motor to run at high speed.
The blower ground path is circuit 75-GA, connector (48), circuits 75-GA and 11-GBB to right cab ground
stud (404).
When the key switch (452) is moved to the ignition position, power is also made available by the auxiliary bunk
relay (441) to circuit 75AS, connector (80), circuits 75AS and 75AL to sleeper temperature control connector
(552). The ground path for the sleeper temperature control is through connector (552), circuit 75-GS, 11-GBJ
and 11-GAN, connector (81), circuits 11-GAN and 11-GBB to right cab ground stud (404).
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512 13 HEATER AND AIR CONDITIONER BLOWER WITH STANDARD TEMPERATURE
CONTROL (SLEEPER)
As above, power is also made available by the auxiliary bunk relay (441) to circuit 75L, connector (45), and
circuit 75L to the heater box damper flat pack. The heater box damper flat pack is grounded through circuit
75-GL, connector (44), circuits 75-G and 11-G to right cab ground stud (404). The flat pack receives a variable
voltage from the sleeper temperature control through connector (552), circuit 75K, connector (80) and circuit
75K. Thus the damper blends hot and cold air as selected by the sleeper temperature control.
When cooling is required in the sleeper and the cab A/C switch is not in the on position, the cab switch must
be moved to the on position by the driver or sleeper occupant. Thus the A/C compressor will engage (the
compressor will cycle with the thermostatic switch), and cooling will be available for the sleeper blower.
3. TROUBLESHOOTING
relay, or solenoid.
3.1. HEATER AND AIR CONDITIONER BLOWER (SLEEPER)

Table 125 Heater and Air Conditioner Blower (Sleeper)
POINTS SPEC.
1. On Does the blower run in Go to Go to next step.
either low, medium, or Step 10.
high fan position?
2. Off/ On Remove auxiliary bunk (441), 12 ± 1.5 Go to Locate cause of low
blower relay (441), move 13AT to volts. next step. or no voltage in circuit
key switch to ignition gnd. 13AT, then repair.
13AT measure voltage to
ground.
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CONTROL (SLEEPER)
Table 125 Heater and Air Conditioner Blower (Sleeper) (cont.)

POINTS SPEC.
3. On At relay socket (441), (441), 12 ± 1.5 Go to Locate open or poor
measure voltage from 13AT to volts. next step. connection in circuit
circuit 13AT to 13–GAT. 13–GAT 13–GAT, 75–GH,
75–GN, or 11–GBB
to right cab ground
stud (404), then
repair.
4. Off At (B2) battery stud (B2) to 12 ± 1.5 Go to Locate cause of low
measure voltage to gnd. volts. next step. or no voltage at (B2)
repair.
5. Off Remove fuse F10–B F10–B. < 1 ohm. Go to Locate cause of
(location may vary) and next step. overload condition,
check for open condition. then repair. Replace
fuse.
6. Off Re-install fuse F10–B and F10–B, 12 ± 1.5 Go to Locate cause of low
at circuit 14AU measure 14AU to volts. next step. or no voltage in circuit
voltage to ground. gnd. 14AU, then repair.
7. Off At relay socket (441), (441), 12 ± 1.5 Go to Locate cause of low
measure voltage from 75AX to volts. next step. or no voltage in circuit
circuit 75AX to ground. gnd. 75AX, then repair.
8. Off Bench test auxiliary bunk Relay < 1 ohm. Go to Replace defective
blower relay (441) by (441), pin next step. auxiliary bunk blower
measuring resistance 30 to 87A. relay.
from pin 30 to 87A.
9. Off Bench test auxiliary bunk Energized < 1 ohm. Go to Replace defective
blower relay (441) by relay next step. auxiliary bunk blower
applying +12V to pin 86, (441), pin relay.
ground to pin 85, and 30 to 87.
from pin 30 to 87.
10. Off/ On Re-install (441) and (550), 12 ± 1.5 Go to Locate cause of low
disconnect switch (550). 75AR to volts. next step. or no voltage in circuit
Move key switch to gnd. 75AS or 75AR, then
ignition position and repair.
at (550) circuit 75AR,
measure voltage to
ground.
11. Off Test bunk heater blower (550), < 1 ohm. Go to Replace defective
switch (550) by placing term. B to next step. blower switch.
switch in low position, and L, and B to
measuring resistance C.
L, and B to C.
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CONTROL (SLEEPER)

POINTS SPEC.
switch in medium speed M, and B
position, and measuring to C.
resistance from switch
terminal B to M, and B to
C.
switch in high speed H, and B to
position, and measuring C.
terminal B to H, and B to
C.
14. Off/ On Re-install blower switch Go to Go to next step.
(550). Move key switch to Step 20.
to low position?
15. Off/ On Disconnect conn. (51) (51), 75AC 12 ± 1.5 Go to Locate cause of low
and with the key switch to gnd. volts. next step. or no voltage in circuit
in ignition position and 75AC, conn. (80), or
blower switch in low circuit 75AC, then
speed position, measure repair.
voltage from circuit 75AC
ground.
16. Off/ On Disconnect resistor and (41), 75AC 12 ± 1.5 Go to Locate cause of low
thermofuse assembly to gnd. volts. next step. or no voltage in circuit
(41) and reconnect inline 75AC, then repair.
connector (51). With key
and blower switch in
low position, measure
to ground.
17. Off At blower resistor and Blower 1.1. to 1.3 Go to Replace defective
thermofuse assembly resistor ohms. next step. blower resistor.
(41), measure resistance (41), term.
18. Off At blower resistor and Blower .25 to .45 Go to Replace defective
thermofuse assembly resistor ohm. next step. blower resistor.
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CONTROL (SLEEPER)

POINTS SPEC.
19. Off/ On Reconnect blower (48), 75AT 12 ± 1.5 Go to Locate cause of low
resistor and disconnect to gnd. volts. next step. or no voltage in circuit
conn. (48). With key 75AT, then repair.
and blower sw. in low
circuit 75AT (coming from
(N/L) measure voltage to
ground.
20. On Remove sleeper high (481), 12 ± 1.5 Go to Locate cause of low
speed relay (481) and 75AT to volts. next step. or no voltage in circuit
reconnect conn. (48). gnd. 75AT, then repair.
At circuit 75AT, measure
voltage to ground.
21. Off Bench test high speed (481), pin < 1 ohm. Go to Replace defective
relay (481) by measuring 30 to 87A. next step. sleeper high speed
resistance from pin 30 to relay (481).
87A.
22. Off Bench test high speed Energized < 1 ohm. Go to Replace defective
relay (481) by applying (481), pin next step. sleeper high speed
+12V to pin 86, ground 30 to 87. relay (481).
to pin 85, and measuring
87.
23. On Move key switch to (481), 12 ± 1.5 Go to Locate cause of low
ignition position, blower 75AH to volts. next step. or no voltage in circuit
switch to high speed gnd. 75AH, conn. (80), or
position, and at (481) circuit 75AH, then
circuit 75AH, measure repair.
voltage to ground.
24. Off At (481) install a test (48), 75AF < 1 ohm. Go to Locate open or poor
jumper from circuit 75AF to gnd. next step. connection in circuit
to 75–GH. Disconnect 75AF, then repair.
conn. (48) and at
circuit 75AF [coming
from (481)], measure
25. Off At connector (48) (48), < 1 ohm. Go to Locate open or poor
measure resistance 75–GA to next step. connection in circuit
from circuit 75–GA [going gnd. 75–GA or 11–GBB to
to (404)] to ground. right cab ground stud
(404), then repair.
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CONTROL (SLEEPER)

POINTS SPEC.
26. Off/ On Reconnect conn. (48) Sleeper 12 ± 1.5 Go to Locate cause of low
and disconnect circuit blower volts. next step. or no voltage in circuit
75AF from sleeper motor, 75AF, then repair.
blower motor. Move key 75AF to
switch to ignition position, gnd.
speed position, and at
75AF measure voltage to
ground.
27. On Measure voltage from Sleeper 12 ± 1.5 Go to Locate open or poor
circuit 75AF to 75–GA. blower volts. next step. connection in circuit
motor, 75–GA, then repair.
75AF to
75–GA.
28. Off/ On With ignition key in off Go to Replace defective
position, reconnect circuit next step. blower motor.
75AF. Move key switch
to ignition position and
blower run?
29. Off/ On Remove medium speed (480), 12 ± 1.5 Go to Locate cause of low
relay (480), move key 75AN to volts. next step. or no voltage in circuit
switch to ignition position, gnd. 75AN, conn. (48), or
and move blower switch 75AN, then repair.
to medium speed. At
circuit 75AN, measure
voltage to ground.
30. Off Remove fuse F10–A F10–A < 1 ohm. Go to Locate cause of
(location may vary) and (location next step. overload condition,
check for open condition. may vary). then repair. Replace
fuse.
31. Off Re-install fuse F10–A and (480), 12 ± 1.5 Go to Locate cause of low
at relay socket (480) and 75AB to volts. next step. or no voltage in circuit
circuit 75AB, measure gnd. 75AB or 75AW, then
32. Off Bench test medium (480), pin < 1 ohm. Go to Replace defective
speed relay (480) by 30 to 87A. next step. medium speed relay
measuring resistance (480).
from pin 30 to 87A.
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CONTROL (SLEEPER)

POINTS SPEC.
33. Off Bench test medium Energized < 1 ohm. Go to Replace defective
speed relay (480) by (480), pin next step. medium speed relay
applying +12V to pin 30 to 87. (480).
86, ground to 85, and
from pin 30 to 87.
34. Off/ On Disconnect conn. (48), (48), 75AM 12 ± 1.5 Go to Locate cause of low
re-install medium speed to gnd. volts. next step. or no voltage in circuit
relay (480), move key 75AM, then repair.
and blower switch to low
speed position. At (48),
circuit 75AM [going to
(41)] measure voltage to
ground.
35. On Disconnect resistor and (41), 75AM 12 ± 1.5 Go to Locate cause of low
thermofuse assembly to gnd. volts. next step. or no voltage in circuit
(41) and reconnect conn. 75AM, then repair.
(48). At (41) circuit
75AM, measure voltage
to ground.
36. Off Reconnect resistor and (481), 12 ± 1.5 Go to Locate cause of low
thermofuse connector 75AD to volts. next step. or no voltage in circuit
(41) and remove high gnd. 75AD, then repair.
speed relay (481).
At (481) circuit 75AD
measure voltage to
ground.
relay (481). Heater
good.
3.2. AIR CONDITIONER (CAB/SLEEPER)

Table 126 Air Conditioner (Cab/Sleeper)
POINTS SPEC. SPEC.
1. Off/ On Remove A/C control relay (447), 77K 12 ± 1.5 Go to Locate cause of
(447). With key switch in to gnd. volts. next low or no voltage
ignition position, cab blower step. in circuit 77K or
switch in low position, and 77S from cab A/C
cab A/C switch on, at (447) switch connector
circuit 77K measure voltage (30), then
to ground. repair. Refer to
HEATER AND AIR
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CONTROL (SLEEPER)
Table 126 Air Conditioner (Cab/Sleeper) (cont.)

POINTS SPEC. SPEC.
CONDITIONER
(CAB) section.
2. On At (447), with switches still (447), 77K 12 ± 1.5 Go to Locate open or
set, measure voltage from to 77–GS. volts. next step poor connection
circuit 77K to 77–GS. in circuit 77–GS,
12–GF, 82–GA,
12–GH, 82–GD, or
11–GD to left cab
ground stud (429),
then repair.
3. On Remove fuse F1–B and F1–B. < 1 ohm. Go to Locate cause
check for open condition. next of overload
step. condition, then
repair. Replace
fuse.
4. On Re-install fuse F1–B and at F1–B, 14Z 12 ± 1.5 Go to Locate cause of
circuit 14Z measure voltage to gnd. volts. next low or no voltage
to ground. step. in circuit 14Z or
14W from (B2),
then repair.
5. On At (447), circuit 77T, (447), 77T 12 ± 1.5 Go to Locate cause of
measure voltage to ground. to gnd. volts. next low or no voltage
step. in circuit 77T, then
repair.
6. Off Bench test A/C control (447), pin < 1 ohm. Go to Replace defective
relay (447) by measuring 30 to 87A. next A/C control relay
resistance from pin 30 to step. (447).
87A.
7. Off Bench test A/C control relay Energized < 1 ohm. Go to Replace defective
(447) by applying +12V to (447), pin next A/C control relay
pin 86, ground to pin 85, 30 to 87. step. (447).
from pin 30 to 87.
8. Off/ On Re-install A/C control relay (45), 77H to 12 ± 1.5 Go to Locate cause of
(447) and disconnect conn. gnd. volts. next low or no voltage
(45). Set A/C switch (30) step. in circuit 77H, then
to on, blower switch (83) repair.
to low, and key switch to
ignition position. At conn.
voltage to ground.
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CONTROL (SLEEPER)

POINTS SPEC. SPEC.
9. Off At conn. (45) [going to (45), 77B to < 1 ohm. Go to Go to next step.
heater box], measure 77F. Step 13.
temperature must be
10. Off Disconnect thermostatic Across < 1 ohm. Go to Replace defective
switch (N/L), and measure thermo- next thermostatic
resistance from terminal 1 to static sw. step. switch (N/L).
2 [evaporator temperature (N/L).
must be greater than 34°F
(1°C)].
11. Off At conn. (N/L), removed (45), 77B to < 1 ohm. Go to Locate open or
from thermostatic switch, gnd. next poor connection in
and circuit 77B, install a step. circuit 77B, then
ground.
12. Off At conn. (N/L), removed (45), 77F to < 1 ohm. Go to Locate open or
from thermostatic switch, gnd. next poor connection
and circuit 77F, install a step. in circuit 77F, then
conn. (45) circuit 77F, going
to heater box, measure
13. Off/ On With thermostatic switch (463)/ R6, 12 ± 1.5 Go to Locate cause of
(N/L) and conn. (45) 77F to gnd. volts. next low or no voltage
reconnected, remove A/C step. in circuit 77F, then
relay (463)/R6. Move key repair.
cab A/C switch (904) to on,
and cab blower switch (83)
to low. At (463)/R6 measure
voltage from circuit 77F to
ground.
14. On With switches still set, (463)/ R6, < 1 ohm. Go to Locate open or
at relay socket (463)/R6, 77F to next poor connection
measure voltage from circuit 77–G. step. in circuit 77–G,
77F to 77–G. 13–GT, 50–GB,
75–GC, 75–GB,
11–GN, or 11–GB
to right cab
ground, then
repair.
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CONTROL (SLEEPER)

POINTS SPEC. SPEC.
15. Off At relay socket (463)/R6 (463)/ R6, < 1 ohm. Go to Locate open or
measure resistance of 77D to 77D. next poor connection in
circuit 77D (terminal that step. circuit 77D, then
relay pin 86 was in, to repair.
terminal that relay pin 87
was in).
16. Off/ On At relay socket (463)/R6 Go to Go to next step.
install jumper wire from Step 20.
circuit 77F to 77A. Set A/C
switch (551) to on, blower
switch (550) to low, and key
switch to ignition position.
Did A/C clutch engage (click
once)?
17. On With switches still set, (102)/(338), 12 ± 1.5 Go to Locate cause of
disconnect connector 77A to gnd. volts. next low or no voltage
(102)/(338) and at circuit step. in circuit 77A, then
77A [coming from (463)/R6] repair.
18. On With switches still set, (N/L), 77A 12 ± 1.5 Go to Locate cause of
reconnect conn. (102)/(338) to gnd. volts. next low or no voltage
and disconnect compressor step. in circuit 77A, then
conn. (N/L). At (N/L) circuit repair.
77A measure voltage to
ground.
19. On With switches still set, Go to Replace defective
reconnect conn. (N/L) at next A/C compressor
the A/C compressor clutch. step. clutch.
Does the clutch engage
(click once)?
20. On With switches still set, (N/L), 77E 12 ± 1.5 Go to Locate cause of
disconnect low pressure to gnd. volts. next low or no voltage
safety switch (N/L) and step. in circuit 77C or
21. On With switches still set, (N/L), 77N 12 ± 1.5 Go to Locate cause of
disconnect high pressure to gnd. volts. next low or no voltage
safety sw. (N/L), and step. in circuit 77N, then
measure voltage from repair.
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CONTROL (SLEEPER)

POINTS SPEC. SPEC.
22. Off/ On At relay socket (463)/R6 (N/L), 77P 12 ± 1.5 Go to Locate cause of
move jumper wire to to gnd. volts. next low or no voltage
between circuit 77F and step. in circuit 77R or
77R. Move key switch to 77P, then repair.
ignition position, A/C switch
(551) to on, and blower
switch (550) to low. At low
pressure safety switch (N/L)
circuit 77P, measure voltage
to ground.
23. On At high pressure safety (N/L), 77J to 12 ± 1.5 Go to Locate cause of
switch (N/L) circuit 77J, gnd. volts. next low or no voltage
measure voltage to ground. step. in circuit 77J, then
repair.
24. Off Measure resistance of low Across low > 100K Go to If refrigerant
pressure safety switch pressure ohms. next charge is within
(N/L). safety sw. step. limits, replace
defective low
pressure switch.
25. Off Measure resistance of high Across high > 100K Go to If refrigerant
pressure safety switch pressure ohms. next charge is within
(N/L). safety sw. step. limits, replace
defective high
pressure switch.
26. Off Bench test A/C relay Relay (463)/ < 1 ohm. Go to Replace defective
(463)/R6 by measuring R6, 30 to next relay.
resistance from terminal 30 87A. step.
to 87A.
27. Off Bench test A/C relay Energized < 1 ohm. Go to Replace defective
(463)/R6 by applying +12V (463)/ R6, next relay.
to terminal 85 and ground 30 to 87. step.
to terminal 86. Measure
resistance from terminal 30
to 87.
check good. Remove test
jumper, re-install relay, and
reconnect the separated
connectors.
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CONTROL (SLEEPER)
3.3. STANDARD TEMPERATURE CONTROL (SLEEPER)

Table 127 Standard Temperature Control (Sleeper)
POINTS SPEC. SPEC.
1. Off/ On Disconnect connector (552), 75AL 12 ± 1.5 Go to Locate cause of
(552), and move key switch to gnd. volts. next low or no voltage
to ignition position. At step. in circuit 75AL,
(552) circuit 75AL, measure then repair.
voltage to ground.
2. On At connector (552) measure (552), 75AL 12 ± 1.5 Go to Locate open or
voltage from circuit 75AL to to 75–GS. volts. next poor connection
75–GS. step. in circuit 75–GS,
11–GBJ, 11–GAN,
conn. (81), or
circuit 11–GBB to
right cab gnd. stud
(404), then repair.
3. Off At connector (552) (552), term. 9K ohms Go to Replace
and pigtail to sleeper A to C. to 11K next defective sleeper
temperature control, ohms. step. temperature
measure resistance from control.
terminal A to C.
4. Off At connector (552) (552), term. 39K ohms. Go to Replace
and pigtail to sleeper B to C. next defective sleeper
temperature control, step. temperature
terminal B to C with control
rotated fully CCW.
5. Off At connector (552) (552), term. 39K ohms. Go to Replace
and pigtail to sleeper A to B. next defective sleeper
temperature control, step. temperature
terminal A to B with control
rotated fully CW.
6. Off/ On Reconnect connector (552), (45), 75K to 2V and Go to Locate cause of
disconnect heater box conn. gnd. 11V. next low or no voltage
(45), move key switch to step. in circuit 75K,
ignition position, and at (45) connector (80) or
circuit 75K [going to (80)] circuit 75K, then
measure voltage to ground repair.
while rotating sleeper temp.
control fully CCW and CW.
7. On At connector (45) measure (45), 75L to 12 ± 1.5 Go to Locate cause of
voltage from circuit 75L gnd. volts. next low or no voltage
[coming from (441)] to step. in circuit 75L, then
ground. repair.
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CONTROL (SLEEPER)
Table 127 Standard Temperature Control (Sleeper) (cont.)

POINTS SPEC. SPEC.
8. On Reconnect conn. (45). Go to Go to next step.
Does heater box damper Step 13.
door function properly?
(Damper door should open
and close with temperature
control, and close when
sleeper blower switch is
moved to off position.)
9. Off/ On Disconnect heater box (N/L), 75L 12 ± 1.5 Go to Locate cause of
damper conn. (N/L) and to gnd. volts. next low or no voltage
with key switch in ignition step. in circuit 75L, then
position, measure voltage repair.
from circuit 75L to ground.
10. On At heater box damper (N/L), 75L 12 ± 1.5 Go to Locate open or
connector (N/L), measure to 75–GL volts. next poor connection
voltage from circuit 75L to step. in circuit 75–GL,
75–GL. conn. (44), circuit
75–G or 11–G to
right cab gnd. stud
(404), then repair.
11. On At heater box damper conn. (N/L), 75K 2V and Go to Locate cause of
(N/L), with sleeper blower to gnd. 11V. next low or no voltage
switch (55) in low position, step. in circuit 75K, then
measure voltage from circuit repair.
75K to ground while rotating
sleeper temperature control
fully CCW and CW.
12. Off/ On Reconnect heater box Go to Replace defective
damper conn. (N/L), move next damper motor
key switch to ignition step. assembly.
position, and place sleeper
blower switch (550) in
low speed position. Note
if damper door closes
completely and opens
completely, when sleeper
temp. control is moved fully
CW and CCW.
13. Off Sleeper temperature control
(B2) Battery Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At power distribution center, above engine tunnel
(I1) Ignition Adapter (518). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Located behind instrument panel — center
(41) Resistor and Thermofuse Assembly. . . . . . . . . . .. . . . . . Inside sleeper blower assembly
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CONTROL (SLEEPER)

(48) Sleeper Heater Connector. . . . . . . . . . . . . . . . . . . . . .. . . . . . Under right dash kick panel
(51) Sleeper Heater Connector #2. . . . . . . . . . . . . . . . . .. . . . . . Under right dash by tunnel
(80) Cab to Sleeper #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind driver under floor
(441) Aux. Bunk Blower Relay R20. . . . . . . . . . . . . . . . .. . . . . . At power distribution center, above engine tunnel
(480) Sleeper Med. Speed Relay. . . . . . . . . . . . . . . . . . .. . . . . . At power distribution center, above engine tunnel
(481) Sleeper High Speed Relay R28. . . . . . . . . . . . . . .. . . . . . At power distribution center, above engine tunnel
(518) Ignition Adapter (I1). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Located behind instrument panel — center
(535) Cab to Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind driver under floor
(550) Bunk Heater Blower Switch. . . . . . . . . . . . . . . . . . .. . . . . . Left rear corner of sleeper — behind control panel
(551) Sleeper A/C Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left rear corner of sleeper — behind control panel
(552) Sleeper Temperature Control. . . . . . . . . . . . . . . . .. . . . . . Left rear corner of sleeper — behind control panel
See Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6.
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CONTROL (SLEEPER)
Figure 167 9800 Sleeper Box Wiring With 110 Inch Cab and Standard Bunk
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CONTROL (SLEEPER)
Figure 168 9800 Sleeper Box Wiring With 89 Inch Cab
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CONTROL (SLEEPER)
Figure 169 Sleeper HVAC Controls With Standard Temperature Control
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CONTROL (SLEEPER)
Figure 170 Sleeper Control Panel
Figure 171 Bunk Blend-Air Door Actuator
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CONTROL (SLEEPER)
Figure 172 Bunk Blower Assembly
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530 13 HEATER AND AIR CONDITIONER BLOWER WITH STANDARD TEMPERATURE CONTROL
(SLEEPER)
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14 HEATER AND AIR CONDITIONER BLOWER WITH THERMOSTAT 531
TEMPERATURE CONTROL (SLEEPER)
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .533
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .533
3.1. HEATER AND AIR CONDITIONER BLOWER (SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534
3.2. AIR CONDITIONER (CAB/SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539
3.3. THERMOSTAT TEMPERATURE CONTROL (SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .545
s08270
532 14 HEATER AND AIR CONDITIONER BLOWER WITH THERMOSTAT TEMPERATURE
CONTROL (SLEEPER)
s08270
Model: 9800
1. DESCRIPTION
The sleeper heater and air conditioner system consists of a blower to provide heat or cooling air from the cab
heater box to the sleeper. The system also includes, at the bunk, a thermostat temperature control to regulate
the bunk temperature, and a blower control for setting the blower to off, low, medium or high speed.
2. OPERATION
When key switch (452) is moved to ignition position, power is applied to I1 ignition adapter (518), circuit 13AT,
and the coil of auxiliary blower relay (441). The ground path for the auxiliary blower relay is circuits 13-GAT,
75-GH, 75-GN, and 11-GBB to right cab ground stud (404). This energizes the auxiliary bunk blower relay
(441) and allows power to flow from (B2) battery stud through circuit 14AU, 15A fuse F10-B [location may
vary], circuit 75AX, aux. bunk relay (441) N.O. contacts, circuit 75AS, connector (80), circuits 75AS and
75AR to bunk heater blower switch (550).
When the bunk heater blower switch (550) is moved to the low speed position, power flows through circuit
75AC, connector (80), circuit 75AC, connector (51), circuit 75AC, resistor and thermofuse assembly, circuit
75AT, connector (48), circuit 75AT, sleeper high speed relay (481) N.C. contacts, circuit 75AF, connector (48),
and circuit 75AF to the sleeper blower motor. This causes the blower motor to run at low speed. The blower
motor ground path is circuit 75-GA, connector (48), circuits 75-GA and 11-GBB to right cab ground stud (404).
When the bunk blower switch (550) is moved to the medium speed position, power flows through circuit 75AN,
connector (80), and circuit 75AN to the sleeper medium speed relay (480). The ground path for the sleeper
medium speed relay (480) is circuits 75-GN and 11-GBB to right cab ground stud (404). This energizes the
sleeper medium speed relay (480) and allows power to flow from (B2) battery stud through circuit 14AU, fuse
F10-A, circuits 75AW and 75AB, sleeper medium speed relay (480) N.O. contacts, circuit 75AM, connector
(48), circuit 75AM, resistor and thermofuse assembly (41), circuit 75AT, connector (48), circuit 75AT, sleeper
high speed relay (481) N.C. contacts, circuit 75AF, connector (48), and circuit 75AF to sleeper blower motor.
This causes the blower motor to run at medium speed. The blower ground path is circuit 75-GA, connector
(48), circuits 75-GA and 11-GBB to right cab ground stud (404).
When the bunk blower switch (550) is moved to the high speed position, power flows through the switch, circuit
75AH, connector (80), and circuit 75AH to the sleeper high speed relay (481). The ground path for the sleeper
high speed relay (481) is circuits 75-GH, 75-GN, and 11-GBB to right cab ground stud (404). This energizes the
sleeper high speed relay (481) and allows power to flow from (B2) battery stud through circuit 14AU, 30A fuse
F10-A [location may vary], circuits 75AW and 75AD, sleeper high speed relay (481) N.O. contacts, circuit 75AF,
connector (48), and circuit 75AF to sleeper blower motor. This causes the blower motor to run at high speed.
The blower ground path is circuit 75-GA, connector (48), circuits 75-GA and 11-GBB to right cab ground
stud (404).
When the key switch (452) is moved to the ignition position, power is also made available by the auxiliary
bunk relay (441) to circuit 75AS, connector (80), circuits 75AS and 75AL to sleeper automatic temperature
control connector (552). The ground path for the sleeper automatic temperature control is through connector
(552), circuit 75-GS, connector (552), circuits 75-GS, 11-GBJ and 11-GAN, connector (81), circuits 11-GAN
and 11-GBB to right cab ground stud (404).
As above, power is also made available by the auxiliary bunk relay (441) to circuit 75L, connector (45), and
circuit 75L to the heater box damper flat pack. The heater box damper flat pack is grounded through circuit
s08270
534 14 HEATER AND AIR CONDITIONER BLOWER WITH THERMOSTAT
75-GL, connector (44), circuits 75-G and 11-G to right cab ground stud (404). The flat pack receives a variable
voltage from the sleeper automatic temperature control through connector (552), circuit 75K, connector (80),
circuit 75K, connector (45), and circuit 75K. Thus the damper blends hot and cold air as selected by the
sleeper temperature control.
When the key switch (452) is in ignition position and the bunk heater blower switch (550) is in low, medium, or
high position, power is applied to circuit 77L, connector (551F)/(905), circuits 77AB and 77AC, and the sleeper
A/C On/Off switch (551). When the switch is moved to the on position, the internal indicator lamp illuminates as
power flows through it. Ground circuits are connector (551), circuits 77-GL, 11-GBJ and 11-GAN, connector
(81), circuits 11-GAN and 11-GBB to right cab ground stud (404). When the switch is moved to on position,
power is also supplied to the A/C control relay (447) by way of the blocking diode, connector (551), circuit 77M,
connector (535) and circuits 77M and 77K. Thus the A/C compressor will engage, if it is not already running
(the compressor will cycle with the thermostatic switch), and cooling will be available for the sleeper blower.
3. TROUBLESHOOTING
relay, or solenoid.
3.1. HEATER AND AIR CONDITIONER BLOWER (SLEEPER)

Table 128 Heater and Air Conditioner Blower (Sleeper)
POINTS SPEC.
1. On Does the blower run in Go to Step Go to next step.
either the low, medium, 10.
or high fan position?
2. Off/ Remove auxiliary bunk (441), 12 ± 1.5 Go to next Locate cause of low
On blower relay (441), move 13AT to volts step. or no voltage in circuit
key switch to ignition gnd. 13AT, then repair.
13AT measure voltage to
ground.
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POINTS SPEC.
3. On At relay socket (441), (441), 12 ± 1.5 Go to next Locate open or poor
measure voltage form 13AT to volts step. connection in circuit
circuit 13AT to 13–GAT. 13–GAT 13–GAT, 75–GH,
75–GN, or 11–GBB
to right cab ground
stud (404), then
repair.
4. Off At (B2) battery stud (B2) to 12 ± 1.5 Go to next Locate cause of low
measure voltage to gnd. volts step. or no voltage at (B2)
repair.
5. Off Remove fuse F10–B F10–B < 1 ohm. Go to next Locate cause of
(location may vary) and step. overload condition,
check for open condition then repair. Replace
fuse.
6. Off Re-install F10–B and at F10–B, 12 ± 1.5 Go to next Locate cause of low
circuit 14AU measure 14AU to volts step. or no voltage in circuit
voltage to ground. gnd. 14AU, then repair.
7. Off At relay socket (441), (441), 12 ± 1.5 Go to next Locate cause of low
measure voltage from 75AX to volts step. or no voltage in circuit
circuit 75AX to ground. gnd. 75AX, then repair.
8. Off Bench test auxiliary bunk Relay < 1 ohm. Go to next Replace defective
blower relay (441) by (441), pin step. auxiliary bunk blower
measuring resistance 30 to 87A. relay.
from pin 30 to 87A.
9. Off Bench test auxiliary bunk Energized < 1 ohm. Go to next Replace defective
blower relay (441) by (441), pin step. auxiliary bunk blower
applying +12V to pin 86, 30 to 87. relay.
ground to pin 85, and
from pin 30 to 87.
10. Off/ Re-install (441) and (550), 12 ± 1.5 Go to next Locate cause of low
On disconnect switch (550). 75AR to volts step. or no voltage in circuit
Move key switch to gnd. 75AS or 75AR, then
ignition position and repair.
at (550) circuit 75AR,
measure voltage to
ground.
11. Off Test bunk heater blower (550), < 1 ohm. Go to next Replace defective
switch (550) by placing term. B step. blower switch.
switch in low speed to L, and B
position, and measuring to C.
terminal B to L, and B to
C.
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POINTS SPEC.
switch in medium speed to M, and
position, and measuring B to C.
terminal B to M, and B to
C.
switch in high speed to H, and
position, and measuring B to C.
terminal B to H, and B to
C.
14. Off/ Re-install blower switch Go to Step Go to next step.
On (550). Move key switch to 19.
to low position?
15. Off/ Disconnect conn. (51) (51), 75AC 12 ± 1.5 Go to next Locate cause of low
On and with the key switch to gnd. volts step. or no voltage in circuit
in ignition position and 75AC, conn. (80), or
blower switch in low circuit 75AC, then
speed position, measure repair.
ground.
16. Off/ Disconnect resistor and (41), 75AC 12 ± 1.5 Go to next Locate cause of low
On thermofuse assembly to gnd. volts step. or no voltage in circuit
(41) and with key switch 75AC, then repair.
in ignition position and
blower switch in low
position, measure voltage
from circuit 75AC to
ground.
17. Off At blower resistor and Blower 1.1 to 1.3 Go to next Replace defective
thermofuse assembly resistor ohms. step. blower resistor.
(41), measure distance (41), term.
18. Off At blower resistor and Blower .25 to .45 Go to next Replace defective
thermofuse assembly resistor ohm. step. blower resistor.
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POINTS SPEC.
19. Off/ Reconnect blower (48), 75AT 12 ± 1.5 Go to next Locate cause of low
On resistor, and disconnect to gnd. volts step. or no voltage in circuit
conn. (48). With key 75AT, then repair.
and blower switch in low
circuit 75AT [going to
(N/L)] measure voltage to
ground.
20. On Remove sleeper high (481), 12 ± 1.5 Go to next Locate cause of low
speed relay (481) and 75AT to volts step. or no voltage in circuit
at circuit 75AT, measure gnd. 75AT, then repair.
voltage to ground.
21. Off Bench test high speed (481), pin < 1 ohm. Go to next Replace defective
relay (481) by measuring 30 to 87A. step. sleeper high speed
resistance from pin 30 to relay (481).
87A.
22. Off Bench test high speed Energized < 1 ohm. Go to next Replace defective
relay (481) by applying (481), pin step. sleeper high speed
+12V to pin 86, ground 30 to 87. relay (481).
87.
23. On Move key switch to (481), 12 ± 1.5 Go to next Locate cause of
ignition position, blower 75AH to volts step. low or no voltage in
switch to high speed gnd. circuit 75AH, conn.
position, and at (481) (80), and circuit
circuit 75AH, measure 75AH, then repair.
voltage to ground.
24. Off At (481) install a test (48), 75AF < 1 ohm. Go to next Locate open or poor
jumper from circuit 75AF to gnd. step. connection in circuit
to 75–GH. Disconnect 75AF, then repair.
conn. (48) and at
circuit 75AF [coming
from (481)], measure
25. Off At conn. (48) measure (48), < 1 ohm. Go to next Locate open or poor
resistance from circuit 75–GA to step. connection in circuit
75–GA [going to (404)] to gnd. 75–GA or 11–GBB to
ground. right cab ground stud
(404), then repair.
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POINTS SPEC.
26. Off/ Reconnect conn. (48) Sleeper 12 ± 1.5 Go to next Locate cause of low
On and disconnect circuit blower volts step. or no voltage in circuit
75AF from sleeper motor, 75AF, then repair.
blower motor. Move key 75AF to
switch to ignition position, gnd.
speed position, and at
75AF measure voltage to
ground.
27. On Measure voltage from Sleeper 12 ± 1.5 Go to next Locate open or poor
circuit 75AF to 75–GA. blower volts. step. connection in circuit
motor, 75–GA, then repair.
75AF to
75–GA.
28. Off/ With ignition key in off Go to next Replace defective
On position, reconnect circuit step. blower motor.
75AF. Move key switch
to ignition position, and
blower run?
29. Off/ Remove medium speed (480), 12 ± 1.5 Go to next Locate cause of low
On relay (480), move key 75AN to volts step. or no voltage in circuit
switch to ignition position, gnd. 75AN, conn. (80), or
and move blower switch circuit 75AN, then
to medium speed. At repair.
circuit 75AN, measure
voltage to ground.
30. Off Remove fuse F10–A F10–A. < 1 ohm. Go to next Locate cause of
(location may vary) and step. overload condition,
check for open condition. then repair. Replace
fuse.
31. Off Re-install fuse F10–A. At (480), 12 ± 1.5 Go to next Locate cause of low
relay socket (480) and 75AB to volts step. or no voltage in circuit
circuit 75AB, measure gnd. 75AB or 75AW, then
32. Off Bench test medium (480), pin < 1 ohm. Go to next Replace defective
speed relay (480) by 30 to 87A. step. medium speed relay
measuring resistance (480).
from pin 30 to 87A.
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POINTS SPEC.
33. Off Bench test medium Energized < 1 ohm. Go to next Replace defective
speed relay (480) by (480), pin step. medium speed relay
applying + 12V to pin 30 to 87. (480).
86, ground to 85, and
from pin 30 to 87.
34. Off/ Disconnect conn. (48), (48), 12 ± 1.5 Go to next Locate cause of low
On re-install medium speed 75AM to volts step. or no voltage in circuit
relay (480), move key gnd. 75AM, then repair.
and blower switch to low
speed position. At (48)
circuit 75AM [going to
(41)], measure voltage to
ground.
35. On Disconnect resistor and (41), 12 ± 1.5 Go to next Locate cause of low
thermofuse assembly 75AM to volts step. or no voltage in circuit
(41) and reconnect conn. gnd. 75AM, then repair.
(48). At (41) circuit
75AM, measure voltage
to ground.
36. Off Reconnect resistor and (481), 12 ± 1.5 Go to next Locate cause of low
thermofuse conn. (41) 75AD to volts step. or no voltage in circuit
and remove high speed gnd. 75AD, then repair.
relay (481). At (481)
circuit 75AD, measure
voltage to ground.
relay (481). Heater
good.
3.2. AIR CONDITIONER (CAB/SLEEPER)

Table 129 Air Conditioner (Cab/Sleeper)
POINTS SPEC.
1. On With key switch in ignition Go to Step Go to next step.
position, sleeper blower 34.
switch (550) in low
position, and sleeper
A/C switch (551) in on
position, does A/C clutch
engage (click once)?
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POINTS SPEC.
2. On With switches still set, (551), 77L 12 ± 1.5 Go to next Locate cause of
disconnect conn. (551) to gnd. volts. step. low or no voltage
and at circuit 77L, in circuit 77L, conn.
measure voltage to (551), then repair.
ground.
3. On With switches still set, at (551), 77L 12 ± 1.5 Go to next Locate open or poor
connector (551) measure to 77–GL. volts. step. connection in circuit
voltage from circuit 77L 77–GL, 11–GBJ,
to 77–GL. 11–GAN, conn. (81),
circuit 11–GAN, or
ground stud (404),
then repair.
4. Off Test switch and blocking (551), pin < 1 ohm. Go to next Replace defective
diode assembly (551) A to pin B. step. switch/ blocking
by placing disconnected diode assembly.
switch in the on position,
from conn. (551) pin A to
pin B. NOTE: “+” lead
must be on pin A.
5. Off/ On Reconnect conn. (551), Go to next Replace defective
move key switch to step. switch/ blocking
ignition position, sleeper diode assembly.
blower switch to low, and
sleeper A/C switch to on.
Does A/C switch indicator
illuminate?
6. On With switches still set, (535), 77M 12 ± 1.5 Go to next Locate cause of
disconnect conn. (535) to gnd. volts. step. low or no voltage
and at circuit 77M, in connector (551),
[coming from (551)] or circuit 77M, then
measure voltage to repair.
ground.
7. Off/ On Remove A/C control relay (447), 77K 12 ± 1.5 Go to next Locate cause of
(447). With key switch in to gnd. volts. step. low or no voltage in
ignition position, sleeper circuit 77M, conn.
blower switch (550) in low (551), circuit 77M,
position, cab A/C switch conn. (535), or circuit
(30) off, and sleeper A/C 77M or 77K from
switch (551) on, at (447) sleeper A/C switch
circuit 77K, measure conn. (551), then
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POINTS SPEC.
8. On At (447), with switches (447), 77K 12 ± 1.5 Go to next Locate open or poor
still set, measure voltage to 77–GS. volts. step. connection in circuit
from circuit 77K to 77–GS, 12–GF,
77–GS. 82–GA, 12–GH,
82–GD, or 11–GD to
left cab ground stud
(429), then repair.
9. On Remove fuse F1–B and F1–B. < 1 ohm. Go to next Locate cause of
fuse.
10. On Re-install fuse F1–B and F1–B, 14Z 12 ± 1.5 Go to next Locate cause of low
at circuit 14Z measure to gnd. volts. step. or no voltage in circuit
voltage to ground. 14Z or 14W from
(B2), then repair.
11. On At (447), circuit 77T, (447), 77T 12 ± 1.5 Go to next Locate cause of low
measure voltage to to gnd. volts. step. or no voltage in circuit
ground. 77T, then repair.
12. Off Bench test A/C control (447), pin < 1 ohm. Go to next Replace defective
relay (447) by measuring 30 to 87A. step. A/C control relay
resistance from pin 30 to (447).
87A.
13. Off Bench test A/C control Energized < 1 ohm. Go to next Replace defective
relay (447) by applying (447), pin step. A/C control relay
+12V to pin 86, ground 30 to 87. (447).
87.
14. Off/ On Re-install A/C control (45), 77H 12 ± 1.5 Go to next Locate cause of low
relay (447) and to gnd. volts. step. or no voltage in circuit
disconnect conn. (45). 77H, then repair.
Set sleeper A/C switch
(551M) to on, sleeper
blower switch (550) to
low, and key switch to
ignition position. At conn.
voltage to ground.
15. Off At conn. (45) (going to (45), 77B < 1 ohm. Go to Step Go to next step.
heater box) measure to 77F. 19.
temperature must be
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POINTS SPEC.
16. Off Disconnect thermostatic Across < 1 ohm. Go to next Replace defective
switch (N/L), and thermostatic step. thermostatic switch
measure resistance sw. (N/L). (N/L).
from terminal 1 to 2
[evaporator temperature
must be greater than
34°F (1°C)].
17. Off At conn. (N/L), removed (45), 77B < 1 ohm. Go to next Locate open or poor
from thermostatic switch, to gnd. step. connection in circuit
and circuit 77B, install a 77B, then repair.
jumper wire to ground. At
ground.
18. Off At conn. (N/L), removed (45), 77F < 1 ohm. Go to next Locate open or poor
from thermostatic switch, to gnd. step. connection in circuit
and circuit 77F, install a 77F, then repair.
jumper wire to ground.
At conn. (45) circuit
77F, going to heater box,
ground.
19. Off/ On With thermostatic switch (463)/ R6, 12 ± 1.5 Go to next Locate cause of low
(N/L) and connector (45) 77F to volts. step. or no voltage in circuit
reconnected, remove A/C gnd. 77F, then repair.
relay (463)/R6. Move key
sw. to ignition position,
sleeper A/C switch (551)
to on, and blower switch
(550) to low. At (463)/R6
circuit 77F, measure
voltage to ground.
20. On With switches still set, (463)/ R6, < 1 ohm. Go to next Locate open or
at relay socket (463)/R6 77F to step. poor connection in
measure voltage from 77–G. circuit 77–G, 13–GT,
circuit 77F to 77–G. 50–GB, 75–GC,
75–GB, 11–GN, or
11–GB to rt. cab
gnd. stud (404), then
repair.
21. Off At relay socket (463)/R6 (463)/ R6, < 1 ohm. Go to next Locate open or poor
measure resistance of 77D to step. connection in circuit
circuit 77D (terminal that 77D. 77D, then repair.
relay pin 86 was in, to
term. that relay pin 87
was in).
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POINTS SPEC.
22. Off/ On At relay socket (463)/R6 Go to Step Go to next step.
install jumper wire from 26.
circuit 77F to 77A. Set
A/C switch (551) to on,
low, and key switch to
ignition position. Did
A/C clutch engage (click
once)?
23. On With switches still set, (102), 77A 12 ± 1.5 Go to next Locate cause of low
disconnect conn. (102) to gnd. volts. step. or no voltage in circuit
and at circuit 77A [coming 77A, then repair.
from (463)/R6] measure
voltage to ground.
24. On With switches still set, (N/L), 77A 12 ± 1.5 Go to next Locate cause of low
reconnect connector to gnd. volts. step. or no voltage in circuit
(102) and disconnect 77A, then repair.
compressor conn. (N/L).
At (N/L) circuit 77A,
measure voltage to
ground.
25. On With switches still set, Go to next Replace defective
reconnect connector step. A/C compressor
(N/L) at the A/C clutch.
compressor clutch. Does
the clutch engage (click
once)?
26. On With switches still set, (N/L), 77E 12 ± 1.5 Go to next Locate cause of
disconnect low pressure to gnd. volts. step. low or no voltage in
safety switch (N/L) and circuit 77C or 77E,
measure voltage from then repair.
27. On With switches still set, (N/L), 77N 12 ± 1.5 Go to next Locate cause of low
disconnect high pressure to gnd. volts. step. or no voltage in circuit
safety switch (N/L), and 77N, then repair.
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POINTS SPEC.
28. Off/ On At relay socket (463)/R6 (N/L), 77P 12 ± 1.5 Go to next Locate cause of
move jumper wire to to gnd. volts. step. low or no voltage in
between circuit 77F and circuit 77R or 77P,
77R. Move key switch then repair.
to ignition position, A/C
switch (551) to on, and
low. At low pressure
safety switch (N/L) circuit
77P, measure voltage to
ground.
29. On At high pressure safety (N/L), 77J 12 ± 1.5 Go to next Locate cause of low
switch (N/L) circuit 77J, to gnd. volts. step. or no voltage in circuit
measure voltage to 77J, then repair.
ground.
30. Off Measure resistance of Across low > 100K Go to next If refrigerant charge
low pressure safety pressure ohms. step. is within limits,
switch (N/L). safety sw. replace defective
low pressure switch.
31. Off Measure resistance of Across > 100K Go to next If refrigerant charge
high pressure safety high ohms. step. is within limits,
switch (N/L). press. replace defective
safety sw. high pressure switch.
32. Off Bench test A/C relay (463)/ R6, < 1 ohm. Go to next Replace defective
(463)/R6 by measuring 30 to 87A. step. relay.
30 to 87A.
33. Off Bench test A/C relay Energized < 1 ohm. Go to next Replace defective
(463)/R6 by applying (463)/ R6, step. relay.
+12V to terminal 85 and 30 to 87.
Measure resistance from
term. 30 to 87.
check good. Remove
test jumper, re-install
relay, and reconnect the
separated connector.
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3.3. THERMOSTAT TEMPERATURE CONTROL (SLEEPER)

Table 130 Thermostat Temperature Control (Sleeper)
POINTS SPEC.
1. Off/ On Disconnect conn. (552), (552), 12 ± 1.5 Go to Locate cause of low
and move key switch to 75AL to volts. next step. or no voltage in circuit
ignition position. At (522) gnd. 75AL, then repair.
circuit 75AL, measure
voltage to ground.
2. On At connector (552) (552), 75L 12 ± 1.5 Go to Locate open or
measure voltage from to 75–GS. volts. next step. poor connection in
circuit 75L to 75–GS. circuit 75–GS, conn.
(552), circuit 75–GS,
11–GBJ, 11–GAN,
conn. (81), or cir.
ground stud (404),
then repair.
3. Off Bench test automatic (552), Full CCW: Go to Replace defective
temperature control by term. B 12 volts, next step. automatic
applying +12 volts to to C. full CW: 0 temperature control
pin “A” at conn. (552), volts. module.
applying ground to pin “C”
and measuring voltage
at pin “B” to ground.
Measure voltage at pin
“B” while turning control
knob full CCW, then fully
CW.
4. Off With bench test wiring (552), 0 to 12 Go to Replace defective
still installed, and control term. B volts. next step. automatic
knob set to center of to C. temperature control
range, does output module.
voltage at pin “B” change
as warm or cool air is
applied to the ambient air
sensor?
5. Off/ On Reconnect connector (45), 75K 2V and Go to Locate cause of
(552), disconnect conn. to gnd. 11V. next step. low or no voltage in
(45), move key switch to circuit 75K, conn.
ignition position, and at (80) or circuit 75K,
(45) circuit 75K [going then repair.
to (80)] measure voltage
to ground while rotating
sleeper temperature
control fully CCW and
CW.
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Table 130 Thermostat Temperature Control (Sleeper) (cont.)

POINTS SPEC.
6. On At connector (45) (45), 75L 12 ± 1.5 Go to Locate cause of low
measure voltage from to gnd. volts. next step. or no voltage in circuit
circuit 75L [coming from 75L, then repair.
(441)] to ground.
7. On Reconnect connector Go to Go to next step.
(45). Does heater box Step 16.
damper door function
properly?
8. Off/ On Disconnect heater box (N/L), 75L 12 ± 1.5 Go to Locate cause of low
damper conn. (N/L), to gnd. volts. next step. or no voltage in circuit
and with key switch in 75L, then repair.
ignition position, measure
voltage from circuit 75L
to ground.
9. On At heater box damper (N/L), 75L 12 ± 1.5 Go to Locate open or poor
connector (N/L), measure to 75–GL. volts. next step. connection in circuit
voltage from circuit 75L 75–GL, 75–G, or
to 75–GL. 11–G to right cab
ground stud (404),
then repair.
10. On At heater box damper (N/L), 75K 2V and Go to Locate cause of low
connector (N/L), measure to gnd. 11V. next step. or no voltage in circuit
voltage from circuit 75K 75K, then repair.
to ground while rotating
sleeper temperature
control fully CCW and
CW.
11. Off/ On Reconnect heater box Sleeper Replace defective
damper conn. (N/L), temperature damper motor
move key switch to control assembly.
ignition position, and circuits
move sleeper blower check
switch. (550) to low good.
speed position. Note
if damper door closes
completely and opens
completely, when the
sleeper temperature
control is moved fully CW
and CCW.
(B2) Battery Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . At power distribution center, above engine tunnel
(I1) Ignition Adapter (518). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Located behind instrument panel — center
(41) Resistor and Thermofuse Assy.. . . . . . . . . . . . . . . .. . . . . . Inside sleeper blower assembly
s08270
(45) Heater box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Pigtail at right front of cab

(48) Sleeper Heater Connector. . . . . . . . . . . . . . . . . . . . . .. . . . . . Under right dash kick panel
(51) Sleeper Heater Connector #2. . . . . . . . . . . . . . . . . .. . . . . . Under right dash by tunnel
(441) Aux. Bunk Blower Relay R20. . . . . . . . . . . . . . . . .. . . . . . At power distribution center, above engine tunnel
(480) Sleeper Med. Speed Relay. . . . . . . . . . . . . . . . . . .. . . . . . At power distribution center, above engine tunnel
(481) Sleeper High Speed Relay R28. . . . . . . . . . . . . . .. . . . . . At power distribution center, above engine tunnel
(518) Ignition Adapter (I1). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Located behind instrument panel — center
(535) Cab to Sleeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind driver under floor
(550) Bunk Heater Blower Switch. . . . . . . . . . . . . . . . . . .. . . . . . Left rear corner of sleeper — behind control panel
(551) Sleeper A/C Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Left rear corner of sleeper — behind control panel
(552) Sleeper Temperature Control. . . . . . . . . . . . . . . . .. . . . . . Left rear corner of sleeper — behind control panel
See Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6.
s08270
Figure 173 9800 Sleeper Box Wiring With 110 Inch Cab and Standard Bunk
s08270
Figure 174 9800 Sleeper Box Wiring With 89 Inch Cab
s08270
Figure 175 Sleeper HVAC Controls With Automatic Temperature Control
s08270
Figure 176 Sleeper Control Panel
Figure 177 Bunk Blend-Air Door Actuator
s08270
Figure 178 Bunk Blower Assembly
s08270
Printed in the United States of America

Electrical System Troubleshooting Guide 9800

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Electrical System Troubleshooting Guide 9800

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SERVICE MANUAL

TRUCK SERVICE MANUAL

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 9800 MODEL

s08270, Formerly CTS-5304

Use with Circuit Diagram Book CTS-5254W

Refer to CTS-5219 for Spicer Automate® 10–Speed Transmission Troubleshooting

Refer to CTS-5258 for Gauges and Warning Lights.

Refer to CTS-5257 for Speedometer/ Tachometer Diagnostics and Service

Refer to CTS-5247 for Bendix M-21, 22 ABS Modulator Assembly Troubleshooting.

Refer to CTS-5249 for Bendix EC-16 ABS Controller Troubleshooting.

4. COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

(B2) Battery Stud

2.4. 3+1 BATTERY SYSTEM

2.5. GROUND ADAPTERS

2.7. PANEL LIGHTS ADAPTER

3.1. START FEED

Table 1 Start Feed (cont.)

Table 2 Accessory (cont.)

Table 2 Accessory (cont.)

3.3. (B1) BATTERY STUD

Table 3 (B1) Battery Stud (cont.)

Table 3 (B1) Battery Stud (cont.)

3.4. (B2) BATTERY STUD

Table 4 (B2) Battery Stud (cont.)

3.5. 3 +1 BATTERY SYSTEM

Table 5 3+1 Battery System (cont.)

3.6. GROUND ADAPTERS

Table 6 Ground Adapters (cont.)

Table 7 Ignition (cont.)

Table 7 Ignition (cont.)

3.8. PANEL LIGHTS ADAPTER

Table 8 Panel Lights Adapter (cont.)

(496) I3 Ignition Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Behind Right Gauge Cluster

Figure 1 Power Distribution Center — 9800 SFA and SBA

Figure 2 Power Distribution Center — 9800 SFA and SBA

Figure 3 Relay Location

Figure 4 Power Distribution Center — 9800 SFA and SBA

Figure 5 Fuse and Circuit Breaker Location

Figure 6 Fuse and Circuit Breaker Location

Figure 7 Power Distribution Center — 9800 SFA and SBA

Figure 8 Cab Wiring — 9800 SFA and SBA

Figure 9 Cab Wiring — 9800 SFA and SBA

Figure 10 Cab Wiring — 9800 SFA and SBA

Figure 11 Cab Wiring — 9800 SFA and SBA

Figure 12 Cab Wiring — 9800 SFA and SBA

Figure 13 Switch and Panel Light Mounting — 9800

1. TRAILER LIGHT SWITCH

4. COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

1.2. ELECTRIC WINDOWS

1.3. WINDSHIELD DEFROSTER FANS

1.5. MIRRORS - HEATED AND LIGHTED

1.6. HEATED MIRRORS AND MOTORIZED RIGHT MIRROR

1.7. DUAL AXIS MOTORIZED MIRRORS

1.8. CB POWER SOURCE

1.9. CB RADIO ACCOMMODATION PACKAGE

1.10. RADIO AND CAB SPEAKERS

1.11. ELECTRIC WINDSHIELD WIPER WITH INTERMITTENT WIPE AND WASH

2.2. ELECTRIC WINDOWS

2.3. WINDSHIELD DEFROSTER FANS

2.5. MIRRORS - HEATED AND LIGHTED

2.6. HEATED MIRRORS AND MOTORIZED RIGHT MIRROR

2.7. DUAL AXIS MOTORIZED MIRRORS

2.8. CB POWER SOURCE

2.9. CB RADIO ACCOMMODATION PACKAGE