Cascadia Instructor's Guide 083010

Cascadia
Instructor Version
Student Guide
© 2010 Daimler Trucks North America

Portland, Oregon 97208
All rights reserved
CVL03
August 18th, 2010
Course Information
Training Manual Use

ii This training manual is intended for use
while attending a Daimler Trucks North student skill level. Many topics that are often
America service training course. Continu- seen as "good information that was left out of
this new class", were actually moved to pre-
ous improvements in our products and ser- requisite classes or web-based training. En-
sure that you are fully familiar with the pre-
vice procedures may make some of the in- requisites of the course you are teaching so
formation in this manual obsolete or invalid. not to dissipate class time re-teaching sub-
jects that were covered in previous training.
Current Manufacturer’s Publications The answers provided to the book exercises
shown in the Instructor Guide and Power-
Always refer to current, approved, manufac- Point slides are provided as examples to the
instructor, and use serial numbers of stan-
turer’s publications when servicing Daimler dard DTNA training vehicles. The instructor
can and should modify these exercises using
Trucks N.A. vehicles. Training materials are trucks and serial numbers available at their
for reference only. training location, in order to make them
more relevant and applicable to the current
class.
Environmental Concerns
Please help identify problems with this
When discarding materials, please attempt course material by reporting them on the
Course Content Update Form, accessible
to recover and recycle them. To preserve through the Daimler Trucks Service Training
Google Group.
our environment, follow appropriate envi-
ronmental rules and regulations for recov-
ery and disposal of materials.
Note to Instructors:
This course has been written to allow you, the
instructor, to efficiently deliver the repair and
troubleshooting information needed for techni-
cians to effectively service DTNA vehicles. It
was created with input from DTNA Service
Training Development, DTNA Service Engi-
neering, DTNA Product Engineering, DTNA
Service Trainers, and Service Trainers from a
wide selection of dealerships.
As an instructor, you should consider the pub-
lished course content to comprise the minimum
amount of information to be covered in the
class, and the source of all of the final exam
questions. You can and should modify the class
material, as appropriate, to satisfy the needs of
the class relating to current field problems and
ii-2 SERVICETRAININGACADEMY.COM i-2 Cascadia

Course Information
Instructor Notes
ii
Cascadia SERVICETRAININGACADEMY.COM SG None ii-3

Course Information
Course Contents
Course Information ............................................................................................. ii-1
ii
Module 1: Cascadia Overview ........................................................................... 1-1
Module 2: Power Distribution............................................................................. 2-1
Module 3: Cascadia Electronic Modules ........................................................... 3-1
Module 4: Multiplexing ....................................................................................... 4-1
Module 5: Service Information ........................................................................... 5-1
Module 6: ServiceLink ....................................................................................... 6-1
Module 7: Troubleshooting ................................................................................ 7-1
ii-4 SERVICETRAININGACADEMY.COM Cascadia

Course Information
Instructor Notes
ii

Course Information
Day One
The following timelines are approximate and may vary.
Time Start Start: Time End

Page Finish: Page
ii 8:00AM Introduction Module 1 10:00AM
Page i-1 Review Questions Page 1-15
Break
15 minutes
10:15AM Module 2 11:30AM

Page1-15 Exercise 2.1 Page 2-13
Lunch
1-hour
12:30PM Module 2 2:00PM

Page 2-13 Review Questions Page 2-18
Break
15 minutes

Page 3-1 Review Questions Page 3-11

Course Information
Day Two
Page Finish: Page
8:00AM
Page 3-11
Module 3 Review Answers
Worksheet Electronic Modules
10:00AM
Page 3-13 ii
Break
15 minutes
10:15AM Exercise 3.2 11:30AM

Page 3-13 Module 4 Datalinks—Cabin CAN Page 4-7
Lunch
1-hour
12:30PM Datalinks—Diagnostic CAN 2:00PM

Page 4-8 Multiplexing/Electronic System Ops. Page 4-10
Break
15 minutes
2:15PM Cruise Control 4:00PM

Page 4-11 Module 5 Service Information Page 5-5

Course Information
Day Three
Page Finish: Page
ii 8:00AM
Page 5-6
Module 5 Service Information
Worksheet—Fault Codes
10:00AM
Page 5-15
Break
15 minutes
10:15AM Worksheet—Finding Module Numbers 11:30AM

Page 5-16 Page 5-16
Lunch
1-hour
12:30PM SAM Hardware and Software Updates 2:00PM

Page 5-17 Module 5 Review Questions Page 5-19
Break
15 minutes

Page 6-1 Exercise 6.3 Page 6-12

Course Information
Day Four
Page Finish: Page
8:00AM
Page 6-12
Exercise 6.4
Module 6 Review Questions
10:00AM
Page 6-15 ii
Break
15 minutes
10:15AM Module 7 11:30AM

Page 7-1 Troubleshooting HVAC Problems Page 7-13
Lunch
1-hour
12:30PM Assigned Troubleshooting Exercises 2:00PM

Page 7-14 Continued
Break
15 minutes
2:15PM Assigned Troubleshooting Exercises 4:00PM

Continued Online Course Survey Finish
Cascadia SERVICETRAININGACADEMY.COM 1-1 ii-9

Introduction
i
Course Information
Welcome ............................................................................................................ i-7
Safety and Shop Rules ....................................................................................... i-8
Computer Protocol ............................................................................................. i-9
Discrimination and Harassment........................................................................ i-10
Course Learning Objectives ............................................................................. i-11
i-1 SERVICETRAININGACADEMY.COM i-6 Cascadia

Introduction
i
Welcome
Instructor Name Smoking
Course Title Meals
Course Length Transportation
Time Telephone Numbers
Breaks Enrollment & Course Catalog
Restrooms
Personal Introductions
1. Instructor Introduction (Personal and Professional)
a. Technical background
b. Teaching Background
2. Student Introduction
a. How long have you been a technician?
b. Do you have a specialty?
What do you expect to learn from this course?
Cascadia SERVICETRAININGACADEMY.COM SG i-7 i-2

Introduction
i
Safety Shop Rules
Some of our course activities require you 1. If you take it apart, please reas-
to turn-on vehicle ignition. Remember semble it properly. Leave the
that safety precautions must always be trucks in ―as good as‖ or better
performed before you turn-on the trucks shape than you found them.
in the shop.
2. If you use a tool, please put it
When working on or around vehicles, ob- back to where you found it. Don’t
serve the following safety precautions: leave it out for the next group to
put away.
To start a vehicle, the technician must
be properly seated in the driver seat. Ve- 3. If anything breaks or you find
hicles are not to be started from the shop something broken, let the instruc-
floor. tor know.
Park the vehicle on a level surface, shut 4. Once you find a ―bug‖, ask your
down the engine, set the parking brake, instructor whether you should re-
and chock the tires before working under move it or leave it.
the vehicle.
5. Work safely. If you don’t have the
In some cases, the whole class will be proper equipment or tools, ask for
working on a single vehicle. If you are in them.
the cab, do not:
Start the engine unless in-

structed
Honk the horn
Release the parking brakes
Depress the clutch pedal
(manual linkage)
Operate anything that may
cause harm to another student
Observe normal sop safety procedures

and be alert to prevent accidents.
i-3 SERVICETRAININGACADEMY.COM SG 1-8 Cascadia

Introduction
i
Computer Protocol
Out of courtesy, please follow our computer protocol throughout this class:
Use the computer only as directed

When not in use, keep the screen lowered to prevent distractions
Do not use the Internet unless directed, and then ONLY as directed.
These measures help us all to stay on schedule and do our best work. They also help
ensure compliance with Daimler Trucks North America corporate policy that prohibits
unauthorized use of the Internet.
Cascadia SERVICETRAININGACADEMY.COM SG 1-9 i-4

Introduction
i
Discrimination and Harassment
It is the policy of Daimler Trucks North America (hereafter DTNA) to provide an envi-
ronment free from unlawful discrimination and harassment. Therefore, all forms of dis-
crimination and harassment related to a student or employee's race, color, religion,
gender, age, national origin, disability or veteran status constitute violations of this pol-
icy. DTNA will not tolerate the use of racial, religious, sexual, gender based, age re-
lated, ethnic or disability related epithets, innuendos, slurs or jokes within its facilities.
Additionally, all forms of harassment; including verbal, non-verbal, and physical, based
on the above categories, are prohibited.
With regard to sexual harassment in particular; unwelcome sexual advances, requests

for sexual favors and other verbal or physical conduct of a sexual nature are consid-
ered instances of sexual harassment when:
Such conduct has the purpose or effect of unreasonably interfering with a student or
employee’s performance or creates an intimidating, hostile or offensive learning/
work environment.
A student or employee’s submission to or rejection of such conduct is used as the ba-

sis of evaluation or employment decisions that affect the student or employee.
It is important to remember that behavior which one individual considers innocent or

harmless may be regarded as sexual harassment by another person. Beyond being in
violation of DTNA policy, sexual harassment is against the law.
If at anytime a student or employee feels that he/she has been subjected to or ob-
served verbal, non-verbal, or physical harassment of a sexual nature or otherwise, the
employee must report such conduct immediately to the instructor or a member of the
Human Resources Department so that appropriate action can be taken. If, for any rea-
son, the employee does not feel comfortable reporting the incident to the instructor, he
or she may use the toll-free help line at (877) 246-4751. The confidentiality of all such
reports will be respected to the fullest extent possible. Persons reporting will not be re-
taliated against in any manner for reporting perceived harassment or for providing in-
formation related to such reports.

Introduction
i
Course Learning Objectives
Module 1— Cascadia Overview
Identify the different Cascadia models

Identify Electronics specific to Cascadia
Module 2—Power Disfribution
Describe MFJB (MEGA Fuse Junction Block) and MGJB (Main Ground Junction
Block)
Describe ground cable return to batteries
Describe battery shut-off switch change to the power side
List circuits protected by Powertrain PDM
Identify power distribution circuits
Identify emergency power responses
Identify Power Distribution changes for EPA 2010 (PNDB / PTPDM)
Module 3— Cascadia Electronic Modules
Explain purpose of Signal detection & Activation Modules (SAMs).

Explain purpose and functionality of Modular Switch Field (MSF) components.
Explain purpose of the Central Gateway module.
Module 4—Multiplexing
Explain the basic concept of multiplexing

Explain multiplexing for the Cascadia electrical system.
Identify the major components in the Cascadia multiplexed system.
Explain the operation of datalinks J1587, J1939, Cabin CAN (Controller Area
Network), and Diagnostics CAN.
Follow the communication between the J1939 and CAN datalinks.
Module 5—Service Information
Use www.AccessFeightliner.com to find service and troubleshooting information

Moldule 6—ServiceLink
Use ServiceLink to monitor Cascadia ECUs

Use ServiceLink to monitor MSF Switches
Use ServiceLink to read/change parameters
Cascadia SERVICETRAININGACADEMY.COM SG 1-11 i-6

Introduction
i
Course Learning Objectives (continued)
Module 7—Troubleshooting
Use of ServicePro and ServiceLink to troubleshoot electronic problems

Understand correct procedures to diagnose potential problems
Understand the proper tools to use when diagnosing a concern

Cascadia Overview
Module 1 Objectives
Exercise 1.1 ECUs and Components ....... 1-13
A. Identify the different Cascadia mod-
els Module 1 Review ....................................... 1-16
B. Identify Electronics specific to Cas-

cadia. 1
Cascadia SERVICETRAININGACADEMY.COM SG 1-1 1-1

Cascadia Overview
Module 1 – Cascadia Overview •Note that this uses fuses, relays, and
FETs in the PDMs (SAM Cab, SAM
This module is a worksheet/discussion Chassis)
•(Keep each topic at a high level over- •Multiplexed wiring
view, stress that each technical subject
will be discussed in depth during the •Additional CAN data buss
course)
•Multiplexed switching
1
The following bullet points is intend as
talking points for a shop walk around, if
the instructor wants to do so
The Cascadia is more aerodynamic

than the Century / Columbia models.
Point out the following on the truck as

you walk around it.
•Hidden door hinges
•More robust door
•Larger interior
•Larger seats
•Sam Chassis location
•Hydraulic Clutch
•Improved HVAC performance
•Show large condenser
•Improved sleeper HVAC unit location
•Power Distribution
•MFJB, MGJB, optional load cut off

switch (not a battery disconnect switch)
1-2 SERVICETRAININGACADEMY.COM Cascadia

Cascadia Overview
Cascadia Models
189.1”
72 inch Sleeper
177.3”
60 inch Sleeper
165.5”
48 inch Sleeper
126.1”
Day Cab
118.5”
Raised Roof
1
93.9”
XT Mid-Roof
77.3”
Day Cab
10-3/16" Rail
49.2"
113″ DAY CAB

125″ DAY CAB
113″ SLEEPERCAB
125″ SLEEPERCAB
Class 7 – 26,001 lb. to 33,000 lb.
Class 8 – 33,001 lb. and over

Cascadia Overview
This is a Shock / Awe Slide
This what make a Cascadia unique
Do not Dwell on slide

From: Cascadia Troubleshooting Manual, August 2007 G02.02/5
Optional: Have student color the lines that depict the data links. Have students write
this information on the page below the legend.
1 Sub-bus – red
Cabin CAN – light blue
Diagnostic CAN – brown
J1939 – green
J1708/J1587 - orange
Drawing from Page G02.02/5

Cascadia Overview
Cascadia Electronic Architecture

Cascadia Network Topology
Diagnostic CAN
Central Gateway
(500kbps)
SAE J1708
(9.6kbps)
1
SAM Cab
Cabin CAN SAE J1939
(125kbps) (250kbps) Engine Control
Module
SAM Chassis
Pneumatic ABS
Module
Modular Switch
Field (Master)
Transmission
Control Module
Sub Bus
Slave Switch Steering Wheel

Instrument
Control Panels Switches
Cluster
HVAC Control
Stalk Switch Switches Front
Head Lamp
(Steering
Switch
Column)
HVAC Control
Switches Rear
Standard
Radio
Optional
VORAD
Engine Display
Qualcomm
07/02/2007 f040753

Cascadia Overview
Cover notes on slide
Introduce ECUs—brief overview
Module 2 provides detailed information on Power Distribution.
Point out load cut-off switch in diagram.

Cascadia Overview
Power Distribution
Power Distribution block diagram
MFJB - MEGA™ Fuse Junction Block

MGJB - Main Ground Junction Block
Load Cut-off Switch
Powertrain PDM
Power Distribution Modules (PDM) contained in SAMs
Auxiliary PDMs, depending on options.

Cascadia Overview
SAM Located in dash on passages side of cab
Houses a number of fuses, relays and FET’s
Is an ECU that controls many of the cab functions
inputs are switches, sensors and Datalink messages
1 outputs are lights, motors and solenoids
Is part of the Multiplexed Electrical System
Software flashed (i.e. reprogrammed) using ServiceLink
Parameters that can be viewed or changed for vehicle configuration
Communicates with Chassis SAM Module, Gateway Module, MSF (Modular Switch
Field) via CAN Data Link

Cascadia Overview
SAM - Cab Module "Signal detection and Actuation Module"
SAM Located in dash on passengers side of cab

Houses fuses, relays and FETs
SAM cab controls most cab functions
Communicates with other modules via CAN datalink

Cascadia Overview
SAM Located under the hood on the front bulkhead, drivers side next to the steering
shaft
Houses a number of fuses, relays and FET’s Is an ECU that controls many of the chas-
sis functions inputs are switches, sensors and Datalink messages outputs are lights,
motors and solenoids
Is part of the Multiplexed Electrical System
1
Software flashed (i.e. reprogrammed) using ServiceLink
Parameters that can be viewed or changed for vehicle configuration
Communicates with Chassis SAM Module, Gateway Module, MSF (Modular Switch
Field) via CAN Data Link

Cascadia Overview
SAM - Chassis Module "Signal detection and Actuation Module"
SAM Located under hood on the front bulkhead on the drivers side of cab
Houses fuses, relays and FETs
SAM chassis controls most chassis functions
Communicates with other modules via CAN
Part of Multiplexed Electrical System

Cascadia Overview
Optional:
Have students color in lines to match the key using the same colors as on the elec-
tronic architecture page.
Cabin can = light blue.
Sub-bus = red
Wire (hard) = black

1

Cascadia Overview
MSF (Modular Switch Field)

MSF Master is also referred to as the "MSF Master ECU" or "Master Control Panel
(MCP)".
(black) 1
(black)
(red)
(black)
(blue)
(blue)
(red)
(black)
MSF Master (ECU) - connected to CAN data link through Starpoint connector
MSF Slave panels - uses a proprietary sub-bus Datalink
Hardwire input to MSF Master
stalk switch
rotary switch
steering wheel switches

Cascadia Overview
Current CGW will not compatible with 2010.
New unit will be either SGW (simplified gateway) or CGW depending on how it is pro-
grammed (flashed with ServiceLInk)

Cascadia Overview
Central Gateway or (CGW) Gateway Module
Located under the dash on the dog house.
CGW acts as a translator and router between the CAN, J1939 and J1587
Is the interface between ServiceLink and the CAN ECU’s
Software can be flashed (i.e. reprogrammed) using ServiceLink

Cascadia Overview
Cover notes on slide.
Cabin CAN ECUs + Starpoint connector.

Cascadia Overview
Starpoint Connector
Located under the dash on doghouse.
Connects the Cabin CAN ECUs to the CAN Datalink
Has a 60 ohm resistor across data bus legs
Has capacity to connect six CAN network components

Cascadia Overview
Common Powertrain Controller Serial AJ1791
Module 283 Drawing G06-61495 Shows OEM supplied Electrical Cab Engine circuits
for Engine MCM and Vehicle CPC. Questions ask about different circuits on page.
Need to confirm that this simple drawing is going to work with the Cascadia. Steve may
look for something that is more accurate. Not multiplexed though.

Cascadia Overview
CPC Common Powertrain Controller
Simplified drawing of CPC inputs and outputs. Not representative of a Cascadia multiplexed system.

Cascadia Overview
1) The ACM is a completely new module to the system. It will control and monitor all the 2010
engine’s aftertreatment related sensors, actuators, and general operations. It is mounted to the
vehicle frame enclosed in a box.
2) The MCM2 is the next generation of engine controller. It will control and monitor all the en-
gine functions it has in the past with the exception of aftertreatment components. It is mounted
on the engine.
1
3) The CPC2+ will oversee all vehicle related activity. It will interact with the MCM2 and ACM via
a dedicated CAN connection and interface with all the other electronic control modules on the
vehicle using J-1939 communications. The CPC2+ is mounted in the cab.

Cascadia Overview
2010 Electronic Control Modules

1. Aftertreatment Control Module
(ACM) – shown in e-tools as
ACM02T
2. Motor Control Module 2 (MCM2) –

shown in e-tools as MCM02T
3. Common Powertrain Controller 2+

(CPC2+) – shown in e-tools as
CPC02T

Cascadia Overview
Vehicle speed will be limited to 5 mph once one of the following conditions occur:
- Fuel tank is refilled by more than 30% (restart not required)
- Engine consumes 350 gallons of fuel and is re-started

Cascadia Overview
Fuel / DEF gauge readings and vehicle behavior

Cascadia Overview
Add tags for 2010 engine vehicle components

Cascadia Overview
Exercise 1.1 ECUs and Components

Your instructor will break the class into 3 groups. Each group will be assigned to a
truck or simulator. Your group will be provided with 22 tags with ECU or component
names on them.
You will work together to attach the tags to the proper ECU or component. You will
have 15 minutes to identify the ECU/components.
At the end of 15 minutes you will rotate to a different truck/simulator and see what one
of the other groups have identified. After 5 minutes you will rotate again so that you see 1
what both other groups have done.
After another 5 minutes you will be given 5 minutes to re-adjust your original tags, if
necessary.
At the end of this time, a spokesman from your group will go through your truck/
simulator and point out each tag and ECU/component. This will be done for each
group.
When all groups are finished, your group will remove the tags and return them to the
instructor.

Cascadia Overview
Briefly review ECUs and components.
Answer any questions relevant to Cascadia and these ECUs.
Instructor can add components to this list that are options that the technician may have
trouble identifying.

Cascadia Overview
Review ECUs and Components
h. Antilock Brakes System Con-

a. SAM Cab
troller (ABS)
i. MFJB (MEGA™ Fuse Junction
b. SAM Chassis
Block)
j. CPC (Common Powertrain
c. Central Gateway
Controller)
d. MSF (Modular Switch Field)
Master
k. MCM (Motor Control Module)
used with DD15 ,DD13, 60S
1
e. MSF (Modular Switch Field ) l. ACM (Aftertreatment Control
Slave Module)
m. PNDB (Powernet Distribution
f. Starpoint connector
Box)
g. HVAC Front Controller n.

Cascadia Overview
Module 1 – Cascadia Overview Review
Review objectives
A. The student will be able to identify the different Cascadia models
B. Identify Electronic specific to Cascadia.
Note: That students will build on this modules.
1 The modules to following cover technical subjects in greater depth during the course
Answers for the review question can be found on the following pages per SG or IG
book.
Answer. SG page IG page
1. 1-2 1-3
2. 1-7, 9 1-13,17
3. 1-4 1-7
4. 1-5 1-9
5. 1-7 1-13

Cascadia Overview
Review Questions
1. What are the two current Day Cab version available?
113― and 125― Bumper to Back or Cab
2. What data link is the Star point connector connected to?
Cabin CAN
3. What is the purpose of the Load Cut –off Switch?

1
Shut off battery power to keep battery from draining
4. Where is the SAM Cabin located?
In the dash on the passenger side of cab.
5. Circle the name of the component below that is a hard wired input to the MSF Mas-
ter.
Starpoint Connector or Rotary Switch or MSF slave panels

__________

Cascadia Overview

Cascadia Overview
Module 1 Review
The student will be able to:
a. Identify the different Cascadia models

b. Identify Electronics specific to Cascadia.

Cascadia Overview
Do
NOT
DELETE
1 INTENTIONALLY
LEFT
Blank

Power Distribution
Module 2 Objectives
Exercise 2.1 Emergency Power ................ 2-13
A. Describe MFJB (MEGA Fuse Junc-
tion Block) and MGJB (Main Worksheet Standard Wiring Colors............ 2-15
Ground Junction Block)
Module 2 Review ....................................... 2-18
B. Describe ground cable return to
batteries
C. Describe battery shut-off switch

change to the power side 2
D. List circuits protected by Powertrain
PDM
E. Identify power distribution circuits
F. Identify emergency power re-

sponses
G. Identify Power Distribution changes

for EPA 2010 (PNDB / PTPDM)

Power Distribution
Use PPT notes pages in slides to cover this section
Power Distribution Drawing:
Slides 1 and 2 see detailed notes in PPT.
Do not cover emergency power or PLVD (LVD) in too much detail at this time.
Emergency power will be covered later in greater detail in this module.

PLVD (LVD) has been moved to module 5 to be covered prior to LVD shop Ser-
viceLink exercise.
Standard Power Distribution Optional Power Distribution

Components Components
Load Cut-off Switch Trailer PDM
MFJB - MEGA™ Fuse Junction Block Inverter
MGJB - Main Ground Junction Block Auxiliary PDMs
Powertrain PDM on all 2007 chassis Body Builder connector
SAM Cab SAM Cab and Sam Chassis

midline and highline levels only
SAM Chassis

Power Distribution
Power Distribution Components
Alt output DD15
Power Distribution block diagram

Power Distribution
Cover notes on slide
Power Net Distribution Box (PNDB) and Switch turn on/off loads plus works to maintain
power for EPA 2010 components for purging DEF fluid from pump and lines

Power Distribution
2010 Updates
Notes:

Power Distribution
The purpose of the PNDB is:
Keep the aftertreatment ECU alive for 5 minutes for purge cycle
This will keep material from freezing inside the pump and lines
Keeps the DPF Fluid from dehydrating
General Information
The Powernet Distribution Box (PNDB) provides up to 4 circuits that are powered even
when the Cab Load Disconnect Switch (CLDS) is in the off position. The PNDB also
provides up to 3 high amperage circuits that are switched on and off with the CLDS.
2 Single switch will have one connector on the bottom
Dual switch will have two connector on the bottom

Power Distribution
The Powernet Distribution Box (PNDB)

Located on the cab frontwall near the steering
column
Supplies power to:
Powertrain PDM
Aftertreatment control module (ACM)
Main PDM (SAM Cab, Chassis - Cascadia)
Also several cab loads including the clock.
2
An optional load disconnect switch.
Triggers the PNDB to turn On/Off

power to:
Powertrain PDM, cab power
ACM after DEF purge has been com-
pleted.
Keeps-alive circuits for the clock and
the emergency power to stay active
Primary module 293
Single or dual switch design.
An optional additional PNDB is used to power any of the following:
Qualcomm, Trailer end-of frame connection, Shore power inverter, and Body builder
PDM.

Power Distribution
Version may differ between models of trucks
Expand on this with examples
Add source material per Mod 33P / A06- 75148

Power Distribution
PNDB Cover Decal Information
Notes:

Power Distribution
Instructor Notes
Information on the PNDB will be in the Powernet Management section of the Cascadia
TM under the Cab group
Single versus the dual and why we have one or the other.
Single switch will have one electrical connector on the bottom.
•Connects to the Main PNDB
Dual switch will have two electrical connectors on the bottom
2 •The second connector connect to the Auxiliary PNDB.
This switch is not a load carrying device. It request the PNDB to turn on or shut off cir-
cuits
Single P/N A06-72623-000 Dual P/N A06-72624-000
P/N may change
See drawings in Print Pack

Power Distribution
PNDB – CLDS Schematic (Cascadia TM C06.09)

Primary Powernet Distribution Box
HAF1
1
Fuse 1 Power Train PDM
175A
Fuse 2
HAF2
125A SAM Chassis
Fuse 3 HAF3
175A Sam Cab
BAT1
Battery Feed Battery
Fuse A A
30A 1 Keep Alive, Output #1 After Treatment System ECU
Fuse B
20A
B 2 Keep Alive, Output #2 SAM Cab Emergency Power
Fuse C
5A 3 Keep Alive, Output #3 Radio/Clock
Fuse D
5A 4 Keep Alive, Output #4 Alternator Remote Sense
Cab Load
Disconnect
Switch Dual
5 Signal Return Signal Return 2
4 Signal On Signal On 1
2 Signal Off Signal Off 4
3 LED Indication LED Indication 3
6
2
1 Ground Main Ground Junction Block
LED Indication 3
Signal Off 2
Signal Return 1
Secondary Powernet Distribution Box (Optional)

HAF3
Fuse 3
125A
Fuse 2
HAF2
150A Body Builder
Fuse 1
HAF1
200A Shore Power Inverter
BAT1
Battery Feed Battery
Fuse A
A
30A 1 Keep Alive, Output #1
Fuse B
30A
B 2 Keep Alive, Output #2
Fuse C
5A 3 Keep Alive, Output #3 Not Used
Fuse D
20A 4 Keep Alive, Output #4 QualComm
1
4
6
PNDB - CLDS Schema
(Cascadia TM C06.06)
3 LED Indication
2 Signal Off
5 Signal Return
06/11/2010 f5
802 — Primary and Secondary Powernet Distribution Box
Notes:

Power Distribution
A enlarged copy of this drawing is in the print pack if need to help explain the operation
of the PNDB and CLDS
P3 2010 Day cab Ser# AS1318
Have student look up drawing per Mod/Ser#
Drawing PNDB – CLDS Schematic (Cascadia TM C06.09)
This slide will need to be update when the Cascadia TM/WSM is updated with PNDB
information
See drawings in Print Pack
2 Drawing G06-73316 WRG-BAT, Low Voltage DISC (PNDB)

Power Distribution
PNDB Troubleshooting
When the Cab Load Disconnect Switch (CLDS) is in the on position, an LED on the
switch and another on the PNDB will be illuminated. If there is an error with the PNDB,
the LED will flash at a ½ second rate. The PNDB will make a double flash if it was not
able to switch on or off when commanded by the CLDS.
If any of the fuses are open, conventional troubleshooting methods need to be used.
The LED’s in the PNDB and switch are not affected by open fuses or load circuits.
LED on Cab Load Disconnect Switch (CLDS) is Flashing
Step Test Procedure Test Action

2
Result
1 Does the LED make a Yes The PNDB failed to switch itself
double flash for 5 sec- on or off when commanded by the
onds when the switch is switch. Replace a defective PNDB
first turned on or off?
No Inspect the connectors in the in-
terconnect harness between the
PNDB and the cab load discon-
nect switch (CLDS). If either was
not correctly seated or there is
corrosion in the connections,
clean and reconnect. Otherwise,
continue with step 2.
2 Measure continuity on Yes Repair the wiring fault as appropri-

the harness between ate.
the PNDB and the
CLDS. Are any of the No Substitute a good CLDS to check
circuits open or shorted if this repair the problem. Other-
to ground? wise replace the PNDB.

Power Distribution
Instructor notes:
Fuse 1-6 IGN power
Fuse 7-12 Battery Power
Explain that figure 6, Powertrain PDM is a view of pin connectors not fuses and relays.
Limited schematics available presently but refer to high level connections reference fig-
ure 1, PDM Diagram.
Added note:
MEIIR stands for Momentary Engine Ignition Interrupt Relay. It is used on vehicles
equipped with a Fuller Ultra-Shift transmission. It is used to break torque when the nor-
2 mal method (blipping the throttle via J-1939) doesn't work. It is also used if the centrifu-
gal clutch is having trouble disengaging (coming up to a stop sign) as breaking torque
may help.
See print pack for drawing A06-64611 #2

Power Distribution
PT-PDM Fuse and Relay Locations

Located on the Driver side cab frontwall / inner fender near the steering column
Supplies IGN and Battery power to:
a. Engine ECU’s
b. Transmission ECU’
c. Powertrain related components
Supplies fuse and relays for:
a. Engine and Transmission related options
Found in PartsPro Mod 286

Power Distribution
Instructor notes: 2010 changes.
PartsPro look in module 286 and find installation drawings and PDM drawings.
2010 PTPDM drawing in Print Pack #3A and #3B
A06-74514
D06-75316-000 In PPT show installation of: PTPDM, PNDB, battery cable routing
Instructor notes:
Example Serial # AS1318 for EPA 2010

Power Distribution
EPA 2010 change to Cascadia PT-PDM

Change in fuses and relay locations
a. SAM Cabin Emergency Power / LVD sense fuse (F7) will move to PNDB
b. Alternator sense will have it own fuse in PNDB.
Hinge Cover

Power Distribution
Note: SB 54-222
Have students locate SB to get this information. It applies to Cascadia and anything
2007.
Find SB54-55 for corrosion protection.
SB are in the link material folder of the PPT.

Power Distribution
Intermittent Loss Of Vehicle Power Due To Mega Fuse Failure
Fusible link broke off of terminals.
Staked fuses increase

copper terminal stiffness
Corrosion can be a problem in this area

Power Distribution
Optional—Point out that PowerNet management (PLVD) is an optional and can be
turned off.
LVD function tables are on page 3.5 –3.6
Slides 15-16 —Instructor notes:
F6 is a 20 amp fuse
IGN relay is 70 amp relay and is R6 in the PTPDM
See slide 52 for relay and fuse location in the PTPDM
Drawings that show emergency power are in the print pack.
2 G06-64121 (modified version in Print Pack and reference here in class)

4A and 4B
G06-61495
5A and 5B
See instructor appendix for modifications needed for the drawings.
Use drawing as needed if questions come up on where the source power come from
for emergency power
Both drawings need to be shown to shown the complete circuit.
Both drawings have inconsistencies and must be corrected
See corrected drawing example in print pack
Point out to MEIR on drawing G06-61495

Power Distribution
Emergency Power
The emergency power feature provides basic functionality to the SAM during the fol-
lowing failure modes:
Power Failure: Loss of main power supply to SAM Cab or SAM Chassis.
SAM Microprocessor Failure: Loss of function of the main microprocessor due to
microprocessor component failure, or memory damage.
CAN Communication Failure: Cabin CAN communication failure between the
SAM Cab and SAM Chassis due to a damaged cable, loose connections, appli-
cation failure, or damage to a transceiver.
Notes:
2

Power Distribution
Review names of exterior light identification for the upcoming exercise.

Power Distribution

Power Distribution
Note:
The lights that are activated during emergency power failure may not be the same for
all trucks because of hard ware, soft ware, and programmable parameters.
Instructor Demo loss of Cabin Can to SAM Cab and Chassis. Make sure that student
knows how to check the ignition relay in the Powertrain PDM for power up:
Clicks when the key is turned on

Relay will be warm if the relay coil is energized
Add details for showing a bad communications in cabin CAN :
2 Remove connector X1? SAM Chassis.

a. Observe results and plug back in
b. Results are it goes into emergency power (loss of communication)
Remove Connector X 13 SAM Cab
a. Observe results and plug back in
b. Results are it won’t go into emergency power because it does not see
ignition signal on from key switch
c. Remove Pins for Cabin CAN high and low one at a time.
d. Each one will give you loss of communication going into emergency
power
Results depend on what SAM and which Cabin CAN wire were removed.

Power Distribution
Exercise 2.1 Emergency Power Symptom Tables

Your instructor will break the class into three groups and you will be assigned to a truck
or simulator. You will cut the power to components as described below. All tests are
with the ignition switch in the ON position.
1. Remove the Mega fuse that feeds power to the SAM cab. Record your response on
the chart below.
2. Replace the SAM cab Mega fuse and remove the Mega fuse feeds power to the
SAM chassis. Record your response on the chart below.
Flashing
3. Replace the SAM chassis Mega fuse and turn off the load cut-off switch. Record
your response on the chart below.

Power Distribution
Student Notes
2-26 SERVICETRAININGACADEMY.COM SG 2-14 Cascadia

Power Distribution
Standard Wiring Color Coding

Power Distribution
Information on color coded wire used on the Cascadia can be found in the:
Cascadia WM 54.06 400/1

Note: circuit number table has module numbers per circuit number listed
(This information will be published September 2010)
Explain why we use color codes.
For optional reference material:
49-00097 Freightliner/SAE circuit Numbers

Sterling Service Bulletin 54-27

Power Distribution
WORKSHEET - STANDARD WIRING COLOR CODING

Using the table on page 2-14, answer the following:
What color of wire corresponds to the following typical usage column: write down the
color from the table, for typical usage in your book.
blue LT
red
Green LT
Red-white 2
brown
Green DK

Power Distribution
Information found on G06-73316 on wire sizes used on the Cascadia can be found in
the:
Wire size table

Wire color
Connector Reference Identifier
Terminal position
Wire size
Freightliner wire #
SAE wire #
Component name
Powertrain PDM
2 Fuse D / fuse amp rating

SAM Chassis
Write out steps for finding terminals in the new A06 drawings if students need this infor-
mation. Use the examples on the page. Use the connector part numbers as shown in
the drawing as a starting point.
Optional:
This page can be used to review new a06 drawings if the student needs a review. Ex-
plain or demonstrate how to find terminals using information from this page and EZWir-
ing.

Power Distribution
Standard Wire Sizes

Power Distribution
Objective - Following the completion of this worksheet you will be able to:
A.Identify circuits that are protected by the ETPDM.
Add page number for answers in student guide????
Give students 3 minutes per question, give hints as needed.
book.
1. 2-2 2-3
2 2. 2-8 2-15
3. 2-11 2-21
4. 2-4,5 2-7, 9
5. 2-7 2-13

Power Distribution

Using the power distribution system schematics, answer the following questions:
1. State the main wiring enhancements that contribute to lower voltage loss to
systems.
MFJB, MFGB; Battery moved closer to starter, shorter cable lengths.
2. The Powertrain PDM provides battery and ignition power to:
Engine Electrical Module, Transmission (TCU), Aftertreatment device (ATD)
3. What symptoms will a driver see if a SAM Cab MEGA™ fuse blows while vehi-
cle is in operation?
2
Emergency Power Mode: Turns on and flashes lights so the vehicle can
be driven off the highway and kept conspicuous until help arrives
4. PNDB can hold how many MEGA fuse?
5. What happen if the PNDB is not able to switch on or off when commanded by
the CLDS.
The PNDB will make a double flash of its LED

Power Distribution

Power Distribution
Module 2 Review:
Student will be able to:
a. Describe MFJB (MEGA Fuse Junction Block) and MGJB (Main Ground
Junction Block)
b. Describe ground cable return to batteries
c. Describe battery shut-off switch change to the power side
d. List circuits protected by Powertrain PDM
e. Identify power distribution circuits
f. Identify emergency power responses
g. Identify Power Distribution changes for EPA 2010 (PNDB / PTPDM)
2

Power Distribution

Cascadia Electronic Modules
Module 3 Objectives
Exercise 3.1 Observing FET short circuit protec-
A. Explain purpose of Signal detection tion ............................................................... 3-5
& Activation Modules (SAMs).
Worksheet Electronic Modules .................. 3-11
B. Explain purpose and functionality of
Modular Switch Field (MSF) com- Exercise 3.2 SAM Outputs and SAM Inputs
ponents.
.................................................................. 3-13
C. Explain purpose of the Central
Gateway module. Module 3 Review ....................................... 3-21

Have Service Bulletins handy when questions come up and to help explain updates to
SAM software.
Go over the SAM’s in very general terms
Have hand out examples or take the students out to the boards, or have one in the
classroom
It wouldn’t hurt to draw the old input-control-output on the board stressing that the SAM
is the control
Go over bullets
Like the BHM and CHM on an M2, the SAM Cab and SAM Chassis control the basic
electrical devices on the truck.
—See service Bulletins 54-230 and 54-231 regarding different hardware levels of
SAM’s
3

Signal detection & Actuation Module - SAM

The Cascadia has two SAMs
SAMs contain:
Circuit protection and relays
Both contain ECUs that control vehicle electrical system
ECUs are connected by a data link
Uses Inputs from Switches or Data
Some Outputs are FET controlled
SAM’s are available in different hardware levels:
Highline
Midline
Baseline.
Must be replaced with like hardware level

Go over talking points
Note that all SAM unfused outputs are really protected by the FETs even though they
say unfused
A MUX input would be via datalink

SAM Internal Wiring Schematic

SAMs use Field Effect Transistors ( FETs)
FETs and the SAM processor are used to protect and control circuits
Cascadia SAMs use relays and fuses in addition to the FETs.
FETs are located inside the processor of the SAMs

Go over bullets on slide
SAM’s are similar to the Bulkhead Module and Chassis Module on the M2
Outputs – FET controlled
Like the BHM and CHM on an M2, the SAM Cab and SAM Chassis control the basic
electrical devices on the truck.
Mention that when a FET is overloaded it shuts down, but will turn back on when the
excess load is removed.
Some FETs will cycle 3 times while others will cycle 5.
When a FET opens due to high amperage it remains open until SAM see a change in
transition. Ex: headlamp goes out due to FET. Attempts to light lamp 5xs before it
stops the change in transition would be change in headlamp switch position.

FET – Field Effect Transistor
(source) (drain)
(gate)
Most SAM outputs are FET Controlled
Solid state device (semi-conductor) 3

Acts much like a relay and circuit breaker
Uses low current to control high current
Works with logic circuits to limit current load
Shuts high current circuit off when load is exceeded

Instructor Notes
Make sure that the truck that you are doing the Demo on has 5.2 or higher software,
see note on slide.
Prepare for this Demo by have the following tool available:
DMM set volts

DMM set Amps (AMP Clamp)
Carbon pile Load bank
Review Legend
1. Unhook electrical harness at Left Hand High beam light.
2. install voltmeter on the red lead, by back probing the connector on the green wire.
Ground the meter black lead at the Sam Chassis ground stud.
3 3. connect a carbon pile load bank or a fused wire lead with a 30 amp fuse into the re-
moved
Left Hand High beam light connector.
4. place an amp clamp over the green wire or the carbon pile lead or fused wire lead.
Have student fill in the question during the Demo.
Note; FETS are rated in watts (V x A). If the volts drop during a demonstration
the amount of amps will go up above the value listed.
Make sure you do this on the left hand high beam circuit.

Exercise 3.1
Observing FET short circuit protection: SAM Cab Headlight
Note: Only perform this exercise on trucks with 5.2 or higher software.
1. The following are the values for the Left Hand High Beam Light:
Nominal Load Current 4.8 AMPS
Maximum Allowable Continuous Current 6.48 AMPS
Maximum Current (at which power is shut off) 10.3 AMPS
2. As the instructor demonstrates the operation of a FET, record DMM voltage reading:
Should see battery voltage
The DMM voltage reading is: ________________________
3. As the instructor demonstrates excessive load or shorted wire:
Highest observed Amp reading: 9 to 10 amps 3

Record the last DMM voltage reading before the circuit shut off: 12-14V
lights flashed 5 times at 5 seconds apart as the
Observation of the head lights: ____________________________________________
SAM tried to turn on the left high beam light
4. Observe what happens when the load and jumper are removed and the head light
High beam connector is reconnected.
Did the light come back on? (Circle one) Yes or No

___
If no, what needs to happen to make the light come back on?
Turn the head light switch off and back on, SAM will try to turn on light again.
IF current draw is ok, light come on, if too high another 5 tries, 5 seconds apart.

Go over bullets.
Put terms and circuit description from bottom of wall chart in the student book.
All SAM outputs have return ground paths.
Looking at a portion of the drawing

(rotated for clarity) we can see:
Top – 12V and Ground
The N.O. and N.C. relays shown are controlled by FETs inside the SAM processor
FETs located inside the processor of the SAMs can be:
Outputs for loads

grounds for loads
Control ground for relays
3 Logic Controlled, Relayed, Fused Outputs
Looking at a portion of the drawing (rotated for clarity) we can see
Look at the first relay, here are the things to note:
Power to the relay control circuit comes from the Relay Control fuse
Power to the contact points comes from the 12V power source
There is a fuse in the output wire from the relay
The control circuit must be grounded from inside the SAM processor
The ground circuit for the relay is controlled by a FET in the SAM processor

Wall chart Relay Notes:
SAM Chassis 704 — Fused and Relayed Outputs
Note: R1
Terms added or different from Wall Chart will be in Note: R3
(parenthesis) Terminal 85 Ground
Terminal 86 Power
All other relays:
Terminal 85 Power
Terminal 86 Ground
7A

Drawing in Cascadia TM G02.05/17
Unfused constant output – these are a pass through in the processor

Logic Controlled Unfused Outputs – these are controlled by FET’s inside the
processor just like an M2
SAM Inputs – switches or data
Grounded pins – a path to the main ground
SAM Chassis input x5/3-Hardwired ISS Chas = Ignition Switch Signal used for
Sam Chassis’ ignition switch key position for emergency power
Fused Pass through direct from the 12V feed.

SAM Chassis 705 Unfused Outputs, Grounded Pins, and Inputs

Terms added or different from Wall Chart will be in (parenthesis)
7B

SAM Inputs – switches or data;

a. Not listed separately X1-X17 are inside the cab X18-X21 are outside the
cab.
Ground pins broken into inside the cab and outside the cab
a. X1-X17 are inside the cab
b. X18-X21 are ground pins outside the cab
Grounded pins – a path to the main ground

SAM Cab 704 — Grounded Pins and Inputs

7C

Un-fused constant outputs (BAT) – these are a pass through in the processor
Logic Controlled Unfused Outputs – these are controlled by FET’s inside the
processor j
Fused battery pass-thrus
Outputs for loads

grounds for loads

SAM Cab 705 — Fused and FET Controlled Outputs

7D

The N.O. and N.C. relays shown are controlled by FETs inside the SAM processor
Control ground for relays
Look at the first relay, here are the things to note:
Power to the relay control circuit comes from the Relay Control fuse
Power to the contact points comes from the 12V power source
There is a fuse in the output wire from the relay
The control circuit must be grounded from inside the SAM processor
The ground circuit for the relay is controlled by a FET in the SAM processor
3 Note R7 relay, fuse 23, (15A)

This circuit has multiple outputs and anyone could be a short causing fuse to
blow.,

SAM Cab 706—Relayed Outputs

7E

Use the drawings in the print pack or workshop manual to answer the following ques-
tions.
Optional: Split classes into two groups and do this exercise as a live demonstration

WORKSHEET - ELECTRONIC MODULES

Explain the function of SAMs.
Using the SAM drawings, answer the following questions:
1. What will happen if fuse F29 in the SAM Cab blows?

None of the SAM Cab relays will operate
2. Will this cause all relay controlled outputs to shut off? (Circle one) Yes or `__
No
If no, why not?

Some are wired through the NC contacts
3. Where does the ignition switch receive its power? (connector/pin type of power)
X13 pin 7, unfused constant outputs
4. How does the SAM Cab know if the ignition switch is turned to on? (connector/pin 3
type of signal)
X13 pin 6, input pins
5. What happens if fuse F10 in the SAM Chassis blows?

Only R9 will still be able to operate
6. Will this cause all relay controlled outputs to shut off? (Circle one) Yes or No
___
7. If no, why not?

R8 may still power F14 if NC relay is used; R9 power and ground is controlled by the internal
SAM PC board
8. Where does the ABS module receive its power? (connector/pin type of power)
X52 pin 7, X52 pin 4, Fused battery passthroughs
a. Fused ______________________________________________________
X52 pin 6, IGN logic controlled, relayed, fused outputs
b. IGN ______________________________________________________
9. Why are there two different relays possible for Relay 8 in the Sam Chassis?
It depends if you want trailer power to be constant or ign. Controlled
IGN – NO type relay / Constant Battery - NC type relay

Develop a slide that will show the signals.
Any software level prior to 5.4 will see a 25-50%. Anything after 5.4 will show
50% duty cycles.
Chopped means the output is not a steady voltage can be:
an on/off signal at approximately a 25% duty cycle. 5hz

an on/off signal at approximately a 50% duty cycle. 10hz
the signal will be on 25 or 50% of the time per cycle
A chopped signal is used so an ECU can monitor a switch, example:
a switch in closed position the feedback return signal is detected

if the return signal was the same chopped wave from the output, the SAM would
know it was a good signal.
if the return signal was a constant 12V, the SAM would know the circuit is
shorted to power
3 The SAM also uses a straight 12 volt power, (output) to the normally open (NO) switch.
Depressing switch sends 12 volt power back to SAM as an input.
The SAM responds to the 12 volt input (feed back) by powering the electric horn
In PPT ADD SQUARE QAVE TO EXPLAIN THIS
HVAC pressure transducer for switch open, switch will have to be removed from the
system or have a spare switch not plugged into system connected to the harness.
50% 50%
On Off
50% 50%
On Off

Signal Types
Chopped signal 5 Hertz / 25% Duty Cycle
Chopped signal 10 Hertz / 50% Duty Cycle
12 Volt signal
3
5 Volt reference signal

Use the drawings in the print pack or workshop manual to answer the following ques-
tions.
Fill out in two parts.
For testing the HVAC pressure transducer
Open voltage would be with the harness remove from transducer.

Close voltage would be with the harness connected in the transducer.

Exercise 3.2 SAM Output and SAM Inputs

Using the SAM drawings/ Wall Chart to fill in the connector/pin columns:
When finished go to a truck/simulator and check voltages, write results in columns.
X13/11
X13/10
X59/1
X59/3
3
X6/18
X13/13
Output HVAC Pressure trans- X19/17

X19/17
ducer supply
Input HVAC Pressure trans- X19/10
X19/10
ducer feedback
GND HVAC Pressure trans- X19/12

X19/12
ducer return

Comes with a fuse relay removal tool.
Fuse 14 is 2 position fuse for battery power without LVD or LVD protect to communica-
tions devices circuits (CB Radio)
See SB54-255 Cascadia Electrical System Update 2010.5 Pre-Series Vehicle Informa-
tion.
In PPT Link Materials

SAM Cabin 6.0 hardware:

Maintain same foot print
Wiring stay mostly the same
Uses 6.0 software level
Not backwards compatible with
current 5.4 SAM’s
No plan to upgrade current 5.4 level
Cascadia’s
Working on 6.1 software to make
backward compatible
Fuse 14 two position fuse for either:
Battery power without LVD or LVD pro-
tect to communication device circuits.
(CB radios)
Uses Bi-Stable relay
Control circuit trips On/Off
Will not draw battery down during LVD 3
Fuse F14 in the #1 (left) position, battery power with LVD protection
Fuse F14 in the #2 (right) position, battery power without LVD protection

Demo:
9 volt battery across terminal 2-3 or 2-1 will cause relay to trip to opposite states.
Part number 06-71082-000 (subject to change). See SB54-255

Bi-Stable Relay – NO/NC depend on trip state of control circuit
Terminal Position/Function
3

Instructor Notes
Step 4: request failed
Do not have source for this drawing.
Wanted state (On)
Operation in the following slides came And
from update information gathered and
is not in WSM. Actual state (Off)
do not agree (ON/Off)
Step 1: No function requested Retry 5 times
to change state (On)
Monitors states (position) between:
If fails 5 retries
Wanted state (Off)
And Sets diagnostic code
Actual state (Off) Monitor actual state (Off)

If Wanted state equals
3 Actual state And wait for new functional request
To verify the fault is fixed or gone historic,

No change of state (Off)
the SAM Cab must see both on/off states.
continues to monitor
similar to what happens with ABS wheel
Step 2: Function requested speed sensor, ABS ECU must see out put
If Wanted state (On) is not equals to of RPM’s from the wheel speed sensor be-
Actual state (Off) fore ABS ECU can confirm the fault has
been repaired.
Looks at state of others relays
If no other relay are changing
states.
Step 3: Acts on request
Trigger a change in state (On)
then looks to see if
Wanted state (On)

And
Actual state (On)

If states agree (On)
Monitors new state

Bi-Stable Relay – Terminal position / operation in SAM

The light switch, turn signal switch and steering wheel switches are similar to the TS
switch in an M2 which is hardwired to the ICU. The MSF then acts like the ICU in an
M2 and sends the switch position out on the databus.
Explain the purpose and functionality of MSF (Modular Actuation Switch Field) compo-
nents.

Modular Switch Field - MSF
Most switches in the Cascadia are part of the Modular Switch Field
The Master ECU is in the 4 way switch

Light switch, stalk switch and steering wheel switches connect via hard wire to
MSF Master
Individual switches are housed in Slave Control Panel (SCP)
There can be up to 9 SCPs
The MSF Master is connected to the SCP’s and their switches via a sub bus
(proprietary data link)
a. Can be ―daisy chained‖
b. Can be direct connection
These switches are not part of the MSF;
a. Horn switch
b. Door switches

Go over bullets
Bullet 3 – the master monitors switch function, i.e., fog lamp, heated mirror, suspension
dump, etc. It even sees the ―hardwired‖ switches, it just can’t tell if they are on or off
Starpoint connector connects all CAN ECU’s, MSF, SAM cab, SAM chassis, CGW
Reference hardwired and MUx switch drawings in print pack for switch ID numbers.
Important: Removing switches must be done while powered down or you can
lock up the sub bus.
A shorted switch will also take the sub bus down.

Modular Switch Field - master/slave
MSF Master and Slave interaction
Connected via sub bus

Two types of Slave switches
a. Signal-Only (multiplexed) or (MUX)
b. Hardwired (load interrupting)
Master monitors the presence of all switches via sub-bus
Master can only monitor switch position on Signal-Only switches via sub-bus
Master communicates with SAMs via Cab CAN
Starpoint Connector connects the MSF Master to the Cab CAN

The CGW can also broadcast that there is a fault detected by one of the CAN ECU’s.
This will be seen on the dash display but only as a generic CAN fault. Also, if there is
more than one CAN fault, the CGW only broadcasts the one that happened first. That
isn’t such a bad thing since the faults it doesn’t broadcast would look like more of the
same. Of course it only broadcasts active faults.
You can only read the actual CAN faults with ServiceLink
2010 note
SGW (Simplified Gateway) will be a stocked part and will flashed to

become a CGW for the Cascadia.

Central Gateway Module - CGW
CGM Interaction
Routes and translates messages between Datalink networks

a. J1587/J1708
b. J1939
c. Cabin CAN
Provides an interface between cabin CAN ECUs and ServiceLink (Diagnostic
CAN)
Provides faults for missing cabin CAN ECUs
2010 CGW will come as a SGW and will be flashed to CGW for use on Cas-
cadia model trucks

book.
1. 3-14 3-27
2. 3-5 3-9
3. 3-14 3-27
4. 3-17 3-33
5. 3-19 3-37

Review Questions
1. What is the benefit of using a Bi-Stable Relay?
Will not draw battery down during LVD
2. What behavior can be seen when a head light circuit is shorted to ground?
SAM Cab will try to energize the circuit 5 times 5 seconds apart and will keep circuit shut off
until circuit is shut off an another request is made to turn it on
3. What is the purpose of the F14 fuse in the 6.0 level SAM Cabin?
Provides LVD or no LVD protection to communication device circuits.
4. Which of the following switches is part of the Modular Switch Field? (circle one)
Headlamp Switch or Horn Switch or Window raise –lower Switch
______________ 3
5. What must happen to a SGW so that will operate on a Cascadia.
Reprogrammed (Flashed) to become a CGW


Module 3 Review
a. Explain purpose of Signal detection & Activation Modules (SAMs).
b. Explain purpose and functionality of Modular Switch Field (MSF) compo-
nents.
c. Explain purpose of the Central Gateway module.


Multiplexing
Module 4 Objectives
Multiplexing/Electronic Systems Operation
A. Explain the basic concept of multi-
plexing .................................................................. 4-10
B. Explain multiplexing for the Cas- Module 4 Review ....................................... 4-18

cadia electrical system.
C. Identify the major components in

the Cascadia multiplexed system.
D. Explain the operation of datalinks

J1587, J1939, Cabin CAN
(Controller Area Network), and Di-
agnostics CAN.
E. Follow the communication between

the J1939 and CAN datalinks.
4

Multiplexing
Go over bullet points
The illustration depicts the Cabin Can data link, don’t go too in-depth with this slide

Multiplexing
Multiplexing
INPUTS OUTPUTS
SAM Cab
INPUTS OUTPUTS
Diagnostic
CAN
Cabin CAN
Central Gate Way
INPUTS SAM Chassis OUTPUTS
(CGW)
J1939
INPUTS OUTPUTS
J1587
Modular Switch
INPUTS OUTPUTS
Field (MSF)
INPUTS OUTPUTS
4
Multiplexed Electrical System
Electrical devices, lamps, gauges, switch outputs – controlled by an ECU

Use data links to send multiple signals to ECUs at tremendous speeds
System can both
a. Perform tasks
b. Monitor components
Communication by Datalinks: decreases total number of wires required.
By connecting switches to ECUs, the ECUs can then share switch information
on the datalink with other ECUs.

Multiplexing
Mention the interchangeability of J1587 and J1708, when they see this in print or on a
drawing it is depicting the same data link
BPS, bits per second, replaces the older term Baud Rate,
We will talk more about the CGW on later slides

Multiplexing
Datalinks – J1587/J1708
Data Links allow ECU’s to communicate
J1587/J1708
4
Low speed – 9600 bps
Twisted pair of wires
Orange/Dark Green
Connected to all ECUs that require this link (some through CGW)
ECU’s share data
Engine transmits a good bit of data
Typically runs dash gauges
Be phased out starting in 2010

Multiplexing
Symptoms of a Malfunctioning J1587
Gauges not working.
ICU displays no J1587, no EnG, or no ABS.
Warning lamp (s) such as ABS or and Check Engine on.
Cannot retrieve fault codes from an ECU.
ServiceLink or DDDL does not connect to vehicle.
One or more ECU’s do not show up on ServiceLink ECU list.
For 2010:
J1587 will be removed from all ECU’s that can function on J1939 without J1587

Multiplexing
Datalink J1587/J1708

Multiplexing
This shouldn’t be new information for most students
Emphasize that J1939 is used where one ECU needs to control another such as the
trans ECU controlling the engine ECU during shifts

Multiplexing
Datalinks – J1939
J1939 Data Link
High speed – 256K bps

Dark Green/Yellow
Backbone architecture
4
Terminating resistors
ECU can broadcast both information and requests
Not all ECUs require J1939
First used widely on automated transmissions

Multiplexing
Note that this drawing isn’t completely correct since it does not show the backbone ar-
chitecture and the terminating resistors.
Symptoms of a Malfunctioning J1939
J1587 fault code indicating problem with J1939.
Autoshift (Eaton) does not function correctly. It reverts to Autoselect mode with an ac-
tive code 35.
See CHECK Engine or ENGINE WARNING indicator is lit.
TRACTION, WHEEL SPIN or ATC indicator is Lit.
ICU displays no Data or no J1939.
ServiceLink does not list any J1939 ECUs
For 2010:
All ICU’s will be connected to J1939 only

Multiplexing
Datalink J1939
Terminating
Resistor #1
SAE J1939-13
9-pin connector
D
E
C
F A B
J
G
H
ENGINE
CONTROL Can Shield (ground)
MODULE
(250kbps)
J1939
PNEUMATIC
ABS
MODULE
TRANSMISSION
CONTROL
MODULE
INSTRUMENT
CLUSTER
4
HVAC CONTROL
SWITCHES · FRONT
HVAC CONTROL
SWITCHES · REAR
Terminating
Resistor #2

Multiplexing
Have the student add the star point connector to the drawing in student book
ServiceLink will be able to connect to the CAN link, but only if they have the USB Link
Note that the Datalink colors are blue and white even though the slide shows blue an
grey, white wouldn’t show up on the slide
Starpoint connector has a 60 ohm load across the CAN High positive buss and CAN
Low negative buss
Sharing of information from Datalink to Datalink is done by the CGW

Multiplexing
Datalinks Cabin CAN
Can Shield (ground)
4
CAN (Controller Area Network)
High speed – 128K bps

Light Blue/White
Proprietary data link
connecting
SAM Cab
SAM Chassis
MFS Master
CGW
Above ECU’s are connected at Starpoint connector with 60 OHMS resistance
Can share information on both J1587/J1708 and J1939
Connect to the CGW so the cabin CAN ECUs can interface with ServiceLink

Multiplexing
Instructor Notes

Multiplexing
Datalinks Diagnostic CAN
Central Gateway
SAE J1939-13
9-pin connector
D
E
C
4
F A B
Diagnostics CAN G
J
(500kbps) H
512k bps
Brown with a blue strip and brown with a white stripe
Connects to CGW diagnostic CAN to diagnostic connector
Note that this is a higher speed than the cabin CAN
CGW houses 60ohms resistance for the Diagnostic CAN
Only active when requested by ServiceLink

Multiplexing
On J1587/J1708, and J1939, the CGW will only route one active fault to the ICU. If
there are multiple active faults on the CAN, the CGW routes only the first fault that oc-
curred. If you connect ServiceLink you will be able to read all active faults because you
connect directly to the CAN.

Multiplexing
Cascadia Network Topology

Multiplexing
At this point have students open their Use brown pencils to draw Diagnostic
books to this worksheet to take notes. CAN data line ____Brown________
Use larger 17 x 14 drawing in the print This slide adds the J1587/J1708 junction
pack to have student draw in the con- block and data link
nection Hardwires and Datalinks Use orange pencils to draw J1587/J1708
Using different color pencils have the data lines ____Orange________
student draw in the connecting lines This slide adds the J1939 data link with
Instructors can keep a list of what col- terminating resisters and the proprietary
ors are used for Hard Wire lines and link between the CPC and MCM (DDC,
Datalink lines on a white board to use MBE engine modules)
as key Use green pencils to draw J1939 data
Have student write in the names of the lines ____Green________
components as the paper is filled out Note: J1939 Backbone construction with
Note that not all truck ECU’s are Terminating Resistors at each end
shown. We are only dealing with the Use darker purple pencils to draw in the
ones involved in the multiplexed wiring data lines between CPC & MCM ____Dark
for this illustrated example. Purple________
4 Slide: This slide adds the hardwired

component for the MSF, note that there
Use Cascadia TM manual to map out the
commutation per function for the following:
are multiple wires going from each to
the MSF Master Wiper – TM G02-06 /4, 16, 20
Use Black color pencils to draw hard- •Headlight –

wire lines ____________ •Low beam
Slide This slide adds the Rest of the •High beam
hardwired components we will be dis- •Turn signal
cussing
•Left turn
Add in the following two boxes and
•Right turn
show as hard wired inputs to SAM Cab
•Marker Interrupt
•Low Air Pressure Switch
•A/C clutch – TM C02.01 / 8
•Ambient Temp Sensor
•Cruise Control TM P04.01 / 1, 7, 8
NOTE: while only one wire is shown on
outputs, all SAM outputs have both a •Starter operation (no start complaint) TM
power and ground connection. P01.01 / 7, 8, 9-13 (symptoms) 14, 15
(parameters)
Use Black color pencils to draw hard-
wire lines ____________ Need more examples

Multiplexing
Multiplexing / Electronic System Operations

Multiplexing
This is an overview of the interaction of the engine control settings. Some students will
have familiarity with the Detroit Diesel information, some may not.
Do not go into too much depth.
Point out that if all component settings (parameters) on the vehicle are correct, the
problem may be the engine settings.
The following pages are examples of the type of inputs the engine ECU may be looking
for. Changes to any of the engine ECU settings will require engine diagnostic software.

Multiplexing
Cruise Control
Cruise Control Disengage
The cruise control disengage feature is an optional safety feature that disengages the 4
cruise control when one of the following conditions occurs:
Hazard lights, headlights, or wipers are on.

Hazard lights or wipers are on.
Hazard lights or headlights are on.
Disengagement of the cruise control is accomplished by sending the cruise control
pause request CAN signal.

Multiplexing
This information came from the DD15 Troubleshooting student guide (page 6-4)
CPC source address inputs to the programs. All switches need to be programmed as
they come from the SAM Cab.
These are a description of what the Caps are doing and which ECU is sending the sig-
nal.

Multiplexing
Cascadia Multiplex Settings
Cascadia chassis uses a multiplex control system.
Multiplex (MUX) control allows a reduction in the volume of chassis wiring
through the use of multiple signals sent down a common wire to ―smart‖ control
devices that recognize and respond to function specific portions of the message.
A number of CPC inputs are affected as a result of this system.
CPC – (001/010) CC2_Source_Address_SAE_J1939 = 33 (Cabin SAM Module)
(013/001) Service_Brake_Switch_Config = 2 (ccvs2)

(013/003) Park_Brake_Switch_Config = 2 (ccvs2)
(013/008) Clutch_Switch_Config = 2 (ccvs2)
CPC – (001/011) CC3_Source_Address_SAE_J1939 = 49 (MSF Module)
(013/004) CC_ON_OFF_Switch_Config = 3 (ccvs3)

(013/005) CC_Set_Cst_Res_Accel_Sw_Config = 3 (ccvs3)
(013/006) CC_Pause_Switch_Config = 3 (ccvs3)
(013/020) Cab_PTO_Switch_Config = 3 (ccvs3)
(013) Stop_Eng_Override_Sw_Config = 3 (ccvs3)
4
CPC – (001/012) EBC1_Source_Address_SAE_J1939 = 49 (MSF Module)
(013/009) Engine_Brake_Switch_Config = 1(info from J1939 (muxed))

CPC – (001/045) CM1_Fan_Source_Addr1_SAE_J1939 = 25 (HVAC Module, AC
Fan Request)
(001/047) CM1_Fan_Source_Addr2_SAE_J1939 = 49 (MSF Module, Fan Override
Switch)
(006/001) Mode_of_ AC_Status_Input = 0 (Disable)

(019/003) Air_Condition_Enable_Auto_Fan = 0 (Disable)
(019/016) J1939_Fan_Request_Enable = 1 (Enable)
Note: If the vehicle has no fan override switch set (001/047)
CM1_Fan_Source_Addr2_SAE_J1939 = 255

Multiplexing
Review options of parameters. Focus on park brake switch configuration options.using
the previous page.
This is an example of how someone would go into the CPC to enter the parameters on
the previous page. This example is the 013 inputs and how the CPC receives those
signals.
Doing this through DDDL.

Multiplexing
DDDL Parameter Screen

Multiplexing
This example is the same thing, just focusing on the Fan and how it is activated via en-
gine, AC or driver. All three inputs need to be recognized by the CPC

Multiplexing
Cascadia Fan Information

Multiplexing

Multiplexing
Cascadia Engine Interface
You may also see a complaint after programming some Cascadia trucks of the
fan running all the time with the A/C on, as opposed to fluctuating with A/C pres-
4
sure.
To correct this make sure that PGR019 "J1939 Fan Request Enable" is set to
"CM1 From SA2 Only".
This parameter will sometimes default after programming to "CM1 From SA1
Only" or "CM1 From SA1 and SA2" which will cause the fan not to fluctuate with
A/C pressure.
Actual parameter selection in DDRS.
CPC Group Parameter Value (Reference 08Ts-14)
PGR006 Mode of AC Status Input 2 - AC Active Open
PGR019 Air Condition Enable Auto Fan 0 - Disabled
PGR019 Fan AC Hold Time 180 sec
PGR019 Hold Time Fan 10 sec (default)

Multiplexing

Multiplexing
Fan Activation
Additional fan operation in a Cascadia chassis.
Vehicle Speed < 20 MPH = Fan on 3 minutes minimum

Vehicle Speed < 40 MPH = Fan on 90 seconds minimum
Vehicle Speed >= 40 MPH = Fan on 30 seconds minimum
Vehicle Parked, HVAC ON, and Park Brake Set = Fan on all the time
Possible Programming Issues
You may also see a complaint after programming some Cascadia trucks of the
fan running all the time with the A/C on, as opposed to fluctuating with A/C pres-
sure.
To correct this make sure that PGR019 "J1939 Fan Request Enable" is set to
"CM1 From SA2 Only".
This parameter will sometimes default after programming to "CM1 From SA1
Only" or "CM1 From SA1 and SA2" which will cause the fan not to fluctuate with
A/C pressure.
Actual parameter selection in DDRS.
CPC Group Parameter Value (Reference 08Ts-14)
PGR006 Mode of AC Status Input 2 - AC Active Open 4

PGR019 Air Condition Enable Auto Fan 0 - Disabled
PGR019 Fan AC Hold Time 180 sec
PGR019 Hold Time Fan 10 sec (default)

Multiplexing
book.
1. 4-8 4-15
2. 4-7 4-13
3. 4-7,8 4-13, 15
4. 4-4 4-7 and PPT slide 4 (note)
5. 4-7 4-13

Multiplexing
Review Questions
1. Where is the 60 ohms for the Diagnostic CAN located?
Inside of the CGW
2. The Cabin CAN uses what wires color.
Blue and white
3. Diagnostic CAN connects to the CGW to provide an interface between ServiceLink

and what datalink ECUs?
Cabin CAN ECUs
4. What Data Link is being phased out starting in 2010.
J1708 / J1587
5. Where is the 60 ohms for the Cabin CAN located.

4
Inside of the Starpoint connector

Multiplexing

Multiplexing
Module 4 Review
a. Explain the basic concept of multiplexing

b. Explain multiplexing for the Cascadia electrical system.
c. Identify the major components in the Cascadia multiplexed system.
d. Explain the operation of Datalinks J1587, J1939, Cabin CAN (Controller
Area Network), and Diagnostics CAN.
e. Follow the communication between the J1939 and CAN Datalinks.

Multiplexing

Service Information
Module 5 Objectives
Worksheet Service Information ................. 5-12
A. Use www.AccessFeightliner.com to
find service and troubleshooting Worksheet Fault Codes ............................. 5-15
information
Worksheet Finding Module Numbers......... 5-16
SAM Hardware and Software Updates ...... 5-17
Module 5 Review ....................................... 5-20

Service Information
Follow the directions on the slides or do as a live demo.
Make sure all student have the computer on and have open ServicePro.
Once all the students have located the Drivers Manual.
Break the student into 3 group and assign a topic that each group must find informa-
tion on.
Group A- Electrical system _ Where is the Emergency Power Supply information lo-
cated? Answer: pages 3.3 and 3.4
Group B- Instrument - how do you access codes on ICU4M using what controls?
Answer: Steering wheel switches and MY Info button. (4.18)
Group C- Climate Control – What are the sleeper control panel temperature ranges?
Answer: 60 to 85 with 74 in the center (page 7.4),
Have a spokes person form each group inform the class what they found.
Repeat this with the Maintenance Manual
Group A- Exhaust – Where do you repair procedure if you find leaks in the DEF tank,
pump, metering unit, and Lines?
Answer: See Section 49.02 of the Cascadia™ Workshop Manual for repair procedures
(MM page 49/2)
5 Group B- When does the power steering fluid and filter need changing?
Answer: 46–02, M3 Maintenance Interval Operations for Service Schedules I and II
(Page 00/11)
Short haul 150,000 miles, Long haul 300,000 miles (Page 00/2)
Group C- What page are Freightliner Approved Antifreeze listed?

Answer: Page 20/4, Table 1, Approved Antifreeze
Have a spokes person form each group inform the class what they found.
Have all student locate the Workshop Manual
Once all student have found the manual follow the direction on the next slide.

Service Information
ServiceLit
Logon to AccessFreightliner.com
Open ServicePro->Select ServiceLit
Select Work without identifying Vehicle Information
Select Freightliner & Cascadia
-Locate the Drivers Manual
-Locate the Maintenance Manual
-Locate the Workshop Manuals
Follow along and take notes as we locate features of the new section in the
Manuals. 5
Service Lit
Open Group 54 & then 01 SAM Cab
050 General Information
100 Removal & Installation
110 Software Flashing
300 Troubleshooting no longer in WS Manual.

Service Information
Go to the very bottom of the manual and click on the Open All button.
Follow the directions on the slides.
Make sure all student have the computer on and have open ServicePro / ServiceLit /
Cascadia TM
Review the TM layout
•TM General = G0._
•TM Cab Systems = C0._
•TM Chassis = H0._
•TM – Powertrain Systems = P0._
Develop a system or cheat sheet that breaks out group, section subject

Service Information
Troubleshooting Manual Layout

Open the following groups and the sections under each group.
TM General
TM Cab Systems
Chassis systems
Powertrain Systems

Service Information
Following the layout in the book, be sure to follow what is in sections in detail:
500 Level - System Overview
600 Level – Components
700 Level – Troubleshooting
800 Level - Specifications

Service Information
Open TM Cab Systems
Open 07 Optional Functions and then open 01 Backup Lamps and Alarm.
Notice new numbering system
500 Level - System Overview

600 Level – Components
700 Level – Troubleshooting
800 Level - Specifications 5

Service Information
Point out that in the 700 section that we now have groups 700-710.

Service Information

There is a separate Troubleshooting Manual section
Open TM - General & 02 Electrical System Overview
Open TM – General & then 02 Electrical System Overview; then open 04 SAM Cab
Then open 04 SAM Cab and locate the Troubleshooting (700) section

Service Information

Service Information
Troubleshooting Manual - Fault Codes

Now open Fault Codes …. 703 hyperlink
Note the following:
SA, SPN, FMI, Fault Description are same style as J1939 codes
Added column for Fault Trigger (depend on code may include):
Vehicle Behavior, Possible Cause, Action

Service Information
A brief review the datalinks and the component IDs on the different datalinks.
In ServicePro / ServiceLit / Cascadia Troubleshooting Manual (TM)
Use link to open SB00-33 Tips for using searching Cascadia TM Manual
Explain Fault codes and where to find them.
Log on to AccessFreightliner.com
Use ServicePro / ServiceLit / Cascadia Troubleshooting Manual (TM) to find the follow-
ing information table.

Service Information
ECU Identification on Datalinks
1. Close Fault Codes …. 703
2. Now locate and open the following

G04.03 CAN Fault Codes
Table 1, ECU Identification on Datalinks
Note: To locate fault code in the Cascadia TM:
Use SPN or SID as a key word in the search feature.

Then pick the one that has the correct SA or MID

Service Information

Service Information
SAM Cab Inputs and Outputs
Then return to the table of content for the SAM Cab (G02.04).
Locate and open Ground Pins and Inputs ….. 704
Note that the drawings listed are the same as the drawings used in module 3.
Drawings can be used to identify the type of circuit used to identify the following;
Type circuit used, Logic Controlled, Input, Outputs and Grounds

Connector/pin locations
Provide a starting point for troubleshooting
Note: SAM Chassis also has drawing of Input, Out puts and Grounds.

Service Information
Follow the instructions on the slide.
Make sure the students computers can access the internet.

Service Information
SAM Output Troubleshooting Procedures

Locate the SAM Cab troubleshooting procedure for:
―Logic Controlled Unfused Output‖ In G02 / 04 / 707 / 32

Service Information

Service Information

Service Information
DEVELOP TABLE OF FET OUTPUTS THAT DRIVE MULTIPLCE CIRCUITS

Service Information

Service Information
Make sure students have access to AccessFreightliner.com to answer the following
questions.
Question 3 is optional for instructor to add if desired.

Service Information
Worksheet Service Information

Group 1 Questions
1. What is the maximum length of the Modular Switch Field (MSF) sub-bus?
DM Chapter ________ Page ________ Answer ______________________
MM Group ________ Page ________ Answer ______________________
WM Group ________ Page ________ Answer ______________________
TM Group ________ Page ________ Answer ______________________
2. What is the fault code description for the CAN fault; SA-37, SPN-628, FMI-12?
3. optional—instructor assigned —————————————————————-- 5


Service Information
questions.

Service Information
Worksheet Service Information

Group 2 Questions
1. When adding a SAM Cab feature upgrade to a truck, where do you obtain any nec-
essary software upgrades?
2. At what temperature does the ambient outside air temperature warning chime actu-
ate?
5
3. optional—instructor assigned —————————————————————--


Service Information

questions.
Current Events would be a good topic.

Service Information
Worksheet Service Information (continued)
Group 3 Questions
1. What is the fault code description for the Diagnostic CAN fault:
SA-37, SPN-523510, FMI-31?
2. How many active fault codes can the ICU3 store simultaneously?
3. optional—instructor assigned —————————————————————--

5

Service Information
Use link to open SBW00-11 Tips for using ServiceLit in ServicePro,
The numbers for the J1939 for SAM Cab, SAM chassis and MSF are important be-
cause you have to use those to set up proper communications with the engine control-
ler and for fault code identification. If you set them wrong you can kill cruise control, en-
gine braking, engine fan and can break up the safety cycle. You can also cause the
truck to not do a parked regen.
Locate appropriate Service Bulletins

Service Information
WORKSHEET - Fault Codes

Explain Fault codes and where to find them.
Login to AccessFreightliner.com
1. What is the fault description of an SA 49; SPN 524033; FMI 31?

Lost communication with Cab SAM
2. Is there a specific vehicle behavior for this fault?
(Circle one) Yes or No
3. If Yes, what is the behavior?

stop lamps, tail lamps, marker lamps and trailer tail lamps are flashing
4. Are there any fault codes related to the Diagnostic CAN?
(Circle one) Yes

___ or No
5. If yes, what is the code?
SA: 37
SPN: 523510
FMI: 31 5
6. What fault is broadcast if the CGW loses contact with the MSF?
SA: 37
52049
SPN:
31
FMI:
7. What would happen if the CGW lost its power or ground?

The MSF, SAM Cab, SAM Chas. would lose all communication with J1587/J1939 Datalink
Will not go into Emergency Power mode. / ServiceLink would not display CAN Datalink

Service Information
Demonstrate finding Mod. 97M
Instructor notes:
Have the student locate modules numbers in:
TM General section (G02.01)
a. Table of Contents
b. 600 Component Locations (G02.01/09)
Electrical Subsystem Guide (EZWiring Tips and Tricks)
a. Locate term Multiplexing in Subsystem Alphabetical Index (see page 6)

b. Multiplexing Controls & Module (MUX)
c. Have students use generic terms to figure out which one is SAM Cab and
SAM Chassis, etc...
Go over the list and see if any student may have an idea of what the other module
Number may be. Example: Starpoint connector: Datalink module 160
Main Cab harness : 320 (make sure to show D06 drawing the in mod.)
Main Wiring Harness: 97M Demonstrate this to show all the standard harness for the
Cascadia are list in this Mod. Other Optional harness are overlays on these harness
and will be found in their respective BOM.
5 Using serial number like AS1318 (Must be an EPA 2010 truck)
Look up relevant drawings in these modules:
32A
32k
860 (show that none of the MUX or hardwired switches are listed in this module).
Demo using part # of switches A06-53782* or A06-53783* for search in PartsPro to
locate module numbers.
160
320
33P

Service Information
WORKSHEET - FINDING MODULE NUMBERS

Use the Troubleshooting Manual and PartsPro to locate the module numbers that give
information on the following component or feature.
5
Load Disconnect Switch
PNDB 33P

Service Information
Have the Student answer the question from FL545A-C
After finding the information from the FL545A-C
Have students do a search on Service Solution using word Leak as the key word
All 4 of the Service Solutions will show up on the list.
•Take a quick look at each Service Solutions.
Have the student locate the Parts (Technical) Bulletins
Have the students locate the Service Bulletin 54-321and do a quick look at it.

Service Information
SAM Hardware and Software Updates

1. Login to AccessFreightliner.com
Open ServicePro
Work with using a Ser # AJ1791
Locate and open Recall / Campaign tab
Locate FL545A-C and FL415A
FL415A has been temporary terminated
Open the Recall Campaign FL545A-C and answer the follow questions In the Work In-
structions section.
Locate and write down the Service Solutions listed: (Page 8)

3495, 3497, 3498, 3499 5
What topic do the Service Solutions cover?
Corrosion, leaks, repairs
54-075
Locate and write down Parts (Technical) Bulletins listed: (Page 12) ________
What topic do the Parts (Technical) Bulletins cover?

Identity part number for connector / pin
54-231
Locate and write down Service Bulletins listed: (Page 16) ________
What topic do the Service Bulletins cover: SAM Cab and SAM chassis Hardware levels
SAM Cab and SAM chassis Hardware levels

Service Information
Have the Student answer the question from SF415A
Then look up the Service Bulletin 54-238 / 54-241 and do a quick review with class.
Software Update 5.4 includes the following:
New software for all four Cabin CAN ECUs:
SAM Cab
Modular Switch Field (MSF)
SAM Chassis
Central Gateway (CGW)
Features
Introduces ~200 new fault codes for both SAMs (many are pin-based)
Dimmable lighting for reading and front dome lamps: Allows the driver to set an illumi-
nation value by performing a long button press.
Headlamp activation with wipers
Issues Fixed
High engine fan cycling: Customers have complained of high engine speed cycles
5
which have led to a perception of reduced fuel economy.
HVAC shut down at high outside air temperatures: Issue was found during summer
test in 2008.
Intermittent Cruise Control Dropout: Cruise control intermittently drops out during nor-
mal use.

Service Information
SAM Hardware and Software Updates

Open the Recall Campaign FL415A and answer the follow questions
In the Labor Allowance section
-Locate and write down the terminate date listed: (Page 2)

December 31,2010
In the Copy of Letter to Owner section (Page 3)
What is covered under the topic IMPORTANT:

What is covered by warranty and what is not
In the Work Instructions section (Page 9)

54-238 , 54-241
-Locate and write down Service Bulletins listed: ______________
What features may need manual parameter changes: (Page 10)

Premium Cab Lighting
Utility lights
Separate Stop and Turn Signal Light present

Service Information
book.
1. 5-4 5-7
2. 5-3 5-5
3. 5-7 5-13 ECU Identification on Datalinks (table)
4. 5-9 5-17
5. 5-16 5-31

Service Information

1. What type of information would be found in the 600 section of the Cascadia Trou-
bleshooting manual
Component Information
2. What is the names of 4 groups that make up the Cascadia Troubleshooting manual
General, Cab Systems, Chassis Systems, Powertrain System
3. The Rear HVAC ECU is Identification by what numbers on the follow Datalinks:
CAN ID NA J1939 SA 58 J1578 MID (200)
4. When testing a SAM Cab (707) Logic Control Unfused Output what list as the first
step.
Determine if template has I/O controls for the affected function.

33P
5. What is the PartsPro Module number for the PNDB? ______________________

Service Information

Service Information
Module 5 Review
a. Use www.AccessFreightliner.com to find service and troubleshooting in-

formation

Service Information
Instructor Notes

ServiceLink
Module 6 Objectives
Worksheet 6.1 Troubleshooting Complaint . 6-5
A. Use ServiceLink to monitor Cas-
cadia ECUs Exercise 6.2 Starter Relay, Crank Enable Tem-
plate ............................................................ 6-9
B. Use ServiceLink to monitor MSF
Switches Exercise 6.3 ServiceLInk ........................... 6-10
C. Use ServiceLink to read/change Exercise 6.4 ECU Compatibility ................. 6-12

parameters
Exercise 6.5 Returning Control to Headlight I/O
D. Use Templates to monitor Cas-
cadia SAM inputs/outputs .................................................................. 6-13
Module 6 Review ....................................... 6-15
Cascadia SERVICETRAININGACADEMY.COM SG 5-1

6-1 6-1
ServiceLink
Check version soft level of Nexiq tool
Add remove program list to find driver version?

ServiceLink down load page to update version
Beware: Nexiq web site may have version that may not be supported by Ser-
viceLink
Other OEM software (Detroit Diesel) may be using a different version drivers for
the USB link tool that may not be compatible with ServiceLink

ServiceLink
ServiceLink Demonstration
• USB-Link replaces Magic Key
• Required to access CAN information
• Must set up for USB-Link in Admin screen

ServiceLink

ServiceLink
6
Offline not part of initial download
• Go to Admin
• Offline Setup
• Click on Download ServiceLink Offline
• An icon will appear on your desktop for ServiceLink Offline
• All templates work in Offline

ServiceLink
Instructor Notes
6.0 SAM hardware Software will supported with ServiceLink version 4.51 and 4.60

ServiceLink
Datalink information is now shown on separate screens
1st Displays CAN
Datalink buttons
6
Software Version displayed
Chooses templates and parameters by version
Problem ECUs shown at bottom of screen

ServiceLink
This is an instructor-led discussion.
Need to add any new LVD information related to the new SAM Cab or EPA 2010
changes.
Logon to AccessFreightliner.com:
Open ServicePro then select ServiceLit
Select work without identifying Vehicle Information
Select Freightliner and Cascadia
Locate Information on Powernet Management

ServiceLink
Worksheet 6.1 Troubleshooting Complaint
Customer Complaint::
Sleeper light shut off when in use,
Driver wants light to stay on to finish book work
What could be possibly causing the light to go out?

Voltage drop to a point that LVD or PLVD (Powernet Management) shuts off
Electrical loads to keep batteries from going so low that they would not start the truck
Where would the driver find information on the possible cause of Sleeper light going
out?
Drivers manual – Electrical section – 3.4, 3.5 ,3.6
Where would the technician find the additional information on LVD?

TM Cab Systems C06 Standard Features, .09 Power Management
6

ServiceLink

ServiceLink
SAM Cab LVD Function

Cascadia Powernet Management
Priority levels 1,2 and 3 shut downs

ServiceLink
Instructor Notes

ServiceLink
SAM Cab LVD
Function
Designated Loads
Priority Level One
Priority Levels 2 and 3

ServiceLink
Instructor Notes
Make sure that LVD function in turn on
3 groups
Group A - Cascadia truck
Group B - Simulator board
Group C - Simulator board
You will need to perform Exercise 6.1 on the truck, so each group will have to rotate
through the simulators and truck
Upon completion of all the exercises, each group will put the truck or boards back to-
gether
Turn on the IGN key and the load interrupter switch
Connect ServiceLink to the truck and open the Progressive Low Voltage Disconnect
Template .
Start the engine to bring the voltage on the template to above 14.5, you only need to
run it for a very short time to do this.
Turn off the engine and remove the ground cables from 3 of the batteries.
Turn the ignition switch to on.
6 Turn on the footwell lamp and the dome lamp.

ServiceLink
Exercise 6.1 Progressive LVD Template

When performing this exercise on a truck:
Connect ServiceLink to the truck and open the Progressive LVD Template.
Start the engine to bring the voltage on the template to above 14.5, you only
need to run it for a very short time to do this.
Turn off the engine and remove the ground cables from 3 of the batteries.
Turn the ignition switch to on.
Turn on the footwell lamp and the dome lamp.
1. Observe the template using ServiceLink.
Now begin pulling the voltage down by turning on the HVAC blowers and the head-
lamps.
You may have to wait two or three minutes. You want to have the voltage below 12.3.
You want to be observing both the truck and the template.
2. Did the LVD cut out?
(Circle one) Yes

___ or No
3. What components shut off?

X
Footwell Lamp : _______
X ____
HVAC Blower: ____
X
Dome Lamp : _________
Head lamps: _____ ____ 6

Turn off the head lamps and wait one or two minutes.
4. Did components turn back on?
(Circle one) Yes

___ or No
5. Locate the following Information in the Note Pad on the top bar of the template
screen. What is the time delays between levels and LVD:
60
Going up _____Sec. 45 Sec.
Going down ____
Turn everything off and rotate to the next station.

ServiceLink
Instructor Notes
Question 7. and 8:
The ServiceLink template needs to have information from the engine ECUs to position
the tachometer needle. By removing the fuse to the MCM, there is no input so the nee-
dle to moves to the far right. The tech can use this information about the tachometer
needle position to help troubleshoot.

ServiceLink
Exercise 6.2 Starter Relay, Crank Enable Template

Driver’s complaint: Intermittent Engine Cranking
Note: If conducting this test on truck make sure to follow safety procedures
1. Where would the driver find engine starting information ?
Driver’s Manual
List Book _________________ 9.1
Page _____
2. Does this vehicle have a safety condition?
(Circle one) Yes

___ or No
Clutch Switch
3. What is the starter (safety) Interlocks? ________________
Connect ServiceLink and open the Crank Enable template.
4. Attempt to crank the engine without depressing the clutch. Did it crank?

___
5. Does the template indicate when the clutch is depressed?
___ or No
(Circle one) Yes
6. Depress the clutch and attempt to crank the engine. Did it crank?
(Circle one) Yes

___ or No
Locate the engine ECU fuse in the PTPDM and remove it (see Module 2). Return fuse
when finished testing.
7. Is there anything on the template that didn’t work?

6
(Circle one) Yes
___ or No
ENG RPM
8. If yes, what was it? _____________
9. Where would the technician find additional information on engine starting/interlock?

Cascadia TM under PowerTrain/Engine: P0101/7 – Theory of Operation P01.01/14 -
parameters

ServiceLink
Prior to doing this exercise make sure the Truck or simulator board has the latest soft-
ware level or be prepare to flash all
The Cabin CAN ECU’s as part of his exercise.

ServiceLink
Exercise 6.3 ServiceLink

Connect ServiceLink to the truck or one of the simulators.
1. How many ECUs show up on the left hand column?

depends on truck, black trucks show 11
2. Which data link is active on the opening screen?

CAN
3. Click on J1939, is the ECU list below the data link bar different?
___ or No
(Circle one) Yes
4. Now click on J1708, are there ECUs "grayed out" on this list?
(Circle one) Yes

___ or No
5. Why are they "grayed out"?
a. they are not installed on this vehicle
b. they are not powered up at this time
c. they report on a different data link and only show up here because of a message
___
generated by the CGW
d. none are "grayed out"
6. Click on the Central Gateway icon in the left column and go to Flashing, go ahead
and reflash the CGW. Was it successful? 6
(Circle one) Yes
___ or No
7. When would you re-flash an ECU? (Choose all that apply)
a. before conducting any troubleshooting
b. as a last resort when no problems are found and you suspect a bad ECU
___
c. when there is an update to the software for a specific problem

___
___
d. when you install a new ECU

ServiceLink
Instructor Notes

ServiceLink
8. What should be done before changing any parameters?
a. Reset parameters
b. Create a save point.
___
c. Restore a save point
9. Find a parameter that is filled in and double click on it. Once the new screen opens
up, click on the arrow to the right of box with the part number options. This should give
you two PARM part numbers and descriptions. One will end in NC. What do you think
NC means?
it turns the switch function off
10. Click the Switches button. This is an interactive list of all switches connected to the
MSF. Activate some of the switches and watch the screen. Were you able to see them
change?
(Circle one) Yes

___ or No
11. Now activate the ID154 switch; did you see it change?

___
12. If No, why not?
not a multiplexed switch

ServiceLink
Instructor Notes
Question 9: The answer will be no if you have 5.2 software. The answer will be yes if
you have 5.4. The switch will override the computer control of output with 5.4.
If the vehicle speed interlock is green but shows yellow !, the template is not getting
MPH signal. Make sure key switch is on or engine or transmission ECU has power.
Results will be different if key is in the off position.

ServiceLink
Exercise 6.4 ECU Compatibility I/O Controls and Safety Interlocks

a. Connect ServiceLink to the truck or simulator board (must have 5.2 or
newer SAM software).
b. Turn IGN key on
c. Open CAN template ―Marker Lamps‖
1. Observe the ―ECU Compatibility‖ area in the upper-left corner, fill and answer the
following:
What is the software Version SAM Cab: ____•____ •____
2. Is the Software version compatible with this template? (Circle one) Yes
___ / No
What is the software Version SAM Chassis: ____•____ •____
3. Is the Software version compatible with this template? (Circle one) Yes
___ / No
6
4. How many marker/clearance lamp circuits have I/O control buttons available? ___
Observe the ―IO Control Safety Interlocks‖ area in the far-left side and answer the fol-
lowing:
Green / Set
5. What is the color and status of the Park Brake interlock? _____________
Green / 0 MPH
6. What is the color and status of the Vehicle Speed interlock? _________________
Make sure the headlight switch in the cab is off. In the template, turn on the output:
Marker Corner Front Left
7. Look at the vehicle. Did the Marker Corner Front Left lamp turn on? YES
___ or NO
Observe the ―IO Control Safety Interlocks‖ area again 6
Release the park brake. (Make sure the engine is not running and the wheels are
chocked)
Yes / Red
8. Did the park brake color and status change? If so, to what ___________
9. Look at the vehicle. Did the marker front left lamp stay on? Why or why not?
Yes / only needs one of the safety interlock needs to be met, (0 MPH)
Click the ―Return Control to Vehicle‖ button.

10. Did the lamp turn off? (Circle one) YES
___ or NO
Close the template

ServiceLink
Additional information for question 2 answer.
any non functioning Low beam light is a chassis wiring problem or failed component
(lamp) or a burned out SAM Cabin FET. G02.04/707/32 – Logic Controlled Unfused
Outputs

ServiceLink
Exercise 6.5 Returning Control and Headlight I/O

a. Connect the shop PC to a Cascadia with 5.2 or newer SAM software.
b. Turn IGN key on
c. Open CAN template ―Headlights, Low beam, High beam, Flash to Pass
and Follow Me Home‖
d. Turn on the headlights (low beam only) with the rotary switch in the dash
1. Which controls changed status in the template?
Input: Rotary Switch Output: Low beam Left / Right (ON)
2. What does this tell you about the Input’s and Output’s of the Headlight Circuit?
Input / Output for the Low beam Left and Right is working,
Turn off the headlight switch in the dash In the template click the ―ON‖ button next to
the Low Beam Left outputs
Low Beam Left
3. Which lights have turned on? _____________________
4. What can this tell you about the Low Beam Left circuit?
Confirms SA output too Low Beam Left is working
In the template, click the ―OFF‖ button next to the low beam outputs
5. Did the low beam lights turn off? (Circle one) YES
___ or NO If No, why not?
N/A answer was yes
Turn on the headlights again using the rotary switch in the dash
6. Did the low beam lights turn on? (Circle one) YES or NO ___
ServiceLink template is controlling the SAB Cabin
If No, why not? ____________________________________________________ 6
In the template, click the ―Return Control to Vehicle‖ button in the upper-right corner.
___ or NO
7. Did the low beam lights turn on? (Circle one) YES
IF Yes, what was keeping the light from being on when the headlight switch was
turned on? Locate the following information in the notepad on the top bar of the tem-
ServiceLink template has controlling SAM Cabin, using the
plate screen. ________________________________________________________
returned control to the vehicle button, removed template control
8. What condition activates the Follow Me Home feature?

Key switch is turned off within 30 seconds after the head light switch being turned off
Close the template

ServiceLink
book.
1. 6-2 6-3
2. 6-4 6-7
3. 6-7 6-13 Designated Loads (table)
4. 6-12 6-23 Exercise 6.4 questions 5 & 6
5. 6-4 6-7

ServiceLink

1. Why does ServiceLink require the use of the Nexiq USB-Link?
To access CAN information
2. What are the names of the 4 ECUs that show up on the ServiceLink CAN ECU list?
SAM Cabin, Central Gateway, Modular Switch Field, SAM Chassis
3. In the LVD function the Utility Light is in which of the following Designated Loads
Circle one
Priority Level I Loads | Priority Level II Loads |

___________________ Priority Level III Loads
4. In the ServiceLink CAN template with IO controls, what are the two IO Control
Safety Interlocks
Park Brake and Vehicle Speed
5. Where on the opening ServiceLink screen does a problem ECU show up?
bottom of the screen

ServiceLink

ServiceLink
Module 6 Review
A. Use www.AccessFreightliner.com to find service and troubleshooting information
B. Use ServiceLink to monitor Cascadia ECUs
C. Use ServiceLink to monitor MSF Switches
D. Use ServiceLink to read/change parameters
E. Use Templates to monitor Cascadia SAM inputs/outputs

Troubleshooting

Troubleshooting
Module 7 Objectives
Exercise 7.1 Calibration Mode ..................... 7-5
A. Use of ServicePro and ServiceLink
to troubleshoot electronic problems Exercise 7.2 HVAC Template ...................... 7-6
B. Understand correct procedures to Exercise 7.3 HVAC Fault Codes .................. 7-7
diagnose potential problems
Troubleshooting HVAC Problems .............. 7-13
C. Understand the proper tools to use
when diagnosing a concern Troubleshooting Headlight Problems ......... 7-14
Troubleshooting Worksheet ....................... 7-15
Troubleshooting Adding Fog lights or Aux High

beams ........................................................ 7-21

Troubleshooting
Operation of HVAC FCU / AUC controller / A/C clutch / Engine Fan
FCU
A/C clutch – TM C02.01 / 8
Need more examples
Pressure transducer in high side used in place of conventional binary & fan cycling
switch
Pressure transducer connected to SAM CAB
Actuators have stepper motor that moves fixed position for each step.
Evaporator temperature sensor used by FCU to control compressor to prevent evapo-

rator freezing..
FCU turns compressor on above 38.5F and off at 38F.
Reminder: reference clutch operation rules:
Maximum 4 clutch cycles/min. – Minimum off 5 seconds, minimum on time 15 seconds.
Engine RPM above 450 for more than 5 seconds.
System air pressure not too low via J1939 message from ICU.
FCU blower switch must be on (EXCEPTION: if ACU requests AC and FCU blower
speed set to off, FCU will operate blower at minimum speed)
Ambient temperature sensed by SAM CAB must be > or = to 40F.
Clutch voltage 12.5 or higher. (disengages if voltage drops lower than 12v)

Troubleshooting
HVAC Controller Network Topology

Troubleshooting
Use this page to show students were components are located on the Front HVAC unit.
Students will need to find component for the following exercise.
Basic Cascadia information use if student have question about the HVAC unit
The front HVAC unit has two air filters, one that filters outside air and another that fil-
ters recirculated air drawn into the unit
Blower motor is brushless direct current (BLDC)
Blower motor power and ground are from SAM CAB
Under normal operation, the feedback signal to FCU and ACU indicates blower speed.
Battery power to front & rear blower motors from SAM CAB through separate 30a
fuses.

Troubleshooting
HVAC Front Unit Component Locations
1. Panel/Defrost vent door actuator 6. Blower motor
2. Floor vent door actuator 7. Recirc/Fresh air door actuator
7
3. Temperature mix door actuator 8. Evaporator Temperature probe
4. Evaporator core 9. Heater core 9. Heater Core
5. Cab air filter 10. Duct Temperature probe

Troubleshooting
Use this page to show students were components are located on the Front HVAC unit.
Students will need to find component for the following exercise.
Basic Cascadia information use if student have question about the HVAC unit
Has one filter that cleans recirculated air drawn into the unit
Battery power to front & rear blower motors from SAM CAB through separate 30a
fuses.
The BLDC blower motor has built in protection that will cause the motor to operate at
reduced speed or shutdown to prevent damage.
If voltage is < 8.5v or > 17v, the blower motor will shut down. Blower feedback circuit
will indicate a fault.
The motor will not operate if polarity reversed.
If motor exceeds maximum current, speed is reduced until normal (23.5a)-fault logged.
If motors internal temperature sensor senses too high, slows to 1000 rpm and com-
pares.
If still too high, speed is reduced to 500 rpm and compared again. If still too high motor
shuts down until cooled. – fault logged.
Valeo - Blend air
Direct drive actuator (No external drive gears)
Blower motor same unit for Front, Aux and M2
Note: Located behind driver seat away from rear of cab and possible damage when
7 cab is damage by jack knifing

Troubleshooting
HVAC Auxiliary Unit Component Locations
1. Heater Core 4. Evaporator
2. Blower Motor 5. Temperature probe

7
3. Sleeper air filter 6. Temperature mix door actuator

Troubleshooting
Go out to shop and perform this exercise.
This exercise can be done by itself or during exercise 7.2 or 7.3.

Troubleshooting
Exercise 7.1 Calibration Mode
It is necessary to calibrate the actuators if they are removed or replaced. To enter, per-
form the following steps:
1. Turn ignition ON (engine OFF)
2. Set blower speed control to Off (counterclockwise)
3. Set the mode control knob to the full counter-clockwise position (FACE)
4. Set the temperature control knob to the full clockwise position (HOT)
5. Press the A/C and RECIRC buttons simultaneously until the A/C and RECIRC
indicators begin flashing simultaneously
6. The calibration process will begin and will continue until the A/C and RECIRC LEDs
stop flashing

Troubleshooting

Troubleshooting
Exercise 7.2 HVAC Template
Go to a truck/simulator and connect ServiceLink. Open the appropriate HVAC tem-
plate.
1. What do you have to do on this template to see all the data?
Check button press to see all data
2. Turn on the front blower motor and observe the indicators. What do you think the
Protect button represents?
Blower is in protection mode
Move the temperature knob to half way and observe the indicators. Now push the bunk
override button.
3. Did you see the bunk indicators respond? (Circle one) Yes
___ or No
Push the override button again and turn off the front blower. With the park brake set,
turn the bunk blower switch to half way.
4. Did the front unit indicators respond? (Circle one) Yes
___ or No
Move the bunk temperature knob from one extreme to the other.
5. Did the front unit indicators respond? (Circle one) Yes
___ or No
Turn on the front blower switch and push the recirc button.
6. Did you see the recirc indicators respond? ___ or No
(Circle one) Yes
Turn the front mode switch to various positions.
7. Did the AC mode ever become active? (Circle one) ___
Yes or No
No engine RPM
If no, why not? ______________________
8. Are the door indicators indicating real door position? (Circle one) Yes
___ or No
9. Record the following:
Eng Temp _____ Ambient Temp _____ HS Press _____% HS Press _____PSI 7
Disconnect ServiceLink, turn ignition off, turn load cut-off switch to off.

Troubleshooting
Instructor Notes
Example:

Troubleshooting
Exercise 7.3 HVAC Fault codes

Go to a truck/simulator and locate following components, once located follow the in-
struction below for each component.
Unhook the harness at the component and record the fault display on the instru-
ment display.
Reconnect harness and clear the fault code
Continue steps above with all components listed until all fault codes are re-
corded in the tables
Note: Use drawing on page 7-3, 7-4 of front and rear HVAC unit to help locate compo-
nents
Note: the following information will be researched after attaining the fault code using
Service Information
The Fault Description / Fault Trigger / Vehicle Behavior / Possible causes / Actions

Troubleshooting
Instructor Notes
Example:
Fault code present on the following Datalinks:
CAN and shown as bold (SAM Cab SA 33 is reporting the fault)

J1939 and shown gray out or not bold (fault not reported by J1939 ECU, trans-
fer here by CGW)
J1587/J1708 and shown gray out or not bold and in Mid style (fault not reported
by J1587/J1708 ECU, transfer here by CGW)
Vehicle Behavior:
On Truck A/C clutch will not engage (must test with engine running) (simulator has no
engine RPM)
Possible Causes:
See answers
Actions:
Test at sensor frist, easer to get to, then at SAM Cab connector. C02.01/44,45 (800
section)
Review section, will find how circuit operates and how to test:
SAM Cab G04.02/34 708 — Logic Controlled Relayed Fused Outputs.

Locate template, Heated Mirror template shows sensor as 255 degrees and in
red. Open or shorted circuit
C06.05 Heated Mirror operation.
If using HVAC temple, it will show Temperature: Outside sensor temperature as
117999 Shorted in red

Troubleshooting

Ambient Air Temperature Sensor

Troubleshooting
Instructor Notes
CAN and shown as bold (SAM Cab SA 33 is reporting the fault)

J1939 and shown as bold (HVAC FCU SA 25 is reporting the fault) and SA 33
shown gray out or not bold (fault not reported by J1939 ECU, transfer here by
CGW)
J1587/J1708 and shown gray out or not bold and in Mid style (fault not reported
by J1587/J1708 ECU, transfer here by CGW)
Vehicle Behavior:
On Truck engine fan on all the time, A/C cutch will not engage PSI too high (must test
with engine running) (simulator has no engine RPM)
Possible Causes:
See answers
Actions:
Test at sensor frist, easer to get to, then at SAM Cab connector.
•SAM Cab G04.02/29, 30, 32

•704 — Grounded Pins and Inputs
•705 — Fused and FET Controlled Outputs
•707 — Logic Controlled Unfused Outputs
Locate template, HVAC template that fit your truck, it will show Temperature:
Outside sensor temperature as 117999 Shorted in red

Troubleshooting

High Pressure Sensor

Troubleshooting
Instructor Notes
J1939 and shown as bold (HVAC FCU SA 25 is reporting the fault)

J1587/J1708 and shown gray out or not bold and in Mid style
Vehicle Behavior:
See answers
(Simulator has no engine RPM)
Possible Causes:
See answers
Actions:
See answers
Test wiring at FCU 26 - Connector. (601 — Component Details
Electrical Connectors—Front HVAC in Table 4, FCU 26-Pin Connector, C02.01/19 and
Table 6, Actuator Stepper Motor 6-Pin Connector (front unit actuators) )

Troubleshooting

Blend Door Actuator

Troubleshooting
Instructor Notes
Example:
To gain access to component on a truck, see instruction on Instructors Notes 7-7

Vehicle Behavior:
On Truck, A/C cutch will not engage Temperature is too low (must test with engine run-
ning)
Possible Causes:
See answers
Actions:
Test at sensor and wiring frist, easer to get to, Table 33, COTC Temperature Sensor
Resistance, C02.01/42
Electrical Connectors—Front HVAC in Table 4, FCU 26-Pin Connector, C02.01/19)
7
Cab / HVAC C02.01/44, 45
Table 33, COTC Temperature Sensor Resistance
Locate template, HVAC template that fit your truck, it will show Temperature:
COTC sensor temperature as Approx 32 degrees on the bar grapth

Troubleshooting

COTC Sensor

Troubleshooting
Instructor Notes

Vehicle Behavior:
See answers
Possible Causes:
See answers
Actions:
See answers
Locate blower operation information on C02.01/29
Electrical Connectors — Table 7, Blower Motor 2-Pin Connector (Front Unit) and
SAM Cab G02.04/30 705 — Fused and FET Controlled Outputs,
G02.04/37 710 — Fused Battery Pass-Through Outputs

Troubleshooting

Blower Motor

Troubleshooting
Exercise 7.4 Troubleshooting HVAC
Cascadia TM C02.01 / 6
Problem
Fig. 3, Front Control Panel
Troubleshooting class Demo number 1.
System Architecture
Bug truck with a Ambient Temp sensor
that has been modified with a fixed resis-
tor installed between the two wires Fig. 4, Rear Control Panel
System Architecture
Complaint – A/C In-Opt
Operations of HVAC FCU/AUC control-

ler ?/ A/C Clutch / engine fan
FCU
ACU
A/C Clutch
Need more examples
Fig. 2, HVAC System
Electrical Control Topology
Also available in PartsPro mod # are G06

drawings
•PartsPro mod ? G06 - ?
•PartsPro mod ? G06 - ?
7 •PartsPro mod ? G06 - ?
Operation of HVAC FCU / AUC control-

ler / A/C clutch / Engine Fan
•FCU
•A/C clutch – TM C02.01 / 8
Need more examples

Troubleshooting
Troubleshooting HVAC Problems

Your instructor will assign a vehicle serial number. SN AJ1791
Complaint: _A/C In - Opt_____________________ Verify Complaint: Yes

___ / No
A/C clutch not engaging, no fault code

Any Symptom/Observation / Fault codes:_____________________________
Cause: Ambient air temperature inaccrate
Correction: Used ServiceLink Observer A/C template, Compared sensor with TM spec. De-
termined that sensor spec.Replace Ambient air temperature sensor
Area below is used to keep track of resources used during this exercise like;
Cascadia TM C02.01 / 5- 8
Workshop Manuals / Sections: _________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes

___ /No
Cascadia HVAC: (that applies to your truck)
ServiceLink (ECU’s / templates): __________________________________________
70B and 70C

PartsPro Modules # / Sub # and any parameters with in: __________________
`70B, G06-53571-000 70C, G06-56341-000
Drawing: ________________________________________________________
Template show low temp reading on the air temp sensor
Useful information: ________________________________________________

Troubleshooting
Instructor Notes
Bug: MSF connector E pin 3 open circuit
474B05
Troubleshooting class Demo number 2.
Bug truck by removing wire from MSF con-

nector E pin 3 open circuit 474B05.
Complaint –Headlight on all the time Fault

code present: 49 523543 2
Cause: see answer
Correction: see answer
Added Information
Vehicle Behavior: headlights come on and

stay on once the headlight switch has been
turn on.
Warning chime on when headlight switch on.
Actions: Cascadia TM C02.06 / 24
With the key ON, check the headlamp/rotary

switch connection. Check the connections of
the wiring harness (mod
311) from the MSF conn E to the headlamp/

rotary switch. Perform continuity tests on the involved pins (circuits 474B01,
7 474B02 and 474B05). Repair as required
Locate the 2 MSF CAN template, Headlight, and MSF switch Input:
Templates should off when headlight as off and Marker when switch is marker
position, Showed N/A instead.

Troubleshooting
Troubleshooting Headlight Problems

Complaint: _Headlights on all the time_________ Verify Complaint: Yes

___/ No
Warning Chime sound when headlight switch is

Any Symptom/Observation / Fault codes:_____________________________
on. / 49 523543 2
Cause: Open circuit 474B05 (MSF connector E pin 3)
Correction: Used ServiceLink to get fault code,, Follow fault proceed TM . Determined that
open circuit 474B05 at MSF connector E at pin 3, Replace wire
Workshop Manuals / Sections: _________________________________________

___ /No
MSF / Switches and Headlight templates
ServiceLink (ECU’s / templates): __________________________________________
311
PartsPro Modules # / Sub # and any parameters with in: __________________
G06-54729
Drawing: ________________________________________________________
Template shows N/A in the off and marker lamp positions
Useful information: ________________________________________________

Troubleshooting
Instructor Notes
Bug Install 2nd Mux Utility light switch in the sleeper Slave Panel

Troubleshooting
Troubleshooting Worksheet
Your instructor will assign a vehicle serial number. SN ___________
Complaint: Utility Lights Flash on and off__________ Verify Complaint: Yes

___ / No
Any Symptom/Observation / Fault codes:

Utility light flash on / off
Cause:
Two Mux Utility light switches installed on the Sub-bus
Correction:
Remove the 2nd Mux Utility light switches installed on the Sub-bus
Workshop Manuals / Sections:

N/A
Is there a template in ServiceLink to be used with this complaint: ___

Yes / No
ServiceLink (ECUs / templates):

MSF switch screen / monitor switch on/off
PartsPro Modules # / Sub # and any parameters with in:

N/A
Drawing:
N/A 7
Useful information:
MSF Master can not recognize two switches with the same ID on the sub-bus

Troubleshooting
Instructor Notes
Bug Install 2nd Mux Utility light switch in the sleeper Slave Panel

Troubleshooting
Complaint: Rear Turn light In - Opt__________ Verify Complaint: Yes

___ / No

Turn light not working
Cause:
Wrong parameter
Correction:
Used ServiceLink Observer Stop, Turn Hazard lamp template,, Compared parameter on vehicle
to TM spec. / ServiceLink Host information

Compared parameter on vehicle to TM spec. / ServiceLink Host information

Yes / No

SAM Chassis, Stop / Turn / Hazard Lamps

301
Drawing:
G06-66939 7
Useful information:
Note on parameter combination /separate turn lamp

Troubleshooting
Instructor Notes
Bug: Parameter set for cursed control disengage while wiper are on
Students will need to be walked thought this scenario.
(This exercise should be done on a truck, because the simulator boards have no en-
gine and it will be hard to demonstrate)
Explain the customer complain.
Have the student give possible causes. (give hint to help student isolative the most
likely causes)
Example: Where would the driver locate information about Cruise Control options?
Drivers Manual: Optional Engine Systems, Cruise Control. page 10.2
Cruise Control Disengage
The cruise control disengage feature is an optional
safety feature that disengages the cruise control
when one of the following conditions occurs:
hazard lights, headlights, or windshield wipers are on
hazard lights or windshield wipers are on
hazard lights or headlights are on.
Explain drivers complaint – Some fleet spec truck with parameter that curse control dis-
engages when
7 Wiper and or head lights are on.
P04.01/8
800 — Parameters

Troubleshooting
Complaint: Cruise Control kick out when raining Verify Complaint: Yes / No
___

Cruise not working when wiper are on
Cause:
Cruise Control parameter is set to disconnect when wiper are on
Correction:
Change parameter or educate owner/drivers

P04.01/8 800 — Parameters

Yes / No

Sam Cab / Cascadia Cruise Control

149
Drawing:
G06-61995 7
Useful information:
Cascadia Cruise Control show input for cruise disconnect

Troubleshooting
Instructor Notes

Troubleshooting
Troubleshooting Worksheet - ________________________________
Complaint: ______________________________ Verify Complaint: Yes / No
Cause:
Correction:
Is there a template in ServiceLink to be used with this complaint: Yes / No
Drawing:
7
Useful information:

Troubleshooting
Instructor Notes

Troubleshooting
Cause:
Correction:
Drawing:
7
Useful information:

Troubleshooting
Instructor Notes

Troubleshooting
Cause:
Correction:
Drawing:
7
Useful information:

Troubleshooting
Instructor Notes
Fog
Look up Parts Tech 54-062
Follow the instruction for adding Fog Lamps
Have students look the information and fill in the worksheet
Students can add circuit to truck or simulator board and add or change the parameters
Remove harness form truck or simulator board as needed.
High Beams
Follow the instruction for adding Aux High Beams
Have students look the information and fill in the worksheet
Students can add circuit to truck or simulator board and add or change the parameters
Remove harness form truck or simulator board as needed.

Troubleshooting
Troubleshooting Worksheet—Adding Fog Lights or Aux High Beams

Complaint: Customer wants to have installed on the truck
1. What is the parts technical bulletins that would used to add this feature?
Fog: 54-062
Hight Beams: 54-062
2. In the parts technical bulletins locate and write down the following:
What are the part numbers of the harness needed to complete the installation?
Fog: A06-53360-000, A06-62970-001, A06-62971-001

Hight Beams: A06-53360-001, A06-62972-001, A06-62973-001
What parameters will need to be changed and to which ECUs?
Fog: 003 447 20 58, SAM Cab

Hight Beams: 000 447 78 23, MSF and 002 447 37 58, SAM Cab
3. What drawing number should be use to locate connector / terminal positions
Fog: 003 447 20 58, SAM Cab

Hight Beams: G06-53365-000

Troubleshooting
Instructor Notes

Troubleshooting
New Electrical Connector and Terminal

Installing terminals in connectors:
• Locate the proper terminal for each connector
• Locate the secondary lock open it or remove it from each connector
• Install terminal into each connector as the following diagram shows
Using the proper tools to remove terminals from the connectors:
• Locate the secondary lock and open it
• Use tool as shown to remove terminal from the connector

Troubleshooting
Instructor Notes
Develop WSHEET for finding connector

terminal review of new A06 part number
terminals

Troubleshooting
• Locate the secondary lock and remove it from the connector

Troubleshooting
Instructor Notes

Troubleshooting
Upon removing all the terminal from the connector.
• Locate the secondary locks and install them in the connectors
• Place the tools, terminals, connector, and wires in the plastic zip lock bag

Troubleshooting

Troubleshooting
Module 7 Review
A. Use of ServicePro and ServiceLink to troubleshoot electronic problems
B. Understand correct procedures to diagnose potential problems
C. Understand the proper tools to use when diagnosing a concern
Cascadia SERVICETRAININGACADEMY.COM SG 7-50

Troubleshooting
Do
NOT
DELETE
INTENTIONALLY
LEFT
Blank

Appendix
A
Appendix
G06-64121 modified drawing....................... A-2
Component Tags ......................................... A-3
Bugs 1 thru 10 ............................................. A-6
Blank Troubleshooting Worksheets ........... A-39
Cascadia SERVICETRAININGACADEMY.COM SG A-1

Appendix
A
G06-64121 modified drawing
MFJB 175A ENG

MCM (7) IGN 439A
MCM (5,6,8)
EMERGENCY POWER
A-2 SERVICETRAININGACADEMY.COM Cascadia

Appendix
A
Component Tags
1 2
SAM Cabin Central Gateway
3 4
J1708
SAM Chassis
Junction Block
5 6
J1939 terminating
MFJB
resistors 1
7 8
J1939 terminating
MGJB
resistors 2
9 10
MSF Starpoint
Master Connector
11 12
MSF
MCM
slave

Appendix
A
Component Tags
13 14
Powertrain
CPC
PDM
15 16
ABS ECU Aux PDM
17 18
Front HVAC Controller Trailer PDM
19 20
Load Disconnect
Rear HVAC Controller
Switch
21 22
9-pin Diagnostic Cab Door
Connector Switch
23 24
PNDB ACM

Appendix
A
Optional Blank Component Tags

Appendix
A
Instructor Notes: Worksheet 1
Bug 1 – CGW - not functioning

Setting up the bug:
Remove glove box and SAM cabin cover.

Remove fuse F20 (2 amp) or replace fuse with a bad fuse.
CGW will not function causing no cross functionality of Datalink and no commu-
nication from the Cabin CAN ECUs and Diagnostic CAN.
Students will need access to Cascadia Troubleshooting Manual (TM) to look informa-
tion on this bug and PartsPro for finding drawings. ServiceLink will be used during ex-
ercise
Tech will need to recognize conditions noted:
Truck equipped with a ICU4M will show 6 active codes.
Can not receive codes from dash, MSF My Info. Switch not working with ICU4M
to display codes.
Using ServiceLink
Missing CAN icon

Missing ECU’s
a. SAM Cabin
b. SAM Chassis
c. CGW
d. MSF
No Cabin or Diagnostic CAN communication
a. Missing ECUs are a result of either Diagnostic CAN or CGW
Missing gray out Cabin Can information on J1587 and J1939
The problem is not just a Diagnostic CAN / ServiceLink not communicating
a. Cabin Can would be working and gray out Cabin Can information on
J1587 and J1939 would not be missing (CGW is functioning)
b. Some Cabin Can ECU are still working on thought the Cabin CAN
(example)
Turn Headlight switch on, the headlights/tail light come on.
MSF to SAM Cabin and Chassis communication on Cabin CAN
Active Fault codes

Appendix
a. J1587
A
Bug 1 continued
128 231 9 SAE J1939 Data abnormal rate
b. J1939
0 527 9 Curse Control erratic abnormal rate
0 973 9 Eng Retarder erratic abnormal rate
Student should start with locating information in Troubleshooting Manual (TM) in the
following place to get an understanding of how the communication / Datalink work.
G02.02 Datalink communications structure.

Diagnostic CAN (G03.04) and Cabin CAN(G03.03)
Troubleshooting Manual (TM) under Diagnostic CAN will list the following
(G02.03/10)
701 — Possible Causes
- Wiring
- Diagnostic Connector
- Central Gateway Module
If student needs help with the next step, hint or suggest Student look at CGW.
From CGW in TS Manual – looking at possible causes will ask him to check
F.20 in Sam CAB.
TM under CGW will list the following (G02.03/8,9)
701 — Possible Causes
• Fuse F20 (CGW power) on the SAM Cab
• Wiring Starpoint Connector (Cabin CAN)
• CGW
• J1939 Terminating Resistors
• J1587/J1708 Junction Block
• Diagnostic Connector
• Cabin CAN ECUs

Appendix
A Bug 1 continued
Additional Instructor info:
Key in this exercise is that CGW will not communicate.
Students need to realize what CGWs role is to datalink communication and know that
when a processor is not working we should check power and ground source.
Resource student will need to use to test the CGW powers and ground.
TM manual (G02.03/8) CGW
601 — Component Details, Table 2, CGW ECU (single connector)

a. Pin 1 – Battery power
b. Pin 7 – Ground
TM manual (G02.04/11) SAM Cab,
602 — Pinout Mapping, Table 2, Pinout Mapping

a. X3 16 CGW (Central Gateway ECU), Ground
b. X3 18 CGW (Central Gateway ECU),Battery
TM manual (G02.04/20) SAM Cab
603 — Fuse Mapping, Table 3, Fuse Mapping

a. F20 CENTRAL GATEWAY 2 X3 18 CGW, BAT
Cascadia SAM Pin Layout (Wall Chart)
Fused Passthroughs
a. F20 (2A) – x3/18 – CGW, Bat
Ground Return Pins
a. X3/16 – GND, CGW
Student can correct problem and test function if time permits.
Make sure to correct all bugs before releasing truck

Appendix
A
Troubleshooting Worksheet (Bug 1)
Complaint: Cruise Control, Eng. Brake, A/C In - Opt Verify Complaint: Yes / No
See complaints – No visual Observations, No Fault codes noted____

Cause:
Bad or Removed SAM Cab Fuse 20 (Power for CGW)

Correction:
Replace bad or missing fuse
Cascadia TM G02.02 and G03.04 and _ G02.03

MSF switches and Eng Brake and Cruise Control templates, but will not work
because CGW/Diagnostic CAN is not working
Mod 860/WRG.MUX CTRL Gateway

Drawing:
G06-53055-000 - SCAB K3B # 18 CRT 433

Useful information:
ServiceLink Observations – No CAN Communications/ Missing ECUs

Appendix
A
Bug 2 – No Crank / No Start (Parameter Starting Controls set wrong)
Setting up the bug: Truck with Manual transmission
Connect ServiceLink and use computer to change the following parameters in

the SAM Chassis (correct parameter is found in Mod. 156)
a. From 002 447 24 58 PARM-CAB,STR,MAN,BCS (bottom clutch)
b. To 002 447 24 58 PARM-CAB, STR, MAN, NS (neutral switch)
Change of parameter will cause No Crank / No Start complaint with no Fault codes set.
Student verification of complaint:
No clicking of starter solenoid and Mag switch

No power to mag switch when key switch is turn to cranks position
Mag switch has a good ground.
ercise
Student should use TM P01.01/7 to review starter theory about what is needed to start.
702 — Starting System Diagnostics
Follow troubleshooting complaint. Starter will not turn, no clicking. P01.01/12
Student should get to step 3, Compare voltages from tests 1 and 2.
Is there more than one volt difference between the magnetic switch ignition terminal
voltage and battery voltage?
Student answer should be: Yes
Student should note the following from the Yes answer
problem in the ignition input circuit to the magnetic switch, or the starter inter-
locks
Signal comes from the SAM Cab.
See 801 — Starter Crank Interlocks, (P01.01/15)
Use the ―Cascadia Crank Enable‖ Datalink Monitor template to view the interlock
signals to the SAM Cab

Appendix
Bug 2 continued
A
Student would check and find interlocks good but no signal to relay.
ServiceLink will not show that the wrong parameter has been selected and applied to
the truck and will show any operating function (bottom clutch switch depressed).
Based on statement (Signal comes from the SAM Cab) student should check SAM Cab
for troubleshooting of I/O of starter.
Wall chart or G02.04/30 705 — Fused and FET Controlled Outputs

a. LOGIC CONTROLLED UNFUSED OUTPUTS
b. X19/3 −Starter Relay
Student should locate Following Sam Cab troubleshooting will tell them to check pa-
rameter.
G02.04/32 707 — Logic Controlled Unfused Outputs

Student can confirm what the proper parameter for the truck by checking PartsPro
Mod. 156 / 002 447 24 58 PARM-CAB,STR,MAN,BCS
Make sure to correct all bugs before release truck

Appendix
A
Complaint: No Crank / No Start Verify Complaint: Yes / No
No clicking of starter solenoid and Mag switch, No Fault codes noted
Cause:
Parameter for Starting Controls set wrong
Correction:
Replace wrong parameter with correct one Correct parameter is found in Mod. 34B
Cascadia TM P01.01/7 and 12 and 15
SAM Chassis / Cascadia Crank Enable
Mod. 156 / 002 447 24 58 PARM-CAB,STR,MAN,BCS
Drawing:
-53055-000 - SCAB K3B # 18 CRT 433
Useful information:
Cascadia SAM Pin Layout Wall chart or G02.04/30 705 — Fused and FET Controlled
Outputs and G02.04/32 707 — Logic Controlled Unfused Outputs

Appendix
A
Bug 3 - No Start / No Crank (Bad Starter mag switch ground)
Setting up the bug: remove ground from mag switch.
Drawing G06-61996 (AJ1791) (Mod 156) show types of Mag switches and op-
tions .001 - .007
Grounds for Mag switch could be the following, check your truck in PartsPro for
which option applies.
a. Wire eyelet on starter solenoid with ground jumper to ½ ground stud on
stare motor (Mag switch mounted on Starter (Integrated)
b. SAM Cab connector/pin X19/2 (Mag switch not mount on starter)

Has power to mag switch when key switch is turn to cranks position
Note: see Thermal Protection Rules, could lead tech towards replacing mag
switch. If they hold switch for more than 5 seconds voltage goes away, must
wait 30 second to reset.
Mag switch has a no ground. (System / Battery Voltage at ground of Mag
switch)
a. If students miss fact that the ground had power on it when cranking, let
students complete the troubleshooting procedure below, they find step in
troubleshooting procedure that will have them test ground side of Mag
switch.
ercise
Student should use TM P01.01/7 to review starter theory about what is needed to oper-
ate the starter.
Student should review theory of operation and engagement rules.
Optional: Student may want to use the
.702 — Starting System Diagnostics
Follow troubleshooting complaint. Starter will not turn, no clicking. P01.01/12
Step 1

Appendix
A Bug 3 continued
a) measure ignition terminal mag 12V
b) Measure voltage ground mag 12V
Step 2 measure available starting voltage 12v
Step 3 compare voltages
No
12v on ground
Repair high resistance on ground.

Appendix
A

Cause:
Open circuit on ground for mag switch

Correction:
Replace / repair ground wire from mag switch to starter motor ground stud.


Mod. 34B / 000 447 11 61 PARM-CHAS,NTS,NO CNT

Drawing:
G06-61996 (AJ1791) (Mod 156)

Useful information:
Cascadia SAM Pin Layout Wall chart or G02.04/30 705 — Fused and FET Con-
trolled Outputs and G02.04/32 707 — Logic Controlled Unfused Outputs

Appendix
A
Bug 4 – No Start/ No Crank (Broken 472S Wire to Mag switch)
Setting up the bug:
Remove circuit 472s from Cavity 2 in the ENG_HFW_EFW_1A 12 pin connector lo-
cated by wiper motor insert dummy wire.
Use drawing # D06-65-976-000 page 6 to locate connector on truck.

Drawing G06-61996 (AJ1791) (Mod 156) shows types of Mag switches and op-
tions .001 - .007, (drawing # 14A-? in the print pack)

Has no power to mag switch when key switch is turn to cranks position
Note: see Thermal Protection Rules, could lead tech towards replacing mag
switch. If they hold switch for more than 5 seconds voltage goes away, must
wait 30 second to reset.
Mag switch has a good ground.
a. If students miss fact that the mag switch had no power on it when crank-
ing, let students complete the troubleshooting procedure below, they find
step in troubleshooting procedure that will have them test power side of
Mag switch.
ercise
No crank or clicking from mag.
Use TM section D01.01.702
Tech should review theory of operation interlocks and thermal rules use starter will not
turn, no clicking noise
Step 1) a measure mag switch ignition 0V
Measure mag switch ground 0V
Step 2 measure available crank voltage 12V
Step 3 compared voltage
Between the Mag and cranking 12V greater than 1v
Ground below .5Vgood

Appendix
Bug 4 continued
A
Troubleshooting tells possible ignition circuit input to mag switch or SAM Cab or starter
interlocks.
Use Cascadia Crank Enable template
Clutch signal good
Crank signal good
Command good
Now Student needs to obtain schematic to perform voltage testing, go to PartsPro,

module 15 subgroup 156 should find drawing G06-61996-004, A06-64529-000, A06-
67151-000
Using diag. G06-61996-004 the tech should measure voltage while cranking from con-
nector X19 cavity 3 Wire # 472s. Student will find 12V. He will then need to move to the
next connector to test circuit. FW_H_ENG_EFW_1A 12 pin connector, cavity 2 wire #
472s. The tech will need to find location of connector in installation drawing.
Tech would need to go to module 54B subgroup 321 and locate diagram (installation
drawing) D06-65076-000 and go to page 6 using reference designator for the connec-
tor test voltage on female side would have 12V on male 12V tech should surmise there
is a break in wire between connector and mag switch
High resistance (open circuit) on power side of Mag switch.

Appendix
A

Cause:
Open circuit on crank circuit for mag switch

Correction:
Replace / repair crank 472S wire from SAM Cab to mag switch


Mod. 34B / 000 447 11 61 PARM-CHAS,NTS,NO CNT

Drawing:
Mod 156 G06-61996, A06-64529-000, A06-67151-000 Mod. 321, D06-65976-000

Useful information:
Cascadia SAM Pin Layout Wall chart or G02.04/30 705 — Fused and FET Con-
trolled Outputs and G02.04/32 707 — Logic Controlled Unfused Outputs

Appendix
A
Instructor Notes:
Bug #5 lost communication (J1939).

Setting up the bug:
Remove connector for radio and shorted J1939 high and J1939 low to each other at
radio plug,
Use the following example Ser # AJ1791 to locate connector / harness / wires / pin
cavities
Radio: Mod 74D, Drawing G06-53896 (note on drawing to go to Mod 160 for J1939 in-
formation G06-56989 (Sheet 4 of 10 locations B-4)
PartsPro note see mod 320 Installation drawing D06-56742 page 19 for location of
connector.
Mod 320 drawing L06-62882 sheet 2 locations K-21
No faults on J1939 due to lack of communication fault.
CAN Fault SA 37 SPN 523512 FMI 31.
No faults on ICU3. No J1939 data appeared on ICU4M.
Able to verify no communication on J1939 due to not able to override rear HVAC con-
troller.
ercise.
Student find no ECU on J1939 ECU list, Using the Cascadia J1939 Test template,
shows ! in the boxes and prompts tech to test for 60 resistance on J1939
Found fault at G03.03/14 (Datalink cabin CAN) J1939 performance
Student should locate J1939 troubleshooting in G02.03
701 — Diagnosing the J1939 Datalink
Student directed to test resistance between J1939 + to J1939 – in step 2.3

Appendix
A Bug 5 continued
Should be 60 ohms, Test results: approx. 8 ohms.
Student directed to go to /9 short between J1939 + and J1939 -
Opened parts pro module 160 found diagram G06-65989-011 to trace harness A06-
66011-000 to find details of connectors.
Student will need to locate J1939 data link in each of it location and test the circuit to
locate the effected area of the Datalink.
Student will find shorted J1939+ and J1939 – at the radio connector.
Student should also located SB 54-226, Radio and J1939 Datalink Wiring for the Cas-
cadia
Make sure to correct all bugs before releasing truck.

Appendix
A
Complaint: (ICU4M) Alert NO J1939 Verify Complaint: Yes / No
No start – No Fault code displayed on ICU4M, CAN Fault SA 37 SPN 523512 FMI
31
Cause:
Shorted J1939 + and J1939 – at radio connector in dash

Correction:
Replace bad or repair shorted missing J1939 + and J1939 – Follow instruction in
SB 54-226, Radio and J1939 Datalink Wiring for the Cascadia
Cascadia TM G03.03/14 fault codes and G02.03 J1939Troubleshooting

Cascadia J1939 Test, but template show ! in the boxes and prompts tech to test
for 60 resistance on J1939
Mod 160
Drawing:
G06-65989-011, A06-66011-000
Useful information:
ServiceLink Observations – No CAN Communications/ Missing J1939 ECUs

Appendix
A
Bug # 6 Complaint: Engine fan on at all time (A/C transducer return
(GND) open circuit)
(Bug best done on truck, so student can see engine fan operation)
Setting up the bug: Remove ground for A/C Pressure transducer
Disconnect the harness at X19 on the SAM Cab
Move the 440G wire, A/C transducer Return (GND) from cavity 12 to unused Cavity
21.
Cause an open in the sensor GND.
X19 connector is located on front wall side of SAM Cabin.

Run truck sees that fan is on all the time.
Students uses ServiceLink or ICU4M to find the following fault codes on the follow-
ing Datalinks:
CAN: SA 33 SPN 522010 FMI 2
J1939: SA 25 SPN 522510 FMI 0

ercise.
Student find fault code: SA33 SPN 522010 FMI 2 in Cascadia TM: CAN Fault Codes
G04.03/15. Fault code list: Subject (where to find more information)
C02.01 — HVAC System
Student will find fault code in C02.01 HVAC System page 36
 See fault code Description / Trigger
G02.04 — SAM Cab

was active on the CAN databus listed in both HVAC front controller and SAM Cab
HVAC template showed high pressure (545psi) in red
Fault is only listed in G04.03/15, not listed in SAM Cab or HVAC front controller.
(Difficulty added to exercise due to HVAC fault codes not listed in HVAC System

Appendix
Bug 6 continued
A
C02.01 Table of Contents, under 700 section, Fault Codes–HVAC are found starting
on page C02.01/35)
Open PartsPro, module 70B open drawing G06-53571-000 and A06-53566-000 for as-
sembly drawing for connector at transducer and Sam Cab X19 connector with HVAC
wires.
Student will back probe and check voltages at HVAC pressure transducer connector
(close circuit results)
5 volt supply (source) voltage at all three wires pins 1,2,3
Pin 1, wire 440G should have been 0 volts (good GND)
Pin 2, wire 440 should have been 5 volts (Supply voltage)
Pin 3, wire 440Y should have been less than 5 volts more than 0 volts
(depending on psi in the system)
Next test point is SAM Cab connector X19 pins 10, 12, 17.
Student should find that wire 440G is in the cavity position 21 and is show in the draw-
ing and wall chart as being in cavity 12.

Appendix
A
Complaint: Engine fan on at all time Verify Complaint: Yes / No
AN: SA 33 SPN 522010 FMI 2 J1939: SA 25 SPN 522510 FMI 0

Cause:
__(A/C transducer return (GND) open circuit 440G at X19/12 on SAM Cab)
Correction:
Replace bad or repair open 440G wire connection at X19/12 on SAM Cab
Cascadia TM CAN Fault Codes G04.03/15

Cascadia HVAC - Sleeper Cab and Day Cab

MOD 70B
Drawing:
G06-53571-000 and A06-53566-000

Useful information:
ServiceLink Observations – SAM Cab HVAC template showed high pressure

(545psi) in red __ Cascadia SAM Pin Layout Wall chart or G02.04/29,30 704 —
Grounded Pins and Inputs and _ 705 — Fused and FET Controlled Outputs_

Appendix
A
Bug # 7 Complaint – Engine fan on all the time
. (Bug best done on truck, so student can see engine fan operation)
Setting up the Bug:
Engine coolant temperature sensor disconnected at coolant collector
Fault codes – J1939/ SA0 SPN 110 FMI 3 and J1708/ 128 110 FMI 3
SPN110 FMI 3 not listed in vehicle J1939 faults.
SPN 110 listed as coolant temp – FMI 3 voltage above normal or shorted high –
fault reported over J1939 from engine.
Verify complaint:
Check engine and light on.
Connect ServiceLink and write down information on fault codes
Tech can connect to truck using DDDL to check engine related for faults, if he has ac-
cess to DDDL
Verify open circuit in the coolant temp sensor (sensor harness not connected).
No diagnostic help on chassis side.
Note: Bug can be repeated or switch up using the Intake air temp sensor, will have the
same symptoms (engine fan on all the time) as engine coolant temp sensor bug, but
different fault codes: (as reported on ICU4M)
J1708/ 128 105 03 INTAKE AIR Temp Sht Hi
J1939/ 00 001636 03 TNTK MANF Temp

Appendix
A
Complaint: Engine fan on at all time Verify Complaint: Yes / No
Fault codes – J1939/ SA0 SPN 110 FMI 3 and J1708/ 128 110 FMI 3 Check En-
gine and Malfunction Indicator lamps on
Cause:
Engine coolant Temperature sensor unplugged or has high resistance

Correction:
Replace bad or repair open wire at the coolant Temp sensor connection at cool-
ant collector front of engine
N/A, Engine problem need Detroit manuals

N/A, Engine problem need Detroit manuals _ServiceLink will display codes and
more fault information___
N/A, Engine problem need Detroit manuals

Drawing:
N/A, Engine problem need Detroit manuals _

Useful information:
ServiceLink Fault code descriptions: Coolant Temp – Voltage above normal or

Shorted High

Appendix
A
Bug 8 - Front HVAC Blower motor Inop
Setting up the bug: remove ground from blower motor
Locate SAM Cab Connector/Pin X7/1 and remove wire GND #1204.
To remove wire from connector:
Use small flat blade pick or screw driver to undo secondary lock (be careful power wire
and GND use same secondary lock and could be short across)
Tyco tool # 1-1579007-6 to remove the wire from the connector (see SB-219 for how
order tool and use the tool)
Hide wire so student will not see loose wire.
blower motor doesn’t operate at any speed setting
ICU4M reports fault code: HVAC2 SA 58 SPN 523318 07
Student should find the motor has power, but no ground.
If students find bad ground, next step is locating test points to isolate open ground cir-
cuit using G06 drawings. See Note:2
If students miss fact that the ground had power on it, let students complete the trouble-
shooting procedure below.
ercise
ServiceLink HVAC
Student should use search for 523318 in the Cascadia TM to locate the fault code in
the following areas.
G04.02/9 J1939 Fault Codes:
58 523318 07 Blower motor, protection mode (speed mismatch or blocked rotor).
C02.01/ 37 HVAC System Table 21, J1939 ACU Fault Codes:
58 523318 thermal protection —7 Blower Motor—protection mode (speed mismatch or

Appendix
A Bug 8 continued
blocked rotor)
C02.03/24 Auxiliary HVAC System with ParkSmart TM Fault codes: (Table 10)
Blower Motor Protection Mode: Speed mismatch or blocked rotor. 523318 7
Transmitting modules: FCU/ACU/ACU
Limitations: Diagnostic feedback PWM signal is 10Hz@75% duty cycle. Use of this FMI
assumes a mechanical problem.
The Blower motor is in Protection mode and fault code will not address the specific of
the problem.
Student should review theory of operation of the blower motor:
C02.01/29,30 HVAC System, Blower Motor:
Blower motor protection refer to Table 28, Blower Motor Protection Modes on page
C02.01/41
Note: 1
After Student review fault code information and Blower motor operation, they may need
help with next test point if they have not related power and ground problems showing
up as a blower protection type fault.
Note: 2
If student found bad ground during verification of complaint, this were they should have
started in their troubleshooting, (finding the next test point) but after completion of
troubleshooting the problem (open ground) have the student do the finding of fault
code and blower motor operation above.
Using the following to locate next test point:
PartsPro, Mod 70C
Drawings: G06-56341-000 and A06-56333-000
SAM Cab Connector/Pin X7/1
Floor LH harness 14 pin connector – cavity 10

Appendix
Bug 8 continued
A
Cascadia SAM Pin Layout Wall chart or G02.04/29,30 704 — Grounded Pins and In-
puts.
SAM Cab Connector/Pin X7/1
Student should find no wire in SAM Cab Connector/Pin X7/1
Repair high resistance on ground (open circuit).

Appendix
A
Complaint: Sleeper HVAC Blower motor Inop. Verify Complaint: Yes / No
HVAC2 SA 58 SPN 523318 07

Cause:
Blower motor has high resistance in ground circuit Missing ground wire a SAM
Cab Connector/Pin X7/1
Correction:
Replace bad or repair open wire at the SAM Cab Connector/Pin X7/1
G04.02/9 J1939 Fault Codes and C02.01/ 37 HVAC System and possibly
C02.03/24 Auxiliary HVAC System with ParkSmart TM Fault codes__
HVAC Auxiliary Control Unit Template: HVAC Sleeper Cab

70C
Drawing:
G06-56341-000 and A06-56333-000

Useful information:
ServiceLink Fault code descriptions: SA 58 SPN 523318 FMI 07 description : me-

chanical system not responding properly HVAC Sleeper Cab template show
blower speed control working, no blower speeds and Protect display shows: yel-
low and Hi Temp Cascadia SAM Pin Layout Wall chart or G02.04/29,30 704 —
Grounded Pins and Inputs

Appendix
A
Bug # 9 Complaint: Dash switches inop
(Bug best done on truck, so student can see all the switches)
Setting up the bug: Remove good Mux switch and replace with defective switch.
Switch will Shorts Sub-bus low (ground) see detail below on how to make bug switch
(Make sure to mark the Bug switch so you can keep track of it)
Using one of the standard features Mux Switches, disassemble switch as fol-
lows
o Remove the switch cover and detent rocker.
o Using four shim the thickness of the 4 tabs that hold the inside section of the
switch inside the switch housing,. Slide the shims between the inside section and the
housing.
o Gently pry the inside section out of the housing
o Be careful to watch for the two detent balls and springs that may come out when
the inside section detent holes line up with the housing detent assembly holes.
Remove ball and spring as needed
o Work the inside section tabs out pass the second set of 4 holes in the housing,
o Be carful not accidently take any of the contact point and spring apart.
o Remove the small three terminal connector for the sub-bus from the inside sec-
tion.
o Solder the Sub-bus data terminal to the Sub-bus ground terminal.
o Cut the tape circuit from the connector and the circuit board and throw the tape
circuit away.
o Install the three wire Sub-bus connector back on to the inside section.
o Reassemble the inside section into the switch housing make sure to install the
detent balls and springs when the detent assembly hole line up.
o Reinstall the detent rocker and switch cover.

Appendix
A Bug 9 continued
Can not retrieve codes using dash (ICU4M)
Students uses ServiceLink to find the following fault codes:
o See answers above, Any Symptoms /Observation / Fault codes for codes
ercise.
G02.06/23.
Details list causes: (sub bus signal) is detected to be less than 4V for at least 3
seconds.
• Action list step to test sub-bus:
o Student will find bad switch by doing sub-bus test or:
A quicker way to eliminate section of the sub-bus by unplugging one sub-bus

harness at a time from the MSF Master until fault goes away or sub-bus MUX switch
appear on ServiceLink MSF ―Switch‖ screen. .
All other fault codes have to do with missing switch also a hint to sub-bus prob-
lem
Open PartsPro, module 860 open drawing G06- 53137 and any A06- assembly draw-
ing for connector and test point needed..
Student will back probe and check voltages at on the sub-bus.
Easiest place to test sub-bus is remove a sub-bus switch

Middle pin is Datalink the other two are power (12 volt) or Ground
Once the student has isolated a Slave Control Panel that as holds a bad switch.
Remove one switch at time watching for one of the following:
sub-bus testing shows problem corrected

watching for fault to go inactive
ServiceLink Switch screen to start displacing switches.

Appendix
A
Complaint: Dash (MUX) switches inop Verify Complaint: Yes / No
CAN: SA 49 SPN 520302 FMI 4, SA 49 SPN 523530 31 J1939: SA 49 SPN 523530

FMI 31, SA 0 SPN 973 13 J1708: MID 164 SID 254 FMI 14, MID 164 SID 254 FMI
13
Cause:
Sub-bus shorted Low Grounded, Defective MSF Switch

Correction:
Replace bad MSF switch (Dash-Mirror Heat A06-53782-002 or Sleeper LWR

LAMP A06-53782-145)__
Cascadia TM CAN Fault Codes G04.03/18. Modular Switch Field G02.06/23,

J1708/J1587 - Routing Active CAN Fault G04.01/2, 3_

___ / No
Cascadia MSF – Switch screen, Parameter screen, Heated mirror template

MSF - Mod 860 All MSF switches have Parameters, can be found in the following
MSF-Hardwire-Switches –Mod- 28F, 329, 32C,330, 74D MSF – Mux –Switches
129, 152, 296, 31J, 32B, 32C, 74E, 811, 81BA06-53414-000, A06-
Drawing:

Appendix
A G06- 53137 and A06-59538-000, -001, -002 A06-53414-000, A06-________
Useful information:
MSF Hardwired Switches work, MY INFO MUX Switch not working (use Service-
Link to get codes), ServiceLink Observations – MSF template showed in red
when no data is being sent __ Part # search in Parts Pro using A06-53782 and 83
switches with a * before and after the part # _____

Appendix
A
Bug # 10 Complaint: Dash switches inop
(Bug best done on truck, so student can see all the switches)
Setting up the bug: Remove good Mux switch and replace with defective switch.
Switch will Shorts Sub-bus High (12 volts) see detail below on how to make bug switch
(Make sure to mark the Bug switch so you can keep track of it)
Using one of the standard features Mux Switches, disassemble switch as follows
Remove the switch cover and detent rocker.
Using four shim the thickness of the 4 tabs that hold the inside section of the switch in-
side the switch housing,. Slide the shims between the inside section and the housing.
Gently pry the inside section out of the housing
Be careful to watch for the two detent balls and springs that may come out when the
inside section detent holes line up with the housing detent assembly holes.
Remove ball and spring as needed
Work the inside section tabs out pass the second set of 4 holes in the housing,
Be carful not accidently take any of the contact point and spring apart.
Remove the small three terminal connector for the sub-bus from the inside section.
Solder the Sub-bus data terminal to the Sub-bus power terminal.
Cut the tape circuit from the connector and the circuit board and throw the tape circuit
away.
Install the three wire Sub-bus connector back on to the inside section.
Reassemble the inside section into the switch housing make sure to install the detent
balls and springs when the detent assembly hole line up.
Reinstall the detent rocker and switch cover.
Can not retrieve codes using dash (ICU4M)
Students uses ServiceLink to find the following fault codes:

Appendix
A Bug 10 continued
See answers above, Any Symptoms /Observation / Fault codes for codes
ercise.
G02.06/22.
Details list causes: (sub bus signal) is detected to be more than normal voltage (2V-
need correct answer) for at least 3 seconds.
Action list step to test sub-bus:
Student will find bad switch by doing sub-bus test or:
A quicker way to eliminate section of the sub-bus by unplugging one sub-bus harness
at a time from the MSF Master until fault goes away or sub-bus MUX switch appear on
ServiceLink MSF ―Switch‖ screen. .
All other fault codes have to do with missing switch also a hint to sub-bus problem
Open PartsPro, module 860 open drawing G06- 53137 and any A06- assembly draw-
ing for connector and test point needed..
Student will back probe and check voltages at on the sub-bus.
Easiest place to test sub-bus is remove a sub-bus switch
Middle pin is Datalink the other two are power (12 volt) or Ground
Once the student has isolated a Slave Control Panel that as holds a bad switch.
Remove one switch at time watching for one of the following:
sub-bus testing shows problem corrected
watching for fault to go inactive
ServiceLink Switch screen to start displaying switches.

Appendix
A
Complaint: Dash (MUX) switches inop Verify Complaint: Yes / No
CAN: SA 49 SPN 520302 FMI 3, SA 49 SPN 523530 31 J1939: SA 49 SPN 523530
FMI 31, SA 0 SPN 973 13 J1708: MID 164 SID 254 FMI 14, MID 164 SID 254 FMI 13
Cause:
Sub-bus shorted High, Defective MSF Switch
Correction:
Replace bad MSF switch (Sleeper LWR LAMP A06-53782-145)_
Cascadia TM CAN Fault Codes G04.03/18. Modular Switch Field G02.06/23, J1708/
J1587 - Routing Active CAN FaultG04.01/2, 3_
Cascadia MSF – Switch screen, Parameter screen, Sleeper Lighting template

: MSF - Mod 860 All MSF switches have Parameters, can be found in the following
MSF-Hardwire-Switches –Mod- 28F, 329, 32C,330, 74D MSF – Mux –Switches 129
, 152, 296, 31J, 32B, 32C, 74E, 811, 81B
Drawing:
G06- 53137 and A06-59538-000, -001, -002 A06-53414-000, A06-________

Appendix
A Useful information:
MSF Hardwired Switches work, MY INFO MUX Switch not working (use ServiceLink to
get codes), ServiceLink Observations – MSF template showed in red when no data is
being sent __ Part # search in Parts Pro using A06-53782 and 83 switches with a * be
fore and after the part # _____

Appendix
A
Cause:
Correction:
Drawing:
Useful information:

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Training Manual Use

ii-2 SERVICETRAININGACADEMY.COM i-2 Cascadia

Cascadia SERVICETRAININGACADEMY.COM SG None ii-3

Module 2: Power Distribution............................................................................. 2-1

Module 3: Cascadia Electronic Modules ........................................................... 3-1

Module 4: Multiplexing ....................................................................................... 4-1

Module 5: Service Information ........................................................................... 5-1

Module 6: ServiceLink ....................................................................................... 6-1

Module 7: Troubleshooting ................................................................................ 7-1

ii-4 SERVICETRAININGACADEMY.COM Cascadia

Cascadia SERVICETRAININGACADEMY.COM SG None ii-5

Time Start Start: Time End

10:15AM Module 2 11:30AM

12:30PM Module 2 2:00PM

2:15PM Module 3 4:00PM

ii-6 SERVICETRAININGACADEMY.COM Cascadia

10:15AM Exercise 3.2 11:30AM

12:30PM Datalinks—Diagnostic CAN 2:00PM

2:15PM Cruise Control 4:00PM

Cascadia SERVICETRAININGACADEMY.COM SG None ii-7

10:15AM Worksheet—Finding Module Numbers 11:30AM

12:30PM SAM Hardware and Software Updates 2:00PM

2:15PM Module 6 4:00PM

ii-8 SERVICETRAININGACADEMY.COM Cascadia

10:15AM Module 7 11:30AM

12:30PM Assigned Troubleshooting Exercises 2:00PM

2:15PM Assigned Troubleshooting Exercises 4:00PM

Cascadia SERVICETRAININGACADEMY.COM 1-1 ii-9

Safety and Shop Rules ....................................................................................... i-8

Computer Protocol ............................................................................................. i-9

Discrimination and Harassment........................................................................ i-10

Course Learning Objectives ............................................................................. i-11

i-1 SERVICETRAININGACADEMY.COM i-6 Cascadia

What do you expect to learn from this course?

Cascadia SERVICETRAININGACADEMY.COM SG i-7 i-2

Start the engine unless in-

Observe normal sop safety procedures

i-3 SERVICETRAININGACADEMY.COM SG 1-8 Cascadia

Use the computer only as directed

Cascadia SERVICETRAININGACADEMY.COM SG 1-9 i-4

With regard to sexual harassment in particular; unwelcome sexual advances, requests

A student or employee’s submission to or rejection of such conduct is used as the ba-

It is important to remember that behavior which one individual considers innocent or

i-5 SERVICETRAININGACADEMY.COM SG 1-10 Cascadia

Module 1— Cascadia Overview

Identify the different Cascadia models

Explain purpose of Signal detection & Activation Modules (SAMs).

Explain the basic concept of multiplexing

Use www.AccessFeightliner.com to find service and troubleshooting information

Use ServiceLink to monitor Cascadia ECUs

Cascadia SERVICETRAININGACADEMY.COM SG 1-11 i-6

Use of ServicePro and ServiceLink to troubleshoot electronic problems

i-7 SERVICETRAININGACADEMY.COM SG 1-12 Cascadia

B. Identify Electronics specific to Cas-

Cascadia SERVICETRAININGACADEMY.COM SG 1-1 1-1

The Cascadia is more aerodynamic

Point out the following on the truck as

Cascadia Instructor's Guide 083010

Cascadia Instructor's Guide 083010

Cascadia Instructor's Guide 083010