09.4.

3 Tests on plug connections of I module

Tests of components and wiring, if malfunctions have occurred showing up

during function check 09.4.2.

Prerequisites for test

Vehicle voltage 24 V
Compressed air above 6.5 bar
Coolant level correct
Test module installed

Special tools

Commercially available tool

Multimeter e.g. made by Sun, DMM-5, by Fluke, 23-DB or 83-DB

and by Hermann, AVO Meter 2003

Contact box connection

Connect test cable harness and contact box with ignition switched off and
perform required measurements with multimeter.

Note
- Cables, plug connections and fuses are taken into consideration during
the tests and in the event of a fault display should be once again
separately tested for interruption, good contact and correct connection in
accordance with the respectively valid wiring diagram.

- Plug IV (C3 connection of tachograph) is tested via the respective

systems,
e.g. ABS/ASR, GBL, GBE, GB etc.

A Test cable harness

B Multimeter
C Contact box
D Consumers

Testing with test cable I

Testing on plug II 18/.. for module with test cable II (warning buzzer and
all indicator lamps)

Attention
Apply voltage to terminal II 18/4 and II 18/2

Test 20 18
module + II 18/4 II 18/2

Test step Test scope Measuring instru- Actuation/Prerequisite Nominal value Possible cause/Remedy
ment/Test connection
1 Indicator lamp coolant level Test 24 Ignition: On. Indicator lamp lighting Indicator lamp defective.
module - II up. Warning buzzer defective.
18/8 Warning buzzer
sounds.
2 Indicator lamp water supply Test 26 Ignition: On. Indicator lamp lighting Indicator lamp defective.
windshield washer tank module - II up.
18/1
0
3 Indicator lamp tipper Test 31 Ignition: On. Indicator lamp lighting Indicator lamp defective.
module - II up.
18/1
5
4 Indicator lamp differential Test 30 Ignition: On. Indicator lamp lighting Indicator lamp defective.
lock front axle/inter-axle lock module - II up.
18/1
4

Test step Test scope Measuring instru- Actuation/Prerequisite Nominal value Possible cause/Remedy
ment/Test connection

© Daimler AG, 09.08.13, G/01/13, dh0904lkw0003x, 09.4 - Module tests, I-module 3 - Tests on plug connections of I module MK/SK Trucks Страница 1 из 4
5 Indicator lamp differential Test 32 Ignition: On Indicator lamp lighting Indicator lamp defective
lock front axle module - II up
18/1
6
6 Indicator lamp differential Test 28 Ignition: On Indicator lamp lighting Indicator lamp defective
lock rear axle module - II up
18/1
2
7 Indicator lamp differential Test 29 Ignition: On Indicator lamp lighting Indicator lamp defective
lock module - II up
18/1
3
8 Indicator lamp inter-axle lock Test 33 Ignition: On Indicator lamp lighting Indicator lamp defective
1st and 2nd front axle module - II up
18/1
7
9 Indicator lamp inter-axle lock Test 27 Ignition: On Indicator lamp lighting Indicator lamp defective
module - II up
18/11
10 Indicator lamp inter-axle lock Test 34 Ignition: On Indicator lamp lighting Indicator lamp defective
1st and 2nd rear axle module - II up
18/1
8
11 Indicator lamp power take-off Test 21 Ignition: On Indicator lamp lighting Indicator lamp defective
1 and 2 module - II up
18/5
12 Indicator lamp low-ratio Test 25 Ignition: On Indicator lamp lighting Indicator lamp defective
group module - II up
18/9
13 Indicator lamp high-ratio Test 23 Ignition: On Indicator lamp lighting Indicator lamp defective
group module - II up
18/7

Test step Test scope Measuring instru- Actuation/Prerequisite Nominal value Possible cause/Remedy
ment/Test connection
14 Clock, tachograph Test 17 Ignition: On. Time clock, tachograph Clockdefective
module + II Check expiration time of running
1 clock.
8
/
1
15 Cable bridge 19 22 Ignition: Off. >5 Bridge defective.
II 18/3 II 18/6 Disconnecting switch (SA).
16 Disconnectiong switch (SA) Test 19 Ignition: Off. 21 - 29 V Power supply A4/F9 interrupted
module II 18/3
17 Disconnectiong switch GBL, C Test 17 Ignition: On. Tachograph Tachograph defective
2 ( SA) module + II Vehicle >10 km/h establishes through-
1 connection for tacho-
8 connected voltage 30
/
1
18 Main switch(SA) Test 19 Ignition: On. Hazard warning Hazard warning flasher system defective.
Hazard warning flasher module + II Switch hazard warning flasher system Interior lamps defective.
system 1 flasher system actuated. flashing.
Interior lamp 8 Interior lamps lighting
/ up.
3
19 Clutch remote control (SA) Test 21 Ignition: On. Indicator lamp lighting Indicator lamp defective
module + II Switch actuated (body up
1 manufacturer).
8
/
2
20 Supply pressure check Test 23 Ignition: On Indicator lamp lighting Indicator lamp defective
Auxiliary consumers (SA) module - II up
18/7
21 Delay relay (SA) Test 24 Ignition: On Buzzer sounds off Relay defective
module - II delayed
18/4
22 Indicator lamp brake Test 31 Test 20 Indicator lamp lighting Indicator lamp defective
pressure (SA) module - II module + up
18/1 Ignition: On.
5

Test step Test scope Measuring instru- Actuation/Prerequisite Nominal value Possible cause/Remedy
ment/Test connection
23 Flashing beacon (SA) Test 33 Test 20 Flashing lamp lighting Flashing beacon defective
module - II module + up
18/1 Ignition: On.
7

Testing on plug I to module with test cable I

© Daimler AG, 09.08.13, G/01/13, dh0904lkw0003x, 09.4 - Module tests, I-module 3 - Tests on plug connections of I module MK/SK Trucks Страница 2 из 4
(Lamps of switches and potentiometers for night-time dimming)

Test step Test scope Measuring instru- Actuation/Prerequisite Nominal value Possible cause/Remedy
ment/Test connection
24 Dimmer 11 13 Turn dimmer to the left and Lighting is changing Dimmer (potentiometer) defective
I 10/3 I 10/1 right
25 Illumination switch 11 12 Parking lamp on Switch illumination Switch defective
lighting up
26 Webasto switch illumination, Test 15 Ignition: On Switch illumination Switch defective
preselection clock, switch for module I 10/5 lightin up
cab or engine preheating
(SA) and switch for
recirculating air
27 Battery separating switch Test 33 Battery disconnecting switch Relay K2 switching Relay defective
(SA) module I 10/4 on

Testing on plug III to module with test cable II

(All switches and sensors: engine, axles, transmission and coolant)

Test step Test scope Measuring instru- Actuation/Prerequisite Nominal value Possible cause/Remedy
ment/Test connection
28 Coolant level sensor Test 28 Ignition: Off. approx. 150 Sensor defective.
module - III No coolant.
18/1
2
29 Tipper indicator lamp Test 19 Tipper not actuated. > 30 k Pressure switch defective
module - III
18/3 Tipper actuated. <5
30 Differential lock 1st front axle Test 22 Differential lock not actuated. > 30 k Switch defective
module - III
18/6 Differential lock actuated. <5
31 Differential lock 2nd front Test 20 Differential lock not actuated. > 30 k Switch defective
axle module - III
18/4 Differential lock actuated. <5
32 Differential lock 1st rear axle Test 24 Differential lock not actuated. > 30 k Switch defective
module - III
18/8 Differential lock actuated. <5
33 Inter-axle lock 1st and 2nd Test 21 Inter-axle lock not actuated. > 30 k Switch defective
front axle module - III
18/5 Inter-axle lock actuated. <5

Test step Test scope Measuring instru- Actuation/Prerequisite Nominal value Possible cause/Remedy
ment/Test connection
34 Inter-axle lock 1st and 2nd Test 17 Inter-axle lock not actuated. > 30 k Switch defective
rear-axle module - III
18/1 Inter-axle lock actuated. <5
35 Inter-axle lock front axle Test 23 Inter-axle lock not actuated. > 30 k Switch defective
module - III
18/7 Inter-axle lock actuated. <5
36 Inter-axle lock 1st and 2nd Test 18 Inter-axle lock not actuated. > 30 k Switch defective
rear-axle module - III
18/2 Inter-axle lock actuated. <5
37 Power take-off 1 Test 27 Power take-off not actuated. > 30 k Pressure switch defective
module - III
18/11Power take-off actuated. <5
38 Power take-off 2 Test 29 Power take-off not actuated. > 30 k Pressure switch defective
module - III
18/1 Power take-off actuated. <5
3
39 Group switch Test 30 High-ratio group engaged > 30 k Group switch defective
module - III
18/1 Low-ratio group engaged <5
4
40 Switch brake pressure circuit Test 19 Switch not actuated. > 30 k Switch defective
1 and 2 (SA) module - III
18/3 Switch actuated. <5
41 Switch auxiliary consumer Test 30 Switch not actuated. > 30 k Switch defective
module - III
18/1 Switch actuated. <5
4

Test step Test scope Measuring instru- Actuation/Prerequisite Nominal value Possible cause/Remedy
ment/Test connection
42 Relay converter clutch (WSK) Test 31 Ignition: On Relay switching Relay K5 defective
ZF retarder (SA) module - III
18/1
5

© Daimler AG, 09.08.13, G/01/13, dh0904lkw0003x, 09.4 - Module tests, I-module 3 - Tests on plug connections of I module MK/SK Trucks Страница 3 из 4
43 Relay auxiliary heater (SA) Test 31 Ignition: On Relay switching Relay defective
module - III
18/1
5
44 Relay clutch remote control Test 31 Ignition: On Relay switching Relay defective
(SA) module - III
18/1
5

Plug IV (C 3 connection from tachograf) is tested by way of the respective systems, e.g. ABS/ASR, GBL, GBE, GB, etc.

© Daimler AG, 09.08.13, G/01/13, dh0904lkw0003x, 09.4 - Module tests, I-module 3 - Tests on plug connections of I module MK/SK Trucks Страница 4 из 4