Service Manual

SERVICE MANUAL
TRUCK SERVICE MANUAL
ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 3200, 4100, 4200,

4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built 05/20/2003
to 02/28/2007
Model: 3200
Start Date: 05/20/2003 End Date: 02/28/2007
Model: 4100
Model: 4200
Model: 4300
Model: 4400
Model: 7300
Model: 7400
Model: 7500
Model: 7600
Model: 8500
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Copyright © 01/04/2008 Navistar, Inc.
Model: 8600
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01/04/2008
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Copyright © 01/04/2008 Navistar, Inc.
TRUCK SERVICE MANUAL i
Table of Contents
SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GROUP 08 ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 POWER DISTRIBUTION AND GROUNDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3 MULTIPLEXING (DATA LINKS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
4 ELECTRICAL SYSTEM CONTROLLER AND SWITCH PACKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
5 ELECTRONIC GAUGE CLUSTER AND AUXILIARY GAUGE SWITCH PACK. . . . . . . . . . . . . . . . . . . .137
6 FANS AND ENGINE ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
7 BATTERY, CHARGING AND CRANKING SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365
8 ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
9 CAB FEATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433
10 CHASSIS FEATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .617
11 LIGHT SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .821
12 TRANSMISSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .955
13 HEATER AND AIR CONDITIONER (HVAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1031
14 DIAGNOSTIC TROUBLE CODES (DTC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1035
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ii TRUCK SERVICE MANUAL
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TRUCK SERVICE MANUAL 1
SAFETY INFORMATION
IMPORTANT – Read the following before starting the service procedure.
The information contained in this International Service Manual Section was current at the time of printing
and is subject to change without notice or liability.
You must follow your company safety procedures when you service or repair equipment. Be sure to understand
all of the procedures and instructions before you begin work on the unit.
International uses the following types of notations to give warning of possible safety problems and to give
information that will prevent damage to the equipment being serviced or repaired.
WARNING – A warning indicates procedures that must be followed exactly. Personal injury
or possible death can occur if the procedure is not followed.
CAUTION – A caution indicates procedures that must be followed exactly. If the procedure is not
followed, damage to equipment or components can occur.
NOTE – A note indicates an operation, procedure or instruction that is important for correct service.
Some procedures require the use of special tools for safe and correct service. Failure to use these special
tools when required can cause injury to service personnel or damage to vehicle components.
This service manual section is intended for use by professional technicians, NOT a “do-it-yourselfer.” It is
written to inform these technicians of conditions that may occur on some vehicles, or to provide information
that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume
that the service section applies to your vehicle. See your International Truck Dealer for information on whether
this service section applies to your vehicle.
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2 TRUCK SERVICE MANUAL
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1 INTRODUCTION 3
Group Electrical
Table of Contents
1. MANUAL INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. VEHICLE ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3. ELECTRICAL CIRCUIT DIAGRAM BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.1. CIRCUIT DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Circuit Diagram Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.2. COMPONENT ILLUSTRATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.3. CONNECTOR BODY COMPOSITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.1. VERIFY THE PROBLEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.2. IMPORTANT STEPS BEFORE TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.3. READ "EXTENDED DESCRIPTION". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.4. CHECK THE CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.5. CHECK FOR CAUSE OF THE PROBLEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.6. MAKE THE REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.7. VERIFY THE REPAIR IS COMPLETE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5. ELECTRICAL TEST EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

5.1. EZ-TECH® ELECTRONIC SERVICE TOOL (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.2. ESC BREAKOUT BOX (ZTSE4477). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.3. FLUKE 88 DIGITAL MULTIMETER (DMM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.4. JUMPER WIRES AND TEST LEADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Jumper Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Test Leads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.5. OHMS LAW REVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.6. VOLTMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Measuring Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5.7. AMMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Measuring Amperage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.8. OHMMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Measuring Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Checking For Open Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Checking For Short Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6. BENCH TESTING RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7. CIRCUIT BREAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

7.1. TYPE I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.2. TYPE III. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8. ABBREVIATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
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4 1 INTRODUCTION
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1 INTRODUCTION 5
1. MANUAL INTRODUCTION
This manual only covers the electrical system of the truck.
Detailed information on engines, transmissions, and antilock brake systems may be found in vendor manuals
and other International Truck and Engine Corporation manuals. These systems are addressed in this manual
only to cover circuits unique to our trucks, which are not addressed in other manuals.
This manual is intended to be used in conjunction with the electrical circuit diagram book that applies to the
specific vehicle requiring repair. There are variations between specific models and periods of manufacture that
may only be addressed in the circuit diagram book.
The circuit diagram book has valuable information that can be very helpful to a technician. Beyond circuit
diagrams, the book provides information on connector composites and parts, circuit identification and location
information, a schematic symbol chart, a relay function and wiring guide, and a lamp bulb chart.
The strategy used in this manual focuses on starting with general information and progressing toward more
specific information to guide a technician to the cause of an electrical failure. The manual is grouped into major
areas. These major areas are divided into sections covering each feature. Each feature section is further
divided into the following areas:
• Circuit Functions include a figure representing the major components associated with the feature and
a general description of how the feature works.
• Diagnostics provides a systematic means of identifying where to start looking for component or circuit
failures. Example: Is there a problem with an input circuit to the ESC from a switch or output circuits from
the ESC to a load device. Diagnostic trouble code explanations are provided in this area if applicable.
• Fault Detection Management provides more detail on circuit operation, a figure identifying typical circuits
and connectors (always refer to the circuit diagram book for the latest circuit information) and a chart with
the voltages or resistances at key connectors, expected during normal operation. Procedures for checking
specific circuits for open or shorted circuits are not provided. It is assumed a technician has received
training on circuit fault identification and repair.
• Extended Description provides more detail on power and ground circuits for the feature.
• Component Locations provides drawings showing locations of important components.
• Other areas such as Removal, Installation and Programming may also be included as required.
Operator observation and warning lights may be used to determine when there is a problem with the vehicle
electrical system.
Technicians must still rely on observation of failed components or malfunctioning features. Once the technician
has identified a failure he may go to the table of contents and refer to the applicable section for troubleshooting
information.
Another way a feature failure may become evident is through the vehicle “on line” diagnostic system of
the electrical system controller (ESC).
The check electrical system warning lamp will illuminate when a detectable fault has occurred. The lamp may
illuminate either continuously or for 5 seconds depending on the fault. When a fault occurs and the ESC is able
to communicate with the electronic gauge cluster (EGC), the lamp will illuminate for 5 seconds. Each time the
ignition is cycled and the EGC completes a gauge sweep, the lamp will illuminate for 5 seconds if an active
fault is present. If the light remains on consistently, there is a communication problem between the ESC and
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6 1 INTRODUCTION
EGC. The technician may retrieve diagnostic trouble codes through the EGC odometer display. The technician
may then look up the diagnostic trouble codes to locate the applicable troubleshooting information.
ESC diagnostics are not capable of identifying all possible system faults. This is why problem identification
through observation is still important.
Diagnostic trouble code retrieval procedures for engines, transmissions, and antilock brake systems vary from
the procedure for retrieving diagnostic trouble codes produced by the ESC.
An electronic service tool (EST), such as the EZ-Tech, running the INTUNE software can be used to list vehicle
diagnostic trouble codes, monitor inputs to the ESC and exercise outputs from the ESC.
This manual is written to attempt troubleshooting without the service tool, as much as possible. The EZ-Tech,
running the appropriate software, can also be used to troubleshoot the engine, transmission and ABS
electrical systems.
2. VEHICLE ELECTRICAL SYSTEM OVERVIEW

The electrical system in this vehicle provides a means to distribute electrical power and provides the driver with
controls and indications of the vehicle performance. Unlike previous electrical system designs, this approach
uses multiplexed wiring technologies for interfacing major functional areas of the vehicle. Furthermore, the
system relies on software algorithms to accomplish logic functions instead of implementing similar features
using complex wire harness designs with relays and switches.
A natural benefit of this system is increased diagnostic capability in terms on line, off line and off board testing.
On–line diagnostics are performed on the vehicle while it is in operation. If a detectable fault occurs, the check
electrical system lamp will illuminate for 5 seconds. If a communication failure between the ESC and EGC
occurs, the lamp will stay illuminated until communications are restored.
Off–line diagnostics are enabled when the system is put in diagnostic mode. While the system is in the
diagnostic mode, diagnostic trouble codes will be displayed on the odometer.
Off–board diagnostics require the use of an electronic service tool, such as the EZ-Tech, and the INTUNE
diagnostic software. The EST is connected to the vehicle diagnostic connector. The INTUNE software will allow
the technician to view diagnostic trouble codes, monitor inputs to the ESC and activate outputs from the ESC.
3. ELECTRICAL CIRCUIT DIAGRAM BOOK

Electrical circuit diagram books can be found in Group 08–Electrical in the Master Service Manual.
3.1. CIRCUIT DIAGRAMS

Circuit diagrams provide a schematic picture of how a circuit is powered, what the current path is to circuit
components, and how the circuit is grounded.
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1 INTRODUCTION 7
Figure 1 Sample Circuit Diagram
In most cases, the power source will appear at the top of the page, and the ground will be at the bottom of
the page (or bottom of circuit). The circuit components are named, using capital letters. Abbreviations may
be used (See Sample Circuit Diagram Instructions and Abbreviations).
IMPORTANT – Switch, relay and solenoid positions, as shown on circuit diagrams, indicate NORMAL position
with the key switch in the OFF position, unless otherwise noted.
Components which work together are shown together. All electrical components used in any circuit are
shown in the circuit diagram. The power source (fuse, circuit breaker, junction point, etc.) is usually shown or
indicated at the top of the page. All wires, connectors, and other electrical components are shown in the signal
flow to the bottom of the page (or bottom of the circuit).
Circuit Diagram Instructions
Examples of the circuit diagram instructions, abbreviations and symbols are included in Sample Circuit Diagram
Instructions, Sample Circuit Diagram Instructions and Abbreviations and Sample Schematic Symbol Chart.
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8 1 INTRODUCTION
Figure 2 Sample Circuit Diagram Instructions
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1 INTRODUCTION 9
Figure 3 Sample Circuit Diagram Instructions and Abbreviations
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10 1 INTRODUCTION
Figure 4 Sample Schematic Symbol Chart
3.2. COMPONENT ILLUSTRATIONS

Each section will provide component location illustrations. The Sample Component Location Illustration shows
the location of a circuit component being discussed.
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1 INTRODUCTION 11
Figure 5 Sample Component Location Illustration

1. FUSED SIDE OF MEGAFUSE
2. UNFUSED SIDE OF MEGAFUSE
3. ENGINE POWER DISTRIBUTION CENTER (PDC)
Connector end views found in the Circuit Diagram book provide information on the location of the various
connectors.
3.3. CONNECTOR BODY COMPOSITE

Connector Composites are located in the back of the Group 08 - Electrical CIRCUIT DIAGRAMS under
Connector Composites. The composites show the pin configuration of the connector and which circuits are
attached to the pins as shown in Sample Pin Configuration.
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12 1 INTRODUCTION
Figure 6 Sample Pin Configuration
4. TROUBLESHOOTING
Before beginning any troubleshooting, there are several important steps to be taken:
4.1. VERIFY THE PROBLEM

Operate the complete system and list all symptoms in order to:
1. Check the accuracy and completeness of the complaint.
2. Learn more that might give a clue to the nature and location of the problem.
3. Analyze what parts of the system are working.
4.2. IMPORTANT STEPS BEFORE TESTING

1. Gather information by talking to the driver if possible. Try to determine the exact symptoms by gathering
relevant information:
a. What happened, and when?
b. Under what conditions?
c. When did the symptoms begin?
d. What else occurred at that time?
2. Verify the problem. Is the complaint due to misunderstood customer selected parameters? Use an EST
to review customer selected parameters.
3. Check for and record any logged diagnostic trouble codes.

a. Do the logged codes correlate to probable causes?
4. Were the codes logged about the same time as the symptoms appeared? Were the codes logged
repeatedly?
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1 INTRODUCTION 13
5. Are the logged codes related to other symptoms? Do they have a common cause?
6. Avoid preconceived ideas! Eliminate any nonelectrical causes for the problem first (contaminated
fuel, clogged air filters, etc.).
7. Perform the following preliminary steps:
A. Before beginning these test procedures, make sure the vehicle batteries are at 75% state of
charge (SOC) or higher. This represents an open circuit voltage (OCV) of 12.4 volts. Batteries
with an OCV of 12 volts or less are either completely discharged or have a dead cell.
B. Before beginning these test procedures, check any light or indicator lamp filaments that are
suspected of being open (burned out). This is done to avoid unnecessary extensive circuit checks.
C. Before beginning these test procedures, inspect all connectors for loose or damaged pins, wires,
etc. Refer to TEST EQUIPMENT AND CONNECTOR REPAIR section in Group 08 Electrical in
the Master Service Manual.
D. When the mechanic determines that a fuse is blown, while checking its condition, he is directed
to locate the cause of the overload condition and to repair it. While no further instruction on this
procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections
of the circuit by disconnecting connectors, and measure the resistance to ground to find the circuit
that is shorted to ground. Then locate the damaged spot in the wire or connector and repair.
E. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not
covered in detail. It is assumed that the mechanic knows to check for a malfunctioning switch,
relay, or solenoid.
4.3. READ "EXTENDED DESCRIPTION"

Read the extended description for the problem circuit (while referring to the circuit diagram). By studying the
circuit diagram and the electrical operation, enough information about circuit operation should be learned to
narrow the cause of the problem to one component or portion of the circuit.
4.4. CHECK THE CIRCUIT DIAGRAM

Refer to the circuit diagram for possible clues to the problem. Location and identification of circuit components
may give some idea of where the problem is located.
The circuit diagrams are designed to make it easy to identify common points in circuits. This can help narrow
the problem to a specific area. For example, if several circuits fail at the same time, check for a common
power source or common ground connection. Refer to POWER DISTRIBUTION AND GROUNDS in the
ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE. If part of a circuit fails, check the connections between
the part that works and the part that doesn’t work.
For example, if the low-beam headlights work, but both high-beam lights and the high-beam indicator do not
work, then the power and ground paths must be good.
Since the dimmer switch is the component that switches the power to the high-beam headlights, it is the most
likely cause of failure.
4.5. CHECK FOR CAUSE OF THE PROBLEM

Diagnostic charts are provided for many of the common faults that may occur. Refer to these charts in each
section. Follow the procedures in the chart until the cause of the problem is located.
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14 1 INTRODUCTION
If the particular symptom found in the problem circuit is not covered by a diagnostic chart, refer to the general
electrical troubleshooting information provided under ELECTRICAL TEST EQUIPMENT, below.
4.6. MAKE THE REPAIR

Repair the problem circuit as directed in the diagnostic charts.
4.7. VERIFY THE REPAIR IS COMPLETE

Operate the system and check that the repair has removed all symptoms, and also that the repair has not
caused any new symptoms.
5. ELECTRICAL TEST EQUIPMENT

5.1. EZ-TECH® ELECTRONIC SERVICE TOOL (EST)
The EZ-Tech® EST is a ruggedized laptop computer capable of running various software programs to perform
vehicle diagnostics.
The EZ-Tech is connected to the vehicle diagnostic connector through an interface connector.
Once connected, the software on the EZ-Tech can be used to monitor certain vehicle parameters, list active
and inactive diagnostic trouble codes, and in some cases override inputs and outputs of electrical controllers.
The INTUNE™ software can be used to diagnose the electrical system controller (ESC). See the INTUNE
software manual for detailed instructions.
The ICAP software must be used to reprogram or restore programming to the electrical system controller.
Other software programs are available for other electrical systems on the vehicle.
5.2. ESC BREAKOUT BOX (ZTSE4477)

The ESC breakout box allows the technician to check ESC inputs and outputs. It should also be used when
taking measurements on ESC connectors. This will prevent damaging connector cavities with test probes.
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1 INTRODUCTION 15
Figure 7 ESC Breakout Box
The breakout box can be connected to the ESC connectors in the engine compartment or the connectors
in the cab.
The breakout box can be used to provide pinouts to a single connector (out of circuit), to test individual wires
for shorts or opens, to test output signals from the ESC, or to test input circuits to the ESC.
The breakout box can also be connected in circuit to allow technicians to monitor signals with the ESC in
operation.
5.3. FLUKE 88 DIGITAL MULTIMETER (DMM)
CAUTION – When probing connectors, always take care not to cause damage by forcing probe tips
into cavities. Use the appropriate tip adapters to prevent damage. Expanded cavities will cause
increased circuit resistance.
The Fluke 88 Digital Multimeter (DMM) is the meter recommended by International Truck and Engine
Corporation and discussions of meter use in this manual will refer to this meter.
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16 1 INTRODUCTION
The Fluke 88 Multimeter is a digital meter, and is recommended because it uses very little current when
performing tests. Digital meters have high impedance (resistance), 10 Mega ohms. Thus they do not damage
components or give misleading readings.
Figure 8 Digital and Analog Meters

1. DIGITAL MULTIMETER
2. ANALOG VOLTMETER
CAUTION – Some of the devices in an electronic control system are not capable of carrying any
appreciable amount of current. Therefore the test equipment used to troubleshoot an electronic
system must be especially designed not to damage any part of it. Because most analog meters
use too much current to test an electronic control system, it is recommended that they not be
used, unless specified. The use of any kind of battery-powered test light, unless specified, is not
recommended when troubleshooting an electronic circuit, since it could also damage an electronic
control circuit.
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1 INTRODUCTION 17
5.4. JUMPER WIRES AND TEST LEADS

Jumper Wires
CAUTION – When using jumpers and test leads, always take care not to cause damage by forcing
probe tips into cavities. Use the appropriate tip adapters to prevent damage. Expanded cavities
will cause increased circuit resistance.
Jumper wires allow "jumping" across a suspected open or break in a circuit.
1. If the circuit (Refer toJumpers in Circuits ) works properly with the jumper wire in place, but does not work
when the jumper wire is removed, the circuit has an open spot.
Figure 9 Jumpers in Circuits
2. A circuit without any opens or breaks has continuity (is continuous) and a DMM can be used to measure
the continuity (resistance of a few ohms) of the circuit with the battery removed.
Jumper wires are fitted with several types of tips or ends. It will be helpful to have several jumper wires
available with different tips.
If bypassing the switch with a jumper wire causes the light to illuminate, but closing the switch does not, it
indicates the switch has failed.
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18 1 INTRODUCTION
If, when the switch is closed, the light does not illuminate, and "jumpering" the switch doesn’t cause the
light to operate, but "jumpering" the light to ground causes the light to operate, then there is an open in
the ground circuit.
The jumper wire can be used to check for open relay contacts, wire breaks, poor ground connections, etc.
Test Leads
CAUTION – When probing connectors, always take care not to damage them by forcing probe tips
into cavities. Use the appropriate tip adapters to prevent damage. Expanded cavities will cause
increased circuit resistance.
NEVER insert the test meter probe tip into connectors where the probe tip will expand the terminal. Expanded
terminals will cause increased circuit resistance.
Construct test leads using a mating terminal, a short lead and an alligator clip. Insert the mating terminal into
the connector and attach the alligator clip to the meter lead.
5.5. OHMS LAW REVIEW

Ohms Law describes the relationship of voltage, current and resistance, and provides us with a formula to
make calculations as is shown in Ohms Law Formula.
Table 1 Ohms Law

Ohms Law
Where:
I = Current (Amperes)
E = Voltage (Volts)
R = Resistance (Ohms)
I = E/R This formula states that current flow (I) = Voltage (E) applied
to a circuit divided by total resistance (R) in the circuit. This
shows that an increase in voltage or a decrease in resistance
increases current flow.
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1 INTRODUCTION 19
Table 1 Ohms Law (cont.)

R = E/I This formula states that resistance (R) = Voltage (E) applied to
a circuit divided by current flow (I) in the circuit. This allows us
to calculate resistance needed for a specific current flow with a
specific voltage applied (like 12V).
E = IR (I multiplied This formula provides the voltage drop across a particular load
by R) device (resistance) that is part of a series of load devices.
Memorize the formula in the circle. You only have to cover the
“letter” that you wish to calculate, with your finger, and you have
the formula. For example: If you cover the letter “I”, the formula
is I = E/R.
If any two of the values are known for a given circuit, the missing one can be found by substituting the values
in amperes, volts, or ohms and solving for the missing value.
In a typical circuit, battery voltage is applied to a bulb through a 10 amp fuse and a switch (Typical Circuit).
Closing the switch turns on the bulb.
Figure 10 Typical Circuit
To find the current flow use the formula:
I=E/R
Filling in the numbers for the circuit in Figure 11 , we have:
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20 1 INTRODUCTION
I = 12V/2 ohms or I= 12 divided by 2 = 6 amperes of current flow.
The bulb in this circuit operates at 6 amps and is rated to operate at this level. With 12 volts applied, the bulb
will glow at the rated output level (candlepower rating). However:
1. If the voltage applied is low (low battery), then (the value of E is lower) current flow will be less and
the bulb will glow less brightly.
2. Or if the connections are loose, or the switch corroded, the circuit resistance will be greater (value of R will
be larger) and the current flow will be reduced and the bulb will glow less brightly.
Being able to determine voltage drops is important because it provides the following information:
• Too high a voltage drop indicates excessive resistance. If, for instance, a blower motor runs too slowly
or a light glows too dimly, one can be sure that there is excessive resistance in the circuit. By taking
voltage drop readings in various parts of the circuit, the problem can be isolated (corroded or loose
terminals for example).
• Too low of a voltage drop, likewise, indicates low resistance. If for instance, a blower motor ran too fast,
the problem could be isolated to a low resistance in a resistor pack by taking voltage drop readings.
• Maximum allowable voltage drop under load is critical, especially if there is more than one high resistance
problem in a circuit. It is important because all voltage drops in a circuit are cumulative. Corroded
terminals, loose connections, damaged wires or other similar conditions create undesirable voltage drops
that decrease the voltage available across the key circuit components.
Remember our earlier discussion, the increased resistance from the undesirable conditions will also decrease
the current flow in the circuit and all the affected components will operate at less than peak efficiency.
A small drop across wires (conductors), connectors, switches, etc. is normal. This is because all conductors
have some resistance, but the total should be less than 10 percent of the total voltage drop in the circuit.
5.6. VOLTMETER
Voltage is an electrical pressure or force that pushes the current through a circuit. The pressure is measured
in Volts and the symbol V (as in 12V) is used in the circuit diagrams. The letter "E" is also used for voltage
and stands for Electromotive Force. Voltage can be compared to the pressure necessary to push water
through a metering valve.
Low voltage to a lamp will cause the lamp to glow dimly. This can be caused by low source voltage (battery
discharged or low alternator output), or by high circuit resistance in the circuit due to a poor connection. The
resistance of the poor connection or poor ground acts as an additional load in the circuit, causing less voltage
to be available to push current through the load device. Before making any meter measurements, it is important
to briefly review the relationship between voltage, current, and resistance (Ohms Law, Ohms Law Formula).
Measuring Voltage
In electrical diagnosis, the voltmeter is used to answer:
1. Is voltage present?
2. What is the voltage reading?
3. What is the voltage drop across a load device?
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1 INTRODUCTION 21
When using a voltmeter to determine if voltage is present to power a device, connect the positive meter lead to
input connection of the device (positive side) and connect the negative meter lead to good vehicle ground
(Voltmeter Lead Connections Diagram). A good ground would be any metallic bracket, body panel, or fastener
that is free of paint, rust or corrosion, and is connected to the frame, engine, or body. The Voltmeter Lead
Connections Diagram shows how much of the source voltage is available to the device. Note that the meter
is connected in parallel to the device.
Figure 11 Voltmeter Lead Connections Diagram
Should we need to determine if voltage is available at a connector where we can’t readily connect to the
device, we can connect the meter in series between ground and the connector (voltage source) as shown in
the Connecting the Meter in Series Diagram. The meter’s internal resistance is very high so little current will
flow in the circuit, and the voltage can be read accurately.
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22 1 INTRODUCTION
Figure 12 Connecting the Meter in Series Diagram
To check the voltage drop across a load device (Checking Voltage Drop Across a Load Device Diagram),
connect the positive lead of the voltmeter to the positive side of the device and the negative meter lead to the
negative side of the device. With the device operating, measure the voltage drop across the device. Notice in
Checking Voltage Drop Across a Load Device Diagram , since we only have one device, all of the voltage
should be dropped at the device. In any circuit, the voltage applied will equal the voltage dropped in the circuit.
If in this circuit we only dropped 9V across the load, that would indicate that our wires, connections, etc. were
dropping the other 3V, which would indicate excessive circuit resistance.
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1 INTRODUCTION 23
Figure 13 Checking Voltage Drop Across a Load Device Diagram
5.7. AMMETER
An ammeter is used to measure current flow (amperage) in a circuit. Amperes are units of electron flow, which
indicate how many electrons are passing through the circuit. Ohms Law indicates that current flow in a circuit
is equal to the circuit voltage divided by total circuit resistance. Since amps (I) is the current in the circuit,
increasing voltage also increases the current level (amps). Also, any decrease in resistance (ohms) will
increase current flow (amps).
At normal operating voltage, most circuits have a characteristic amount of current flow, referred to as current
draw. Current draw can be measured with an ammeter. Referring to a specified current draw rating for
a component (electrical device), measuring the current flow in the circuit, and comparing the two (the rated
versus the actual measured) can provide valuable diagnostic information.
Measuring Amperage
An ammeter is connected in series with the load, switches, resistors, etc. (Measuring Current Flow Diagram).
This causes all of the current to flow through the meter. The meter will measure current flow only when the
circuit is powered and operating. Before measuring current flow, we need to know approximately how much
current will be present to properly connect the meter. The DMM is fused to measure up 10 amps using the
10A connection point.
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24 1 INTRODUCTION
Figure 14 Measuring Current Flow Diagram

1. DMM SET TO MEASURE DC CURRENT
2. FUSE SHOWN REMOVED
3. LIGHT BULB (2 OHMS RESISTANCE)
4. METER LEAD CONNECTED TO 10A METER JACK
The estimate of current flow can easily be calculated. In the Measuring Current Flow Diagram, the resistance
of the light bulb is 2 ohms. Applying Ohms Law, we can calculate that current flow will be 6 amps (6A = 12V/2
ohms). If we remove the fuse, and install the ammeter as shown, with the switch closed we will measure 6
amperes of current flowing in the circuit. Notice that the ammeter is installed so that all the current in the circuit
flows through it. The ammeter is installed in series.
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1 INTRODUCTION 25
WARNING – Never attempt a voltage measurement with the test probe lead in the current jack
(10A or 300mA). Meter damage or personal injury may result!
Always make sure the power is off before cutting, soldering or removing a circuit component to
insert the DMM for current measurements. Even small amounts of current can be dangerous.
Excessive current draw means that more current is flowing in a circuit than the fuse and circuit were designed
for. Excessive current will open fuses and circuit breakers. Excessive current draw can also quickly discharge
batteries. An ammeter is useful to help diagnose these conditions.
On the other hand, there are times reduced current draw will cause a device (electric window motor for
example) to operate poorly. Remember increased circuit resistance causes lower current to be available to the
device. Loose or corroded connections can frequently cause this problem.
5.8. OHMMETER
The ohmmeter is used to measure resistance (ohms) in a circuit. Like the ammeter and voltmeter, there are
both analog and digital meters available. It is recommended that the digital meter (Fluke 88 DMM) be used.
CAUTION – Some of the devices in an electronic control system are not capable of carrying any
appreciable amount of current. Therefore the test equipment used to troubleshoot an electronic
system must be especially designed not to damage any part of it. Because most analog meters use
too much current to test an electronic control system, it is recommended that they not be used,
unless specified. The use of any kind of battery-powered test light may not be recommended when
troubleshooting an electronic circuit, since it, too, could damage an electronic control circuit.
CAUTION – The ohmmeter can only be used on circuits where power has been removed. The meter
contains its own low voltage power supply and the power from 12-volt systems may damage the
meter.
Ohmmeters use a small battery to supply the voltage and current which flow through the circuit being tested.
The voltage of the meter battery and the amount of current flow in the circuit are used with Ohms Law, and
the meter calculates the circuit resistance which is displayed by the meter. With the Fluke 88 DMM, range
selection and meter adjustment are not necessary.
Measuring Resistance
Resistance measurements determine:
1. Resistance of a load
2. Resistance of conductors
3. Value of resistors
4. Operation of variable resistors.
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26 1 INTRODUCTION
To measure the resistance of a component or a circuit, power must first be removed from the circuit.
The component or circuit that is to be measured must be isolated from all other components or circuits so that
meter current (from probe to probe) only flows through the desired circuit or component or the reading will
not be accurate.
Notice in the Measuring Resistance Diagram that if we wanted to measure the resistance of the load, most
of the current flow from the meter would flow through the indicator lamp because it has less resistance. To
measure the load, one connector to the load should be removed. It is not always apparent when a component
must be isolated in such a manner, so it is usually a good practice to isolate the circuit or component by
physically disconnecting one circuit.
Figure 15 Measuring Resistance Diagram
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1 INTRODUCTION 27
The ohmmeter leads are then placed across the component or circuit and the resistance will be displayed
in ohms (Placing Ohmmeter Leads Across a Component or Circuit Diagram ). When checking a sensor or
variable resistor such as fuel level gauge, heating the element or moving the arm should move the meter
through a range of resistance that can be compared to a specification.
Figure 16 Placing Ohmmeter Leads Across a Component or Circuit Diagram
Checking For Open Circuits
Electrical circuits can be checked for opens using an ohmmeter. The circuit must first be disconnected from
the power supply. The circuit to be checked must also be isolated from other circuits. Connect the meter to
the open ends of the circuit as shown in the Checking For Open Circuits diagram. A high reading (infinity)
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28 1 INTRODUCTION
indicates there is an open in the circuit. A near zero reading is an indication of a continuous circuit. Notice
also in the Checking For Open Circuits Diagram that we disconnected the circuit between the light and the
ground. This precaution prevents reading a circuit as complete that may be open at the load (light) and
shorted to ground ahead of the load device.
Figure 17 Checking For Open Circuits

A. DISCONNECTED CONNECTOR
Checking For Short Circuits
Checks for short circuits are made in a similar manner to that used to check for open circuits, except that the
circuit to be checked must be isolated from both the power source and the ground point.
Connecting the ohmmeter, as shown in the Checking For Short Circuits diagram, between an isolated circuit
and a good ground point will allow checking the circuit for a short to ground. A short to ground will be indicated
by a near zero reading, while a circuit not shorted to ground will cause the meter to read very high (near
infinity). With the Fluke 88 DMM, an open circuit will read "OL" on the meter display.
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1 INTRODUCTION 29
Figure 18 Checking For Short Circuits
6. BENCH TESTING RELAYS

International circuits use suppressed relays for controlling power to load devices. The suppression feature
(a resistor circuit parallel to the relay coil) prevents voltage spikes from damaging electronic components
in the vehicle. These relays must be replaced with approved International parts. The part number
and relay circuit diagram are embossed on the relay body. The terminals are numbered on the relay in the
same manner as in the circuit diagrams.
Relay Test Procedure:
1. With relay removed, measure resistance between terminals 30 and 87A. If resistance is less than 5
ohms, go to Step 2; otherwise replace the relay.
2. Measure resistance between terminals 30 and 87. If resistance is 100K ohms or more, go to Step 3;
otherwise replace the relay.
3. Using 12V battery source and test leads, connect (+) lead to terminal 85 and (-) lead to terminal 86. If relay
energizes with an audible click sound, go to Step 4; otherwise replace the relay.
4. While relay is energized, measure resistance between terminals 30 and 87. If resistance is less than 5
ohms, go to Step 5; otherwise replace the relay.
5. While the relay is energized, measure resistance between terminals 30 and 87A. If resistance is 100K
ohms or more, the relay is good; otherwise replace relay.
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30 1 INTRODUCTION
Figure 19 Relay Schematic
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1 INTRODUCTION 31
Table 2 Bench Check Relay

STEP KEY ACTION TEST SPEC. YES- IN NO-OUT OF
POINTS SPEC. SPEC.
1. OFF Bench test relay by Relay pin <1 ohm. Go to next Replace relay.
measuring resistance 30 to 87A. step.
from terminal 30 to 87A.
2. OFF Bench test relay by Energized <1 ohm. Go to next Replace relay.
applying +12 V to pin 85, relay pin step.
ground to pin 86, and 30 to 87.
measuring resistance
from pin 30 to 87.
7. CIRCUIT BREAKERS
7.1. TYPE I
Type I circuit breakers will automatically reset after a circuit overload has occurred.
The headlight and windshield wiper output circuits from the ESC will act like Type I circuit breakers.
7.2. TYPE III

Type III circuit breakers must be manually reset after a circuit overload has occurred.
The 20 amp and 10 amp output circuits from the ESC, except the headlight and windshield wiper outputs will
act like Type III circuit breakers. The ESC will reset these circuits when the feature is turned off.
8. ABBREVIATIONS
ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Antilock Brake System
AGSP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Auxiliary Gauge Switch Pack
CEC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Consolidated Engine Controller
DTC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Diagnostic Trouble code
ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Electronic Control Module
ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Electronic Control Unit
EGC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Electronic Gauge Cluster
ESC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Electrical System Controller
FMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Failure Mode Indicator
ISO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . International Standardization Organization
LCD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Liquid Crystal Display
NSBU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Neutral Safety and back up Switch (Used on Allison
LCT transmission)
PAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Pyrometer Ammeter Module
PDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Power Distribution Center
RASM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Remote Air Solenoid Module
RESCM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Remote Engine Speed Control Module
RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Remote Power Module
SPN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Suspect Parameter Number
TCM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Transmission Control Module
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32 1 INTRODUCTION
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2 POWER DISTRIBUTION AND GROUNDS 33
Table of Contents
1. CIRCUIT FUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
2. BATTERY POWER DISTRIBUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

2.1. FAULT DETECTION MANAGEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
2.2. EXTENDED DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3. ACCESSORY POWER DISTRIBUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

3.2. EXTENDED DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
4. IGNITION POWER DISTRIBUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

4.1. CAB IGNITION POWER DISTRIBUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Fault Detection Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Extended Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2. CHASSIS IGNITION POWER DISTRIBUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Fault Detection Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Extended Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5. COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
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34 2 POWER DISTRIBUTION AND GROUNDS
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1. CIRCUIT FUNCTIONS
Refer to power distribution function diagram.
Figure 20 Power Distribution Function Diagram

1. BATTERY
2. CRANK MOTOR SOLENOID
3. GROUND STUD ADAPTER (INSIDE AND OUTSIDE OF CAB)
4. MAXIFUSES IN ENGINE POWER DISTRIBUTION CENTER (4000)
5. ENGINE COMPARTMENT POWER DISTRIBUTION CENTER (4000), (4001), (4002)
& (4003)
6. PRIMARY (R9) IGNITION RELAY (4003)
7. STOP LAMPS (R7), STARTER (R12) & CEC (R11) POWER RELAYS (4003)
8. CAB POWER DISTRIBUTION CENTER (1011), (1012), (1013) & (1014)
9. IGNITION RELAYS (IN FUSE BLOCK 2 AND 3) (1012), (1013)
10. ACCESSORY RELAY (IN FUSE BLOCK 2) (1012)
11. 5 AMP KEY SWITCH FUSE F20 (1012)
12. 100 AMP MEGAFUSE
13. CRANKING MOTOR
14. KEY SWITCH
The primary power distribution points in the electrical wiring are the batteries, key switch, megafuse block,
engine compartment power distribution center (PDC), cab power distribution center (PDC) and the ground
connections. Refer to Power Distribution Function Diagram.
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For relay and fuse/circuit breaker locations in the cab PDC, see the product graphics on the back side of the
close out panel. For relay and fuse/circuit breaker locations in the engine compartment PDC, see the engine
compartment PDC lid.
NOTE – Fuse locations vary from one vehicle to another. Always use the product graphics to identify
relay and fuse locations.
A wire connects the negative battery terminal to the frame ground stud. A wire is also connected between
the frame ground stud and the ground connector on the dash panel. Circuits from the dash panel ground
connectors provide ground throughout the vehicle.
Power from the battery is supplied to the “B” terminal of the starter solenoid and from the “B” terminal to the
unfused side of the 100 amp megafuse.
Power to the engine PDC is supplied from the unfused side of the megafuse to the maxifuse block.
Power to the cab PDC is supplied from the fused side of the megafuse.
2. BATTERY POWER DISTRIBUTION

2.1. FAULT DETECTION MANAGEMENT
NOTE – The testing method for troubleshooting the electrical systems portrayed in this manual is a
basic voltage test. An alternative method of checking for voltage drops within a given circuit may be a
quicker method of identifying an exact problem.
A malfunction in the battery power distribution circuits will be apparent when battery power is not available in
systems that are provided unswitched battery voltage. If a fusible link or megafuse is open, power may be
missing from the whole vehicle.
Problems with battery power circuits may be due to loose power connections, loose ground connections, blown
fuses, open fusible links or circuits shorted to ground.
Refer to Power Distribution Diagram.
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Figure 21 Battery Power Distribution Diagram

1. BATTERY
2. STARTER SOLENOID
LOCATED ON STARTER
3. FUSIBLE LINK
4. MEGAFUSE
(1011) CAB FUSE BLOCK
LOCATED IN CAB PDC
LOCATED IN CAB PDC
LOCATED IN CAB PDC
LOCATED IN CAB PDC
(1100) KEY SWITCH CONNECTOR
(4000) A1-A6 MAXIFUSES
LOCATED IN ENGINE COMPARTMENT PDC
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Table 3 Battery Power Connector Checks

Refer to the Power Distribution Diagram.
Test Points Spec. Comments
Circuit K14H at megafuse 12 ± 1.5 volts Power feed to megafuse. If no or low power,
to ground. check fusible link, cabling and connections from
starter solenoid.
Circuit J14H at maxifuse block, 12 ± 1.5 volts Power feed to maxifuses, in engine PDC. If
in engine PDC, to ground. no or low power, check J14H connections to
engine PDC and connection to megafuse.
Circuit A14AA at megafuse 12 ± 1.5 volts Power after megafuse. If no or low power,
to ground. check A14AA connections to megafuse. Also
check for blown megafuse.
(1012) fuse F-20 terminal 12 ± 1.5 volts Power input to cab power distribution center,
F2 to ground fuse block 2, from megafuse. If voltage is
incorrect, check wiring from megafuse to cab
power distribution center.
Key switch (1100) terminal 12 ± 1.5 volts Fused power feed to key switch. If voltage is
A to ground incorrect, check fuse F-20 and circuit A15.
There are no diagnostic trouble codes associated with power circuits.
2.2. EXTENDED DESCRIPTION

Power is supplied from the vehicle batteries to the cranking motor solenoid “B” terminal on a 2/0 or 4/0 red
cable. Power from the “B” terminal is supplied through a fusible link and circuit J14H to the 100 amp megafuse.
Power from the unfused side of the megafuse connector is fed through circuit J14H to maxifuse block (4000).
Power from two 60A fuses in the maxifuse block is fed to the system controller on circuits J14A and J14B.
Power from the fused side of the 100A megafuse is supplied on several circuits to power distribution fuse
blocks (1011), (1012), (1013) and (1014). Each fuse block provides 12 volts to the fuses connected directly to
battery power. This includes circuit A15 to the key switch.
3. ACCESSORY POWER DISTRIBUTION

A malfunction in the accessory power circuits will be apparent when accessory power is not available in
several systems.
Problems with power circuits may be due to loose power connections, loose ground connections, blown fuses,
open fusible links, faulty relays, open circuits or circuits shorted to ground.
Diode assembly 467404C91 insures power to energize the accessory relay during cranking. This prevents
diagnostic trouble codes from being logged during engine cranking.
Refer to Accessory Power Distribution Diagram.
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Figure 22 Accessory Power Distribution Diagram—Always Refer to Circuit Diagram Book for Latest
Circuit Information
LOCATED ON BACK OF KEY SWITCH
(1106) DIODE ASSEMBLY 467404C91
LOCATED BEHIND INSTRUMENT PANEL NEAR KEY SWITCH
(1012) FUSE BLOCK #2
LOCATED IN CAB POWER DISTRIBUTION CENTER
(1851) NEGATIVE STUD
LOCATED ABOVE ELECTRICAL SYSTEM CONTROLLER (ESC) ON DASH
PANEL
F17–F23 ACCESSORY FUSES
Table 4 Accessory Power Connector Checks

Megafuse Voltage Check Refer to the Accessory Power Distribution Diagram.
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Table 4 Accessory Power Connector Checks (cont.)

Circuit A14AA at MEGAFUSE 12 ± 1.5 volts Power feed from megafuse. If no or low
to ground. power, check for open megafuse, cabling and
connections from starter solenoid.
Fuse Block (1012) Voltage Checks (Check With Key In Accessory Position and Accessory
Relay Removed.)Refer to the Accessory Power Distribution Diagram.
(1012) (relay 30) terminal 12 ± 1.5 volts Cab power distribution center, accessory relay
G4 to ground. power, input from megafuse. If voltage is
incorrect, check wiring from megafuse to cab
power distribution center.
(1012) fuse F20 terminal 12 ± 1.5 volts Fused power feed to key switch. If voltage is
F2 to ground. incorrect, check fuse F-20 and circuit A15.
(1012) (relay 86) terminal 12 ± 1.5 volts Key voltage to accessory relay. If voltage is
J4, accessory relay socket, incorrect, check for faulty wiring or failed key
to ground. switch. Perform key switch resistance checks.
(1012) (relay 86) terminal J4, 12 ± 1.5 volts Ground to accessory relay coil. If voltage is
accessory relay socket, to incorrect, check for faulty wiring between G3
(relay 85) terminal G3. and negative stud (1851).
Fuse Block (1012) Voltage Checks (Check With Key In Accessory Position and Accessory
Relay Installed.) Refer to the Accessory Power Distribution Diagram.
Remove fuse F17. Measure 12 ± 1.5 volts Voltage from accessory relay to accessory
voltage between fuse socket fuses. If voltage is incorrect, check for failed
G1 to ground. accessory relay or faulty wiring between fuse
and relay .
Key Switch Resistance Checks (Check With Key Connector (1100) removed
With key switch in off position, >100K ohms or If resistance is incorrect replace defective
measure resistance between O.L. switch.
key switch terminal A to D, B
and C.
With key switch in start position, >100K ohms or If resistance is incorrect replace defective
measure resistance between O.L. switch.
key switch terminal A and C.
With key switch in accessory <1 ohm If resistance is incorrect replace defective
position, measure resistance switch.
between key switch terminal A
and C.
With key switch in ignition <1 ohm If resistance is incorrect replace defective
position, measure resistance switch.
between key switch terminal A
and D.
There are no diagnostic trouble codes associated with these circuits.
3.2. EXTENDED DESCRIPTION

When the key is moved to the ignition or accessory position, power will be supplied on circuit A12AB and A12
to the accessory relay in power distribution fuse block (1012). The accessory relay will energize. Power
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from circuit A14AV will pass through the accessory relay contacts on circuit A12B, providing 12 volts to the
accessory fuses.
4. IGNITION POWER DISTRIBUTION

4.1. CAB IGNITION POWER DISTRIBUTION
Fault Detection Management
A malfunction in the cab ignition power circuits will be apparent when ignition power is not available in several
cab systems.
Refer to Cab Ignition Power Distribution Diagram.
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Figure 23 Cab Ignition Power Distribution Diagram—Always Refer to Circuit Diagram Book for Latest
Circuit Information
(1003) GROUND ADAPTER
LOCATED IN INSTRUMENT PANEL
(1012) FUSE BLOCK #2,
(1013) FUSE BLOCK #3, CAB POWER DISTRIBUTION CENTER
(1013) & (1014) FUSE BLOCK 3&4 IGNITION FEED
(1851) NEGATIVE STUD
F5–F32 ACCESSORY FUSES
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Table 5 Cab Ignition Power Connector Checks

Megafuse Voltage Check Refer to the Cab Ignition Power Distribution Diagram.
Circuit A14AA at 12 ± 1.5 volts Power feed from megafuse. If no or low power,
MEGAFUSE to ground. check for open megafuse, cabling and connections
from starter solenoid.
Fuse Block (1012) Voltage Checks (Check With Key In Ignition Position and Ignition
Relay Removed.) Refer to the Cab Ignition Power Distribution Diagram.
(1012) (relay 30) terminal 12 ± 1.5 volts Cab power distribution center, ignition relay power,
D4 to ground. input from megafuse. If voltage is incorrect, check
wiring from megafuse to cab power distribution
center.
(1012) fuse F20 terminal 12 ± 1.5 volts Fused power feed to key switch. If voltage is
F2 to ground. incorrect, check fuse F-20 and circuit A15.
(1012) (relay 86) terminal 12 ± 1.5 volts Key voltage to ignition relay. If voltage is incorrect,
F4, ignition relay socket, check for faulty wiring or failed key switch. Perform
to ground. key switch resistance checks.
(1012) (relay 86) terminal 12 ± 1.5 volts Ground to ignition relay coil. If voltage is incorrect,
F4, ignition relay socket, to check for faulty wiring between D3 and negative
(relay 85) terminal D3. stud (1851).
Relay Installed.) Refer to the Cab Ignition Power Distribution Diagram.
Remove fuse F15. Measure 12 ± 1.5 volts Voltage from ignition relay to igniting fuses. If
voltage between fuse socket voltage is incorrect, check for failed ignition relay or
A3 to ground. faulty wiring between fuse and relay .
Relay Removed.) Refer to the Cab Ignition Power Distribution Diagram.
(1013) (relay 30) terminal 12 ± 1.5 volts Cab power distribution center, ignition relay power,
G4 to ground. input from megafuse. If voltage is incorrect, check
wiring from megafuse to cab power distribution
center.
(1013) (relay 86) terminal 12 ± 1.5 volts Key voltage to ignition relay. If voltage is incorrect,
J4, ignition relay socket, check for faulty wiring or failed key switch.
to ground.
(1013) (relay 86) terminal 12 ± 1.5 volts Ground to ignition relay coil. If voltage is incorrect,
J4, ignition relay socket, to check for faulty wiring between G3 and ground
(relay 85) terminal G3. adapter (1003).
Relay Installed.) Refer to the Cab Ignition Power Distribution Diagram.
Remove any fuse between 12 ± 1.5 volts Voltage from ignition relay to ignition fuses. If
F29 and F32. Measure voltage is incorrect, check for failed ignition relay or
voltage between the right faulty wiring between fuse and relay .
fuse socket cavity to ground.
Key Switch Resistance Checks (Check With Key Connector (1100) removed
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Table 5 Cab Ignition Power Connector Checks (cont.)

With key switch in off >100K ohms or If resistance is incorrect replace defective switch.
position, measure resistance O.L.
between key switch terminal
D to A, B and C.
With key switch in start >100K ohms or If resistance is incorrect replace defective switch.
position, measure resistance O.L.
C and D.
With key switch in accessory <1 ohm If resistance is incorrect replace defective switch.
position, measure resistance
D and C.
With key switch in ignition <1 ohm If resistance is incorrect replace defective switch.
position, measure resistance
A and D.
Extended Description
When the key switch is in the ignition position, power will be supplied to circuit A13DH, A13DD and A13AG to
the ignition relay in power distribution fuse block (1012). The ignition relay will energize. Power from circuit
A14AT will pass through the accessory relay contacts on circuit A13AH, providing 12 volts to the circuits
requiring power when the key switch is in the ignition position.
4.2. CHASSIS IGNITION POWER DISTRIBUTION

A malfunction in the chassis ignition power circuits will be apparent when ignition power is not available in
several chassis systems.
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Figure 24 Chassis Ignition Power Distribution Diagram

(1012) FUSE BLOCK #2,
LOCATED BEHIND KEY SWITCH
(4000) MAXIFUSE BLOCK STUD
LOCATED ON MAXIFUSE BLOCK IN ENGINE PDC
(4001) MINI FUSE BLOCK
LOCATED IN ENGINE PDC
(4003) R9 PRIMARY IGNITION RELAY
LOCATED IN MINI RELAY BLOCK OF ENGINE PDC
(4005)/4006) CAB GROUND
LOCATED ABOVE ESC ON DASH PANEL
(4014) 48 WAY PASS THRU CONNECTOR
LOCATED ABOVE ESC ON DASH PANEL
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Table 6 Chassis Ignition Power System Connector Checks

Megafuse Voltage Check Refer to the Chassis Ignition Power Distribution Diagram.
Circuit A14AA at 12 ± 1.5 volts Power feed from megafuse. If voltage is incorrect,
Megafuse to ground. check for open megafuse, cabling and connections
from starter solenoid.
(4003) ISO and Power Relay Block (Primary Ignition Relay) R9 Voltage Checks (Check With Key
In Ignition Position and R9 Removed.) Refer to the Chassis Ignition Power Distribution Diagram.
(4003) Primary ignition 12 ± 1.5 volts Engine power distribution center ignition voltage from
relay R9 (relay 85) key switch. If voltage is incorrect, check wiring from
cavity 5 to ground. megafuse, through cab fuse F20 and key switch to
engine power distribution center.
(4003) Primary ignition 12 ± 1.5 volts If voltage is incorrect, check wiring from R9 cavity
relay R9 (relay 85) 2 to cab ground (4005).
cavity 5 to (relay
86) cavity 2.
(4003) Primary ignition 12 ± 1.5 volts Battery voltage from maxifuse stud. If voltage is
relay R9 (relay 30) incorrect, check for faulty wiring between unfused
cavity 1 to (relay side of megafuse to maxifuse stud.
86) cavity 2.
Primary Ignition Relay to Mini Fuse Block (4001) Voltage Checks (Check With Key In Ignition
Position and R9 Installed) Refer to the Chassis Ignition Power Distribution Diagram.
Remove washer pump 12 ± 1.5 volts Voltage from primary ignition relay. If voltage is
fuse (5 amp) from incorrect replace primary ignition relay.
mini fuse block.
Measure voltage at
cavity F1–C2.
When the key switch is in the ignition position, power will be supplied to circuit A13DH, A13DD, A13C and pass
through connector (4014) to circuit J13C.
This will energize primary ignition relay (R9). Power from circuit J14D will pass through the relay contacts
on circuit J13CW, providing battery voltage to several fuses in the engine PDC, which require power when
the key switch is in the ignition position.
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5. COMPONENT LOCATIONS
Figure 25 In-Cab Power Distribution Panel (Located on Passenger Side of Instrument Panel Behind
Closeout Panel)
(1011) FUSE BLOCK 1
(1012) FUSE BLOCK 2
(1013) FUSE BLOCK 3
(1014) FUSE BLOCK 4
Figure 26 In-Cab Power Distribution Panel Graphic (Located on Back of Passenger Instrument panel
Cover
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Figure 27 ESC and Ground Stud Location (Viewed From Inside of Cab with Cover Removed)
1. ELECTRICAL SYSTEM CONTROLLER (ESC)
2. GROUND STUD
3. (4014) PASS THROUGH CONNECTOR
4. GROUND STUD
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Figure 28 Engine Ground Stud Location (Viewed From Engine Compartment)

1. GROUND STUD
2. GROUND STUD
3. (4014) PASS THROUGH CONNECTOR
4. ELECTRICAL SYSTEM CONTROLLER
5. MEGAFUSE
6. POWER DISTRIBUTION CENTER
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Figure 29 Engine Compartment Wiring

1. FUSED SIDE OF MEGAFUSE
2. UNFUSED SIDE OF MEGAFUSE
3. ENGINE POWER DISTRIBUTION CENTER (PDC)
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Figure 30 Typical Engine Power Distribution Center – Refer to the Label on the PDC Lid for Specific
Configuration
(4000) MAXIFUSE BLOCK
(4001) MINI RELAY BLOCKS
(4002) MICRO RELAY BLOCKS
(4003) STARTER, IGNITION & CEC POWER RELAY BLOCKS
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Figure 31 Starter Wiring

1. CABLING TO BATTERY BOX
2. “B” TERMINAL OF STARTER SOLENOID
3. TO FRAME GROUND
4. GROUND TERMINAL ON STARTER MOTOR
5. AMMETER CIRCUIT
6. CLEAN POWER CABLE TO DASH HARNESS FORWARD OF STARTER
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Figure 32 Battery Cable Wiring — Typical, Location And Number Of Batteries May Change Depending
On Model And Options
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Figure 33 Battery Cable Wiring — Typical (Location And Number Of Batteries May Change Depending
On Model And Options)
1. NEGATIVE BATTERY TERMINAL
2. AMMETER SENSE CIRCUIT
3. ECM POWER FEED
4. POSITIVE BATTERY TERMINAL
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3 MULTIPLEXING (DATA LINKS) 55
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2. DIAGNOSTIC SOFTWARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
3. DRIVETRAIN 1939 DATA LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

3.1. CIRCUIT FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3.3. COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
4. BODY BUILDER DATA LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

5. SWITCH DATA LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

6. 1708 DATA LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

7. DATA LINK REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

7.1. J1708. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
7.2. J1939. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Wire Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Wire Splicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
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56 3 MULTIPLEXING (DATA LINKS)
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1. DESCRIPTION
The electrical system on these vehicles has been significantly redesigned. Unlike the electrical systems on
previous models, which utilized point to point wiring for all input signals and output loads, this system uses
multiplexed wiring technologies to provide control and communication between major functional areas of the
vehicle. Multiplexing simply means, Communicating information through a small number of wires (called a
data link) without requiring a wire for each piece of information. This information could be gauge information
such as engine oil pressure, or switch information that controls vehicle functions such as headlamps. The
electrical system relies on a collection of electronic circuit modules and software to perform vehicle functions
instead of implementing similar features using complex wire harness designs with electromechanical relays
and switches. These electronic module components are connected together by electronic data links. These
data links can be thought of as computer networks that allow the electronic components on the vehicle to
communicate with one another.
The concept of multiplexing is not new to International®. Data links for communicating between engine
controllers, the instrument cluster and the diagnostic connector have been used for several years.
The goal of multiplexing is to reduce cab harness wiring and to simplify circuits. This is accomplished by using
low current data link circuits for communication between cab switches and the electrical system controller
and the instrument cluster. Other data links in the vehicle allow other electrical controllers and the instrument
cluster to communicate with each other.
International multiplexing uses two types of data links; J1708 and J1939. The J1708 data link is often referred
to as ATA and J1939 is often referred to as CAN.
There are four separate data links used on the vehicle.
• Drivetrain 1939 data link - This J1939 data link provides a path for communication between the engine
controller, transmission controller, antilock brake system (ABS) controller, pyrometer ammeter module
(PAM), electrical system controller (ESC), auxiliary gauge switch pack (AGSP) and the electronic gauge
cluster (EGC).
• Body builder data link - This J1939 data link provides a path for communication between the remote power
module(s), remote PTO, air solenoid 7 pack(s) and the ESC.
• Switch data link - This J1708 data link provides a path for communication between the center panel
switches, door pods and ESC.
• 1708 data link - This is the same J1708 data link (sometimes referred to as ATA) that has been used in
the past. This data link will be used almost exclusively for diagnostics and programming of engines
and other controllers.
The heart of the multiplexed system is the electrical system controller (ESC). The ESC communicates with
the switches on the switch data link, controllers from other features on the drivetrain 1939 data link and
remote power modules on the body builder data link. It also receives input from various sensors and hard
wire inputs throughout the truck. The ESC converts these inputs into data to be transmitted on the data links.
It is also the power source for circuits that feed the components, controlled by the multiplexed switches,
inside and outside of the cab.
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Figure 34 Electrical System Controller (ESC)

(1600) 36 WAY CONNECTOR
(1601) BROWN 8 WAY CONNECTOR
(4014) 48 WAY PASS THROUGH CONNECTOR
(4008) BLUE 8 WAY CONNECTOR
(4007) BROWN 8 WAY CONNECTOR
(4009) & (4010) POWER CONNECTORS
(4004) 36 WAY CONNECTOR
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2. DIAGNOSTIC SOFTWARE
On vehicles with International engines, the master diagnostics (MD) software may be used to verify the status
of the 1708 data link (diagnostic trouble codes cannot be read from the engine controller if the data link is not
available). See the MD software manual for instructions.
The ESC will log a DTC if communication with an electronic device is lost on the drivetrain 1939 data link, body
builder data link and switch data link. The DTC’s may be read with the INTUNE diagnostic software. See the
INTUNE diagnostic software manual for instructions.
The INTUNE diagnostic software is run on the EZ-Tech (a light version can be run on a personal computer for
body builder and fleet customers). An interface cable is required to connect the computer to the diagnostic
connector of the truck.
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3. DRIVETRAIN 1939 DATA LINK

3.1. CIRCUIT FUNCTION
Figure 35 Drivetrain 1939 Data Link Functional Diagram

1. 120 OHM TERMINATING RESISTOR
2. DIAGNOSTIC CONNECTOR (1650)
3. ELECTRONIC GAUGE CLUSTER (1500)
4. AUXILIARY GAUGE AND SWITCH PACK (1510)
5. PYROMETER/AMMETER MODULE (4087)
6. (YELLOW) HIGH SIGNAL WIRE
7. DRAIN WIRE
8. (GREEN) LOW SIGNAL WIRE
10. TRANSMISSION CONTROLLER
11. ABS CONTROLLER
12. ENGINE CONTROLLER
13. BACKBONE CABLE
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The drivetrain 1939 data link (a much faster data link than the J1708) provides a path for communication
between the ESC, engine controller, transmission controller, ABS controller, auxiliary gauge switch pack
(AGSP), electronic gauge cluster (EGC) and any other electronic communication devices as required.
The drivetrain 1939 datelined backbone is composed of three wires. All wires are twisted and circuits in the
engine compartment are shielded. The twisted pair of wires are terminated at each end, one outside of the cab
and one behind the instrument panel, with a 120 ohm resistor. Devices are connected to the backbone by
shorter runs of twisted wire called stubs.
Connections to the backbone in the cab are hard wired. Connections to the backbone outside of the cab
are accomplished using “Y” connectors.
Figure 36 J1939 Termination Resistor and “Y” Connector

1. 120 OHM TERMINATION RESISTOR
2. “Y” CONNECTOR

If the electronic gauge cluster (EGC) is unable to communicate on the data link, all gauges will sweep to zero
and the check electrical system indicator will light.
If communication between the EGC and ESC is lost but the EGC can still communicate with the engine
controller, information from the engine controller will continue to be displayed on the EGC until the key is
cycled. The check electrical system indicator will still light.
If the engine controller alone is unable to communicate on the data link the gauges in the EGC controlled by
the engine controller will sweep to zero.
The “INTUNE” diagnostic software, running on the EZ-Tech (a light version can be run on a personal computer
for body builder and fleet customers), may be used to view DTC’s logged for communication problems on the
drivetrain 1939 data link. An interface cable is required to connect the computer to the diagnostic connector of
the vehicle. See the “INTUNE” diagnostic software manual for instructions.
Refer to Off-Line Diagnostics for DTC retrieval instructions. (See OFF- LINE DIAGNOSTICS, page 1037)
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Figure 37 Typical (In Cab) Drivetrain 1939 Data Link connectors Diagram (Connectors Used Will
Vary Depending On Features Installed In Vehicle)
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(1500) EGC CONNECTOR

LOCATED ON BACK OF ELECTRONIC GAUGE CLUSTER
(1510) AGSP CONNECTOR
LOCATED ON BACK OF AUXILIARY GAUGE SWITCH PACK (OPTIONAL
FEATURE)
(1600) 36-WAY CAB ESC CONNECTOR
LOCATED ON CAB SIDE OF ESC
(1650) DIAGNOSTIC CONNECTOR
LOCATED BELOW INSTRUMENT PANEL– LEFT SIDE OF CAB
(1657) DATA LINK TERMINATING RESISTOR
TAPED TO INSTRUMENT PANEL HARNESS BEHIND CIGAR LIGHTER
(1658) AUTO HVAC CONNECTOR
LOCATED BEHIND HVAC CONTROL (OPTIONAL FEATURE)
(4014) PASS THROUGH CONNECTOR
LOCATED IN DASH PANEL ABOVE ESC
(7905) EATON AUTOSHIFT SELECTOR
LOCATED BEHIND EATON AUTOSHIFT SELECTOR (OPTIONAL FEATURE)
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Figure 38 Typical (Outside Of Cab) Drivetrain 1939 Data Link Connectors Diagram (Connectors Used
Will Vary Depending On Features Installed On Vehicle)
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(4024) AIR ABS CONNECTOR

LOCATED ON AIR ABS ECU (WITH AIR ABS ONLY)
(4051)(4052)(4062) PAM SPLICE CONNECTORS
LOCATED NEAR ENGINE COMPARTMENT POWER DISTRIBUTION CENTER
(4060)(4061)(4056) AIR ABS SPLICE CONNECTORS
LOCATED NEAR ENGINE COMPARTMENT POWER DISTRIBUTION CENTER
(4087) PYROMETER/AMMETER (PAM) MODULE CONNECTOR
LOCATED ON PAM MODULE MOUNTED NEAR AIR FILTER (OPTIONAL
FEATURE)
(4103) ENGINE/DASH HARNESS
LOCATED NEAR WIPER MOTOR BRACKET
(6007) ENGINE ECM CONNECTOR
LOCATED ON ENGINE ECM
(6012) ENGINE ECM CONNECTOR
LOCATED ON ENGINE ECM
(6008)(6009)(7801) ENGINE SPLICE CONNECTORS
LOCATED NEAR ENGINE ECM
(7207)(7208) TRANSMISSION SPLICE CONNECTORS
LOCATED ABOVE TRANSMISSION
(7209) TERMINATING RESISTOR
LOCATED ON ENGINE SPLICE CONNECTOR OR TRANSMISSION SPLICE
CONNECTOR
(7204) MD (WTEC) ECU CONNECTOR
LOCATED ON TRANSMISSION ECU
(7205) LCT ECU
LOCATED ON LCT TRANSMISSION ECU
Problems with the drivetrain 1939 data link could be the result of crossed or open circuits in the backbone or
stubs, shorts to ground in any of the circuits, missing or incorrect terminating resistors, interference on the data
link, internal shorts or incorrect output from any electronic device (controller) connected to the data link.
The starting point for isolating drivetrain data link problems is to establish communications between the ESC
and EGC. This may require disconnecting other electronic controllers from the data link.
When the diagnostic trouble codes identify only one controller is not communicating with the ESC, check
power and data link circuits unique to that device. If there is power to the device, an internal malfunction
may be causing the problem.
When the ESC and EGC are communicating but several other controllers are not communicating there is
probably an open or crossed circuits in the data link .
It may be necessary to disconnect components from the data link to isolate a device that is causing the problem.
Table 7 Drivetrain 1939 Data Link Circuit Checks

Drivetrain 1939 Circuit Voltage Checks
Check with ignition on.
NOTE – Voltages on J1939 data links vary depending on the amount of traffic on the data link.
Presence of voltages will eliminate shorts to ground and may help identify open circuits.
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Table 7 Drivetrain 1939 Data Link Circuit Checks (cont.)

(1650) Diagnostic Approximately 2.5 If voltage is missing, check for open or short to
connector pin volts ground in yellow data link circuits.
C, or any other
yellow drivetrain
1939 data link
circuit, to ground
(1650) Diagnostic Approximately If voltage is missing, check for open or short to
connector pin 2.5 volts ground in green data link circuits.
D, or any other
green drivetrain
1939 data link
circuit, to ground
Drivetrain 1939 Circuit Resistance Checks
Check with battery disconnected.
This procedure checks for open circuits or missing terminating resistors in the data link backbone.
(1650) Diagnostic 60 ± 10 ohms If resistance is closer to 120 ohms, check for missing
connector Pin terminating resistor or open circuit. If resistance is higher
C to D both terminating resistors may be missing.
If resistance is low check for shorts between data link circuits.

(1650) Diagnostic >100K ohms If resistance is low check for short to ground in
connector Pin C yellow data link circuits
to ground
(1650) Diagnostic >100K ohms If resistance is low check for short to ground in
connector Pin D green data link circuits
to ground
If voltages and resistances check good, the data link backbone is good. Check for crossed circuits
throughout data link or open circuits between the electronic device and the backbone.
If problems persist, something is interfering with data link communication. This could be the result
of erratic signals from one of the electronic controllers or some kind of interference.
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3.3. COMPONENT LOCATIONS
Figure 39 Drivetrain 1939 Data Link Engine Splice (I6 Engine Shown)
1. ENGINE SPLICE (6008) (6009)
2. (7801) WITH ELECTRONIC AUTOMATIC TRANSMISSION -TERMINATING RESISTOR
WITH AUTOSHIFT OR MANUAL TRANSMISSION
3. TRANSMISSION HARNESS
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Figure 40 Drivetrain 1939 Data Link Transmission Splice (MD Transmission Shown)
2. DRIVETRAIN 1939 "Y" CONNECTOR TERMINATOR
3. DRIVETRAIN 1939 "Y" CONNECTOR (7208)
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4. BODY BUILDER DATA LINK

Figure 41 Typical Body Builder Data Link Function Diagram

1. REMOTE POWER MODULE (UNDER CAB, BACK OF CAB OR END OF FRAME)
2. REMOTE POWER MODULE (FORWARD OF CAB)
3. BODY BUILDER DATA LINK
5. AIR SOLENOID (7-PACK)
The body builder data link (a J1939 style data link) provides communication between the ESC and the remote
power module(s), 7-pack air solenoid module(s) and remote engine speed control module. The actual wiring
associated with this data link will vary depending on the modules installed on the vehicle.
Refer to Body Builder Data Link Diagram.
The vehicle may be equipped with several remote power modules (RPM), up to two 7-pack air solenoid
modules (RASM) and/or a remote engine speed control module (RESCM). A “Y” connector splits the data
link to components mounted forward of the cab and to components mounted under or behind the cab. If no
components are installed on one side of the Y connector, a terminating resistor assembly (3537129C1)
must be installed in the open connector. The last component in each chain must have a terminating resistor
assembly (3559775C1) on the output connector.
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Figure 42 J1939 Termination Resistor and “Y” Connector

1. 120 OHM TERMINATION RESISTOR (3537129C1)
2. “Y” CONNECTOR (3537130C1)
The body builder data link backbone cable consists of three wires. All wires are twisted and shielded. Devices
are connected to the data link at the “Y” connector or are daisy chained from one component to the other.
Problems with the body builder data link could be the result of crossed or open circuits in the backbone or
stubs, shorts to ground in any of the circuits, missing or incorrect terminating resistors and internal shorts or
incorrect output from any electronic device (module) connected to the data link.

The ESC will log a diagnostic trouble code when messages from installed remote controllers are missing on
the body builder data link. Refer to Off-Line Diagnostics for DTC retrieval instructions. (See OFF- LINE
DIAGNOSTICS, page 1037)
The “INTUNE” diagnostic software, running on the EZ-Tech (a light version can be run on a personal computer
for body builder and fleet customers), may be used to check for diagnostic trouble codes for components
communicating to the ESC on the body builder 1939 data link. An interface cable is required to connect
the computer to the diagnostic connector of the vehicle. See the “INTUNE” diagnostic software manual for
instructions.
Refer to Off-Line Diagnostics for DTC retrieval instructions. (See OFF- LINE DIAGNOSTICS, page 1037)
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Figure 43 Typical Body Builder Data Link Connector Diagram (Devices Used Determined by Features
Installed on Vehicle)
(4004) ELECTRICAL SYSTEM CONTROLLER
(4410) REMOTE SOLENOID POWER MODULE
(4410B & C) SOLENOID MODULE
(4410D & E) REMOTE POWER MODULE
(4410H) REMOTE POWER MODULE CENTER/REAR
(4410M) REMOTE POWER MODULE
(4415) FORWARD REMOTE POWER MODULE UNIT
Problems with the body builder data link could be the result of open circuits in the backbone or stubs, shorts to
ground in any of the circuits, missing or incorrect terminating resistors, interference on the data link, internal
shorts or incorrect output from any electronic device (module) connected to the data link.
When the diagnostic trouble codes identify only one module is not communicating with the ESC, check power
and data link circuits unique to that device. If the device has power it may have an internal failure preventing
it from communicating on the data link.
When several devices are not communicating with the ESC there is probably an open in the data link or
a crossed circuit.
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It may be necessary to disconnect components from the data link to isolate a device that is affecting the
data link.
Table 8 Body Builder Data Link Connector Check Chart

Body Builder Data Link Voltage Checks
Take measurements by installing breakout box ZTSE4477 between ESC connector

(4004) and harness connector (4004).
Check with key on.
Presence of voltages will eliminate shorts to ground and may help identify open circuits.
(4004) Breakout box Approximately 2.5 If voltage is missing, check for open or short in yellow
test point 34 to ground volts. data link circuits or shorts in components.
(4004) Breakout box Approximately 2.5 If voltage is missing, check for open or short in green
test point 35 to ground volts data link circuits or shorts in components.
Body Builder 1939 Circuit Resistance Checks
Check with battery disconnected.
This procedure checks for open circuits or missing terminating resistors in the data link backbone.
(4004) Breakout box 60 ± 10 ohms If resistance is closer to 120 ohms, check for missing
test point 34 to 35 terminating resistor or open circuit. If resistance is higher
both terminating resistors may be missing.
If resistance is low check for shorts between

data link circuits.
(4004) Breakout box >100K ohms If resistance is low check for short to ground
test point 34 to ground in yellow data link circuits
(4004) Breakout box >100K ohms If resistance is low check for short to ground
test point 35 to ground in green data link circuits
If voltages and resistances check good, the data link backbone is good. Check for crossed circuits
throughout data link or open circuits between the electronic device and the backbone.
If problems persist, something is interfering with data link communication. This could be the result
of erratic signals from one of the electronic controllers or some kind of interference.
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5. SWITCH DATA LINK

Figure 44 Typical Switch Data Link Function Diagram

1. DRIVER SIDE CREW DOOR POD
2. DRIVER’S DOOR POD
3. SWITCH PACK
4. PASSENGER DOOR POD
5. PASSENGER SIDE CREW DOOR POD
7. SWITCH DATA LINK TWISTED PAIR
The switch data link is a twisted pair of wires. This data link provides a path for communication between the
ESC, the instrument panel switches and the door pods. This data link allows the switch packs, door pods
and ESC to send messages to each other eliminating the need for individual high current wires between
switches and components.

The ESC will detect an open/short on the data link or an absence of message traffic from other components on
the switch data link. A diagnostic trouble code will be logged and the check electrical system indicator will light.
Problems with the switch data link could be the result of open circuits in the data link, shorts to ground in
any of the circuits, and internal shorts or incorrect output from any electronic device (module) connected to
the data link.
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Figure 45 Typical Switch Data Link Function Diagram
Table 9 Switch Data Link Connector Check Chart

Switch Data Link Voltage Checks
Take measurements on open connector (1101) behind switch pack(s)

(1101) Pin B to ground 12 ± 1.5 volts If voltage is missing, check for blown fuse (F19) or open
or short in circuits A12P.
(1101) Pin A to ground 0 volts Ground circuit to pod.
(1101) Pin D to Approximately 3 volts (+) data link circuit. If voltage is low check for open or
ground short in circuit A3J(+) or shorted components on data link.
(1101) Pin E to ground Approximately .1 volt (-) data link circuit. If voltage is low check for open in
circuit A3K(-) or shorted components on data link. If
voltage is high check for crossed data link wires.
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6. 1708 DATA LINK

Figure 46 Typical 1708 Data Link Function Diagram

2. TRANSMISSION CONTROLLER
3. DIAGNOSTIC CONNECTOR
4. ABS CONTROLLER
The 1708 data link is a twisted pair of wires. This data link connects the diagnostic connector, engine controller,
transmission controller, air or hydraulic ABS controller as required. The primary purpose of this data link is to
provide an electronic service tool the capability to program and diagnose the electrical controllers.

The ESC is not connected to the 1708 data link. If there is an open/short on the 1708 data link the engine
controller will log a diagnostic trouble code and the yellow engine warning lamp on the EGC will light.
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Figure 47 Typical 1708 Data Link Function Diagram
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Table 10 1708 Data Link Connector Check Chart

1708 Data Link Voltage Checks at Diagnostic Connector (1650)
(1650) Pin B to 12 ± 1.5 volts If voltage is missing, check for blown fuse (F20)
ground or open or short in circuits A98 to fuse block.
(1650) Pin A to 0 volts Ground circuit.
ground
(1650) Pin F to Approximately 4 volts (+) data link circuit. If voltage is low check for
ground open in positive data link circuits.
(1650) Pin G to Approximately 1 volt (-) data link circuit. If voltage is low check for
ground open in negative data link circuits. If voltage is
high check for crossed data link circuits.
7. DATA LINK REPAIR

7.1. J1708
Repairs to damaged J1708 circuits should be accomplished using similar types of wiring. Splices should be
crimped and soldered. Insure the twist in the wire pair is maintained and individual wires are covered with
heat shrink.
7.2. J1939
Repairs to damaged J1939 circuits should be accomplished using similar types of wiring. Splices should be
crimped, soldered and covered with heat shrink. Insure the twist in the wire pair is maintained and that any
wire bundles in the engine compartment are shielded and covered with heat shrink.
Wire Repair
This instruction addresses termination and splicing of J1939 wire.
WARNING – Always turn off power to any electrical circuit before starting work.
CAUTION – Incorrect Connection or splicing of J1939 wire may result in compromise of function.
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Preparation of J1939 wire for connection.
Figure 48
A. Strip back outer shield 3 1/8 in. (76 mm).

B. Strip green wire and yellow wire 1/4 in. (6.35mm) being careful not to cut individual strands.
Re-twist the wires if they have separated.
C. Sleeve drain wire. Drain wire may be soldered to aid in sleeving.
D. Install terminals on the wire ends, and crimp.
E. The 1/4” heat shrink tube will be shrunk later after the wires have been inserted into the connector.
Wiring the Connector
CAUTION – The wires must be installed in the correct cavities. Refer to following Figure.
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Figure 49 J1939 Connector
A. Yellow wire inserts to position 1.

B. Drain wire inserts to position 2.
C. Green wire inserts to position 3.
D. A plug occupies position 4.
CAUTION – Be sure that the connector pins are fully seated (locked) in the connector. If pins are
fully seated, they will not pull back out with moderate pressure.
NOTE – After pins are seated they can only be released by depressing the pin lock (red plastic) at the
front side of the connector.
Figure 50
A. PIN LOCK
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Wire Splicing
1. Strip wire ends 1/4 inch.
Figure 51
2. Re-twist any loose wire strands
3. Slide 2 inch pieces of heat shrink tube over wire for later use per
Figure 52
4. Insert ends of wires into splice joint and crimp.
5. Solder the wires and crimp joint together.
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Figure 53
6. Center heat shrink tube over splice and shrink.
Figure 54
7. Wrap wires and drain with foil tape. Maintain at least 1/2 wrap overlap.
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Figure 55
8. Center heat shrink tube over the splice and shrink.
Figure 56
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4 ELECTRICAL SYSTEM CONTROLLER AND SWITCH PACKS 83
Table of Contents
1. ELECTRICAL SYSTEM CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

1.1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
1.2. DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Electrical System Controller Preliminary Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
1.3. ESC POWER AND GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
1.4. ESC SWITCHED 5 VOLT SENSOR SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
1.5. ESC ZERO VOLT REFERENCE LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
1.6. ESC DATA LINKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
1.7. ESC CONNECTOR PIN-OUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
1.8. ADDING TERMINALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
8-Way Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
36–Way Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
1.9. PROGRAMMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
ESC Programmable Features and Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Changing Gauge Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Programming Switch Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Programming Templates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
1.10. ESC REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
2. SWITCH PACK MODULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

2.1. FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
2.2. DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
2.3. SWITCH PACKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Fault Detection Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Extended Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
2.4. INDIVIDUAL SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
2.5. COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
2.6. SWITCH AND BULB REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
L.E.D. Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Switch or Blank Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Switch/Blank Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
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84 4 ELECTRICAL SYSTEM CONTROLLER AND SWITCH PACKS
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1.1. DESCRIPTION
Figure 57
(1600) 36 WAY ESC CONNECTOR (INSIDE CAB)
(1601) BROWN 8 WAY ESC CONNECTOR (INSIDE CAB)
(4004) 36 WAY ESC CONNECTOR (ENGINE COMPARTMENT)
(4007) BROWN 8 WAY ESC CONNECTOR (ENGINE COMPARTMENT)
(4008) BLUE 8 WAY ESC CONNECTOR (ENGINE COMPARTMENT)
(4009) ESC POWER CONNECTOR
(4010) ESC POWER CONNECTOR
(4014) 48 WAY DASH PASS THROUGH CONNECTOR
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The Electrical System Controller (ESC) is an electronic assembly providing multiple analog and switched input
interfaces to read the status of various user switches and sensors. The ESC System provides a means to
distribute electrical power and provide the driver with controls and indications of the vehicle performance.
Unlike previous electrical system designs, this approach uses multiplexed wiring technologies for interfacing
major functional areas of the vehicle. Furthermore, the system relies on software algorithms to accomplish
logic functions instead of implementing similar features using complex wire harness designs with relays and
switches. A natural benefit of this system is increased diagnostic capability in terms on line, off line and
off board testing.
The Electrical System Controller (ESC) is the heart of the vehicle electrical system. It performs the following
functions:
A. Communicates with most of the instrument panel and door switches through a switch (J-1708)
data link (multiplex system).
B. Receives input from the HVAC system for HVAC diagnostics and compressor control.
C. Receives inputs from steering column switches to control the horn, turn signal, wash/wipers and
cruise control.
D. Receives inputs from the brake switch(es) and clutch switch, while monitoring for open or shorted
circuits for each switch.
E. Communicates with the Electronic Gauge Cluster (EGC), on the drivetrain 1939 data link, to
display vehicle parameters and system diagnostics.
F. Provides power to several components, inside and outside of the cab, which are controlled by the
multiplexed switches or direct inputs.
G. Provides a body builder data link to control remote power modules, remote air solenoids, and
remote PTO modules.
H. Communicates with the engine controller, transmission controller and ABS controller on the
drivetrain 1939 data link.
The table below contains the list of features controlled by the ESC.
Table 11 Features Controlled by the Multiplex System

Standard Features Optional Features
Headlights, Park Lights Air Conditioning Control & Protection
Wiper/Washer System Mirror Heat
Electric Horn Work Lights
Turn Signals and Hazard Flashers Fog Lights
Stop Lights Powered Park Brake System and Warning
Lights
Dome Lights Drive Line Air Controlled Accessories (Power
Divider, Differential. Lock, Suspension. Dump,
etc.)
Hydraulic Brake System Monitor and Warning Warning Lights for Electronic Transmissions
Lights
Warning Lights for Anti-Lock Brakes Engine Brake Systems (Compression Brake,
Exhaust Brake, Drive Line Retarder)
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Table 11 Features Controlled by the Multiplex System (cont.)

Standard Features Optional Features
Cruise Control Interface with Engine Optional Gauges (Transmission Oil Temp, Axle
Oil Temp, Ammeter)
Air Pressure Gauge System Optional Warning Light Systems (Fuel Filter,
Change Oil, Water In Fuel, etc.)
Standard Gauge Package (Speedometer,
Tach, Volt Meter, Water Temp, Oil Pressure,
Fuel Level)
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Figure 58 Electrical System Controller Block Diagram

1. MICROPROCESSOR
2. 10 AMP SOLID STATE SWITCHES
3. 20 AMP SOLID STATE SWITCHES
4. 16 CHANNEL RELAY DRIVER
5. SENSOR 5 VOLT SUPPLY OUTPUT
6. SWITCH DATA LINK– J1708 DATA TRANSCEIVER
7. BODY BUILDER DATA LINK J1939 TRANSCEIVER
8. DRIVETRAIN 1939 DATALINK TRANSCEIVER
9. DIGITAL INPUT CONDITIONING CIRCUITS
10. ANALOG INPUT CONDITIONING CIRCUITS
11. ESC MODULE POWER SUPPLY
12. DRIVE SIGNAL
13. STATUS SIGNAL
Since the ESC has electronically programmable inputs and outputs, ESC configuration will vary from vehicle
to vehicle.
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The ESC is mounted in the dash panel between the cab and the engine compartment. It has a power connector,
from switched ignition, inside the cab and a power connector, from the batteries, in the engine compartment.
Power for components controlled by switches and the switch packs is supplied from the ESC.
NOTE – The ESC is not a repairable module. Once it has been determined that the ESC has an internal
malfunction, it must be replaced and the replacement must be programmed. There is a chance that
reloading the programming might repair some problems.
1.2. DIAGNOSTICS
Should the Electrical System Controller fail to operate, the problem could be attributed to missing power, a
problem with a data link, corrupted programming or a failure inside the ESC
Diagnostic trouble codes (DTC’s) are generated by the ESC and can be read on the odometer display.
An electronic service tool, running the "INTUNE" diagnostic software, can be used to monitor signals to and
from the ESC and will also display DTC’s. See the diagnostic software manual for details on using the software.
Electrical System Controller Preliminary Check
Table 12 Electrical System Controller Preliminary Check

STEP KEY ACTION TEST SPEC. YES - IN NO - OUT OF SPEC.
POINTS SPEC.
1. On Turn key to ignition Observe Warning Go to next If electrical problems
position. Does “Check Elec lamp step. persist refer to the
“Check Elec System” System” remains section in this manual
warning lamp remain warning lamp illuminated for the specific
illuminated after and gauges and malfunction. A
gauge sweep? on gauge speedometer problem with the
cluster. and engine controller
Tachometer may also cause the
are “Check Elec System”
working. warning lamp to stay
on.
2. On Check for ESC Read display Codes Go to ESC Go to next step.
diagnostic trouble on odometer. 627 14 1 Power And
codes (See 1 or 1542 Ground.
Diagnostic Trouble 14 1 1 are (See ESC
Codes , page 90) Are active. POWER
codes 627 14 1 1 or AND
1542 14 1 1 active? GROUND,
page 91)
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Table 12 Electrical System Controller Preliminary Check (cont.)

STEP KEY ACTION TEST SPEC. YES - IN NO - OUT OF SPEC.
POINTS SPEC.
3. On Is code 1705 14 150 1 Read display Code Go to Go to next step.
active (EGC Version on odometer. 1705 14 ESC Data
8.7), is code 2023 150 1 Links (See
14 150 1 active or is is active ESC DATA
code 2023 14 250 1 (EGC LINKS,
active (EGC Version Version page 94)
9.3 and later)? 8.7), is
code 2023
14 150 1
active or is
code 2023
14 250
1 active
(EGC
Version
9.3 and
later)
4. On Is code 1557 0 1 1 Read display Code Go to ESC
active? on odometer. 1557 0 1 REPLACEMENT
1 is active. (See ESC
REPLACEMENT,
page 123)
Diagnostic Trouble Codes
To display diagnostic codes, set the parking brake and turn the Ignition key “ON”. Then press the Cruise “ON”
switch and the Cruise “Resume” switch simultaneously for at least 3 seconds. If no faults are present, the
cluster odometer will display “NO FAULT”. If faults are present, the gauge cluster display will show each
diagnostic trouble code for 5 seconds and then automatically scroll to the next entry and continue to cycle
through the faults. To manually cycle through the fault list, press the cluster display selector button. The last
character of the diagnostic trouble code will end in “A” for active faults or “P” for previously active faults.
Turning the ignition key off will take the ESC and the gauge cluster out of the diagnostic mode.
After all repairs have been made, the diagnostic trouble codes may be cleared by putting the key switch
in the accessory position, turning on the left turn signal and pressing the cruise “ON” and “SET” switches
simultaneously for 3 seconds.
Table 13 Electrical System Controller Diagnostic Trouble Codes

FAULT CODE FAULT DESCRIPTION
610 14 1 0 Loss of Ignition feed for 10 seconds while the engine is running
610 14 2 1 Loss of Accessory feed for 10 seconds while
the engine is running
612 14 0 1 Ignition out of range low
Short to ground or open circuit
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Table 13 Electrical System Controller Diagnostic Trouble Codes (cont.)

612 14 0 2 Ignition out of range high
Shorted high
627 14 1 1 Open or short in circuit J14A to ESC power supply
#1 or maxifuse A4 is blown
1542 14 1 1 Open or short in circuit J14B to ESC power supply
#2 or maxifuse A3 is blown
1557 0 1 1 ESC internal fault software main loop time exceeded.
1705 14 150 1 ESC not communicating with the EGC (EGC Version 8.7)
2023 14 150 1 Loss of data link from ESC to primary EGC (150)
(EGC Version 9.3 and later)
2023 14 250 1 Loss of data link from ESC to secondary EGC (250)
1.3. ESC POWER AND GROUND

Battery voltage is supplied to the ESC through two 60A fuses in maxi fuse block (4000) in the engine
compartment power distribution center.
NOTE – If one 60 amp maxifuse should happen to blow, the ESC will still be able the operate half of the
system outputs. For example: If the maxifuse which feeds the ESC to supply voltage to the low beam
headlights blows, the high beam headlights will still operate.
The ESC receives power, with the key switch in the ignition position, from the ignition relay through 10 amp
fuse F15.
The ESC receives power on pin 2 of connector (1600), with the key switch in the accessory position, from the
accessory relay through 5 amp fuse F19.
The ESC ground is to the negative terminal of the batteries via ground stud (1851).
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Figure 59 ESC Power and Ground Diagram

(1012) IGNITION RELAY (IN CAB POWER DISTRIBUTION PANEL)
(1100) KEY SWITCH (ON INSTRUMENT PANEL)
(1851) GROUND STUD (ABOVE ESC)
(4009) ESC POWER FEED #2 CONNECTOR (IN ENGINE COMPARTMENT)
(4010) ESC POWER FEED #1 CONNECTOR (IN ENGINE COMPARTMENT)
A3 60 AMP MAXIFUSE ESC #2 (IN ENGINE COMPARTMENT POWER DISTRIBUTION
CENTER)
A4 60 AMP MAXIFUSE ESC #1 (IN ENGINE COMPARTMENT POWER DISTRIBUTION
CENTER)
F19 SYSTEM CONTROLLER IGNITION FUSE (IN CAB POWER DISTRIBUTION CENTER)
F20 KEY SWITCH AND DIAGNOSTIC CONNECTOR FUSE (IN CAB POWER DISTRIBUTION
CENTER)
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Table 14 ESC Power and Ground System Circuitry Voltage Check Chart
ESC connector (4009) – Battery Voltage Check – Check with the Ignition Key
“Off” and (4009) disconnected.
NOTE – Always check connectors for damage and pushed–out terminals.

(4009) harness pin, circuit 12 ± 1.5 volts If voltage is incorrect, check for blown maxifuse
J14B, to ground. A3, blown megafuse or open wiring.
ESC connector (4010) – Battery Voltage Check – Check with the Ignition Key
“Off” and (4010) disconnected.
NOTE – Always check connectors for damage or pushed–out terminals.

(4010) harness cavity, circuit 12 ± 1.5 volts If voltage is incorrect, check for blown maxifuse A4,
J14A, to ground. missing voltage from starter solenoid to megafuse
terminal, or open wiring.
ESC Power– Ignition Voltage Check (Check with the Ignition Key “On” and (1600) disconnected)
NOTE – ESC breakout box ZTSE-4477 should be used to make measurements at ESC connectors

Harness connector (1600) 12 ± 1.5 volts If voltage is incorrect, check for blown fuse F15,
cavity 12 to ground. missing voltage from ignition relay, missing voltage
to relay from key switch or missing voltage from
megafuse.
Harness connector (1600) 12 ± 1.5 volts If voltage is incorrect, check for open in ground
cavity 12 to cavity 1. circuit from (1600) to ground stud (1851).
ESC Power–Accessory Voltage Check (Check with the Ignition Key “On” and (1600) disconnected)

cavity 2 to ground. missing voltage from accessory relay, missing
voltage to relay from key switch or missing voltage
from megafuse.
Harness connector (1600) 12 ± 1.5 volts If voltage is incorrect, check for open in ground
cavity 2 to cavity 1. circuit from (1600) to ground stud (1851).
1.4. ESC SWITCHED 5 VOLT SENSOR SUPPLY

The ESC provides a 5 volt sensor signal for several sensors on the vehicle. A DTC will be logged if the 5
volt signal is shorted to ground. A short in any sensor using the signal or on any circuit carrying the signal
will cause all sensors to be inoperative.
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1.5. ESC ZERO VOLT REFERENCE LEVEL

The ESC provides a zero volt reference level which is a clean ground for the system. If this signal is missing
several features will be inoperative.
1.6. ESC DATA LINKS

The ESC communicates on 3 of the 4 data links on the vehicle. For details on vehicle data links refer to
Multiplexing (Data Links).
Figure 60 ESC Data Link Diagram

F19 SYSTEM CONTROLLER IGNITION FUSE (CAB POWER DISTRIBUTION CENTER)
(1851) GROUND STUD (ABOVE ESC)
A. TO BODY BUILDER 1939 DATA LINK
B. TO DRIVE TRAIN 1939 DATA LINK
C. TO SWITCH DATA LINK
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Table 15 ESC Data Link Circuits

ESC Ignition Voltage Check — Check with the Ignition Key “On” and (1600) disconnected

cavity 2 to ground. missing voltage from ignition relay, missing voltage
to relay from key switch or missing voltage from
megafuse.
Harness connector (1600) 12 ± 1.5 volts If voltage is incorrect, check for open in ground circuit
cavity 2 to cavity 1. from (1600) to ground stud (1851).
ESC Switch Data Link Voltage Check — Check with the Ignition Key “On” and (1600) disconnected

Harness connector (1600) Approximately 3 If voltage is incorrect, check for open or short in (+)
cavity 29 to 1. volts data link circuits or modules.
Harness connector (1600) Approximately .2 If voltage is incorrect, check for open or short in (-)
cavity 30 to 1. volt data link circuits or modules.
ESC Drivetrain 1939 Data Link Resistance Check — Check with battery disconnected

Harness connector (1600) Approximately 60 If resistance is incorrect, check for missing or open
cavity 34 to cavity 35. ohms terminating resistors in data link, open or shorts in
data link, and open or shorted modules.
1.7. ESC CONNECTOR PIN-OUTS

NOTE – Pin 3 of the cab 36-way connector and pin 26 of the chassis 36-way connector are 0 volt reference
for various sensors on the vehicle and should NEVER have battery voltage applied to them. Doing so
will permanently damage the ESC. Do not connect other ground signals to the zero volt reference.
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Table 16 Electronic System Controller Module 8–way Connectors

NOTE – NO CONNECTIONS OR SPLICES ARE ALLOWED ON ANY SIGNALS MARKED WITH AN
ASTERISK (*).
Connector on ESC Connector on ESC Connector on ESC

(4007) Brown Engine Side (4008) Blue Engine Side (1601) Brown Inside
Front End Output Bottom Chassis Output Top 8-way Inside Cab Output Cab 8-way
8-way Connector Connector
Connector
Pin Source Description Pin Source Description Pin Source Description
(Circuit) (Circuit) (Circuit)

A 20 Amp Fog Lights/ A 10 Amp Solenoid A 1 Amp Spare
FET Spare 1 FET Power Relay Dr.
(J64A) (J59E)
B 10 Amp Right Front B 10 Amp Right Rear B Ground Ground
FET Turn Signal FET Turn Signal
(A11–GAH)
(J57AA) (J57J)
C 10 Amp Left Front C 10 Amp Left Rear C 10 Amp Dome
FET Turn Signal FET Turn Signal FET Lights
(J56AA) (J56J) (A63E)

Dealer 20 Amp Low Beams Dealer 10 Amp Wiper Park Dealer 20 Amp Spare
FET FET Input FET
(J53A)
(J82E)
E 10 Amp Horn, E 10 Amp Spare E 1 Amp Spare
FET Electric FET Relay Dr.
(J85AA)
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Table 16 Electronic System Controller Module 8–way Connectors (cont.)

ASTERISK (*).
Connector on ESC Connector on ESC Connector on ESC

(4007) Brown Engine Side (4008) Blue Engine Side (1601) Brown Inside
Front End Output Bottom Chassis Output Top 8-way Inside Cab Output Cab 8-way
8-way Connector Connector
Connector
Pin Source Description Pin Source Description Pin Source Description
(Circuit) (Circuit) (Circuit)

Fleet 10 Amp Work Light Fleet 20 Amp Wiper Fleet 10 Amp Spare
FET FET Control FET
(J65)
(J82F)
G 20 Amp High Beams G 10 Amp AC Clutch G 20 Amp Mirror Heat
FET FET FET
(J52A) (J77B) (A78)
H 20 Amp Park Lights H Ground Ground H 20 Amp Park Lights
FET FET
(J58A) Plug (A58F)
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Table 17 Electronic System Controller Module Power Connectors
View in Direction of ESC View in Direction of ESC

#4009 Engine Side Input Power Feed #4010 Engine Side Input Power Feed
#2 (Circuit J14B) #1 (Circuit J14A)
Pin Source Description Pin Source Description
A Maxi Fuse 60 Amp Power Source A Maxi Fuse 60 Amp Power Source
Block Block
Table 18 ESC Module Connector (1600)

ASTERISK (*).
(1600) In Cab 36-way Air Chassis Hydraulic Chassis

Connector
Pin Description Pin Description
Pin Type Automatic Manual Automatic Manual
Transmission Transmission Transmission Transmission
(Circuit)
1 Chassis Ground Connect to Connect to Connect to Connect to
Ground Stud Ground Stud Ground Stud Ground Stud
(A11–GAB)
2* Input (12V Accessory Input* Accessory Input* Accessory Input* Accessory Input*
active)*
(A12N)
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Table 18 ESC Module Connector (1600) (cont.)

ASTERISK (*).

Connector
(Circuit)
3* Zero Volt Zero Volt Zero Volt Zero Volt Zero Volt
Reference* Reference* Reference* Reference* Reference*
(A9H)
4 Output (Ground Park Brake On Park Brake On Park Brake On Park Brake On
Active)
(128D)
5 Input (Ground Spare Spare Spare Spare
Active)
(A85C)
6 Output (Ground Spare Spare Spare Spare
Active)
7* Input (Ground A/C Request* A/C Request* A/C Request* A/C Request*
Active)*
(A77)
8* Input (Ground HVAC Diagnostic HVAC HVAC HVAC
Active)* 1* Diagnostic 1* Diagnostic 1* Diagnostic 1*
(A75A)
9** Input (Ground Spare Spare Hydraulic Hydraulic
Active) Booster Control Booster Control
Monitor Monitor
(A90P)
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ASTERISK (*).

Connector
(Circuit)
10* Input (Ground Cruise Control Cruise Control Cruise Control Cruise Control
Active)* Switches* Switches* Switches* Switches*
(A96)
11 Output (Ground Spare Spare Spare Spare
Active)
12* Input (12V Ignition Input* Ignition Input* Ignition Input* Ignition Input*
Active)*
(A13AF)
13* Input (12V Horn Switch* Horn Switch* Horn Switch* Horn Switch*
Active)*
(A85B)
14* Input (12V Head Light Head Light Head Light Head Light
Active)* Enable* Enable* Enable* Enable*
(A50)
15* Input* Primary Air Primary Air Auxiliary Air Auxiliary Air
Sensor* Sensor* Pressure* Pressure*
(A40)
16# Input Secondary Air Secondary Air Spare Spare
Sensor# Sensor#
(A40A)
17 Input (Ground Spare Clutch Switch Spare Clutch Switch
Active) Input Input
(A96A)
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ASTERISK (*).

Connector
(Circuit)
18* Input (Ground Right Turn* Right Turn* Right Turn* Right Turn*
Active)*
(A57A)
19* Input (Ground Left Turn* Left Turn* Left Turn* Left Turn*
Active)*
(A56A)
20* Input (Ground High Beam High Beam High Beam High Beam
Active)* Switch Input* Switch Input* Switch Input* Switch Input*
(A52A)
21* Input (Ground Flash to Pass* Flash to Pass* Flash to Pass* Flash to Pass*
Active)*
(A102A)
22* Input (Ground Wiper_0* Wiper_0* Wiper_0* Wiper_0*
Active)*
(A82)
Active)*
(A82A)
Active)*
(A82B)
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ASTERISK (*).

Connector
(Circuit)
25* Input (Ground Dome Light Dome Light Dome Light Dome Light
Active)* Switch Input* Switch Input* Switch Input* Switch Input*
(A63A)
Active)
27* Output (5 v, 100 Sensor 5 Vdc Sensor 5 Vdc Sensor 5 Vdc Sensor 5 Vdc
milliamp)* Out* Out* Out* Out*
(A6H)
28* Input (Ground Washer Pump* Washer Pump* Washer Pump* Washer Pump*
Active)*
(A87A)
29* Switch Data J1708+ J1708+ J1708+ J1708+
Link +* (Switches Only)* (Switches Only)* (Switches Only)* (Switches Only)*
(A3E(+))
30* Switch Data J1708- (Switches J1708- J1708- J1708-
Link -* Only)* (Switches Only)* (Switches Only)* (Switches Only)*
(A3F(-))
Active)
32* Input (Ground Park Brake Input* Park Brake Park Brake Park Brake
Active)* Input* Input* Input*
(A44BB)
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ASTERISK (*).

Connector
(Circuit)
33* Input (Ground No Connection No Connection Brake Switch Brake Switch
Active)* Allowed* Allowed* Input* Input*
(A70C)
34 Drive Train Power Train Power Train Power Train Power Train
J1939+ J1939+ J1939+ J1939+ J1939+
(A5AN(+))
J1939- J1939- J1939- J1939- J1939-
(A5AP(-))
J1939 Shield J1939 Shield J1939 Shield J1939 Shield J1939 Shield
*The circuit attached to this pin should NOT have additional connections or splices added.
** The circuit attached to this pin should NOT have additional connections or splices added on a
hydraulic chassis.
#The circuit attached to this pin should NOT have additional connections or splices added on an
air chassis.
NOTE: All outputs will handle up to a 500 milliamp load unless stated otherwise.
NOTE: Circuits labeled “Ground Active,” “12V Active,” or “5V Active are open circuit until active.
NOTE – NO CONNECTIONS OR SPLICES ARE ALLOWED ON ANY SIGNALS THAT HAVE AN

ASTERISK(*).
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Table 19 ESC Module Connector #4004

ASTERISK(*).
#4004 Chassis Harness Air Chassis Hydraulic Chassis

Connector
(Circuit)
1* Input* RR Axle Oil RR Axle Oil RR Axle Oil RR Axle Oil
Temperature* Temperature* Temperature* Temperature*
(J32A)
2* Input* FR Axle Oil FR Axle Oil Hyd Brake Pump Hyd Brake Pump
Temperature* Temperature* Monitor* Monitor*
(J32)
3* Input* Spare* Transmission Spare* Transmission
Oil Temp* Oil Temp*
(J31)
4* Input* Fuel Level Fuel Level Fuel Level Fuel Level
Sensor #1* Sensor #1* Sensor #1* Sensor #1*
(J36B)
5* Input* Fuel Level Fuel Level Fuel Level Fuel Level
Sensor #2* Sensor #2* Sensor #2* Sensor #2*
(J36A)
6* Input* HVAC Sensor 1* HVAC Sensor 1* HVAC Sensor 1* HVAC Sensor 1*
(J77A)
7* Input* HVAC Sensor 2* HVAC Sensor 2* HVAC Sensor 2* HVAC Sensor 2*
(J77D)
8* Input* HVAC High Side HVAC High Side HVAC High Side HVAC High Side
Xducer* Xducer* Xducer* Xducer*
(J77C)
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Table 19 ESC Module Connector #4004 (cont.)

ASTERISK(*).

Connector
(Circuit)
9 Input (Ground Spare Spare Powered Powered Parking
Active) Parking Brake Brake Float
Float Switch Switch
(J44A)
10 Input (Ground Spare Spare Powered Powered Parking
Active) Parking Brake Brake Pump
Pump Monitor Monitor
(J44B)
11* Input (12V Water In Fuel Water In Fuel Water In Fuel Water In Fuel
Active)* Warn Light* Warn Light* Warn Light* Warn Light*
(J19D)
12* Input (Ground Low Washer Low Washer Low Washer Low Washer
Active)* Fluid W/L* Fluid W/L* Fluid W/L* Fluid W/L*
(J87C)
13* Input (12V Brake Brake ABS Drive Axle ABS Drive Axle
Active)* Application Air* Application Air* Event* Event*
(J94HH)
14* Input (Ground Fuel Filter Fuel Filter Fuel Filter Fuel Filter
Active)* Plugged W/L* Plugged W/L* Plugged W/L* Plugged W/L*
(J19B)
15* Input (12V Neutral Switch* Neutral Switch* Neutral Switch* Neutral Switch*
Active)*
(J17B)
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ASTERISK(*).

Connector
(Circuit)
16* Input (Ground Check Trans* Spare* Check Trans* Spare*
Active)*
(plug)
17 Output (Ground Trailer Marker Trailer Marker Trailer Marker Trailer Marker
Active) Relay Relay Relay Relay
(J58B)
18 Input (Ground Spare 2 Spd Axle Spare 2 Spd Axle
Active) Switch Switch
(J44C)
19 Output (Ground Suspension Suspension Suspension Suspension
Active) Inflate Coil Inflate Coil Inflate Coil Inflate Coil
(J92DL)
20# Output (Ground High speed High speed High speed High speed
Active) Wiper Wiper Wiper Wiper
()
21 Output (Ground Separate Stop Separate Stop Separate Stop Separate Stop
Active) Relay Relay Relay Relay
(J70C)
22 Output (Ground 4 Pack Solenoid 4 Pack Solenoid 4 Pack Solenoid 4 Pack Solenoid
Active) Chan 1 Chan 1 Chan 1 Chan 1
(J59C)
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ASTERISK(*).

Connector
(Circuit)
23 Output (Ground Spare Spare ABS Warning ABS Warning
Active) Lamp/ Test* Lamp/ Test*
(J94HP)
(J59B)
25 Output (Ground Spare Spare Hyd. Pow Park Hyd. Pow Park
Active) Brk Monitor Brk Monitor
(J44D)
26* Zero Volt Ref* Zero Volt Zero Volt Zero Volt Zero Volt
Reference* Reference* Reference* Reference*
(J9A)
27* Output (5 volt, Sensor 5 Vdc Sensor 5 Vdc Sensor 5 Vdc Sensor 5 Vdc
100 milliamp)* Out* Out* Out* Out*
(J6A)
28 Output (1 Amp) Not Used Not Used Not Used Not Used
(12V Active)
(J9OJ)
29 Output (Ground Low Speed Low Speed Low Speed Low Speed
Active) Wiper Wiper Wiper Wiper
()
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ASTERISK(*).

Connector
(Circuit)
(J59D)
(J59A)
32 Output (1 Amp) Suspension Suspension Suspension Suspension
(12V Active) Dump Coil Dump Coil Dump Coil Dump Coil
(J44A)
Active)
(plug)
34 Body Data Link + Body Link Body Link Body Link Body Link
J1939+ J1939+ J1939+ J1939+
(J5M(+))
35 Body Data Link - Body Link J1939- Body Link J1939- Body Link Body Link J1939-
J1939-
(J5M(-))
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ASTERISK(*).

Connector
(Circuit)
36 Body Data Link Body Link J1939 Body Link J1939 Bod Link J1939 Body Link J1939
Shield Shield Shield Shield Shield
(J5M(S))
*The circuit attached to this pin should NOT have additional connections or splices added.
NOTE: All outputs will handle up to a 500 milliamp load unless stated otherwise.
NOTE: Circuits labeled “Ground Active,” “12V Active,” or “5V Active” are open circuit until
active.
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1.8. ADDING TERMINALS

8-Way Connectors
Figure 61 ESC Connectors (Viewed From Engine Compartment)

1. 8–Way Connectors
2. 36–Way Connector
To gain access to the terminals of the 8–way connectors remove the connector from the ESC. Remove
the secondary terminal lock from the rear of the connector. Looking into the face of the connector, pry the
primary lock away from the terminal being serviced while pulling the wire connected to the terminal out the
backside of the connector.
When new terminals are being added the cavity plug must be removed before the new terminal is inserted.
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Figure 62 8-Way connector and Secondary Lock

1. SECONDARY LOCK
2. CONNECTOR SHELL
Figure 63 8–Way Connector Face

1. TERMINAL LOCK
2. TERMINAL
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Figure 64 Terminal Removal

1. TERMINAL
2. CONNECTOR SHELL
36–Way Connectors
Figure 65 36–Way Connector (Shell Opened)

1. CONNECTOR TABS
2. TERMINAL CAVITY
To gain access to the terminals of the 36–way connectors remove the connector from the ESC. Snap the outer
shell of the wiring cover by prying open the three tabs on the back side of the shell. Remove the secondary
terminal lock from the front of the connector by pushing in the locking tabs on each end of the lock. Looking
into the face of the connector, pry the primary lock away from the terminal being serviced while pulling the wire
connected to the terminal out the backside of the connector.
When new terminals are being added the cavity plug must be removed before the new terminal is inserted.
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Figure 66 Secondary Lock

1. SECONDARY LOCK
2. LOCKING TABS
Figure 67 Primary Terminal Lock

1. TERMINAL LOCK
2. THIN TOOL
1.9. PROGRAMMING
When switches or switch packs are added or removed, gauge configurations are changed, features are
added, programmable parameters are changed or the ESC is replaced, the ESC must be reprogrammed with
an EZ-Tech running the” ICAP” software. The ICAP software can download the current configuration from
the truck or from International. When programming changes are completed the software will update the
ESC with the new configuration. The new configuration will have to be uploaded to International. This is
accomplished by dialing in and uploading the updated programming. A copy of the programming is stored at
International and updated each time there is a change. This is required in case there is a need to restore the
programming during ESC replacement.
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ESC Programmable Features and Parameters
The following parameters may be programmed in the ESC when the applicable feature is enabled. The ICAP
software must be used to program the system. Some parameters can only be changed by dealers while others
may be changed by body builders (TEMs) or Fleets.
Table 20 ESC Programmable Parameters

Signal Name Access Rights Description
Ammeter_Alrm_Ty_Param Dealer, TEM Gauge Alarm Type
Ammeter_Filter_Param Dealer Gauge update rate
Ammeter_Max_WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Ammeter_Min_WL_Param Dealer, TEM Minimum set point for in-gauge warning light
Dealer, TEM, The speed at which the vehicle doors will lock
AutoLock_Speed Fleet automatically (requires power locks)
Battery_Voltage_Alrm_Ty_ Param Dealer, TEM Gauge Alarm Type
Battery_Voltage_Filter_Param Dealer Gauge update rate
Battery_Voltage_Max_WL_ Param Dealer, TEM Maximum set point for in-gauge warning light
Battery_Voltage_Min_WL_ Param Dealer, TEM Minimum set point for in-gauge warning light
Brake_App_Alrm_Ty_Param Dealer, TEM Gauge Alarm Type
Brake_App_Filter_Param Dealer Gauge update rate
Brake_App_Max_WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Brake_App_Min_WL_Param Dealer Minimum set point for in-gauge warning light
Enables the Chirp when you hit the Keyless
Chirp_Enable Dealer, TEM Remote Lock
Deactivate/activate cruise control warning
light in the EGC. Cruise control operation not
Cruise_Active_Ind_Enabled Fleet affected by this setting.
This parameter defines the maximum speed
Dealer, TEM, at which a vehicle will allow the Differential
Diff_Lock_Engmt_Spd Fleet Lock to engaged.
Dealer, TEM,
Dome_Light_Dim_Enable Fleet Theatre dome light disable/enable.
The level at which the dome light should be
Dome_Light_PWM_Percent_ Level Dealer, TEM set at while it is waiting to dim
Dealer, TEM, This is the amount of time the dome light
Dome_Light_Wait_Time Fleet should wait before dimming.
DTRL_Enabled Dealer Activate/deactivate daytime running lights.
Eng_Oil_Press_Alrm_Ty_Param Dealer, TEM Gauge Alarm Type
Eng_Oil_Press_Filter_Param Dealer Gauge update rate
Eng_Oil_Press_Max_WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Eng_Oil_Press_Min_WL_Param Dealer, TEM Minimum set point for in-gauge warning light
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Table 20 ESC Programmable Parameters (cont.)

Eng_Oil_Temp_Alrm_Ty_Param Dealer, TEM Gauge Alarm Type
Eng_Oil_Temp_Filter_Param Dealer Gauge update rate
Eng_Oil_Temp_Max_WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Eng_Oil_Temp_Min_WL_Param Dealer, TEM Minimum set point for in-gauge warning light
Eng_Speed_Alrm_Ty_Param Dealer, TEM Gauge Alarm Type
Eng_Speed_Filter_Param Dealer Gauge update rate
Eng_Speed_Max_WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Eng_Speed_Min_WL_Param Dealer, TEM Minimum set point for in-gauge warning light
Eng_Watr_Temp_Alrm_Ty_ Param Dealer, TEM Gauge Alarm Type
Eng_Watr_Temp_Filter_Param Dealer Gauge update rate
Eng_Watr_Temp_Max_WL_ Param Dealer, TEM Maximum set point for in-gauge warning light
Eng_Watr_Temp_Min_WL_ Param Dealer, TEM Minimum set point for in-gauge warning light
Fuel_Level_Alrm_Ty_Param Dealer, TEM Gauge Alarm Type
Fuel_Level_Filter_Param Dealer Gauge update rate
Fuel_Level_Max_WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Fuel_Level_Min_WL_Param Dealer, TEM Minimum set point for in-gauge warning light
Fuel_Press_Alrm_Ty_Param Dealer, TEM Gauge Alarm Type
Fuel_Press_Filter_Param Dealer Gauge update rate
Fuel_Press_Max_WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Fuel_Press_Min_WL_Param Dealer, TEM Minimum set point for in-gauge warning light
Fwd_RR_Axle_Temp_Alrm_ Ty_Param Dealer, TEM Gauge Alarm Type
Fwd_RR_Axle_Temp_ Filter_Param Dealer Gauge update rate
Fwd_RR_Axle_Temp_Max_ WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Fwd_RR_Axle_Temp_Min_ WL_Param Dealer, TEM Minimum set point for in-gauge warning light
Dealer, TEM,
LOWW_Enabled Fleet Deactivate/activate lights on with wipers
This parameter defines the maximum
vehicle speed at which a vehicle will allow
Max_Dump_Spd Dealer, TEM suspension dump to occur
This parameter defines the maximum vehicle
speed at which a vehicle will allow the rear
Max_Low_Range_Spd Dealer, TEM axle to shift to a lower ratio.
Dealer, TEM,
Mirror_Heat_Timeout_Enable Fleet Enable Mirror Heat Intervals
Dealer, TEM, Enables the Panic Mode for the Keyless
Panic_Enable Fleet Remote
Sets the maximum vehicle speed at which
PDL_Warning_Spd Dealer, TEM the PDL warning light is illuminated.
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Enable/disable PTO/Throttle Warning Light
PTO_Throttle_Light_Enable Dealer, TEM in the EGC.
This parameter indicates what the current
shut-off threshold of output 1 of RPM1 should
PwrMod1_Fuse_Level1_ Param Dealer, TEM be set to when the output is turned on.
This parameter indicates if output 1 of RPM1
should be turned on or off initially when the
PwrMod1_Init_State1_ Param Dealer, TEM vehicle is turned on.
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Pyrometer_Alrm_Ty_Param Dealer, TEM Gauge Alarm Type
Pyrometer_Filter_Param Dealer Gauge update rate
Pyrometer_Max_WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Pyrometer_Min_WL_Param Dealer, TEM Minimum set point for in-gauge warning light
Rear_RR_Axle_Temp_Alrm_ Ty_Param Dealer, TEM Gauge Alarm Type
Rear_RR_Axle_Temp_ Filter_Param Dealer Gauge update rate
Rear_RR_Axle_Temp_Max_ WL_Param Dealer, TEM Maximum set point for in-gauge warning light
Rear_RR_Axle_Temp_Min_ WL_Param Dealer, TEM Minimum set point for in-gauge warning light
Dealer, TEM, Enable/disable stoplights override hazard
Stop_Override_Hazard_ Enabled Fleet lights.
Susp_Air_Press_Alrm_Ty_ Param Dealer, TEM Gauge Alarm Type
Susp_Air_Press_Filter_ Param Dealer Gauge update rate
Susp_Air_Press_Min_WL_ Param Dealer, TEM Minimum set point for in-gauge warning light
Trans_Oil_Temp_Alrm_Ty_ Param Dealer, TEM Gauge Alarm Type
Trans_Oil_Temp_Filter_ Param Dealer Gauge update rate
Trans_Oil_Temp_Max_WL_ Param Dealer Maximum set point for in-gauge warning light
Turbo_Boost_Press_Alrm_ Ty_ Param Dealer, TEM Gauge Alarm Type
Turbo_Boost_Press_Filter_ Param Dealer Gauge update rate
Turbo_Boost_Press_Max_ WL_ Param Dealer, TEM Maximum set point for in-gauge warning light
Turbo_Boost_Press_Min_ WL_ Param Dealer, TEM Minimum set point for in-gauge warning light
Dealer, TEM,
Work_Light_Timeout_Enable Fleet Enables/disables Work Light timeout
Changing Gauge Configurations
NOTE – Refer to the ICAP software manual for instructions on the use of the programming software.
When a new gauge is added to the current configuration, the EZ-Tech® programming software must be used to
determine if there is room to add the desired gauge. Some gauges will only fit in certain locations in the EGC.
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If the gauge cannot be located in the EGC, the gauge may be able to fit in the optional auxiliary gauge switch
pack (AGSP) module. Adding the AGSP module to the instrument panel can be expensive, especially if only
one gauge is being added and the switches in the AGSP are not going to be used. The EZ-Tech programming
software must be used to program the ESC and EGC or AGSP to recognize the new gauge.
After the appropriate gauge location has been identified in the EGC or AGSP, the sensor for the gauge
and the required wiring must be installed.
The EZ-Tech programming software must be used to determine available circuit locations on the ESC
connectors and to program the ESC to recognize the added circuits and sensor.
Installing the new circuits in the ESC connector is accomplished by removing the plug and inserting new
connector pins in the appropriate slots of the connector.
Pins with pigtails already connected to them should be available to insert into the connector. The new circuits
should be spliced to the pigtail.
NOTE – The 36-way ESC connectors are not very rugged. Take care when disassembling the connector,
inserting new pins and reassembling the connector.
Programming Switch Configurations
NOTE – Refer to the EZ-Tech programming software manual for instructions on the use of the
programming software.
When a new feature requiring a multiplexed switch is added to the vehicle, the EZ-Tech programming
software must be used to determine where the switch should be installed. Hopefully, there will be a vacant
position in one of the switch pack modules. If there are no vacant positions, it may be necessary to install
an additional switch pack module. The EZ-Tech programming software must be used to program the ESC
to recognize the new switch.
After the appropriate switch location has been identified, the wiring and other hardware for the feature must
be installed.
The EZ-Tech running the “ICAP” programming software must be used to determine available circuit locations
on the ESC connectors and to program the ESC to recognize the added circuits and the feature sensor.
Installing the new circuits in the ESC connector is accomplished by removing the plug from the cavity and
inserting new connector pins in the appropriate slots of the connector.
Pins with pigtails already connected to them should be available to insert into the connector. The new circuits
should be spliced to the pigtail.
NOTE – The 36-way ESC connectors are not very rugged. Take care when disassembling the connector,
inserting new pins and reassembling the connector.
Programming Templates
Mark the following templates to keep track of new switch, gauge or pin requirements assigned by the “ICAP"
software.
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Figure 68 Switch Pack Templates
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Figure 69 Gauge and AGSP Location Templates
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Figure 70 ESC Harness Connector Templates (Mating Views Shown)

(1600) 36–WAY CAB ESC CONNECTOR
(1601) 8–WAY, BROWN, CAB ESC CONNECTOR
(4004) 36–WAY ENGINE ESC CONNECTOR
(4007) 8–WAY, BROWN, ENGINE ESC CONNECTOR
(4008) 8–WAY, BLUE, ENGINE ESC CONNECTOR
1.10. ESC REPLACEMENT

NOTE – When an ESC malfunction is suspected, reloading the ESC programming is recommended
prior to replacement. There is a chance the programming may have been corrupted. The “ICAP”
software must be used to download the configuration file from International. Refer to the “ICAP”
users manual. The “ICAP” software can then be used to reload the configuration file to the ESC. If the
malfunction is present after reprogramming, replace the ESC. The “ICAP” software must be used to
load the configuration file to the replacement ESC.
To remove the ESC:
1. Remove the kick panel at the side of the drivers left foot which covers the ESC inside the cab.
2. Remove all electrical connections to the ESC, both inside the cab and in the engine compartment.
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3. Remove the four nuts in the engine compartment that secure the ESC to the dash panel.
4. Remove the ESC from the inside of the cab.
Install the new ESC by reversing these steps. The new ESC must be loaded with the configuration file from
International. Refer to the “ICAP” programming software manual.
2. SWITCH PACK MODULES

2.1. FUNCTION
Figure 71 Switch Pack Function Diagram

2. 12 PACK SWITCH MODULE
3. 6 PACK SWITCH MODULE
4. SWITCH DATA LINK
The switch pack modules contain the electronics required to communicate with the ESC, on the switch data
link, and the electronics for each switch receptacle.
Switch packs are available in 6 and 12 switch configurations. The 12 pack configuration uses 2 of the 6
pack circuit boards.
The mechanical assembly for each switch snaps into the switch receptacle and can be released from the rear
of the switch pack. Different mechanical assemblies determine the actuation of the switch. Blank covers are
used when a switch receptacle is not being used.
The function of each switch location is programmed in the ESC as well as the output from the ESC to the
appropriate feature controlled by the switch.
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The EZ-Tech running the "INTUNE" diagnostic software can be used to identify the programmed function of
each switch and to override the switch input to the ESC. See the diagnostic software manual for details
on using the software.
Amber LED’s are used for panel lighting of the switches. Green LED’s, as required, are used to indicate that
the switch is on. Both types of LED’s are replaceable.
Switch packs are daisy chained together. The first switch pack connected to the instrument panel harness is
identified as switch pack #1. The next switch pack (connected to first switch pack) will be identified as switch
pack #2. A maximum of four switch packs could be installed on the vehicle.
Switches are identified by number from left to right.
When switches or switch packs are added or relocated, the ESC must be programmed before the changes will
work. Refer to Programming Switch Locations. (See Programming Switch Configurations, page 120)
NOTE – If more than one switch pack is being used and the switch pack positions were swapped, the
switch functionality may also swap or may not work at all. Be sure not to unintentionally swap positions
when working on switches or switch packs.
NOTE – The optional auxiliary gauge and switch pack (AGSP) has three gauges and a row of 6 switches.
The AGSP switches do not communicate on the switch data link. The AGSP connects at the end of the
switch pack daisy chain for power and dimmer light circuits. The gauges and switches on the AGSP
communicate with the ESC on the drivetrain 1939 data link.
2.2. DIAGNOSTICS
Refer to the Diagnostic Trouble Code section (See DIAGNOSTICS, page 1037) of this manual for DTC
retrieval procedures and the complete list of diagnostic trouble codes.
The ESC continuously monitors the switch pack communication on the switch data link. If a switch pack fails to
communicate with the ESC within the expected period of time, a fault will be logged.
In most cases, the switch pack will also notify the ESC if one of the individual switches has failed. Every switch
location contains two microswitches. In addition, as part of normal operation, these two switches will never be
closed simultaneously. For all switches, except switches using the center position, these two switches will
never be open simultaneously.
Depending on the feature, some switches will flash when a switch is malfunctioning or there is an error
associated with the feature controlled by the switch.
There are over 100 DTC’s which apply to possible failures in the switch packs. Refer to the Diagnostic Trouble
Code section (See DIAGNOSTICS, page 1037) of this manual for the complete list of diagnostic trouble codes.
Problems with switch packs can be attributed to lack of power, missing ground, a faulty data link, poor
connections, or circuit board problems.
Problems with individual switches can be attributed to faulty microswitches, broken mechanical switch
assemblies or circuit board failures.
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Table 21 Switch Pack(s) Preliminary Check

STEP KEY ACTION TEST SPEC. YES - IN NO - OUT OF
POINTS SPEC. SPEC.
1. On Are panel lights in Operate Panel Go to next Refer to Switch
switch pack switches panel lights lights step. Packs. (See
operating correctly. through entire operate SWITCH PACKS,
range. correctly page 127)
2. On Verify switch Attempt to Switch(es) Problem Go to next step.
problem. Identify operate all are doesn’t
switches that are not switches operating exist or is
functioning correctly. and observe correctly. intermittent.
reaction of
indicator
lamps.
3. On Check for diagnostic Read display Switch Go to next Refer to the section
trouble codes. on odometer. pack step. in this manual for
diagnostic the specific feature
Refer to the trouble controlled by the
Diagnostic Trouble codes are inoperative switch.
Code section (See displayed.
DIAGNOSTICS,
page 1037) of this
manual for DTC
retrieval procedures
and the complete list
of diagnostic trouble
codes.
4. On Are switch packs Read display DTC Refer to Go to next step.
communicating on on odometer. identifies Switch
the switch data link? a switch Packs.(See
pack is not SWITCH
commun- PACKS,
icating page 127)
with the
ESC.
5. On Are there faults with Read display DTC Refer to Go to next step.
individual switches? on odometer. identifies Individual
an Switches.
individual (See
switch INDIVIDUAL
fault in SWITCHES,
a switch page 129)
pack.
6. On Are any switch Look for No Go to next Refer to the section
indicators flashing? flashing Indicator step. in this manual for
switch in any the specific feature
indicators. switch is controlled by the
flashing. flashing switch.
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2.3. SWITCH PACKS

Refer to Switch Pack Circuits
The ESC continuously monitors the switch pack communication on the switch data link. If a switch pack fails to
communicate with the ESC within the expected period of time, a fault will be logged.
Problems with switch packs can be attributed to lack of power, missing ground, a faulty data link, poor
connections, or circuit board problems.
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Figure 72 Switch Pack Circuits

(1101) SWITCH PACK CONNECTOR (TO INSTRUMENT PANEL HARNESS OR PREVIOUS
SWITCH PACK)
LOCATED BEHIND SWITCH PACK
(1101A) SWITCH PACK CONNECTOR (TO NEXT SWITCH PACK)
LOCATED BEHIND SWITCH PACK
(1500) 12 WAY ELECTRONIC GAUGE CLUSTER CONNECTOR (VOLTAGE FOR PANEL
LIGHTS)
LOCATED ON BACK OF ELECTRONIC GAUGE CLUSTER
(1600) 36 WAY ELECTRICAL SYSTEM CONTROLLER CONNECTOR (SWITCH DATA LINK)
LOCATED ON CAB SIDE OF ELECTRICAL SYSTEM CONTROLLER
(1851) GROUND STUD CONNECTOR
F19 SWITCH PACK FUSE (1012)
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Table 22 Switch Pack Connector Check Chart

Switch Pack Connector (1101) Voltage Checks
This chart assumes there is power to cab fuse block (1012) from the mega fuse.
(1101) Pin B to ground 12 ± 1.5 volts If voltage is missing, check for blown fuse or open or
short in circuits A12P.
(1101) Pin A to ground 0 volts Ground circuit to pod.
(1101) Pin D to ground Approximately 4.5 volts (+) data link circuit. If voltage is low check for open or
short in circuit A3J(+) or shorted components on data
link.
(1101) Pin E to ground Approximately .2 volt (-) data link circuit. If voltage is low check for open in
circuit A3K(-) or shorted components on data link. If
voltage is high check for crossed data link wires.
If voltage and data link circuits to the pod are good, and a communication fault is still
active, the switch pack should be replaced.
(1101) Pin C to pin A 12 ± 1.5 volts (with Panel dimmer voltage from electronic gauge cluster
park lights on and panel (EGC).
dimmer at maximum).
If voltage is missing check circuits between switch pack
and EGC.
Inoperative panel lights in individual switches should be replaced. If the panel light voltage to the switch
pack is correct, but none of the panel lights operate, the switch pack should be replaced.
Battery voltage to switch pack connector (1101) terminal B is provided from fuse block (1012), fuse F19 on
circuit A12P.
System ground to switch pack connector (1101) terminal A is provided from negative stud (1850) on circuit
A11–GA and A11–GDB.
The switch data link is connected to switch pack connector (1101) terminal D and E from ESC connector (1600)
terminals 29 and 30 on twisted pair A3F(-)/A3E(+), to a splice and on A3K(-)/A3J(+).
Panel light voltage to switch pack connector (1101) terminal C is supplied from EGC connector (1500) on
circuits A62 and A62C.
Additional switch packs are connected to the loose connector on the first switch pack.
2.4. INDIVIDUAL SWITCHES

In most cases, the switch pack will notify the ESC if one of the individual switches has failed.
Every switch location contains two microswitches. In addition, as part of normal operation, these two switches
will never be closed simultaneously. For all switches, except switches using the center position, these two
switches will never be open simultaneously.
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Depending on the feature, some switches will flash when a switch is malfunctioning or there is an error
associated with the feature controlled by the switch.
Problems with individual switches can be attributed to faulty microswitches, broken mechanical switch
actuators or circuit board failures.
If inspection of the switch actuator determines it is broken, replace the switch actuator.
2.5. COMPONENT LOCATIONS

Refer to Typical Switch Pack Locations and Switch Pack Exploded View .
Figure 73 Typical Switch Pack Locations

1. 6 POSITION SWITCH PACK
2. 12 POSITION SWITCH PACK
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Figure 74 Switch Pack Exploded View (12 Pack Shown)

1. SWITCH PACK CONNECTOR (1101)
2. SWITCH PACK LIGHTS
3. SWITCH PACK CONNECTOR (1101A)
4. TYPICAL SWITCH ACTUATOR
5. UNUSED SWITCH, COVER
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2.6. SWITCH AND BULB REPLACEMENT

L.E.D. Bulb Replacement
WARNING – Turn off ignition switch to prevent damage to components or personal injury.
Figure 75 “Twelve Pack” Switch Module with L.E.D. bulbs and Switches
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NOTE:The upper bulb socket is a dual-purpose socket. That is, it will accept both backlighting (yellow)
bulbs and “ON” indication type (green) bulbs. All upper positions of the switch modules are outfitted this
way. There is no specific position that accepts one but not the other. The bottom bulbs are always yellow
for backlighting. The bulb apertures are asymmetrical and bulbs are keyed to be inserted into the circuit
board in only one orientation.
Refer to Back Side Of Panel. (See Figure 76, page 133)
If the bulb will not insert into the circuit board rotate the bulb one-half turn and try again. Do not force the bulb
into the board. Use a wide blade flat screwdriver or a coin to lock the bulb into place with a short clockwise
rotation. Do not overtighten the socket. To gain access to the bulbs, carefully remove the snap in the rear
corner of the switch assembly.
Figure 76 Back Side Of Panel
Instructions For Switches With “ON” Indication

For switches with indication of “ON” the bulbs are colored green and yellow. Install the green bulb in the
upper section of the switch on the printed circuit card. Install the yellow bottom section corresponding to
the position that this switch is installed.
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Instructions For Switches Without “ON” Indication

Install yellow bulbs in both upper and lower sections on the printed circuit board corresponding to the position
that this switch is installed.
Switch or Blank Replacement
WARNING – Turn Off the ignition switch to prevent damage to components or personal injury.
CAUTION – There is very little clearance for the switch / blank tabs between the module and the
circuit board. Use caution to avoid breaking off the tabs.
To remove switch/blank from Switch Module squeeze the tabs toward each other and push the switch/blank
out the front.
Refer to NOTE Tabs. (See Figure 77, page 134)
Figure 77 NOTE Tabs
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Switch/Blank Installation
All switches/blanks are indexed and can only be installed in one orientation.
Refer to Switch Blank Showing Indexing Key. (See Figure 78, page 135)
Figure 78 Switch Blank Showing Indexing Key
Slide the switch or blank into the module until the tabs lock in place.
Reinstall switch module in Instrument Panel.
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5 ELECTRONIC GAUGE CLUSTER AND AUXILIARY GAUGE SWITCH PACK 137
Table of Contents
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
1.1. GAUGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
1.2. WARNING LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
1.3. DIGITAL DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Select/Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Total Vehicle Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Trip Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Default Odometer Turn On Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Hours Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Total Engine Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Trip Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Change Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Diagnostic Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Digital Display Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
1.4. AUDIBLE ALARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
One-time Five-short-beeps Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Repetitive One-long-beep Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
One-time Ten-short-beeps Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
One-time Three-long-beeps Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Repetitive Short Duration Blips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
1.5. ELECTRONIC GAUGE CLUSTER SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Head Lamp/Park Lamp Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Panel Dimmer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Work Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Mode and Select/Reset Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
1.6. FAIL SAFE STRATEGIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
2. PROGRAMMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
3. DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
3.1. GAUGE SWEEP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
3.2. ON-LINE DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
3.3. GAUGE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
3.4. LOSS OF DATA LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
3.5. THE "INTUNE" DIAGNOSTIC SOFTWARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
4. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
4.1. IMPORTANT STEPS BEFORE TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
4.2. INSPECTING ELECTRICAL CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Replacing International Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
4.3. EGC PRELIMINARY SYSTEM CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
EGC Preliminary System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
4.4. AGSP PRELIMINARY SYSTEM CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
AGSP Preliminary System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
4.5. EGC POWER AND DATA LINK CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Circuit function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
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138 5 ELECTRONIC GAUGE CLUSTER AND AUXILIARY GAUGE SWITCH PACK
Fault Detection/Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164

4.6. MALFUNCTIONING EGC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
4.7. AGSP POWER AND DATA LINK CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Circuit function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
4.8. MALFUNCTIONING AGSP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Diagnostic Trouble Codes (DTC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Fault Detection/ Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
4.9. MALFUNCTIONING AGSP SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
4.10. CHECK ELECTRICAL SYSTEM WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Circuit Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
4.11. RANGE INHIBITED WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
System Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
4.12. ECONOMY MODE WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
System Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
4.13. FUEL FILTER WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Circuit Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
4.14. “YELLOW” ENGINE WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
4.15. “RED” ENGINE WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
4.16. BRAKE PRESSURE WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
4.17. TRACTION CONTROL LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
4.18. CHECK TRANSMISSION LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
4.19. TRAILER ABS LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
4.20. WASHER FLUID LOW WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
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4.21. WATER IN FUEL WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
4.22. COOLANT LEVEL WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
4.23. PARK BRAKE WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
4.24. SERVICE PARK BRAKE WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
4.25. CRUISE CONTROL LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
4.26. ABS WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
4.27. WAIT TO START WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
4.28. CHECK A/C WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
4.29. RETARD OVERHEAT WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
4.30. PTO/ THROTTLE WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
4.31. ALTERNATOR WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
4.32. DIFFERENTIAL LOCK WARNING LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
Snow Valve Warning Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
Optimized Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
4.33. VOLTMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
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Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
4.34. ENGINE COOLANT TEMPERATURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
4.35. ENGINE OIL PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
4.36. ENGINE OIL TEMPERATURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
4.37. PYROMETER GAUGE – (THIS FEATURE IS NOT CURRENTLY AVAILABLE). . . . . . . . . . . . . . .249
4.38. SPEEDOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
4.39. TACHOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
4.40. FUEL LEVEL GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
4.41. TRANSMISSION OIL TEMPERATURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
4.42. REAR-REAR AXLE OIL TEMPERATURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
4.43. FORWARD-REAR AXLE OIL TEMPERATURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
Forward-Rear Axle Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
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4.44. PRIMARY AIR PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
Circuit Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
4.45. SECONDARY AIR PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
4.46. AUXILIARY AIR PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Auxiliary Air Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
4.47. BOOST PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
4.48. AMMETER GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
4.49. FUEL PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308
4.50. SUSPENSION AIR GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
4.51. AIR APPLICATION GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313
4.52. AUDIBLE ALARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318
4.53. SELECT/RESET SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
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Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
4.54. HEAD LAMP/PARK LAMP SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
4.55. PANEL LIGHT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
4.56. WORK LIGHT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
4.57. DIGITAL DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
5. REMOVE AND INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322

5.1. EGC FRONT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
5.2. REMOVE ELECTRONIC GAUGE CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
5.3. FUEL, VOLTS, WATER OR ENGINE OIL GAUGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
5.4. OPTIONAL GAUGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
5.5. CIRCUIT BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
5.6. LCD DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
5.7. SELECT/RESET SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
5.8. AUDIBLE ALARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326
5.9. EGC PANEL LAMPS AND GAUGE BACKLIGHTING LAMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326
5.10. EGC WARNING LAMPS AND GAUGE WARNING LAMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326
5.11. EGC SWITCH PACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326
5.12. EGC SWITCH PACK SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
5.13. EGC SWITCH PACK LAMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
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1. DESCRIPTION
The Electronic Gauge Cluster (EGC) components include gauges, warning lamps, an alarm, a digital display, a
display set/reset button, and a switch pack containing up to three switches.
The EGC communicates with the electrical system controller (ESC) and other controllers connected to the
Drivetrain 1939 data link.
Figure 79 Electronic Gauge Cluster
The AGSP has locations for three gauges and also contains locations for 6 programmable switches.
The AGSP gauges and switches communicate with the electrical system controller (ESC) and other controllers
on the Drivetrain 1939 Data Link.
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Figure 80 Auxiliary Gauge Switch Pack (AGSP)
1.1. GAUGES
The EGC has locations for 10, stepper motor driven, gauges. Refer to Gauge Locations. The speedometer,
tachometer, fuel level gauge, engine oil pressure gauge, engine coolant temperature gauge, and voltmeter
gauge are in fixed locations. The other gauges, as required, may be placed in other EGC locations or in an
AGSP as programmed in the ESC. Most gauges have their own warning light which signals the operator
when a gauge reading is outside of preset limits.
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Figure 81 Gauge Locations
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Table 23 Gauge Table

Gauge Type Standard/ Location Gauge Warning Parameter Troubleshooting
Optional Min./ Light Trip Group Cross
Gauge Point Description Reference
Max.
Voltmeter Gauge Standard 9 10/16 <12 or Vehicle Voltmeter (See
with Integral Volts >15.0 electric power: VOLTMETER,
Warning Light VDC and Electrical page 238)
Engine potential
Speed (voltage)
>325 RPM
Engine Coolant Standard 3 140/260 °F >230 °F Engine Engine Coolant
Temperature (60/126°C) (>110 °C) temperature: Temperature
Gauge with Engine coolant Gauge (See
Integral Warning temperature ENGINE
Light COOLANT
TEMPERATURE
GAUGE, page
241)
Engine Oil Standard 5 0/100 PSI <7 PSI and Engine fluid Engine Oil
Pressure Gauge Engine level/pressure: Pressure Gauge
with Integral Speed Engine Oil (See ENGINE
Warning Light >325 RPM Pressure OIL PRESSURE
GAUGE, page
244)
Engine Oil Optional Varies 100/300 >230 °F Engine Engine Oil
Temperature °F (38/149 (>110 °C) temperature: Temperature
Gauge with °C) Engine oil Gauge (See
Integral Warning temperature ENGINE OIL
Light TEMPERATURE
GAUGE, page
247)
Pyrometer Inlet/exhaust This feature was
Gauge conditions: not available
Exhaust gas at the time of
temperature publication.
Speedometer Standard 2 0/85 MPH N/A Cruise Speedometer
(0/137 control/vehicle (See
KPH) speed: SPEEDOMETER,
wheelbased page 250)
vehicle speed.
Tachometer Standard 1 0/3000 N/A Electronic Tachometer
RPM engine (See
controller #1: TACHOMETER,
Engine speed page 253)
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Table 23 Gauge Table (cont.)

Max.
Fuel Level Gauge Standard 7 Empty/ <12.8% Dash display: Fuel Level
with Integral Full Fuel level Gauge (See
Warning Light FUEL LEVEL
GAUGE, page
256)
Transmission Optional Varies 100/400 >250 °F ( Transmission Transmission
Oil Temperature °F (38/204 121 °C) fluids: Oil Temperature
Gauge with °C) transmission Gauge (See
Integral Warning oil temperature TRANSMISSION
Light OIL
TEMPERATURE
GAUGE, page
264)
Rear-rear axle Optional Varies 100/300 °F 230 °F Rear-rear axle Rear-rear axle
oil temperature (38/149°C) (110°C) oil temperature oil temperature
gauge with gauge gauge (See
Integral Warning REAR-REAR
Light AXLE OIL
TEMPERATURE
GAUGE, page
270)
Forward-rear Optional Varies 100/300 °F 230 °F Forward-rear Forward-rear
axle (38/149°C) (110°C) axle axle oil
oil temperature oil temperature temperature
gauge with gauge gauge (See
Integral Warning FORWARD-REAR
Light AXLE OIL
TEMPERATURE
GAUGE, page
275)
Primary Air Optional 8 0/150 PSI <70 PSI Brakes: Primary Air
Pressure Gauge (1034 (482 KPa) brake primary Pressure Gauge
with Integral KPa) pressure (See PRIMARY
Warning Light AIR PRESSURE
GAUGE, page
281)
Secondary Air Optional 10 0/150 PSI <70 PSI Brakes: brake Secondary
Pressure Gauge (1034 (482 KPa) secondary Air Pressure
with Integral KPa) pressure Gauge (See
Warning Light SECONDARY
AIR PRESSURE
GAUGE, page
289)
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Max.
Auxiliary Air Optional Varies 0/150 PSI <70 PSI Supply Auxiliary Air
Pressure Gauge (1034 (482 KPa) pressure: Pressure
with Integral KPa) Auxiliary Gauge (See
Warning Light Equipment AUXILIARY AIR
supply PRESSURE
Pressure GAUGE, page
296)
Boost Pressure Optional Varies 0/50 PSI N/A Inlet/ exhaust Boost Pressure
Gauge with conditions: Gauge (See
Integral Warning boost pressure BOOST
Light PRESSURE
GAUGE, page
303)
Ammeter Gauge Optional Varies -150/+150 N/A Vehicle Ammeter Gauge
with Integral Amps electrical (See AMMETER
Warning Light power: Net GAUGE, page
battery current 305)
or Vehicle
electrical
power:
alternator
current
Ammeter Gauge Optional Varies -300/+300 N/A Vehicle Ammeter Gauge
(High Resolution) Amps electrical (See AMMETER
with Integral power: Net GAUGE, page
Warning Light battery current 305)
or Vehicle
electrical
power:
alternator
current
Fuel Pressure Optional Varies 0/150 PSI N/A Engine fluid Fuel Pressure
Gauge with (1034 level/ pressure: Gauge
Integral Warning KPa) Fuel delivery (See FUEL
Light pressure PRESSURE
GAUGE, page
308)
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Max.
Suspension Optional Varies 0/150 PSI N/A Supply Suspension Air
Air Gauge with (1034 pressure: air Gauge (See
Integral Warning KPa) suspension SUSPENSION
Light supply AIR GAUGE,
pressure page 310)
Air Application Optional Varies 0/150 PSI N/A Brakes: Brake Air Application
Gauge with (1034 application Gauge (See AIR
Integral Warning KPa) pressure APPLICATION
Light GAUGE, page
312)
1.2. WARNING LIGHTS

The EGC also contains warning and indicator lamps to monitor conditions not monitored by the gauges.
Figure 82 Warning and Indicator Lamps
Table 24 Warning Lamp Table

WARNING REPRESENTATION
COLOR DRIVEN BY Loc. Troubleshooting
LIGHT Num. Cross Reference
Range RANGE Yellow Status transmitted on 1 Range inhibited
inhibited INHIBITED Drivetrain 1939 data link (See RANGE
from ESC. Input to ESC from INHIBITED
transmission controller. WARNING LAMP,
page 179)
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Table 24 Warning Lamp Table (cont.)

Economy ECONOMY Yellow Status transmitted on 2 Economy
Mode (ECON) [icon] Drivetrain 1939 data link Mode(See
from ESC. Input to ESC from ECONOMY MODE
page 181)
Fuel Filter FUEL FILTER Yellow ON when fuel filter input to 3 Fuel Filter (See
ESC from fuel filter. FUEL FILTER
WARNING LAMP,
page 183)
Warn ENGINE Yellow Status transmitted on 4 Warn Engine
Engine Drivetrain 1939 data link (See “YELLOW”
from engine controller. ENGINE
WARNING LAMP,
page 189)
Stop Engine ENGINE Red Status transmitted on 5 Stop Engine (See
Drivetrain 1939 data link “RED” ENGINE
from engine controller. WARNING LAMP,
page 190)
Brake BRAKE Red Status transmitted on 6 Brake Pressure
Pressure PRESSURE Drivetrain 1939 data link (See BRAKE
from ESC. Input to ESC from PRESSURE
Hydromax hydraulic brake WARNING LAMP,
monitor. page 192)
Brake Fluid Park Icon Red This warning lamp is not 7
implemented at this time.
Wait to Start WAIT TO Yellow Status transmitted on 8 Wait to Start (See
START Drivetrain 1939 data link WAIT TO START
from ESC. Input to ESC from WARNING LAMP,
engine controller. page 226)
Check CHECK Yellow Status transmitted on 9 Check
Transmission TRANS Drivetrain 1939 data link Transmission
from ESC. Input to ESC from (See CHECK
transmission controller. TRANSMISSION
LAMP, page 197)
Trailer ABS Trailer ABS Yellow Status transmitted on 10 Trailer ABS (See
Icon Drivetrain 1939 data link TRAILER ABS
from ESC. Input to ESC from LAMP, page 199)
trailer ABS controller.
Washer WASH FLUID Yellow Status transmitted on 11 Washer Fluid Low
Fluid Low LOW Drivetrain 1939 data link (See WASHER
from ESC. Input to ESC from FLUID LOW
washer reservoir probe. WARNING LAMP,
page 202)
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Left Turn Left Turn Green Status transmitted from ESC 12
Signal Icon on Drivetrain 1939 data link.
Input to ESC from turn signal
switch.
Traction TRAC CTRL Green Status transmitted on 13 Traction Control
Control Drivetrain 1939 data link (See TRACTION
from ESC. Input to ESC from CONTROL LAMP,
ABS controller. page 195)
Water in WATER IN Yellow Status transmitted on 14 Water in Fuel (See
Fuel FUEL Drivetrain 1939 data link WATER IN FUEL
fuel filter. page 206)
Service Park SERVICE Red Status transmitted on 15 Service Park Brake
Brake PARK BRAKE Drivetrain 1939 data link (See SERVICE
(SERVICE) from ESC. Input to ESC from PARK BRAKE
[icon] SAAR park brake. WARNING LAMP,
page 219)
Check CHECK ELEC Yellow On when there is no 16 Check Electrical
Electrical SYS communication on drivetrain System (See
System 1939 data link from engine CHECK
controller or ESC is inactive ELECTRICAL
for more than 10 seconds. SYSTEM
Will also come on for one WARNING LAMP,
minute when an active fault page 178)
occurs.
Park Brake PARK BRAKE Red Status transmitted on 17 Park Brake (See
Drivetrain 1939 data link PARK BRAKE
park brake switch. page 212)
Cruise CRUISE Green Active Status transmitted on 18 Cruise Control
Control Drivetrain 1939 data link from (See CRUISE
Active ESC. Input to ESC from cruise CONTROL LAMP,
switch. page 222)
Antilock ABS Icon Yellow Status transmitted on 19 ABS (See ABS
Braking Drivetrain 1939 data link WARNING LAMP,
system from ESC. Input to ESC from page 224)
ABS controller.
Right Turn Right Turn Green Status transmitted on 20
Signal Icon Drivetrain 1939 data link
from ESC. Input to ESC from
turn signal switch.
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Coolant COOLANT Red Status transmitted on 21 Coolant Level (See
Level LEVEL Drivetrain 1939 data link COOLANT LEVEL
from ESC. On when Coolant WARNING LAMP ,
Level < 25%. Input to ESC page 210)
from surge tank.
Seat Belt SEAT BELT Red Status transmitted on 22
Drivetrain 1939 data link
from ESC.
High Beam High Beam Blue Status transmitted on 23
Icon Drivetrain 1939 data link
from ESC. Input to ESC from
high beam switch.
Check Air CHECK A/C Yellow Status transmitted on 24 Check Air
Conditioner Drivetrain 1939 data link Conditioner (See
from ESC. CHECK A/C
WARNING LAMP,
page 228)
Retard Over RETARD Red Status transmitted on 25 Retard Over Heat
Heat OVER HEAT Drivetrain 1939 data link (See RETARD
from ESC. Input to ESC from OVERHEAT
page 230)
PTO/Throttle PTO/ Red Status transmitted on 26 PTO/ Throttle (See
THROTTLE Drivetrain 1939 data link PTO/ THROTTLE
engine controller. page 231)
Optional Varies Yellow These are optional hard wired 28 Refer to the
Warning warning lamps. Example: applicable section
Lamps Alternator Warning, Snow for the feature
Valve, Optimized Idle or associated with
Differential locks. the warning lamp.
1.3. DIGITAL DISPLAY

The digital display is an LCD located in the bottom-center of the EGC.
The three lines of the digital display provide a transmission shift display, a numeric display, and an
alphanumeric line.
The display will dim to match the back lights when the park lights are switched on. The brightness of the
display is adjusted with the panel light dimmer switch.
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Figure 83 Electronic Gauge Cluster Display

1. EGC DISPLAY WITH ALLISON TRANSMISSIONS
2. EGC DISPLAY WITH EATON AUTOSHIFT TRANSMISSION
Select/Reset Switch
The EGC includes a Select/Reset switch used to control the digital display. The switch interfaces directly with
the EGC and is located on the lower right of the EGC lens. The switch allows the user to select modes within
each major functional area of the display, as listed below, and perform reset functions. Each time the switch is
momentarily depressed it will progress to the next mode. Depressing the switch for period of three seconds,
while in the odometer mode, will switch the display between miles and kilometers. Depressing the switch for
period of three seconds or more in other modes will clear the display or toggle between options depending
upon the current mode. The reset function has no effect if the parameter cannot be reset.
Total Vehicle Distance
The EGC displays the total distance the vehicle has traveled. This value may be toggled between miles and
kilometers by depressing the select/reset switch and holding it for 3 seconds while in this mode. The digital
display visually indicates whether the current reading is in miles or kilometers. The display indicates the
elapsed mileage from 0 to 1,999,999 miles in 1 mile/kilometer increments.
Trip Distance
The display function also includes trip distance. Trip distance is calculated as the total vehicle distance
minus total vehicle distance when the trip distance was last cleared. Depressing the select/reset switch
for at least three seconds while in this mode will clear the trip distance function and store the total vehicle
distance. The digital display visually indicates whether the current reading is trip miles or trip kilometers based
upon the current odometer mode. The display indicates the elapsed mileage from 0 to 199,999.9 miles in
0.1 mile/kilometer increments.
Default Odometer Turn On Mode
The display remembers, after the power-on, the last miles or kilometers mode that it was set to before
power-off. It will return to this mode upon the next start-up.
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Hours Functions
The EGC display provides several engine hours modes.
Total Engine Hours
The hours display is based on engine hours extracted from the engine controller. The digital display visually
indicates that the current reading is hours.
Trip Hours
The hours functions also includes trip hours. Trip hours are totaled as accumulated engine hours minus
accumulated engine hours when the trip hours function was last cleared. By depressing the select/reset switch
for at least three seconds while in this mode, trip hours function will be cleared.
Change Oil
Vehicles with International engines will display a “CHG OIL” message when a programmed engine hours
or engine miles interval has been exceeded. Refer to the appropriate engine manual for information on
programming the interval and clearing the message.
Diagnostic Message
The LCD is capable of displaying a diagnostic trouble code (DTC) message when requested by the ESC or
service tool (EZ-Tech). Refer to On-Line Diagnostics.(See ON-LINE DIAGNOSTICS, page 157)
NOTE – Diagnostic messages from the engine controller, antilock brake system or transmission are not
displayed on the electronic gauge cluster (EGC) digital display.
Digital Display Lighting
The display will dim to match the back lights when the park lights are switched on. The brightness of the
display is adjusted with the panel light dimmer switch.
1.4. AUDIBLE ALARM

The EGC contains an audible alarm that is capable of producing different beep counts and beep durations.
The alarm type for each gauge is determined by the alarm code programmed for that gauge in the ESC.
Pressing and holding the top of the panel dimmer switch and the set/reset switch for 5 seconds shall disable
the cluster alarm for all warning conditions until the engine speed reaches 325 RPM or the ignition is cycled.
One-time Five-short-beeps Alarm
An out of range value in any of the following gauges will trigger a one-time, five-short-beep, audible alarm
and visual indicator light in the corresponding gauge. The alarm shall sound only once per gauge during
each ignition cycle.
• Fuel level
• Voltmeter
• Engine oil pressure
• Engine coolant temperature
• Transmission oil temperature
• Engine oil temperature
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• Rear axle temperature

• Front axle temperature
• Boost pressure
• Fuel pressure
• Auxiliary air pressure
• Service Park Brake
Repetitive One-long-beep Alarm
An out of range value in any of the following gauges will trigger a repetitive one-long-beep audible alarm
and visual indicator light in the corresponding gauge. The alarm shall stop as soon as normal conditions
are reestablished.
• Primary air pressure

• Secondary air pressure
One-time Ten-short-beeps Alarm
The loss of communication to the EGC from the ESC or engine controller, on the Drivetrain 1939 data link, will
trigger a one-time, ten-short-beep audible alarm.
One-time Three-long-beeps Alarm
A sensor fault error will result in the small gauge pointer being driven clockwise to the 6 o’clock position and
a three long beep audible alarm. The gauge pointers in the speedometer and tachometer will repeat the
following three times and then park the pointer at the minimum position until the sensor fault is no longer active.
• Go immediately to the zero position

• Sweep up to a 50% position
• Immediately sweep back to zero
• Pause
Repetitive Short Duration Blips
The turn signal shall be accompanied by a sequence of short blips synchronized with the flashing of the lamps.
This audio indicator repeats each time the ESC requests that the EGC turn on the turn signal lights. The audio
indicator does not accompany the application of the hazard lights.
1.5. ELECTRONIC GAUGE CLUSTER SWITCHES

The EGC houses up to three user switches. Each switch is interfaced to the gauge cluster microprocessor.
The microprocessor transmits the switch status to the ESC on the drivetrain 1939 data link.
Head Lamp/Park Lamp Switch
The EGC directly interfaces with a head lamp switch. The head lamp switch has a latched off position, a
latched ’park lamp’ position, and a latched ’head lamp’ position. The ’head lamp’ switch does not have a center
off position. Each position of the switch position is back lighted in yellow.
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Panel Dimmer
The panel dimmer switch is located in the center position of the left pack of switches. The switch is back lighted
in yellow. The panel light dimmer control is a momentary push up/push down, or a press and hold rocker switch.
The dimmer retains its brightness level after the key is cycled, but will default to 100% ’on’ after a hard reset.
Work Light Switch
The work light switch is a momentary push up/push down rocker switch. The work light switch is located in the
right position of the left bank of cluster switches. The work light switch is back lighted in yellow, the ’on’ position
is back lighted in green. Status of the work light switch is communicated to the electrical system controller.
Mode and Select/Reset Switch
The switch allows the user to select modes within each major functional area of the display and perform reset
functions. Momentarily depressing the switch will cause the display to scan through the various modes.
Depressing the switch for a period of three seconds or more will clear the display or toggle between options
depending upon the current mode. The reset function has no effect if the parameter cannot be reset.
1.6. FAIL SAFE STRATEGIES

The EGC provides fail-safe strategies to provide safe vehicle operation during certain malfunctions in the
electrical system.
1. If communication between the EGC and electrical system controller is lost for more than five seconds, the
EGC will illuminate the CHECK ELEC SYS warning light and maintain the status of all the other warning
lights for as long as the ignition key is in the on position and communication is interrupted.
2. If communication from the electrical system controller is lost for more than two seconds, the EGC will
enable a single control circuit between the EGC and the ESC. This circuit will enable control of the park
and low beam headlights for as long as the ignition key is in the on position and communication between
the EGC and ESC is interrupted.
3. If the cluster itself dies, the CHECK ELEC SYS warning lamp will illuminate.
2. PROGRAMMING
When gauge configurations are changed, or the ESC is replaced, the ESC must be programmed with the
“ICAP” programming software. The ESC will store the current configuration and update the configuration after
changes are made. The new configuration will have to be uploaded to International. This is accomplished by
dialing in and uploading the updated programming. A copy of the programming is stored at International and
updated each time there is a change. This is required in case there is a need to download the programming for
ESC replacement. Refer to Programming in the Electrical System Controller section of this manual. (See
PROGRAMMING, page 113)
The EGC faults, with electronic gauge cluster version 8.7, the diagnostic trouble code will display SPN field
“1705” and with electronic gauge cluster version 9.3 and later, the diagnostic trouble code will display SPN
field “2023”.
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3. DIAGNOSTICS
3.1. GAUGE SWEEP
After the ignition is turned on, a gauge sweep of the EGC and AGSP will be performed. Each gauge must
sweep from zero to maximum to zero in unison. All of the gauge warning lights will illuminate along with the
panel warning lights that are applicable to features installed on the vehicle. The yellow and red “ENGINE”
warning lamps should also illuminate (they are turned on by the engine controller not the gauge cluster test).
The alarms associated with each gauge warning light do not sound. All of the segments of the EGC LCD
should display while the gauges sweep. At the end of the sweep the LCD will turn off all segments for .5
seconds, display the firmware version number, then return to operational mode. The lights controlled by the
panel dimmer in the EGC will also come on during the gauge sweep.
A gauge that points between the 9 and 10 o’clock position is most likely connected to the wrong location on the
circuit board inside the EGC.
If the instrument cluster or any of the remote modules experience a system fault, they will transmit a fault
message to the ESC.
3.2. ON-LINE DIAGNOSTICS

On-line Diagnostics are automatically performed by the ESC while the key is in the accessory or ignition
position. Any faults encountered will be entered in the active fault list.
On power up the check electrical system light will turn on then off after the gauge sweep. If there is an active
fault the light will stay on for an extra minute. If a fault occurs during operation of the vehicle the light will come
on for 1 minute. This will alert the driver that an active fault exists.
If the check electrical system light comes on and stays on after the gauge sweep is completed then the EGC is
not communicating with the engine controller and/or the ESC.
If the EGC loses communication with the ESC or engine controller during vehicle operation, the check electrical
system light will turn on and stay on. The light will be accompanied by 10 short beeps from the EGC alarm.
Diagnostic trouble codes will be moved to the “previously active” list after the condition creating the fault
is repaired.
Placing the EGC in diagnostic mode will allow the EGC to display up to 40 active and previously active
diagnostic messages from the ESC.
To engage the diagnostic mode turn the Ignition key “ON” (or in accessory) then press the Cruise “ON” switch
and the Cruise “RESUME” switch simultaneously. If no faults are present, the gauge cluster display will read
“NO FAULT”. If faults are present, the gauge cluster will display a message with the number of faults followed
by the diagnostic codes. Refer to Diagnostic Trouble Code Display. The display will show each DTC for 10
seconds then automatically scroll to the next entry and continue to cycle through the faults. To manually cycle
through the fault list, press the cluster display selector button.
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Figure 84 Diagnostic Trouble Code Display

1. BYTE 7 FIELD
2. BYTE 8 FIELD
3. SPN FIELD
4. FMI FIELD
5. ACTIVE/PREVIOUSLY ACTIVE STATUS INDICATOR
6. COMPILED FORMAT OF DIAGNOSTIC TROUBLE CODE
Refer to the Diagnostic Trouble Code List.(See DIAGNOSTIC TROUBLE CODE (DTC) LIST, page 1039)
While in the diagnostic mode, diagnostic trouble codes may be cleared by turning the left turn signal on and
pressing the cruise “ON” switch and the cruise “SET” switch simultaneously. All previously active faults will be
cleared. Active faults will reappear as the ESC updates faults once a second.
To exit the diagnostic mode, cycle the key switch or release the parking brake.
The diagnostic service tool, running the INTUNE software, can be used to view diagnostic trouble codes and
occurrence counts. The tool can also be used to clear previous active ESC diagnostic trouble codes. Other
diagnostic software can be used to view and clear engine controller, ABS and transmission diagnostic trouble
codes. Refer to the appropriate software manual for details.
3.3. GAUGE DATA

The EGC and AGSP continuously monitor incoming gauge data for out-of-range or data-not-present conditions.
If the data is out of range, the Cluster or gauge pack will turn on the LED embedded in the respective gauge.
Missing data to a small gauge in the EGC or AGSP will cause the needle to be driven clockwise to the 6
o’clock position. Missing data to the speedometer or tachometer will cause the gauge to repeat the following
three times:
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• Go immediately to the zero position

• Sweep up to the 50% position
• Sweep back to zero
• Pause
3.4. LOSS OF DATA LINK

If the EGC or AGSP loses the connection with the data link, all gauges will sweep to zero and the check
electrical system indicator will light.
If communication between the ESC or AGSP and EGC is lost but the EGC or AGSP is able to communicate
with the engine controller, information from the engine controller will continue to be displayed. The check
electrical system indicator will light.
If a communication between the EGC or AGSP and the engine controller is lost but the EGC or AGSP is able
to communicate with the ESC, information from the ESC will continue to be displayed. The check electrical
system indicator will light.
3.5. THE "INTUNE" DIAGNOSTIC SOFTWARE

The "INTUNE" diagnostic software can be run on the EZ–Tech. An interface cable is required to connect the
EZ–Tech to the diagnostic connector of the truck.
The "INTUNE" diagnostic software may be used to exercise individual gauges, and all programmed warning
lights to verify their operation. See the "INTUNE" diagnostic software manual for instructions.
The "INTUNE" diagnostic software can also be used to check programmed cluster gauge locations.
4. TROUBLESHOOTING
A. Before beginning these test procedures, make sure the vehicle batteries are at 75% state of
charge (SOC) or higher. This represents an open circuit voltage (OCV) of 12.4 volts. Batteries
with an OCV of 12 volts or less are either completely discharged or have a dead cell.
B. Check any light or indicator lamp filaments that are suspected of being open (burned out). This is
done to avoid unnecessary extensive circuit checks.
C. Inspect all connectors for loose or damaged pins, wires, etc. Refer to TEST EQUIPMENT AND
CONNECTOR REPAIR section in GROUP 08 — ELECTRICAL in the Master Service Manual.
D. When the technician determines that a fuse is blown, while checking its condition, he is directed
to locate the cause of the overload condition and to repair it. While no further instruction on this
procedure is listed in the diagnostic tables, the common procedure is as follows: isolate sections
of the circuit, by disconnecting connectors, and measure the resistance to ground to find the circuit
that is shorted to ground. Then locate the damaged spot in the wire or connector and repair.
E. Diagnostics for circuits that are malfunctioning by sticking in the on position are generally not
covered in detail. It is assumed that the technician knows to check for a malfunctioning switch,
relay, or solenoid.
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4.1. IMPORTANT STEPS BEFORE TESTING

1. Gather information by talking to the driver if possible. Try to determine the exact symptoms by gathering
relevant information:
a. What happened, and when?
b. Under what conditions?
c. When did the symptoms begin?
d. What else occurred at that time?
2. Verify the problem. Is the complaint due to misunderstood customer selected parameters? Use an EST
to review customer selected parameters.
3. Check for and record any logged diagnostic trouble codes.

a. Do the logged codes correlate to probable causes?
4. Were the codes logged about the same time as the symptoms appeared? Were the codes logged
repeatedly? (This can only be checked with the EZ-Tech.)
5. Are the logged codes related to other symptoms? Do they have a common cause?
6. Avoid preconceived ideas! Eliminate any non-electrical causes for the problem first (contaminated
fuel, clogged air filters, etc.).
4.2. INSPECTING ELECTRICAL CONNECTORS

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

Problems with EGC operation can be caused by a lack of power, a malfunctioning EGC, a malfunctioning
ESC, a malfunctioning data link, incorrect or lost programming in the ESC, problems in the engine controller,
problems in the ABS controller, problems in the transmission controller, or problems with wiring or sensors
feeding the electronic controllers throughout the system.
EGC Preliminary System Check
The preliminary system check should guide the mechanic to a general area to start troubleshooting.
Table 25 EGC Preliminary System Check

STEP KEY ACTION SPEC. YES-IN NO-OUT OF SPEC.
SPEC.
1. Off/ Turn key to ignition EGC responds to Go to next Go to EGC power and
On position while observing key on. step. ground troubleshooting.
the EGC. Did the EGC (See EGC POWER AND
have any response to key DATA LINK CIRCUITS,
on? page 164)
2. Off/ Turn key to ignition EGC gauge sweep Go to next Go to troubleshooting
On position while observing performs without step. malfunctioning EGC (See
the EGC. Does the gauge any errors. MALFUNCTIONING
sweep perform without EGC , page 166)
any errors? See gauge
sweep (See GAUGE
SWEEP, page 157)
3. On After the gauge sweep Check electrical Go to next Go to troubleshooting
is finished and most system light step. for the check electrical
warning lamps have illuminate for 1 system light. (See
gone out, does the check second or remain CHECK ELECTRICAL
electrical system light lit. SYSTEM WARNING
illuminate for 1 second or LAMP, page 178)
remain illuminated?
4. On After the gauge sweep No warning lamps Go to next Go to troubleshooting
is finished, do any other illuminated. step. for specific warning light.
warning lights remain Cross reference from
illuminated for more than Warning Light Table.
15 seconds, without (See Table 24, page 149)
turning off?
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Table 25 EGC Preliminary System Check (cont.)

SPEC.
5. On After the gauge sweep or Gauges operate Go to next Go to troubleshooting for
during vehicle operation, correctly. step. specific gauge. Cross
do any gauges point to reference from Gauge
the 6 o’clock position Table. (See Table 23,
or provide an incorrect page 146)
reading?
6. On Does Select/Reset button Select/ Reset Go to next Go to troubleshooting for
function correctly? button functions step. the Select/Reset switch.
correctly? (See SELECT/RESET
SWITCH, page 319)
7. On Do the headlight and Headlight and Go to next Go to troubleshooting
dimmer switch work dimmer switch step. for the headlight and
correctly? works correctly? dimmer switch (See
HEAD LAMP/PARK
LAMP SWITCH, page
320)
8. On Does the audible alarm Alarm sounds EGC alarm Go to troubleshooting
sound when a turn signal when a turn signal is working for the alarm. (See
has been left on after has been left on correctly. AUDIBLE ALARM, page
traveling more than one after traveling 318)
mile? more than one
mile?
4.4. AGSP PRELIMINARY SYSTEM CHECK

Problems with AGSP operation can be caused by a lack of power, a malfunctioning AGSP, a malfunctioning
ESC, a malfunctioning data link, incorrect or lost programming in the ESC, problems in the engine controller,
problems in the ABS controller, problems in the transmission controller, or problems with wiring or sensors
feeding the electronic controllers throughout the system.
AGSP Preliminary System Check
The preliminary system check should guide the mechanic to a general area to start troubleshooting.
Table 26 AGSP Preliminary System Check

SPEC.
1. Off/ Turn key to ignition AGSP responds to Go to next Go to AGSP power and
On position while observing key on. step. ground troubleshooting.
the AGSP. Did the AGSP (See AGSP POWER
have any response to key AND DATA LINK
on? CIRCUITS, page 168)
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Table 26 AGSP Preliminary System Check (cont.)

SPEC.
2. Off/ Turn key to ignition AGSP gauge Go to next Go to troubleshooting
On position while observing sweep performs step. malfunctioning
the AGSP. Does the without any errors. AGSP. (See
gauge sweep perform MALFUNCTIONING
without any errors? AGSP, page 170)
See gauge sweep (See
GAUGE SWEEP, page
157)
3. On After the gauge sweep or Gauges operate Go to next Go to troubleshooting
during vehicle operation, correctly. step. for specific gauge.
do any gauges point to Cross reference from
the 6 o’clock position Gauge Table. (See
or provide an incorrect Table 23, page 146)
reading?
4. On Are all of the AGSP AGSP switches AGSP is Go to Malfunctioning
switches operating operate correctly. operating AGSP switches. (See
correctly? correctly. MALFUNCTIONING
AGSP SWITCHES,
page 178)
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4.5. EGC POWER AND DATA LINK CIRCUITS

Circuit function
Figure 85 EGC Power And Ground Function Diagram

1. BATTERY
2. ELECTRONIC GAUGE CLUSTER
3. GROUND STUD
4. KEY SWITCH
Refer to EGC Power And Ground Function Diagram.
The EGC receives battery power through fuse block (1012). Switched ignition power is supplied from the
ignition relay in fuse block (1012).
The EGC communicates with the ESC and the engine controller on the Drivetrain 1939 Data Link.
Fault Detection/Management
Refer to EGC Power And Ground Simplified Diagram
If the EGC is not receiving ignition power, it will not respond when the key switch is turned on.
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Figure 86 EGC Power And Ground Simplified Diagram–Always Refer To Circuit Diagram Book For
Latest Circuit Information
F18 BATTERY FUSE (1012)
F14 IGNITION FUSE (1011)
(1500) ELECTRONIC GAUGE CLUSTER CONNECTOR
Table 27 EGC Power Voltage Check Chart

EGC Connector (1500) Voltage Checks (Check with EGC connector
Disconnected and Ignition Key “On”)
This chart assumes there is power to fuse block (1011) F14 and (1012) F18 from the
mega fuse and ignition relay is functioning properly.
(1500) Cavity 3 to 12 ± 1.5 volts If voltage is incorrect, check for blown fuse (F18) or an
ground. open or short in circuit A28.
ground. open or short in circuit A28A.
(1500) Cavity 8 to 7. 12 ± 1.5 volts If voltage is incorrect, check for an open in circuit
A28-G.
If all voltages are correct and the EGC does not power
up, the EGC should be replaced
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Table 27 EGC Power Voltage Check Chart (cont.)

EGC Connector (1500) Voltage Checks (Check with EGC connector
This chart assumes there is power to fuse block (1011) F14 and (1012) F18 from the
mega fuse and ignition relay is functioning properly.
EGC Connector (1500) Data Link Voltage Checks (Check with EGC connector
(1500) Cavity 4 to Approximately 2.5 If voltage is missing check for short to ground or open
ground. volts. in circuit A5AL(+) to the cab harness.
(1500) Cavity 5 to Approximately 2.5 If voltage is missing check for short to ground or open
ground. volts. in circuit A5AM(+) to the cab harness.
If voltages are missing and the circuits are not shorted to ground or open, refer to Drivetrain Data Link Circuits
Battery voltage to the instrument cluster connector (1500), terminal 3, is provided on circuit A28 from fuse
(1012) F18.
Switched ignition voltage to the instrument cluster connector (1500), terminal 8, is provided on circuit A28A
from (1011) F14. F4 receives power from the ignition relay.
System ground to EGC connector (1500), terminal 7, is provided on circuit A28–G from DS2 and circuit
A11–G to the negative stud (1851).
4.6. MALFUNCTIONING EGC

Malfunctions in the EGC can be caused by improper programming, an inoperative gauge, an inoperative
warning lamp, an inoperative display panel, breaks in the circuit board, or a problem in the microprocessor.
The speedometer, tachometer, microprocessor and circuit board in the EGC are combined in one assembly.
When there is a problem in one of these features the whole circuit board assembly must be replaced.
When an EGC is replaced, the current EGC programming will be taught to the new assembly by the ESC. No
manual programming should be required.
Table 28 Troubleshooting Malfunctioning EGC

STEP KEY ACTION SPEC. YES-IN SPEC. NO-OUT OF SPEC.
1. Off Has the preliminary Preliminary Go to next Go to preliminary system
system check been system check step. check. (See EGC
performed? performed. PRELIMINARY SYSTEM
CHECK, page 161)
2. Off Did all gauges sweep All gauges swept Go to step 4. Go to next step.
correctly? correctly.
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Table 28 Troubleshooting Malfunctioning EGC (cont.)

3. Off/ Swap a working gauge, The gauge Replace the Replace the circuit board
On from the same side that worked defective assembly.
of the cluster, with previously still gauge.
the inoperative gauge. works in the new
Perform gauge sweep. position.
4. On Connect the EZ-Tech Gauge is Go to next step Insure the gauge is
and run the cluster the programmed. supposed to be installed.
"INTUNE" diagnostic Program the gauge with
software. Check if the the “ICAP” software.
malfunctioning gauge is Refer to the ICAP
programmed. programming software
manual for details.
5. On Did all warning lamps, Warning lamps Go to step 7. Go to next step.
for installed features, on during gauge
light during gauge sweep.
sweep.
6. Off Replace the suspect Warning lamp Go to next Replace the EGC circuit
warning lamp bulb. works. step. board assembly.
7. On Did the panel lights Panel lights Go to step 9. Go to next step.
illuminate while the illuminate during
gauges swept? gauge sweep.
8. On Replace the suspect Panel light Replace the circuit board
panel light bulb. works. assembly.
9. On Did all LCD segments All LCD EGC is Go to next step.
display while the gauges elements working
swept? displayed during correctly.
gauge sweep.
If the LCD is the only problem, the LCD is probably bad. If other problems occur along with
the LCD, the circuit board assembly probably needs to be replaced.
10. On Replace the LCD LCD display EGC is Replace the circuit board
display. Perform gauge works during working assembly.
sweep gauge sweep. correctly.
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4.7. AGSP POWER AND DATA LINK CIRCUITS

Circuit function
Figure 87 AGSP Power And Ground Function Diagram

1. BATTERY
2. AUXILIARY GAUGE SWITCH PACK (AGSP)
3. GROUND STUD
4. 6 SWITCH PACK
5. KEY SWITCH (ACCESSORY FEED)
Refer to AGSP Power And Ground Function Diagram.
The AGSP receives battery power through fuse block (1011) F12. Switched ignition power is supplied from the
ignition relay in fuse block (1012) F19 through the 6 position or 12 position switch pack.
Refer to AGSP Power And Ground Simplified Diagram
If the AGSP is not receiving ignition power, it will not respond when the key switch is turned on.
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Figure 88 AGSP Power And Ground Simplified Diagram–Always Refer To Circuit Diagram Book
For Latest Circuit Information
F12 BATTERY FUSE (1011)
(1510) AGSP CONNECTOR
(1101A) SWITCH PACK CONNECTOR
(1659) DRIVETRAIN 1939 DATA LINK CONNECTOR
Table 29 AGSP Power Voltage Check Chart

AGSP Connector (1510) Voltage Checks (Check with AGSP Connector
ground. open or short in circuit A14FF.
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Table 29 AGSP Power Voltage Check Chart (cont.)

AGSP Connector (1510) Voltage Checks (Check with AGSP Connector
ground. open or short in circuit A13FC and circuits through the
switch packs.
Refer to the Switch Pack Module section of this manual.

(See SWITCH PACK MODULES, page 124)
(1510) Cavity 1 to 3. 12 ± 1.5 volts If voltage is incorrect, check for an open in circuit A11-GJ
and circuits through the switch packs.
Refer to the Switch Pack Module section of this manual.

(See SWITCH PACK MODULES, page 124)
If all voltages are correct and the AGSP does not function, the AGSP should be replaced.
Battery voltage to the AGSP connector (1510), terminal 3, is provided on circuit A14FF from fuse (1011) F12.
Switched accessory voltage to the AGSP connector (1510), terminal 2, is provided on circuit A13FC from
switch pack connector (1101A).
System ground to AGSP connector (1510), terminal 3, is provided on circuit A11–GJ from switch pack
connector (1101A).
4.8. MALFUNCTIONING AGSP

Malfunctions in the AGSP can be caused by improper programming, an inoperative gauge, an inoperative
warning lamp, an inoperative display panel, breaks in the circuit board, or a problem in the microprocessor.
When an AGSP is replaced, the current AGSP programming will be taught to the new assembly by the
ESC. No manual programming should be required.
Table 30 Troubleshooting Malfunctioning AGSP

1. Off Has the preliminary Preliminary Go to next Go to preliminary
system check been system check step. system check. (See
performed? performed. AGSP PRELIMINARY
SYSTEM CHECK, page
162)
2. On Did any gauges sweep Some gauges Go to next Replace AGSP circuit
correctly? swept correctly. step. board.
3. On Did all gauges sweep All gauges swept Go to next step Go to next step.
correctly? correctly. 5.
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Table 30 Troubleshooting Malfunctioning AGSP (cont.)

4. Off/ Swap a working gauge The gauge Replace the Replace the circuit board
On with the inoperative that worked defective assembly.
gauge. Perform gauge previously still gauge.
sweep. works in the new
position.
5. On Check for AGSP AGSP Go to fault Go to next step
diagnostic trouble codes. diagnostic detection
(See Diagnostic Trouble trouble codes management.
Codes (DTC), page 171) are active. (See Fault
Detection/
Read display on Management,
odometer. page 178)
6. On Connect the EZ-Tech Gauge is Go to next step Insure the gauge is
and run the cluster the programmed. supposed to be installed.
"INTUNE" diagnostic Program the gauge with
software. Check if the the “ICAP” software.
malfunctioning gauge is Refer to the ICAP
programmed. programming software
manual for details.
7. On Did the panel lights Panel lights AGSP is Go to next step.
illuminate while the illuminate during working
gauges swept? gauge sweep. correctly.
8. On Replace the suspect Panel light AGSP is Replace the circuit board
panel light bulb. works. working assembly.
correctly.
Diagnostic Trouble Codes (DTC)
To display diagnostic codes, put the vehicle in diagnostic mode. Set the parking brake and turn the Ignition
key “ON”. Then press the Cruise “ON” switch and the Cruise “Resume” switch. If no diagnostic trouble
codes are present, the cluster odometer will display “NO FAULT”. If diagnostic trouble codes are present,
the gauge cluster will display the total number of faults and cycle to the next diagnostic trouble code after 10
seconds. To manually cycle through the diagnostic trouble code list, press the cluster display select/reset
button. The last character of the diagnostic trouble code will end in “A” for active diagnostic trouble codes
or “P” for previously active diagnostic trouble codes. Turning the ignition key off or releasing the park brake
will take the ESC and the gauge cluster out of the diagnostic mode.
The previously active diagnostic trouble codes may be cleared, while in the diagnostic mode, by turning on the
left turn signal and pressing the cruise on and set switches simultaneously.
Table 31 AGSP Diagnostic Trouble Codes

DIAGNOSTIC TROUBLE CODE FAULT DESCRIPTION
614 14 40 1 Auxiliary Gauge Switchpack #1 checksum error fixed by reteach.
The configuration checksum in the AGSP did not match the

teach/reteach checksum in the ESC. This situation was corrected
by the teach/reteach operation.
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Table 31 AGSP Diagnostic Trouble Codes (cont.)

614 14 40 2 Auxiliary Gauge Switchpack #1 checksum error could not be fixed.
The configuration checksum in the AGSP did not match the

teach/reteach checksum in the ESC. This situation could not be
corrected by the teach/reteach operation.
2023 14 50 1, ESC not communicating with AGSP 1 (50), AGSP 2 (20), AGSP 3
(30), AGSP 4 (40).
2023 14 20 1,
Loss of communication in excess of 10 seconds.
2023 14 30 1 or
Drivetrain J1939 data link.
2023 14 40 1
2023 14 50 10, Ignition signal from datalink from ESC does not match hardwired
ignition signal on AGSP 1 (50), AGSP 2 (20), AGSP 3 (30), AGSP
2023 14 20 10, 4 (40).
2023 14 30 10 or Ignition Circuit to ESC/AGSP.
2023 14 40 10
2023 14 1 5, Gauge location 1 sensor fault on AGSP 1 (1), AGSP 2 (11), AGSP 3
(21), AGSP 4 (31).
2023 14 11 5,
There is a problem with the sensor that provides the data for this
2023 14 21 5 or gauge.
2023 14 31 5
2023 14 1 6, Gauge location 1 data unavailable on AGSP 1 (1), AGSP 2 (11),
AGSP 3 (21), AGSP 4 (31).
2023 14 11 6,
The data that this gauge displays should be, but is not available at
2023 14 21 6 or this time.
2023 14 31 6
2023 14 1 7, Gauge location 1 data missing on AGSP 1 (1), AGSP 2 (11), AGSP 3
(21), AGSP 4 (31).
2023 14 11 7,
The data for this gauge is not being transmitted on the datalink.
2023 14 21 7 or
2023 14 31 7
(22), AGSP 4 (32).
2023 14 12 5,
2023 14 22 5 or gauge.
2023 14 32 5
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AGSP 3 (22), AGSP 4 (32).
2023 14 12 6,
2023 14 22 6 or this time.
2023 14 32 6
(22), AGSP 4 (32).
2023 14 12 7,
2023 14 22 7 or
2023 14 32 7
(23), AGSP 4 (33).
2023 14 13 5,
2023 14 23 5 or gauge.
2023 14 33 5
AGSP 3 (23), AGSP 4 (33).
2023 14 13 6,
2023 14 23 6 or this time.
2023 14 33 6
(23), AGSP 4 (33).
2023 14 13 7,
2023 14 23 7 or
2023 14 33 7
2040 14 1 1 AGSP #1 Switch #1, microswitch inputs are in an invalid state. Both
microswitches are not depressed.
The ESC sets the status of AGSP #1 Switch #1 to the default value.
Replace switch acturator

microswitches are depressed.
Replace faulty microswitch
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2040 14 1 3 AGSP #1 Switch #1, microswitch inputs are in an invalid state. Top
microswitch depressed, bottom microswitch not depressed.

microswitch not depressed, bottom microswitch depressed.

2040 14 1 5 AGSP #1 Switch #1, This switch should be empty but one or both
of the microswitches is pressed.
Replace switch acturator or faulty microswitch




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Fault Detection/ Management
The service tool (EZ-Tech) running the "INTUNE" diagnostic software can be used to check operation of
the gauge.
Refer to Air Application Gauge Transducer Circuits.
4.9. MALFUNCTIONING AGSP SWITCHES

Malfunctions in the AGSP switches can be caused by improper programming, a broken switch actuator, breaks
in the circuit board, or a problem in the microprocessor.
When an AGSP is replaced, the current AGSP programming will be taught to the new assembly by the
ESC. No manual programming should be required.
4.10. CHECK ELECTRICAL SYSTEM WARNING LAMP

Circuit Function
Figure 89 Check Electrical System Warning Lamp Function Diagram

2. DRIVE TRAIN 1939 DATA LINK
3. ELECTRONIC GAUGE CLUSTER (EGC)
The check electrical system warning lamp will light and stay on any time the EGC loses communication with
the ESC or power to ESC connector (4009) or (4010). The lamp will also light if communication from the
engine controller is lost. The gauges controlled by the ESC will go to zero if communication between the EGC
and ESC is lost. The gauges controlled by the engine controller will go to zero if communication between
the EGC and engine controller is lost.
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The check electrical system warning lamp should light during the EGC gauge sweep, after the key is turned to
the ignition position. If the lamp doesn’t light during the gauge sweep the lamp could be burned out or there
may be a problem in the EGC.
The check electrical system warning lamp should come on for 1 minute when a fault is detected by the ESC.
If the stays on continuously and none of the gauges are working correctly after the gauge sweep, the EGC is
not communicating on the Drivetrain 1939 Data Link or there is a problem with the data link. Refer to Drivetrain
1939 Data Link. (See DRIVETRAIN 1939 DATA LINK, page 60)
If the lamp stays on continuously when no active faults are present or doesn’t come on when active faults are
present, the problem may be in ESC/EGC programming or ESC/EGC hardware.
The service tool (EZ-Tech) running the "INTUNE" diagnostic software can be used to turn all warning lamps on
and off. The service tool can also be used to verify if the problem is limited to the ESC, EGC or the data link.
4.11. RANGE INHIBITED WARNING LAMP

System Function
Figure 90 Range Inhibited Warning Lamp Function Diagram

1. TRANSMISSION CONTROL MODULE (TCM)
If an Allison automatic transmission is installed on the vehicle, the range inhibited warning lamp should light
during the EGC gauge sweep after the key is turned to the ignition position. If the lamp doesn’t light during the
gauge sweep the lamp could be burned out or there may be a problem in the EGC.
The range inhibited warning lamp lights when the transmission controller (only used with electronic
transmissions) has restricted shifting.
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This may be due to a problem in the transmission or use of a P.T.O.
See the manual for the specific transmission installed in the vehicle if a problem is suspected.
Diagnostics
the warning lamp.
The service tool (EZ-Tech) running transmission diagnostic software can also be used to verify correct
operation of the range inhibited warning lamp and check for faults logged in the transmission control module.
See the appropriate transmission service manual for information on using the diagnostic software.
If the lamp stays on continuously or doesn’t come on when commanded by the transmission controller, the
problem may be in ESC/EGC programming or ESC/EGC hardware.
Table 32 Range Inhibited Warning Lamp Preliminary Check

SPEC.
1. On Verify range inhibited Range inhibited Problem Go to next step.
warning lamp is warning lamp doesn’t
malfunctioning. is on only when exist or is
transmission range intermittent.
is inhibited.
2. Off/ Connect diagnostic tool Warning lamp Go to next Program the warning
On (EZ-Tech) to the diagnostic and warning step. lamp with the "ICAP"
connector. Turn key to lamp inputs are software. Refer to
accessory position. Start programmed to Programing in the
the "ICAP" programming operate. Electrical System
software. Verify warning Controller section of
lamp and warning lamp this manual. (See
inputs are programmed to PROGRAMMING, page
operate. 113)
3. On Attempt to exercise the Range inhibited Go to next Insure bulb is not burned
range inhibited warning warning lamp step. out. Replace EGC circuit
lamp with the "INTUNE" responds to EGC board.
diagnostic software. diagnostic input.
4. On Use "INTUNE" diagnostic Commands from Go to next Message from
software to verify range the transmission step. transmission controller is
inhibited commands from controller are being not being transmitted.
the transmission controller generated and Refer to the
are being generated and match transmission troubleshooting manual
match transmission status. status. for the transmission
installed in the vehicle.
5. Off/On Temporarily swap a known Lamp operates Message Message from ESC is
good cluster with the current correctly. from ESC not being transmitted.
cluster and check operation is being Consider replacing
of the lamp. transmitted. ESC. (See ESC
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Table 32 Range Inhibited Warning Lamp Preliminary Check (cont.)

SPEC.
Replace REPLACEMENT, page
circuit board 123)
on original
EGC.
4.12. ECONOMY MODE WARNING LAMP

System Function
Figure 91 Economy Mode Function Diagram

1. TRANSMISSION CONTROL MODULE (TCM) FROM THE SHIFTER MODE BUTTON
The "ECON" lamp indicates the transmission is using it’s secondary shift schedule. The operator selects this
shift schedule using a button on the shifter. Normal function, you press the MODE button once, the ECON
lamp turns on, you press the button again, the ECON lamp turns off.
If an Allison automatic transmission is installed on the vehicle, the economy mode warning lamp should light
during the EGC gauge sweep after the key is turned to the ignition position. If the lamp doesn’t light during the
gauge sweep the lamp could be burned out or there may be a problem in the EGC.
The economy mode warning lamp lights when the transmission is using it’s secondary shift schedule.
See the manual for the specific transmission installed in the vehicle if a problem is suspected.
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the warning lamp.
For the WT’s: The MODE button is used. The activation of the button is communicated over existing shifter
wiring. If the lamp doesn’t turn on when requested, make sure the shifter is communicating with the TCM
(will the truck go into gear?), make sure the TCM is communicating to the ESC (fault code for missing trans
message?), make sure the ESC is communicating to the cluster (fault code for missing cluster or ESC
message?), and make sure the lamp in the cluster works (bulb check at gauge sweep or use diagnostic tool).
For the LCT’s: The button on the shift lever is used. The contacts on this button connect to two pins on the
transmission controller. If the lamp doesn’t turn on when requested, make sure the shifter is communicating
with the TCM (do the wires at the TCM short and open with the switch is cycled?), make sure the TCM is
communicating to the ESC (fault code for missing trans message?), make sure the ESC is communicating to
the cluster (fault code for missing cluster or ESC message?), and make sure the lamp in the cluster works
(bulb check at gauge sweep or use diagnostic tool).
The service tool (EZ-Tech) running transmission diagnostic software can also be used to verify correct
operation of the economy mode warning lamp and check for faults logged in the transmission control module.
See the appropriate transmission service manual for information on using the diagnostic software.
If the lamp stays on continuously or doesn’t come on when commanded by the transmission controller, the
problem may be in ESC/EGC programming or ESC/EGC hardware.
Table 33 Economy Mode Lamp Preliminary Check

1. On Verify Economy Mode Economy Mode Go to next Problem doesn’t exist or
lamp is malfunctioning. lamp is on when step. is intermittent.
running engine is
cold.
2. Off/On Connect diagnostic Warning lamp Go to next Program the warning
tool (EZ-Tech) to the and warning step. lamp with the "ICAP"
diagnostic connector. lamp inputs are software.
Turn key to accessory programmed to
position. Start the operate. Refer to Programingin
"ICAP" programming the Electrical System
inputs are programmed PROGRAMMING, page
to operate. 113)
3. On Attempt to exercise the Warning lamp Go to next Insure bulb is not burned
warning lamp with the responds to EGC step. out. Replace EGC circuit
"INTUNE" diagnostic diagnostic input. board.
software.
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Table 33 Economy Mode Lamp Preliminary Check (cont.)

4. On Use "INTUNE" Commands from Go to next Message from
diagnostic software the transmission step. transmission controller
to verify Economy Mode controller are is not being transmitted.
commands from the being generated Refer to the
transmission controller and match troubleshooting manual
are being generated transmission for the transmission
and match transmission status. installed in the vehicle.
status.
5. Off/On Temporarily swap a Lamp operates Message from Message from ESC is
known good cluster with correctly. ESC is being not being transmitted.
the current cluster and transmitted. Consider replacing
check operation of the Replace circuit ESC. (See ESC
lamp. board on REPLACEMENT, page
original EGC. 123)
4.13. FUEL FILTER WARNING LAMP

Circuit Functions
Figure 92 Fuel Filter Warning Lamp Function Diagram

1. VACUUM SWITCH
The fuel filter warning lamp should light during the EGC gauge sweep, after the key is turned to the ignition
position. If the lamp doesn’t light during the gauge sweep the lamp could be burned out or there may be
a problem in the EGC.
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The fuel filter warning lamp lights when there is a restriction in the fuel filter system. A vacuum switch in the
fuel filter provides a ground to the ESC which will generate the signal to activate the lamp. The light should go
out when the fuel restriction is removed.
The most probable cause of a warning lamp malfunction, other than a burned out lamp, is a problem with the
vacuum sensor.
Diagnostics
The electronic service tool (EZ-Tech) running the "INTUNE" diagnostic software can be used to check
operation of the light and monitor activation of the fuel filter vacuum switch.
Table 34 Fuel Filter Warning Lamp Preliminary Check

SPEC.
1. On Fuel filter warning lamp Fuel filter warning Problem Go to next step.
is malfunctioning. lamp is only doesn’t
on when fuel is exist or is
restricted. intermittent.
position. Start the "ICAP" operate. Refer to Programingin
programming software. the Electrical System
Verify warning lamp and Controller section of
warning lamp inputs are this manual. (See
programmed to operate. PROGRAMMING, page
113)
warning lamp with the responds to EGC step. out. Replace EGC circuit
"INTUNE" diagnostic diagnostic input. board.
software.
4. On Use "INTUNE" Vacuum switch Go to next Go to Fault Detection
diagnostic software to circuit inputs to step. Management. (See
monitor vacuum switch the ESC match Fault Detection
circuit inputs to the ESC. fuel restriction. Management, page
184)
check operation of the Replace ESC. (See ESC
lamp. circuit board REPLACEMENT, page
on original 123)
EGC.
The electronic service tool (EZ-Tech) running the "INTUNE" diagnostic software can be used to check
operation of the light and monitor activation of the fuel filter vacuum switch.
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If the lamp stays on when there is no restriction or doesn’t come on when there is a fuel restriction, the problem
may be in ESC/EGC programming, ESC/EGC hardware or problems with the vacuum switch or wiring.
Figure 93 Fuel Filter Sensor Wiring to ESC

1. FUEL FILTER VACUUM SWITCH (4041)
LOCATED ON FUEL FILTER
2. FUEL FILTER WARNING LIGHT CONNECTOR (4030)
LOCATED AT FUEL FILTER
3. ELECTRICAL SYSTEM CONTROLLER CONNECTOR (4004)
LOCATED ON ENGINE SIDE OF ESC
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Table 35 Fuel Filter Warning Lamp Voltage Check Chart

Fuel Filter Warning Lamp Connector (4041) Voltage Checks (Check with Vacuum
Switch Pigtail Disconnected and the Ignition Key “On”)
NOTE – Always use breakout box ZTSE 4477 to take measurements on ESC connectors.
(4041) harness connector, 12 ± 1.5 volts If voltage is correct the sensor is defective.
cavity B to ground.
If voltage is incorrect, check circuit J19B and
K19B for an open or short.
If no shorts or opens exist and voltage is not being

supplied by ESC. Consider replacing ESC. Refer
to ESC Replacement in this manual. (See ESC
REPLACEMENT, page 123)
Fuel Filter Warning Light Connector (4041) Resistance Checks (Check with Vacuum
Switch Pigtail Disconnected and the Ignition Key “Off”)
(4041) connector on > 100K ohms. If resistance is incorrect, the vacuum switch is
fuel filter, terminal A on stuck closed or there is a restriction in the fuel line.
vacuum switch to ground.
There are no diagnostic trouble codes associated with this feature.
When there is a restriction in the fuel line, the fuel filter vacuum switch will close supplying ground through
the switch, fuel warning light connector (4030) terminal B, and circuit J19B to system controller connector
(4004) terminal 14.
The light will go out when the fuel filter has been replaced or the fuel restriction is removed.
The EGC activates the fuel filter indicator when it receives a message on the drivetrain 1939 data link from the
ESC.
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Component Locations
Figure 94 Engine ESC Connector Location

1. 48 WAY DASH CONNECTOR (4014)
2. 8 WAY (4008)
3. 8 WAY (4007)
4. POWER CONNECTORS (4009) & (4010)
5. 36 WAY CONNECTOR (4004)
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Figure 95 Fuel Filter Sensor Location

1. WIF LIGHT FUEL FILTER VACUUM SWITCH (4041)
2. FUEL HEATER CONNECTOR
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4.14. “YELLOW” ENGINE WARNING LAMP

Circuit Function
Figure 96 Yellow Engine Lamp Function Diagram

1. ELECTRONIC ENGINE CONTROLLER
The "yellow" engine lamp should light should be commanded on by engine controller, during the EGC gauge
sweep, after the key is turned to the ignition position.
The "yellow" engine lamp should light when the engine controller detects certain faults. The light will be
accompanied with a message on the odometer display.
The light will go out when the fault is cleared from the engine controller.
If the lamp stays on continuously when not commanded by the engine controller or doesn’t come on when
commanded by the engine controller, the problem may be in ESC/EGC programming or ESC/EGC hardware.
The service tool (EZ-Tech) running the "INTUNE" diagnostic software will not check operation of the light.
The service tool (EZ-Tech) running the Master Diagnostics software will list diagnostic trouble codes in the
engine controller.
See the engine diagnostic manual on the engine installed in the truck for details.
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Diagnostics
Table 36 Yellow Engine Lamp Preliminary Check

SPEC.
1. On Put the vehicle in Warning lamp Warning lamp Go to next step.
diagnostic mode and responds to is operating.
check for activation of EGC diagnostic
the warning lamp. mode.
2. Off/On Temporarily swap a Lamp operates If LED in There is a problem in the
known good cluster with correctly. warning lamp engine controller. Refer
the current cluster and is good, to the troubleshooting
check operation of the replace circuit manual for the engine
lamp. board on controller installed on the
original EGC. truck.
4.15. “RED” ENGINE WARNING LAMP

Circuit Function
Figure 97 “Red” Engine Warning Lamp Function Diagram

The "red" engine warning lamp should light while the key is turned to the ignition position and the engine is
not running.
If the lamp stays on continuously when not commanded by the engine controller or doesn’t come on when
commanded by the engine controller, the problem may be in ESC/EGC programming or ESC/EGC hardware.
The EGC activates the "red" engine warning indicator when it receives a message on the Drivetrain 1939
data link from the engine controller. The engine controller will send this message when warning thresholds for
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coolant temperature, coolant level and/or low engine oil pressure have been exceeded. The indicator lamp will
be accompanied by a message on the odometer display and the EGC alarm will sound.
The light will go out when the condition is resolved and the fault is cleared from the engine controller.
The service tool (EZ-Tech) running the "INTUNE" diagnostic software can be used to turn on all of the warning
lamps
See the engine diagnostic manual, EGES 215, for detailed information on operation of this warning lamp.
Diagnostics
Table 37 “Red” Engine Warning Lamp Preliminary Check

SPEC.
1. On Put the vehicle in Warning lamp Warning Go to next step.
diagnostic mode and responds to EGC lamp is
check for activation of diagnostic mode. operating.
the warning lamp.
2. Off/On Temporarily swap a Lamp operates If LED in There is a problem
known good cluster with correctly. warning in the engine
the current cluster and lamp is good, controller. Refer to
check operation of the replace the troubleshooting
lamp. circuit board manual for the engine
on original controller installed on
EGC. the truck.
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4.16. BRAKE PRESSURE WARNING LAMP

Circuit Function
Figure 98 Brake Pressure Warning Lamp Function Diagram

2. DIFFERENTIAL PRESSURE SWITCH
3. FLOW SWITCH
4. HYDROMAX PUMP RELAY
5. HYDROMAX PUMP
6. HYDROMAX BRAKE MODULE
LOCATED BEHIND INSTRUMENT PANEL
The brake pressure warning lamp is only used with the hydraulic brake system. The EGC activates the brake
pressure warning lamp when it receives a message on the Drivetrain 1939 data link from the ESC. An alarm
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should sound while the lamp is illuminated. The ESC generates this information based on input from the
Hydromax brake monitor module. The brake module monitors a circuit from the differential pressure switch
and the power steering pump flow switch as well as a circuit from the pump motor.
The light will go out when the condition is resolved.
The brake pressure warning lamp should light during the EGC gauge sweep, after the key is turned to the
ignition position. If the lamp doesn’t light during the gauge sweep the lamp could be burned out or there
may be a problem in the EGC.
Figure 99 Hydromax Monitor Module And Warning Circuits—Always Refer To Circuit Diagram Book
(1400) HYDROMAX MONITOR MODULE
(1600) 36–WAY ELECTRICAL SYSTEM CONTROLLER CONNECTOR
(4005) GROUND STUD
LOCATED ON DASH PANEL ABOVE ESC
(4031) FLOW SWITCH CONNECTOR
LOCATED ON HYDROMAX BOOSTER ASSEMBLY
(4032) DIFFERENTIAL PRESSURE SWITCH CONNECTOR
LOCATED BELOW BRAKE FLUID RESERVOIR ASSEMBLY
Diagnostics
The service tool (EZ-Tech) running the "INTUNE" diagnostic software can command the ESC to turn on all of
the warning lamps. This will verify that the EGC is working and communicating on the data link.
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If the lamp illuminates when there are no problems in the brake system or doesn’t illuminate when conditions
exist that should turn it on, the problem may be in ESC/EGC programming, ESC/EGC hardware or problems
with the sensors or sensor wiring to the ESC.
Table 38 Brake Pressure Warning Lamp Preliminary Check

1. Off/ Connect diagnostic Warning lamp Go to next step. Program the warning
On tool (EZ-Tech) to the and warning lamp with the "ICAP"
inputs are programmed PROGRAMMING,
to operate. page 113)
2. On Attempt to exercise the Warning lamp Go to next step. Insure bulb is not
warning lamp with the responds to EGC burned out. Replace
"INTUNE" diagnostic diagnostic input. EGC circuit board.
software.
3. On Monitor the inputs to Inputs are Go to next step. Refer to Monitor
the ESC for the warning correct. Module and Warning
lamp with the "INTUNE" Circuit Inputs To ESC.
diagnostic software.
lamp. board on REPLACEMENT,
original EGC. page 123)
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4.17. TRACTION CONTROL LAMP

Circuit Function
Figure 100 Traction Control Lamp Function Diagram

1. AIR ABS ELECTRONIC CONTROL MODULE
The EGC activates the traction control indicator when it receives a message on the Drivetrain 1939 data link
from the ESC. The ESC generates the command when it receives a command from the ABS controller. The
ABS controller generates this information when traction control is activated.
Diagnostics
If the lamp stays on continuously or doesn’t come on when commanded by the ABS controller, the problem
may be in ESC/EGC programming, ABS Controller/EGC hardware or problems with the sensors or sensor
wiring to the ABS Controller.
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Table 39 Traction Control Lamp Preliminary Check

SPEC.
1. Off/ Connect diagnostic Warning lamp Go to next Program the warning lamp
On tool (EZ-Tech) to the and warning step. with the "ICAP" software.
diagnostic connector. lamp inputs are
Turn key to accessory programmed to Refer to Programingin
position. Start the "ICAP" operate. the Electrical System
programming software. Controller section of
Verify warning lamp and this manual. (See
warning lamp inputs are PROGRAMMING, page
programmed to operate. 113)
warning lamp with the responds to step. out. Replace EGC circuit
"INTUNE" diagnostic EGC diagnostic board.
software. input.
3. On Monitor the commands Commands are Go to next Refer to the
to the ESC from the correct. step. troubleshooting manual for
ABS controller with the the specific ABS controller.
"INTUNE" diagnostic
software.
4. Off/On Temporarily swap a Lamp operates Message Message from ESC is
known good cluster with correctly. from ESC not being transmitted.
the current cluster and is being Consider replacing
check operation of the transmitted. ESC. (See ESC
lamp. Replace REPLACEMENT, page
circuit board 123)
on original
EGC.
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4.18. CHECK TRANSMISSION LAMP

Circuit Function
Figure 101 Check Transmission Lamp Function Diagram

1. TRANSMISSION CONTROL MODULE
The EGC activates the check transmission lamp when it receives a message on the Drivetrain 1939 data link
from the ESC. The ESC generates this message when the transmission controller notifies it that a fault
has been detected.
The lamp should go out after the fault is corrected and cleared.
If the lamp stays on continuously or doesn’t come on when commanded by the ESC, the problem may
be in ESC/EGC programming, ESC/EGC hardware or problems with the sensors or sensor wiring to the
transmission controller.
See the appropriate troubleshooting manual for the particular transmission installed in the truck for details.
Diagnostics
The service tool (EZ-Tech) running the “INTUNE” diagnostic software can command the ESC to turn on all of
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Table 40 Check Transmission Lamp Preliminary Check

1. On Check for transmission No transmission Go to next Refer to the
diagnostic codes. Refer to diagnostic step. Transmission section
On-Line Diagnostics.(See codes are of this manual.
ON-LINE DIAGNOSTICS, present.
page 157)
2. Off/On Connect diagnostic tool Warning lamp Go to next Program the warning
(EZ-Tech) to the diagnostic and warning step. lamp with the "ICAP"
connector. Turn key to lamp inputs are software.
accessory position. Start programmed to
the "ICAP" programming operate. Refer to Programingin
software. Verify warning the Electrical System
lamp and warning lamp Controller section of
inputs are programmed to this manual. (See
operate. PROGRAMMING,
page 113)
3. On Attempt to exercise the Warning Lamp Go to next Insure bulb is not
warning lamp with the responds to step. burned out. Replace
"INTUNE" diagnostic EGC diagnostic EGC circuit board.
software. input.
4. On Monitor command from Commands are Go to next Refer to the
transmission controller to correct. step. troubleshooting
ESC with the "INTUNE" manual for the specific
diagnostic software. transmission installed
on the truck.
5. Off/On Temporarily swap a known Lamp operates Message from Message from ESC is
good cluster with the correctly. ESC is being not being transmitted.
current cluster and check transmitted. Consider replacing
operation of the lamp. Replace circuit ESC. (See ESC
board on REPLACEMENT,
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4.19. TRAILER ABS LAMP

Circuit Function
Figure 102 Trailer ABS Function Diagram

1. BENDIX EC-30 AIR ABS ELECTRONIC CONTROL UNIT
6. TRAILER SOCKET
7. POWER CIRCUITS TO AIR ABS CONTROLLER AND TRAILER SOCKET
Beginning March 1, 2001, all tractors used to tow trailers must have an in–cab trailer ABS warning lamp.
The request to illuminate this warning lamp originates from the air ABS controller and is communicated on the
drive train 1939 data link. The air ABS controller also communicates with the trailer ABS controller over a
power line carrier (PLC) on the blue wire of the trailer electrical socket.
The EGC activates the ABS warning lamp when it receives a message on the Drivetrain 1939 data link
from the ESC. The ESC commands the EGC when it receives a message from the air ABS controller. The
air ABS controller generates this information when it detects a fault from the trailer ABS controller or when
trailer ABS is active.
The lamp should go out after the trailer ABS event is over, the fault is corrected and cleared or the trailer
is disconnected.
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See the appropriate air ABS and trailer ABS troubleshooting manuals for details.
Diagnostics
If the lamp stays on continuously or doesn’t come on when commanded by the trailer ABS controller, the
problem may be in ESC/EGC programming, air ABS controller problems, EGC hardware or problems with
the trailer ABS controller.
See the appropriate air ABS and trailer ABS troubleshooting manuals for details.
Table 41 Trailer ABS Lamp Preliminary Check

SPEC.
inputs are programmed PROGRAMMING, page
to operate. 113)
warning lamp with the responds to EGC step. burned out. Replace
software.
3. On Monitor commands from Commands from Go to next Refer to the
the ABS controller to the ABS controller are step. troubleshooting manual
ESC with the "INTUNE" correct. for the air ABS installed
diagnostic software. on the truck.
4. On Check for Trailer ABS Trailer ABS Lamp Go to fault Go to next step
Lamp diagnostic trouble diagnostic trouble detection
codes. (See Diagnostic codes are active. management.
Trouble Codes (DTC), (See Fault
page 201) Detection/
Management,
Read display on page 201)
odometer.
lamp. Replace REPLACEMENT, page
circuit board 123)
on original
EGC.
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Table 42 Trailer ABS Lamp Diagnostic Trouble Codes

2023 14 150 9 or 2023 14 250 9 Trailer ABS warning light malfunction on primary EGC (150) or
secondary EGC (250)
When the ignition is on the trailer ABS center pin relay will energize providing battery voltage to the blue
connector of the trailer socket and the trailer ABS controller, when an ABS equipped trailer is connected.
The trailer ABS controller will transmit information to the air ABS controller over the battery power circuits.
When the air ABS controller receives a command from the trailer ABS controller the air ABS controller will
transmit a message to the ESC to command the trailer ABS warning lamp on.
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4.20. WASHER FLUID LOW WARNING LAMP

Circuit Function
Figure 103 Washer Fluid Low Warning Lamp

1. WASHER FLUID LEVEL SENSOR
The washer fluid low warning lamp lights when the washer fluid level is low.
The light will go out when the condition is resolved and the fault is cleared from the system controller.
Diagnostics
If the lamp stays on continuously or doesn’t come on when commanded by the ESC, the problem may be in
ESC/EGC programming, EGC hardware or problems with the input circuits to the ESC from washer fluid sensor.
Table 43 Washer Fluid Low Warning Lamp Preliminary Check

1. Off/On Connect diagnostic Warning lamp Go to next step. Program the warning
tool (EZ-Tech) to the and warning lamp with the "ICAP"
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Table 43 Washer Fluid Low Warning Lamp Preliminary Check (cont.)

2. On Attempt to exercise the Warning Lamp Go to next step. Insure bulb is not
warning lamp with the responds to EGC burned out. Replace
software.
3. On Monitor inputs from the Inputs are correct. Go to next step. Go to Fault Detection
washer fluid sensor with Management. (See
the "INTUNE" diagnostic Fault Detection
software. Management, page
203)
If the lamp stays on continuously or doesn’t come on when the washer fluid level is low, the problem may be in
ESC/EGC programming, ESC/EGC hardware or problems with the sensors or sensor wiring to the ESC.
Refer to Washer Fluid Level Sensor Circuits.
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Figure 104 Washer Fluid Level Sensor Circuits

(4004) 36–WAY SYSTEM CONTROLLER CONNECTOR
ON ENGINE COMPARTMENT SIDE OF ESC
(4022) WASHER FLUID LEVEL SENSOR CONNECTOR
ON WASHER BOTTLE
(4830) ZERO VOLT REFERENCE GROUND SPLICE
LOCATED NEAR POWER DISTRIBUTION CENTER
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Table 44 Washer Fluid Level Sensor Connector Chart

There are no diagnostic trouble codes associated with the washer fluid level sensor circuits.
Washer Fluid Level Sensor Harness Connector (4022) Voltage Checks
Check with ignition on and (4022) disconnected.

(4022) Harness 11 ± 1.5 volts If voltage is missing, check for open or
connector, cavity short in circuit J87C.
1 to ground
If circuits check good and fault is still present,
verify voltage out of ESC.
NOTE – Always use breakout box ZTSE 4477 to

take measurements on ESC connectors.
Washer Fluid Level Sensor Harness Connector (4022) Resistance Checks
Check with (4022) disconnected.

(4022) Harness <1 ohm If resistance is incorrect, check for open in circuit J87H.
connector, cavity
2 to ground Also insure proper signal at (4830) from ESC.
NOTE – Always use breakout box ZTSE 4477 to

take measurements on ESC connectors.
Washer Fluid Level Sensor Resistance Checks
Check at sensor with (4022) disconnected.

Across washer Washer bottle empty; If resistance is incorrect, replace failed sensor.
fluid sensor >50K ohms
terminals
Washer bottle full; <1 ohm
The ESC supplies 11 volts from system controller connector (4004) terminal 12 to washer fluid level sensor
connector (4022) terminal 1.
Ground for the washer fluid level sensor is supplied from zero volt reference ground splice (4830) to washer
fluid level sensor connector (4022) terminal 2.
When the washer fluid level drops below the switch, the switch will open removing the ground to the ESC. The
ESC will send a message to the electronic gauge cluster commanding the washer fluid level warning light on.
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4.21. WATER IN FUEL WARNING LAMP

Circuit Function
Figure 105 Water In Fuel Warning Lamp Function Diagram

1. WATER PROBE
2. WATER IN FUEL MODULE
The EGC activates the water in fuel indicator when it receives a message on the Drivetrain 1939 data link from
the ESC. The ESC will send this information based on input from the water in fuel (WIF) module.
A short in the water in fuel probe, water in fuel (WIF) module or wiring to the ESC can also cause the lamp
to light.
Diagnostics
If the lamp stays on continuously or doesn’t come on when commanded by the ESC, the problem may be
in ESC/EGC programming, EGC hardware or problems with the input circuits to the ESC from water in
fuel module.
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Table 45 Water in Fuel Warning Lamp Preliminary Check

SPEC.
position. Start the "ICAP" operate. Refer to Programingin
programmed to operate. PROGRAMMING,
page 113)
software.
3. On Monitor inputs from the Inputs are correct. Go to next Go to Fault Detection
water in fuel module with step. Management.
the "INTUNE" diagnostic (See Fault
software. Detection/Management,
page 208)
lamp. Replace REPLACEMENT,
circuit board page 123)
on original
EGC.
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Figure 106 Water in Fuel Circuits (Frame Mounted Fuel Filter)—Always Refer to Circuit Diagram
Book for Latest Circuit Information
(4001) MINI FUSE BLOCK
LOCATED IN ENGINE POWER DISTRIBUTION CENTER
(4002) FUEL HEATER RELAY
LOCATED IN ENGINE POWER DISTRIBUTION CENTER
(4004) ELECTRICAL SYSTEM CONTROLLER (ESC) CONNECTOR
(4006) GROUND
(4040) WATER IN FUEL MODULE
LOCATED NEAR EXTERIOR DASH PANEL, LEFT SIDE
(4043) WATER PROBE
LOCATED AT FUEL FILTER
(4305) AUXILIARY FORWARD CHASSIS CONNECTOR
LOCATED IN ENGINE COMPARTMENT NEAR LEFT FRAME RAIL
(4840) IGNITION SPLICE
LOCATED INSIDE POWER DISTRIBUTION CENTER
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The service tool (EZ-Tech) running the "INTUNE" diagnostic software can be used to check operation
of the light.
To quickly verify operation of the water in fuel circuits, remove the connector from the water in fuel sensor.
When the key is on the WIF warning lamp should not be illuminated. Connect a jumper from the sensor
harness connector to ground. When the key is on the WIF lamp should illuminate. If both of these checks
work, the problem is in the sensor.
If the lamp stays on continuously or doesn’t come on when there is water in the fuel, the problem may be
in ESC/EGC programming, ESC/EGC hardware, water in fuel probe, water in fuel (WIF) module or wiring
to the ESC.
Table 46 Water in Fuel Warning Lamp Circuits Voltage Check Chart

Water in Fuel Module Connector (4040) Voltage Checks (Check with Water in Fuel
Module Disconnected and the Ignition Key “On”)
NOTE – Always use breakout box ZTSE 4477 to take measurements on ESC connectors.
(4040) harness connector, 12 ± 1.5 volts If voltage is incorrect, check for voltage from fuel
cavity A to ground. heater relay. Also check circuit J19E for an open
or short circuit.
(4040) harness connector, 12 ± 1.5 volts If voltage is incorrect, check circuit J19D for an
cavity A to cavity B. open circuit.
If no opens exist, there is a problem with the ESC.

Water Probe Connector (4043) voltage Checks (Check with WATER in Fuel Module Connected,
Water Probe Connector Disconnected and the Ignition Key “On”)
(4043) harness connector, 12 ± 1.5 volts If voltage is incorrect, check for opens or shorts in
terminal A to ground. circuits K19C or J19C. If no circuits are open or
shorted, replace the WIF module.
If voltage is correct and the feature is not operating

correctly, replace the sensor.
With the key on, 12 volts from mini fuse block (4001) is supplied on circuit J19E to WIF module connector
(4040) terminal A.
The ground path for the water-in-fuel module (432) is not a dedicated circuit. The fuel filter housing is grounded
through its mounting bracket and whenever water builds up to an unacceptable level in the filter, the water
completes the circuit between the probe contacts and the housing. This energizes the water-in-fuel module.
When the water-in-fuel module becomes energized, power is supplied on circuit J19D to ESC connector (4004)
terminal 11. This will cause the ESC to send a message to the EGC to illuminate the warning lamp.
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4.22. COOLANT LEVEL WARNING LAMP

Circuit Function
Figure 107 Coolant Level Warning Lamp Diagram

1. COOLANT SURGE TANK
The EGC activates the coolant level indicator when it receives a message on the Drivetrain 1939 data link
from the engine controller. The engine controller will generate this message based on input from the sensor in
the coolant surge tank.
The lamp should go out when the coolant level is restored.
Diagnostics
The INTUNE diagnostic software can be used to command all of the warning lamps on and monitor the
coolant level command from the engine controller.
The most probable cause of malfunctions with the warning lamps, besides burnt out lamps, is input circuits
from sensors to the ESC or engine controller. Although unlikely, it is possible for the malfunction to be in
the ESC or EGC.
Refer to the engine manual on the specific engine installed in the vehicle for (sensor to engine controller)
troubleshooting procedures.
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Table 47 Coolant Level Warning Lamp Preliminary Check

1. On Verify coolant warning Coolant warning Go to next Problem doesn’t exist
lamp is malfunctioning. lamp is on when step. or is intermittent.
Check level in coolant coolant level is not
tank. low or lamp is off
when coolant is low.
2. Off/On Connect diagnostic Warning lamp and Go to next Program the warning
tool (EZ-Tech) to the warning lamp inputs step. lamp with the "ICAP"
diagnostic connector. are programmed to software.
Turn key to accessory operate.
position. Start the Refer to Programingin
3. On Attempt to exercise Coolant warning Go to next Insure bulb is not
the coolant warning lamp responds to step. burned out. Replace
lamp with the "INTUNE" EGC diagnostic EGC circuit board.
diagnostic software. input.
4. On Use "INTUNE" Commands from Go to next Message from engine
diagnostic software the engine controller step. controller is not
to verify coolant level are being generated being transmitted.
commands from the and match coolant Refer to the engine
engine controller are level. troubleshooting
being generated and manual for the
match coolant level. engine installed in
the vehicle.
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4.23. PARK BRAKE WARNING LAMP

Circuit Function
Figure 108 Park Brake Warning Lamp Function Diagram

1. PARK BRAKE SWITCH
The EGC activates the park brake indicator when it receives a message on the Drivetrain 1939 data link from
the ESC. The ESC generates this message based on input from the park brake switch.
The light should go out when the park brake is released.
The park brake input to the ESC is also used in the diagnostic trouble code retrieval procedure and to turn
off the daytime running lights when the headlights are off, the engine is not running and the key is in the
ignition position.
Diagnostics
in ESC/EGC programming, EGC hardware or problems with the input circuits to the ESC from the park
brake switch.
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Table 48 Park Brake Warning Lamp Preliminary Check

SPEC.
software.
3. On Check for Park Park Brake Go to fault Go to next step
Brake Warning Lamp Warning Lamp detection
diagnostic trouble codes. diagnostic trouble management.
(See Diagnostic Trouble codes are active. (See Fault
Codes (DTC), page 213) Detection/
Management,
odometer.
lamp. Replace REPLACEMENT,
circuit board page 123)
on original
EGC.
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Table 49 Park Brake Warning Lamp Diagnostic Trouble Codes

70 14 1 0 Air Powered Park Brake is stuck.
Occurs when the park brake switch does not match the spring
apply air release (SAAR) chamber travel sensor. This indicates
the park brake cannot be applied or cannot be released.
70 14 1 1 The auto apply portion with the Air Powered Park Brake is not
operating.
Occurs when the park brake switch is not set within 5 seconds of
the receipt of the Park as the requested gear. This failure would
indicate a failure in the auto apply or in the air lines between the
auto apply relay and the Park Brake switch.
The service tool (EZ-Tech) running the "INTUNE" diagnostic software can command the ESC to turn on all
of the warning lamps. This will verify that the EGC is working and communicating on the data link. See the
diagnostic software manual for details on using the software.
If the lamp stays on continuously or doesn’t come on when the park brake is on, the problem may be in
ESC/EGC programming, ESC/EGC hardware, the park brake switch or the park brake switch wiring to the ESC.
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Figure 109 Park Brake Circuits—Always Refer to Circuit Diagram Book for Latest Circuit Information
(1600) ESC CONNECTOR
(1800) DRIVER CONTROL MODULE CONNECTOR
LOCATED TO THE RIGHT OF STEERING COLUMN
(1813) PARK BRAKE SWITCH (WITH AIR BRAKES)
LOCATED NEAR ENGINE CONTROLLER
(1815) PARK BRAKE SWITCH (WITH HYDRAULIC BRAKES)
LOCATED NEAR ENGINE CONTROLLER
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Table 50 Park Brake Lamp Circuits Voltage Check Chart

Park Brake Switch Connector (1813) or (1815) Voltage Checks (Check with Brake
Switch Disconnected and the Ignition Key “On”)
(1813) harness connector, 12 ± 1.5 volts If voltage is incorrect, check circuit B44BB or
cavity C or (1815) cavity A44BB for open or short circuits. If circuits check
A to ground. good voltage is missing from ESC connector
(1600) pin 32.
(1813) harness connector, 12 ± 1.5 volts If voltage is correct and condition still exists, the
cavity C or (1815) cavity brake switch has failed. Replace brake switch.
A to (1813) cavity D or
(1815) cavity B. If voltage is incorrect, check circuit B9V, A9V or
A9H for an open circuit or good connection to
ground.
On vehicles with hydraulic brakes, the zero volt reference level is supplied from ESC connector (1600) terminal
3 to park brake switch connector (1815) terminal B.
On vehicles with air brakes, the zero volt reference level is supplied from ESC connector (1600) terminal 3
to park brake switch connector (1813) terminal C.
When the park brake is engaged the switch is closed and the zero volt reference level is supplied to ESC
connector (1600) terminal 32 signaling the ESC that the park brake has been applied.
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Component Locations
Figure 110 Park Brake Switch Location (With Hydraulic Brakes)

1. PARK BRAKE SWITCH
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Figure 111 Air Park Brake Switch Location (Steering Column Support View)
(1813) PARK INDICATION PRESSURE SWITCH
(1800) DCM CONNECTOR
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4.24. SERVICE PARK BRAKE WARNING LAMP

Circuit Function
Figure 112 Service Park Brake Warning Lamp Function Diagram

1. AIR ACTUATED PARK BRAKE SAAR TRAVEL SENSOR
The electrical circuits for the Travel Sensor integrated within the Spring Apply / Air Release (SAAR) Chamber
used on the powered park brake system. The powered park brake system is an option for vehicles equipped
with a hydraulic park brake system.
The electrical output is provided to indicate the SAAR piston has moved when air pressure is released from the
chamber. A failure of the piston to move may indicate a park brake malfunction or maladjustment. The sensor
output will interface with a digital input on the ESC.
SAAR – Spring Apply / Air Release: A component that actuates the park brake via a cable attached to a
piston. Then air is applied to the chamber at a great enough pressure to compress the spring, the park
brake is released. When air is evacuated from the chamber, the spring pushes back on the piston, which in
turn pulls the cable, which then actuates the piston.
Inputs to the device shall consist of a nominal voltage of 14 VDC, and a ground connection.
Outputs:
Apply condition. The device shall deliver a HI signal when SAAR stroke is less than 19.05 +/- 3.175 mm (.75
+/- .125 inches) and when the SAAR stroke exceeds 64.8 +/- 3.175 mm (2.55 +/- .125 inches) in the apply
condition. At all other times the device shall deliver a low signal.
Release condition. The device shall deliver a HI signal when the SAAR stroke is less than 17.78 +/- 3.175 mm
(.70 +/- .125 inches) and when the SAAR stroke exceeds 63.50 +/- 3.175 mm (2.50 +/- .125 inches) in the
release condition. At all other times the device shall deliver a low signal.
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The device is meant to drive a low-current, digital input.
The EGC activates the Service Park Brake warning lamp when it receives a message on the Drivetrain
1939 data link from the ESC.
Diagnostics
The Service Park Brake Warning lamp is on when the Air Powered Park Brake is stuck. This occurs when the
park brake switch does not match the spring apply air release (SAAR) chamber travel sensor. This indicates
The Service Park Brake Warning lamp is on when the auto apply portion with the Air Powered Park Brake is
not operating. This occurs when the park brake switch is not set within 5 seconds of the receipt of the Park as
the requested gear. This failure would indicate a failure in the auto apply or in the air lines between the auto
apply relay and the Park Brake switch.
in ESC/EGC programming, EGC hardware or problems with the input circuits to the ESC from the park
brake switch.
Table 51 Service Park Brake Warning Lamp Preliminary Check

SPEC.
position. Start the operate. Refer to
"ICAP" programming Programmingin the
software. Verify warning Electrical System
lamp and warning lamp Controller section of
inputs are programmed this manual. (See
to operate. PROGRAMMING,
page 113)
2. On Attempt to exercise the Warning Lamp Lamp circuits Insure bulb is not
warning lamp with the responds to EGC from data burned out. Replace
"INTUNE" diagnostic diagnostic input. link to EGC EGC circuit board.
software. are working
correctly.
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Table 51 Service Park Brake Warning Lamp Preliminary Check (cont.)

SPEC.
3. On Check for Service Service Park Go to the Go to next step
Park Brake Warning Brake Warning Air Actuated
Lamp diagnostic trouble Lamp diagnostic Park Brake in
codes. (See Diagnostic trouble codes are the Chassis
Trouble Codes (DTC), active. Features
page 221) section of the
manual.(See
Read display on AIR Actuated
odometer. Park Brake,
page 809)
check operation of the Replace ESC. (See ESC
lamp. circuit board REPLACEMENT,
on original page 123)
EGC.
Table 52 Service Park Brake Warning Lamp Diagnostic Trouble Codes

70 14 1 0 Air Powered Park Brake is stuck.
Occurs when the park brake switch does not match the spring
apply air release (SAAR) chamber travel sensor. This indicates
70 14 1 1 The auto apply portion with the Air Powered Park Brake is not
operating.
Occurs when the park brake switch is not set within 5 seconds of
the receipt of the Park as the requested gear. This failure would
indicate a failure in the auto apply or in the air lines between the
auto apply relay and the Park Brake switch.
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4.25. CRUISE CONTROL LAMP

Circuit Function
Figure 113 Cruise Control Lamp Function Diagram

1. CRUISE ON/OFF SWITCH
2. CRUISE SET/RESUME SWITCH
3. DIRECT CIRCUITS TO ESC
4. ESC
8. BRAKE AND CLUTCH SWITCH CIRCUITS (NOT SHOWN)
The EGC activates the cruise control indicator when it receives a message on the Drivetrain 1939 data link from
the ESC. The ESC generates this message when it receives a cruise on message from the engine controller.
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The light should go out when the cruise control is deactivated.
Diagnostics
The service tool (EZ-Tech) running the "INTUNE" diagnostic software can be used to illuminate all of the
warning lamps and monitor inputs to the ESC from the cruise control switches on the steering wheel.
A problem with the cruise lamp will be apparent when the cruise control is activated and the lamp doesn’t
illuminate or the lamp stays on when the cruise is deactivated.
For problems with the cruise control activating refer to Cruise Control.
There are no diagnostic trouble codes for cruise control circuits
If the lamp stays on continuously or doesn’t come on when the cruise control is engaged, the problem may
be in ESC/EGC programming, ESC/EGC hardware, engine controller.
Table 53 Cruise Control Lamp Preliminary Check

1. On Verify cruise control is Cruise control is Go to next step. Go to Cruise Control.
functioning. Insure the functioning.
brake and clutch are
released, there are no
active brake or clutch
DTC’s and no ABS/ATC
events.
3. On Attempt to exercise the Cruise lamp Go to next step. Insure bulb is not
cruise lamp with the responds to burned out. Replace
software. input.
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Table 53 Cruise Control Lamp Preliminary Check (cont.)

4. Off/On Temporarily swap a Lamp operates Message from Go to next step.
known good cluster with correctly. ESC is being
the current cluster and transmitted.
check operation of the Replace circuit
lamp. Activate cruise board on original
control and verify lamp EGC.
operation.
5. On Use "INTUNE" Message from Message from engine
diagnostic software to ESC is not being controller is not
verify cruise commands transmitted. being transmitted.
from the engine Consider Refer to the engine
controller are being replacing ESC troubleshooting
generated. . (See ESC manual for the engine
REPLACEMENT, installed in the vehicle.
page 123)
4.26. ABS WARNING LAMP

Circuit Function
Figure 114 ABS Warning Lamp Function Diagram

1. ABS ELECTRONIC CONTROL MODULE
The EGC activates the ABS indicator when it receives a message on the Drivetrain 1939 data link from the
electrical system controller (ESC). The ABS controller sends a message to the ESC requesting the lamp be
turned on when ABS is activate or there is a failure in the ABS system.
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The lamp should go out after the ABS event is over or the failure is repaired and the fault is cleared.
See the appropriate ABS manual for details.
Diagnostics
The EZ-Tech can also run ABS diagnostic software to validate operation of the warning lamp. Refer to the
applicable ABS manual for the vehicle.
If the lamp stays on continuously or doesn’t come on when commanded by the ABS controller, the problem
may be in ESC/EGC programming, ESC/EGC hardware or problems with the ABS controller.
Table 54 ABS Warning Lamp Preliminary Check

2. On Attempt to exercise the Warning lamp Lamp circuits Insure bulb is not
warning lamp with the responds to from data link to burned out. Replace
"INTUNE" diagnostic EGC diagnostic EGC are working EGC circuit board.
software. input. correctly.
Go to next step.
3. On Check for ABS Warning ABS Warning Go to fault Go to next step
Lamp diagnostic trouble Lamp detection
codes. (See Diagnostic diagnostic management.
Trouble Codes (DTC), trouble codes (See Fault
page 225) are active. Detection/
Management,
odometer.
4. On Monitor the inputs for Inputs are Go to next step. Refer to the
the warning lamp with correct. troubleshooting
the "INTUNE" diagnostic manual for the specific
software. ABS installed on the
truck.
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Table 55 ABS Warning Lamp Diagnostic Trouble Codes

2023 14 150 8 or 2023 14 250 8 ABS warning light malfunction on primary EGC (150) or
secondary EGC (250)
4.27. WAIT TO START WARNING LAMP

Circuit Function
Figure 115 “Wait To Start” Warning Lamp Function Diagram

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The EGC activates the “wait to start” indicator when it receives a message on the drivetrain 1939 data link from
the electrical system controller (ESC). The ESC will generate this message when it receives a message from
any engine controller that requires a “wait to start” function.
The light should go out when the glow plugs have reached a sufficient temperature to start the engine.
If the lamp stays on continuously or doesn’t come on when the engine is cold, the problem may be in ESC/EGC
programming, ESC/EGC hardware or problems with the engine controller or wiring to the engine controller.
See the engine diagnostic manual for detailed information on troubleshooting problems with the “wait to
start” warning lamp inputs.
Diagnostics
Table 56 Wait To Start Warning Lamp Preliminary Check

SPEC.
position. Start the "ICAP" operate. Refer to Programmingin
programmed to operate. PROGRAMMING, page
113)
2. On Attempt to exercise the Warning Lamp Lamp circuits Insure bulb is not burned
warning lamp with the responds to from data out. Replace EGC circuit
"INTUNE" diagnostic diagnostic input. link to EGC board.
correctly.
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4.28. CHECK A/C WARNING LAMP

Circuit Function
Figure 116 Check A/C Warning Lamp Function Diagram

4. HVAC CONTROL HEAD
The EGC activates the check A/C warning lamp when it receives a message on the drivetrain 1939 data link
from the electrical system controller (ESC). The ESC will generate this message when it determines there is a
failure in the air conditioning system or the HVAC control head notifies it of an HVAC failure.
Diagnostics
If the lamp stays on continuously when there is not an HVAC system failure or doesn’t come on when there is
an HVAC system failure, the problem may be in ESC/EGC programming, ESC/EGC hardware, or problems
with the HVAC control head or control head circuits.
Refer to the Heater and Air Conditioner (HVAC) section of this manual.
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Table 57 Check A/C Warning Lamp Preliminary Check

1. Off/ Connect diagnostic Warning lamp Go to next step. Program the warning
On tool (EZ-Tech) to the and warning lamp with the "ICAP"
warning lamps with the responds to burned out. Replace
software. input.
3. On Monitor the inputs to Inputs are Go to next step. Refer to AC
the ESC for the warning correct. Compressor Circuits
lamp with the "INTUNE" in the HVAC service
diagnostic software. manual section
S16025.
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4.29. RETARD OVERHEAT WARNING LAMP

Circuit Function
Figure 117 Retard Overheat Warning Lamp Function Diagram

1. TRANSMISSION ELECTRONIC CONTROL MODULE
The EGC activates the retard overheat warning lamp when it receives a message on the drivetrain 1939 data
link from the electrical system controller (ESC). The ESC will generate this message when it receives a
message from the transmission controller informing it that the retarder is overheating.
The lamp should go out after the retarder has cooled off.
Diagnostics
If the lamp stays on continuously or doesn’t come on when the transmission retarder is overheating, the
problem may be in ESC/EGC programming, ESC/EGC hardware or problems with engine controller circuits
or the engine controller.
See the appropriate transmission manual for details.
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Table 58 Retard Overheat Warning Lamp Preliminary Check

warning lamp with the responds to EGC from data burned out. Replace
"INTUNE" diagnostic diagnostic input. link to EGC EGC circuit board.
correctly.
4.30. PTO/ THROTTLE WARNING LAMP

Circuit Function
Figure 118 PTO/Throttle Warning Lamp Function Diagram

The EGC activates the PTO/throttle warning lamp when it receives a message on the drivetrain 1939 data link
from the ESC. The ESC will generate this message when it receives a message from the engine controller
that the PTO is engaged.
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The lamp should go out when PTO is disengaged.
Diagnostics
If the lamp stays on continuously or doesn’t come on when commanded by the ESC, the problem may
be in ESC/EGC programming, ESC/EGC hardware or problems with the sensors or sensor wiring to the
transmission controller.
See the appropriate engine manual for details on PTO operation.
Table 59 PTO/throttle Warning Lamp Preliminary Check

warning lamp with the responds to burned out. Replace
software. input.
warning lamp with the responds to from data link to burned out. Replace
"INTUNE" diagnostic EGC diagnostic EGC are working EGC circuit board.
software. input. correctly.
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4.31. ALTERNATOR WARNING LAMP

Circuit Function
Refer to Alternator Warning Lamp Function Diagram.
Figure 119 Alternator Warning Lamp Function Diagram

1. ALTERNATOR
2. DIRECT CIRCUIT FROM ALTERNATOR TO WARNING LAMP
The optional alternator warning lamp is directly controlled by the alternator.
The light will illuminate when the output from the alternator is incorrect.
The light will go out when the output from the alternator is corrected.
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4.32. DIFFERENTIAL LOCK WARNING LAMP

Circuit Function
Figure 120 Differential Lock Warning Lamp Function Diagram

1. DIFFERENTIAL LOCK SWITCH (ON DIFFERENTIAL)
2. DIRECT CIRCUIT FROM DIFFERENTIAL TO WARNING LAMP
The optional differential lock warning lamp is directly controlled by the switch on the axle differential. There
is no interaction with the ESC.
On vehicles with dual rear axles, a separate warning lamp is provided for each axle.
Diagnostics
When the key is in ignition position, the light will illuminate when the differential is locked. The light will go
out when the differential lock is released.
Table 60 Differential Lock Warning Lamp Preliminary Check

SPEC.
1. On Turn on differential Warning Go to next Insure bulb is not burned
lock switch. Lamp should step. out. Check for open
come on. circuits between lamp
and axle switch.
2. On Warning lamp should Warning Warning lamp Check for short to
go out. lamp turns is operating ground in circuits
off. correctly. between lamp and
axle switch. Also check
for failed axle switch.
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A fault in the differential lock warning lamps will be evident when the lamps fail to illuminate.
When the key is in ignition position, the light will illuminate when the differential is locked. The light will go
out when the differential lock is released.
If the lamp fails to illuminate the bulb could be burned out or there could be a an open or shorted circuit
between the axle switch and the lamp.
Refer to Differential Lock Warning Lights Circuit.
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Figure 121 Differential Lock Warning Lights Circuit (Connectors Viewed From Mating End) — Always
Refer to Circuit Diagram Book for Latest Circuit Information
(1555) OPTIONAL WARNING LIGHT CONNECTOR
LOCATED ON EGC
(4006) GROUND STUD
(8803) CHASSIS GROUND SPLICE PACK
LOCATED NEAR LEFT FRAME RAIL
(9700) DASH/CENTER CHASSIS CONNECTOR
LOCATED IN ENGINE COMPARTMENT NEAR LEFT FRAME
(9800) CENTER/REAR CHASSIS CONNECTOR
LOCATED BY LEFT FRAME RAIL NEAR REAR AXLES
(9814) FRONT REAR AXLE DIFFERENTIAL LOCK SWITCH CONNECTOR
LOCATED ON AXLE
(9815) REAR-REAR AXLE DIFFERENTIAL LOCK SWITCH CONNECTOR
LOCATED ON AXLE
F9 OPTIONAL WARNING LIGHT FUSE
LOCATED ON FUSE BLOCK 1 OF CAB POWER DISTRIBUTION PANEL
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Table 61 Rear-Rear Differential Lock Warning Light Voltage Check

Rear-Rear Warning Light Switch Connector (9815) Voltage Checks (Check with
switch disconnected and the ignition key “On”)
(9815) harness connector, 12 ± 1.5 volts Insure fuse and lamp are not open.
cavity A to ground.
If voltage is incorrect, check for open or short in
circuits R49A, N49A, J49A or A49F.
(9815) harness connector, 12 ± 1.5 volts If voltage is incorrect, check for an open in circuits
cavity A to B. R49-GA, R10-GB, N49-G, N10-G, J11–GA or
J11–GJ to ground.
If voltage is correct and lamps do not light when the

differential is locked, the axle switch has failed or is
not actuating. Replace axle switch if it is faulty.
Table 62 Front Rear Differential Lock Warning Light Voltage Check

Front Rear Warning Light Switch Connector (9814) Voltage Checks (Check with
switch disconnected and the ignition key “On”)
(9814) harness connector, 12 ± 1.5 volts Insure fuse and lamp are not open.
cavity A to ground.
If voltage is incorrect, check for open or short in
circuits R49, N49B, J49B or A49D.
(9814) harness connector, 12 ± 1.5 volts If voltage is incorrect, check for an open in circuits
cavity A to B. R49-G, R10-GB, N49-G, N10-G, J11–GA or
J11–GJ to ground.
If voltage is correct and condition still exists, the

axle switch has failed or is not actuating. Replace
axle switch.
Battery voltage is applied to the warning light lamps from fuse F9 when the key is in the ignition position.
When the rear axle(s) are locked the axle switch(es) will close supplying a ground to the lamp(s) causing
them to illuminate.
Snow Valve Warning Lamp
Refer to Snow Valve (Engine Intake). (See SNOW VALVE (ENGINE INTAKE), page 346)
Optimized Idle
This feature is not implemented.
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4.33. VOLTMETER
Circuit Function
Figure 122 Voltmeter Function Diagram

1. BATTERY
Information for the voltmeter is provided on the Drivetrain 1939 data link from the ESC. The ESC generates
this information based on the system voltage.
Assuming the gauge swept at gauge sweep. Check gauge with service tool (EZ-Tech). If gauge
responds to service tool (EZ-Tech), data is not being transmitted from the ESC.
Diagnostics
the gauge.
The pointer in a small gauge, pointing to the six o’clock position, indicates that there is a sensor error for that
gauge. A gauge pointing to 10 o’clock is connected to an unprogrammed connector on the EGC circuit board.
A problem with the data link will demonstrate several problems on the EGC, as well as a diagnostic trouble
code. If other gauges are not operating correctly, the problem is not isolated to the voltmeter inputs.
A gauge with an incorrect reading may be the result of incorrect programming, an incorrect jumper connection
between the EGC circuit board and the gauge or a problem in the sensor circuitry for that gauge. The following
procedures will provide guidance for determining why the gauge is malfunctioning.
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Table 63 Voltmeter Preliminary Check

1. Off/On Does the gauge Gauge sweeps Go to next step. Replace gauge and
operate correctly during from minimum check jumper harness.
gauge sweep? to maximum and If problem persists,
back. replace EGC circuit
board. Refer to
Remove and Install.
2. On Check for Voltmeter Voltmeter gauge Go to fault Go to next step.
gauge diagnostic diagnostic trouble detection
trouble codes. (See codes are active. management.
Diagnostic Trouble (See Fault
Codes (DTC), page Detection/
239) Management,
page 240)
Read display on
odometer.
3. Off/On Connect diagnostic Gauge and Go to next step. Program the gauge with
tool (EZ-Tech) to the gauge inputs the “ICAP” software.
diagnostic connector. are programmed Refer to the ICAP
Turn key to accessory correctly. programming software
position. Start the manual for details.
"ICAP" programming
software. Verify gauge
and gauge inputs are
programmed correctly.
4. On Attempt to exercise Gauge responds If gauge Verify jumper harness
the gauge with the to "INTUNE" responds to between gauge and
"INTUNE" diagnostic diagnostic input. diagnostic tool, circuit board is in
software. but doesn’t work correct locations. If
during normal jumper locations are
operations, correct, replace EGC
replace the ESC. circuit board.
5. Consider replacing ESC. (See ESC REPLACEMENT, page 123)
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Table 64 Voltmeter Gauge Diagnostic Trouble Codes

1705 14 109 3 (EGC Version 8.7) EGC gauge location 9 (Voltmeter) out of range high
Data for this gauge is above the value that the gauge can display.
For example: a value exceeding the gauge maximum scale value.
1705 14 109 4 (EGC Version 8.7) EGC gauge location 9 (Voltmeter) out of range low
Data for this gauge is below the minimum value the gauge can
display. For example: the lowest scale value on the gauge.
1705 14 109 5 (EGC Version 8.7) EGC gauge location 9 (Voltmeter) sensor fault
There is a problem with the sensor that provides the data for
this gauge.
1705 14 109 6 (EGC Version 8.7) EGC gauge location 9 (Voltmeter) data unavailable
The data that this gauge displays should be, but is not available
at this time.
2023 14 109 5 or 2023 14 209 5 Voltmeter sensor fault to primary EGC (109) or secondary EGC
(EGC Version 9.3 and later) (209)
this gauge.
2023 14 109 6 or 2023 14 209 6 Voltmeter gauge data unavailable to primary EGC (109) or
(EGC Version 9.3 and later) secondary EGC (209)
at this time.
2023 14 109 7 or 2023 14 209 7 Voltmeter gauge data missing to primary EGC (109) or secondary
(EGC Version 9.3 and later) EGC (209)
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4.34. ENGINE COOLANT TEMPERATURE GAUGE

Circuit Function
Figure 123 Engine Coolant Temperature Gauge Function Diagram

1. ENGINE COOLANT TEMPERATURE SENSOR
Information for the engine coolant temperature gauge is provided on the drivetrain 1939 data link from the
engine controller. The engine controller generates this information based on input from a sensor on the engine.
Diagnostics
the gauge.
code. If other gauges are not operating correctly, the problem is not isolated to the engine coolant temperature
gauge inputs.
See the engine diagnostic manual for detailed information on troubleshooting problems with the engine
coolant temperature sensor circuits.
Problems with the engine coolant temperature gauge can be caused by a malfunctioning gauge, a malfunction
in EGC circuitry, an incorrect connection inside the EGC, a loss of programming, a problem in the engine
controller, a problem with the engine coolant temperature sensor or a problem with wiring to the sensor.
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The following procedures will provide guidance for determining why the gauge is malfunctioning.
Table 65 Engine Coolant Temperature Preliminary Check

board. Refer to
Remove and Install.
2. On Check for Engine Engine Coolant Go to fault Go to next step.
Coolant Temperature Temperature detection
gauge diagnostic gauge diagnostic management.
trouble codes. (See trouble codes are (See Fault
Diagnostic Trouble active. Detection/
Codes (DTC), page Management,
242) page 243)
Read display on
odometer.
"ICAP" programming
5. Engine coolant temperature message is not being generated by the engine controller.
Refer to the applicable engine troubleshooting manual for this vehicle.
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Table 66 Engine Coolant Temperature Gauge Diagnostic Trouble Codes

1705 14 103 3 (EGC Version 8.7) EGC gauge location 3 (Engine Coolant Temperature) out of
range high
1705 14 103 4 (EGC Version 8.7) EGC gauge location 3 (Engine Coolant Temperature) out of
range low
1705 14 103 5 (EGC Version 8.7) EGC gauge location 3 (Engine Coolant Temperature) sensor fault
this gauge.
1705 14 103 6 (EGC Version 8.7) EGC gauge location 3 (Engine Coolant Temperature) data
unavailable
at this time.
2023 14 103 5 or 2023 14 203 5 Engine Coolant Temperature sensor fault to primary EGC (103)
(EGC Version 9.3 and later) or secondary EGC (203)
this gauge.
2023 14 103 6 or 2023 14 203 6 Engine Coolant Temperature gauge data unavailable to primary
(EGC Version 9.3 and later) EGC (103) or secondary EGC (203)
at this time.
2023 14 103 7 or 2023 14 203 7 Engine Coolant Temperature gauge data missing to primary EGC
(EGC Version 9.3 and later) (103) or secondary EGC (203)
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4.35. ENGINE OIL PRESSURE GAUGE

Circuit Function
Figure 124 Engine Oil Pressure Gauge Function Diagram

1. ENGINE OIL PRESSURE SENSOR
Information driving the engine oil pressure gauge is provided on the Drivetrain 1939 data link from the engine
controller. The engine controller generates this information based on signals from sensors on the engine.
Diagnostics
the gauge.
code. If other gauges are not operating correctly, the problem is not isolated to the engine oil pressure gauge
inputs.
coolant temperature inputs.
Problems with the engine oil pressure gauge can be caused by a malfunctioning gauge, a malfunction in EGC
circuitry, an incorrect connection inside the EGC, a loss of programming, a problem in the engine controller, a
problem with the engine oil pressure sensor or a problem with wiring to the sensor.
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Table 67 Engine Oil Pressure Preliminary Check

board. Refer to
Remove and Install.
2. On Check for Engine Engine Oil Go to fault Go to next step.
Oil Pressure gauge Pressure gauge detection
diagnostic trouble diagnostic trouble management.
codes. (See Diagnostic codes are active. (See Fault
Trouble Codes (DTC), Detection/
page 245) Management,
page 246)
Read display on
odometer.
"ICAP" programming
5. Engine oil pressure message is not being generated by the engine controller. Refer
to the applicable engine troubleshooting manual for this vehicle.
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Table 68 Engine Oil Pressure Gauge Diagnostic Trouble Codes

1705 14 105 3 (EGC Version 8.7) EGC gauge location 5 (Engine Oil Pressure) out of range high
1705 14 105 4 (EGC Version 8.7) EGC gauge location 5 (Engine Oil Pressure)) out of range low
1705 14 105 5 (EGC Version 8.7) EGC gauge location 5 (Engine Oil Pressure) sensor fault
this gauge.
1705 14 105 6 (EGC Version 8.7) EGC gauge location 5 (Engine Oil Pressure) data unavailable
at this time.
2023 14 105 5 or 2023 14 205 5 Engine Oil Pressure sensor fault to primary EGC (105) or
this gauge.
2023 14 105 6 or 2023 14 205 6 Engine Oil Pressure gauge data unavailable to primary EGC
at this time.
2023 14 105 7 or 2023 14 205 7 Engine Oil Pressure gauge data missing to primary EGC (105)
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4.36. ENGINE OIL TEMPERATURE GAUGE

Circuit Function
Figure 125 Engine Oil Temperature Gauge Function Diagram

1. ENGINE OIL TEMPERATURE SENSOR
Information driving the engine oil temperature gauge is provided on the Drivetrain 1939 data link from the
engine controller. The engine controller generates this information based on signals from sensors on the
engine.
Diagnostics
A gauge with an incorrect reading may be due to incorrect programming, an incorrect jumper connection
between the EGC circuit board and the gauge or a problem in the sensor circuitry for that gauge. The following
procedures will provide guidance for determining why the gauge is malfunctioning.
the gauge.
oil temperature sensor inputs.
Problems with the engine oil temperature gauge can be caused by a malfunctioning gauge, a malfunction
in EGC circuitry, an incorrect connection inside the EGC, a loss of programming, a problem in the engine
controller, a problem with the engine oil temperature sensor or a problem with wiring to the sensor.
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Table 69 Engine Oil Temperature Gauge Preliminary Check

1. Off/On Does the gauge operate Gauge sweeps Go to next Replace gauge
correctly during gauge from minimum step. and check jumper
sweep? to maximum harness. If problem
and back. persists, replace EGC
circuit board. Refer
toRemove and Install.
2. Off/On Connect diagnostic tool Gauge Go to next Program the gauge
(EZ-Tech) to the diagnostic and gauge step. with the “ICAP”
connector. Turn key to inputs are software. Refer to the
accessory position. Start programmed ICAP programming
the "ICAP" programming correctly. software manual for
software. Verify gauge details.
3. On Check for Engine Oil Engine Oil Go to fault Go to next step
Temperature Gauge Temperature detection
diagnostic trouble codes. Gauge management.
(See Diagnostic Trouble diagnostic (See Fault
Codes (DTC), page 248) trouble codes Detection/
are active. Management,
Read display on odometer. page 249)
4. On Attempt to exercise the Gauge Go to next Verify jumper harness
gauge with the "INTUNE" responds to step. between gauge and
diagnostic software. "INTUNE" circuit board is in
diagnostic correct locations. If
input. jumper locations are
correct, replace EGC
circuit board.
5. On Engine oil temperature message is not being generated by the engine controller.
Refer to the applicable engine troubleshooting manual for this vehicle.
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Table 70 Engine Oil Temperature Gauge Diagnostic Trouble Codes

612 14 33 1 Engine Oil Temperature/Power Park Brake out of range low
Short to ground or open circuit

612 14 33 2 Engine Oil Temperature/Power Park Brake out of range high
Shorted high
4.37. PYROMETER GAUGE – (THIS FEATURE IS NOT CURRENTLY AVAILABLE)
Figure 126 Unused Figure
Table 71 Unused Table

STEP KEY ACTION TEST SPEC. YES-IN NO-OUT OF SPEC.
POINTS SPEC.
This table is no longer used and was intentionally left blank.
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4.38. SPEEDOMETER
Circuit Function
Figure 127 Speedometer Function Diagram

1. VEHICLE SPEED SIGNAL (VSS)
Information driving the speedometer is provided on the Drivetrain 1939 data link from the engine controller.
The engine controller generates this information based on the vehicle speed signal from a sensor on the
transmission or from the transmission control module.
Diagnostics
If the speedometer go to zero, sweep up to 50% and return to zero three times, there is a sensor error.
the gauge.
code. If other gauges are not operating correctly, the problem is not isolated to the speedometer inputs.
Problems with the speedometer can be caused by a malfunctioning gauge, a malfunction in EGC circuitry,
a loss of programming, a problem in the engine controller or missing signal from the vehicle speed sensor
(VSS) or transmission controller.
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Table 72 Speedometer Preliminary Check

board. Refer to
Remove and Install.
2. On Check for Speedometer Speedometer Go to fault Go to next step.
gauge diagnostic gauge diagnostic detection
trouble codes. (See trouble codes are management.
Diagnostic Trouble active. (See Fault
251) Management,
page 252)
Read display on
odometer.
"ICAP" programming
5. Speedometer signal is not being transmitted from the engine controller. Refer to the applicable
engine troubleshooting manual for this vehicle. Also refer to the appropriate transmission
troubleshooting manual. Manual transmissions use the traditional vehicle speed sensor
(VSS). Automatic transmissions transmit the signal from the transmission ECU.
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Table 73 Speedometer Gauge Diagnostic Trouble Codes

1705 14 102 3 (EGC Version 8.7) EGC gauge location 2 (Speedometer) out of range high
1705 14 102 4 (EGC Version 8.7) EGC gauge location 2 (Speedometer) out of range low
1705 14 102 5 (EGC Version 8.7) EGC gauge location 2 (Speedometer) sensor fault
this gauge.
1705 14 102 6 (EGC Version 8.7) EGC gauge location 2 (Speedometer) data unavailable
at this time.
2023 14 102 5 or 2023 14 202 5 Speedometer sensor fault to primary EGC (102) or secondary
this gauge.
2023 14 102 6 or 2023 14 202 6 Speedometer gauge data unavailable to primary EGC (102) or
at this time.
2023 14 102 7 or 2023 14 202 7 Speedometer gauge data missing to primary EGC (102) or
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4.39. TACHOMETER
Circuit Function
Figure 128 Tachometer Function Diagram

1. TACHOMETER SENSOR
Information driving the tachometer is provided on the Drivetrain 1939 data link from the engine controller.
Diagnostics
If the tachometer go to zero, sweep up to 50% and return to zero three times, there is a sensor error.
the gauge.
code. If other gauges are not operating correctly, the problem is not isolated to the tachometer inputs.
Problems with the tachometer can be caused by a malfunctioning gauge, a malfunction in EGC circuitry, a
loss of programming, a problem in the engine controller, a problem with the engine tachometer sensor or a
problem with wiring to the sensor.
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Table 74 Tachometer Preliminary Check

board. Refer to
Remove and Install.
2. On Check for Tachometer Tachometer Go to fault Go to next step.
gauge diagnostic gauge diagnostic detection
trouble codes. (See trouble codes are management.
Diagnostic Trouble active. (See Fault
254) Management,
page 255)
Read display on
odometer.
"ICAP" programming
5. Tachometer signal is not being transmitted from the engine controller. Refer to the
applicable engine troubleshooting manual for this vehicle.
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Table 75 Tachometer Gauge Diagnostic Trouble Codes

1705 14 101 3 (EGC Version 8.7) EGC gauge location 1 (Tachometer) out of range high
1705 14 101 4 (EGC Version 8.7) EGC gauge location 1 (Tachometer) out of range low
1705 14 101 5 (EGC Version 8.7) EGC gauge location 1 (Tachometer) sensor fault
this gauge.
1705 14 101 6 (EGC Version 8.7) EGC gauge location 1 (Tachometer) data unavailable
at this time.
2023 14 101 5 or 2023 14 201 5 Tachometer sensor fault to primary EGC (101) or secondary
this gauge.
2023 14 101 6 or 2023 14 201 6 Tachometer gauge data unavailable to primary EGC (101) or
at this time.
2023 14 101 7 or 2023 14 201 7 Tachometer gauge data missing to primary EGC (101) or
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4.40. FUEL LEVEL GAUGE

Circuit Function
Figure 129 Fuel Level Gauge Function Diagram

1. FUEL LEVEL SENSOR
Information driving the fuel level gauge is provided on the Drivetrain 1939 data link from the ESC. The ESC
generates this information based on input from the fuel level sensor.
Diagnostics
the gauge.
Problems with the fuel level gauge can be caused by a malfunctioning gauge, a malfunction in EGC circuitry,
an incorrect connection inside the EGC, a loss of programming, a problem in the ESC, a problem with the
fuel level sensor or a problem with wiring to the sensor. The following procedures will provide guidance
for determining why the gauge is malfunctioning.
Table 76 Fuel Level Gauge Preliminary Check

POINTS SPEC.
1. Off/On Does the fuel level Gauge Go to next Replace gauge
gauge operate during performs step. and check jumper
the gauge sweep? during harness. If problem
gauge persists, replace EGC
sweep. circuit board. Refer to
Remove and Install.
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Table 76 Fuel Level Gauge Preliminary Check (cont.)

POINTS SPEC.
2. On Check for fuel level Read Fuel level Go to fault Go to next step.
gauge diagnostic display gauge detection
trouble codes. (See on diagnostic management.
Diagnostic Trouble odometer. trouble (See Fault
Codes (DTC), page codes are Detection/
257) active. Management,
page 259)
3. Off/On Connect diagnostic Gauge Go to next Program the gauge
tool (EZ-Tech) to the and gauge step. with the “ICAP”
diagnostic connector. inputs are software. Refer to the
Turn key to accessory programmed ICAP programming
position. Start the correctly. software manual for
"ICAP" programming details.
4. On Attempt to exercise Gauge Go to next Insure gauge
the gauge with the responds step. operates during
"INTUNE" diagnostic to gauge sweep. Insure
software. "INTUNE" jumper harness
diagnostic between gauge and
input. circuit board is in
correct location. If
jumper is correct,
replace EGC circuit
board.
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Table 77 Fuel Level Gauge Diagnostic Trouble Codes

612 14 25 1 Draw tank, fuel level sensor out of range low.
This code is associated with a short to ground on the fuel level

sensor on the draw tank for both single tank and dual tank
vehicles.
Short to ground.
612 14 25 2 Draw tank, fuel sensor out of range high.
This code is associated with a short to accessory or open circuit

on the fuel level sensor on the draw tank for both single tank
and dual tank vehicles.
Shorted high or open circuit.

612 14 23 1 Storage tank, fuel level sensor out of range low.
This code is associated with a short to ground on the fuel level

sensor on the storage tank for dual tank vehicles.
Short to ground.
612 14 23 2 Storage tank, fuel level sensor out of range high.
This code is associated with a short to accessory or open circuit

on the fuel level sensor on the storage tank for dual tank vehicles.

1705 14 107 3 (EGC Version 8.7) EGC gauge location 7 (fuel level) out of range high
1705 14 107 4 (EGC Version 8.7) EGC gauge location 7 (fuel level) out of range low
1705 14 107 5 (EGC Version 8.7) EGC gauge location 7 (fuel level) sensor fault
this gauge.
1705 14 107 6 (EGC Version 8.7) EGC gauge location 7 (fuel level) data unavailable
at this time.
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Table 77 Fuel Level Gauge Diagnostic Trouble Codes (cont.)

2023 14 107 5 or 2023 14 207 5 Fuel gauge sensor fault to primary EGC (107) or secondary EGC
this gauge.
2023 14 107 6 or 2023 14 207 6 Fuel gauge data unavailable to primary EGC (107) or secondary
at this time.
2023 14 107 7 or 2023 14 207 7 Fuel gauge data missing to primary EGC (107) or secondary
NOTE – For vehicles with dual fuel tanks refer to the Fuel Transfer section of this manual. (See FUEL
TRANSFER PUMP SYSTEM, page 681) The transfer pump circuits can affect fuel gauge operation.
A fault in the fuel sensor circuits will be apparent when the fuel gauge points straight down. Fuel sensor
diagnostic trouble codes will also be present.
Problems in sensor circuits could be the result of open or shorted sensors, open circuits, shorted circuits,
or a failure in the ESC.
Refer to Fuel Sensor Circuits.
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Figure 130 Fuel Sensor Circuits—Always Refer to Circuit Diagram Book for Latest Circuit Information
(4830) ELECTRONIC REF GROUND SPLICE
(8802) ISOLATED GROUND SPLICE PACK
LOCATED CHASSIS
(9100) LEFT FUEL SENSOR CONNECTOR
LOCATED IN LEFT DUAL FUEL TANKS
(9101) RIGHT FUEL SENSOR CONNECTOR
LOCATED IN RIGHT DUAL FUEL TANKS
(9700) CHASSIS/DASH INTERCONNECT
LOCATED IN REAR CHASSIS
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Table 78 Fuel Level Gauge Diagnostic Trouble Codes

612 14 25 1 Draw tank, fuel level sensor out of range low.
This code is associated with a short to ground on the fuel level sensor
on the draw tank for both single tank and dual tank vehicles.
Short to ground.
612 14 25 2 Draw tank, fuel sensor out of range high.
This code is associated with a short to accessory or open circuit on

the fuel level sensor on the draw tank for both single tank and dual
tank vehicles.

612 14 23 1 Storage tank, fuel level sensor out of range low.
This code is associated with a short to ground on the fuel level sensor
on the storage tank for dual tank vehicles.
Short to ground.
612 14 23 2 Storage tank, fuel level sensor out of range high.
This code is associated with a short to accessory or open circuit on

the fuel level sensor on the storage tank for dual tank vehicles.

1705 14 107 3 (EGC Version 8.7) EGC gauge location 7 (fuel level) out of range high
Data for this gauge is above the value that the gauge can display. For
example: a value exceeding the gauge maximum scale value.
1705 14 107 4 (EGC Version 8.7) EGC gauge location 7 (fuel level) out of range low
Data for this gauge is below the minimum value the gauge can display.
For example: the lowest scale value on the gauge.
1705 14 107 5 (EGC Version 8.7) EGC gauge location 7 (fuel level) sensor fault
gauge.
1705 14 107 6 (EGC Version 8.7) EGC gauge location 7 (fuel level) data unavailable
this time.
2023 14 107 5 or 2023 14 207 5 Fuel gauge sensor fault to primary EGC (107) or secondary EGC (207)
gauge.
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Table 78 Fuel Level Gauge Diagnostic Trouble Codes (cont.)

2023 14 107 6 or 2023 14 207 6 Fuel gauge data unavailable to primary EGC (107) or secondary
this time.
2023 14 107 7 or 2023 14 207 7 Fuel gauge data missing to primary EGC (107) or secondary EGC
Table 79 Fuel Level Gauge Tests

Left Fuel Level Gauge Voltage Checks
Check with ignition on and fuel level sensor disconnected.
Always use breakout box ZTSE 4477 to take measurements on ESC connectors.
(9100) cavity A to ground. 10 ± 1 volts If voltage is missing, check for open or
shorts in circuit N36E, N36H or J36B to ESC
connector (4004) cavity 4.
If circuits check good, check for missing 10

volt signal from ESC.
(9100) cavity A to B. 10 ± 1 volts If voltage is present replace or repair fuel
sensor
If voltage is missing, check for open in circuits

N9A, N9, J9G or J9A to ESC connector (4004)
cavity 26.
If circuits check good, check for missing zero

volt reference from ESC.
A zero volt reference signal from ESC connector (4004) terminal 26 is supplied to fuel sensor connector (9100)
terminal B through circuits J9A, J9G, Dash/Chassis connector (9700) terminal D8, circuit N9 and N9A.
The signal from the fuel sensor is supplied from fuel sensor connector (9100) terminal A to ESC connector
(4004) terminal 4 through circuit N36E, Dash/Chassis connector (9700) terminal C10, and circuit J36B.
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Component Locations
Figure 131 Fuel Sensor Connector Locations

(9100) FUEL LEVEL SENSOR CONNECTOR
(9700) REAR CHASSIS CONNECTOR
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4.41. TRANSMISSION OIL TEMPERATURE GAUGE

Circuit Function
Figure 132 Transmission Oil Temperature Gauge Function Diagram

1. TRANSMISSION OIL TEMPERATURE SENSOR
On a vehicle with a manual transmission, information driving the transmission oil temperature gauge is
provided on the Drivetrain 1939 data link from the ESC. The ESC generates this information based on input
from a sensor on the transmission.
On a vehicle with an automatic transmission manual transmission, information driving the transmission oil
temperature gauge is provided on the Drivetrain 1939 data link from transmission electronic control Unit (ECU)
Diagnostics
the gauge.
Problems with the transmission oil temperature gauge can be caused by a malfunctioning gauge, a malfunction
in EGC circuitry, an incorrect connection inside the EGC, a loss of programming, a problem in the ESC, a
problem with the transmission oil temperature sensor or a problem with wiring to the sensor.
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Table 80 Transmission Oil Temperature Gauge Preliminary Check

POINTS SPEC.
1. Off/On Does the Gauge Go to next Replace gauge
transmission performs step. and check jumper
temperature gauge during gauge harness . If problem
operate during the sweep. persists, replace
gauge sweep? EGC circuit board.
Refer to Remove and
Install.
2. On Check for Read Transmission Go to fault Go to next step.
transmission display on temperature detection
temperature gauge odometer. gauge management.
diagnostic trouble diagnostic (See Fault
codes. (See trouble Detection/
Diagnostic Trouble codes are Management,
Codes (DTC), page active. page 266)
266)
3. On There are no DTC’s Observe Transmission Go to fault Go to next step.
for an open in sensor gauge temperature detection
circuits. temperature gauge reads management.
reading minimum (See Fault
Does gauge read when when Detection/
minimum when it transmission transmission Management,
should obviously is hot. is hot. page 266)
be reading a higher
temperature.
4. Off/On Connect diagnostic Gauge Go to next Program the
tool (EZ-Tech) to and gauge step. gauge with the
the diagnostic inputs are “ICAP” software.
connector. Turn programmed Refer to the ICAP
key to accessory correctly. programming
position. Start the software manual
"ICAP" programming for details.
software. Verify
gauge and
gauge inputs
are programmed
correctly.
S082504
Table 80 Transmission Oil Temperature Gauge Preliminary Check (cont.)

POINTS SPEC.
the gauge with the responds to step. operates during
"INTUNE" diagnostic "INTUNE" gauge sweep. Insure
software. diagnostic jumper harness
input. between gauge and
circuit board is in
jumper is correct,
replace EGC circuit
board.
6. On a vehicle with a manual transmission, Consider replacing ESC. (See
ESC REPLACEMENT, page 123)
On a vehicle with automatic transmission, refer to the applicable transmission manual.
Table 81 Transmission Temperature Gauge Diagnostic Trouble Codes

612 14 36 1 Transmission temperature sensor shorted to ground
A short in the transmission temperature sensor circuits will be apparent when the temperature gauge points
straight down. Transmission temperature sensor diagnostic trouble codes will also be present.
The ESC and EGC are not able to recognize an open circuit to the temperature sensor or an open sensor.
There is no DTC for this condition.
Problems in sensor circuits could be the result of open or shorted sensor, open circuits, shorted circuits, a
failure in the ESC or a transmission ECU problem.
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Refer to Manual Transmission Temperature Sensor Circuits.
Figure 133 Manual Transmission Temperature Sensor Circuits—Always Refer to Circuit Diagram
(4004) ESC CONNECTOR
(4705) TRANSMISSION/DASH CONNECTOR
(4830) ZERO VOLT REFERENCE SPLICE
(7700) TRANSMISSION OIL TEMPERATURE
LOCATED ON MANUAL TRANSMISSION
Table 82 Transmission Oil Temperature Gauge Diagnostic Trouble Codes

612 14 36 1 Transmission temperature sensor shorted to ground
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Table 83 Transmission Oil Temperature Gauge Tests

Transmission Oil Temperature Gauge Voltage Checks
Check with ignition on and transmission oil temperature sensor (7700) disconnected.
(7700) cavity A to ground. 10 ± 1 volts If voltage is missing, check for open or shorts in circuit
L31B or J31 to ESC connector (4004) cavity 3.
If circuits check good, check for missing 10 volt signal

from ESC.
(7700) cavity A to cavity 10 ± 1 volts If voltage is missing, check for open in circuits L31GB,
B. J9X or J9A to ESC connector (4004) cavity 26.
If circuits check good, check for missing zero volt

reference from ESC.
If voltage is present, circuits to temperature sensor

are good. Replace sensor.
A zero volt reference signal is supplied from ESC connector (4004) terminal 26 to transmission oil temperature
sensor connector (7700) terminal B through circuit J9A, J9X and L31–GB.
10 volts from ESC connector (4004) terminal 3 is supplied to the transmission oil temperature sensor connector
(7700) terminal through circuit J31 and L31B. This voltage will drop across the sensor providing the ESC
with temperature information.
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Component Locations
Figure 134 Typical Manual Transmission Oil Temperature Sensor Location

1. MANUAL TRANSMISSION OIL TEMPERATURE SENSOR
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4.42. REAR-REAR AXLE OIL TEMPERATURE GAUGE

Circuit Function
Figure 135 Rear-Rear Axle Oil Temperature Gauge Function Diagram

1. REAR-REAR AXLE OIL TEMPERATURE SENSOR
Information driving the rear-rear axle oil temperature gauge is provided on the Drivetrain 1939 data link from
the ESC. The ESC generates this information based on input from a sensor on the rear-rear axle.
Diagnostics
the gauge.
Problems with the rear-rear axle temperature gauge can be caused by a malfunctioning gauge, a malfunction
problem with the rear-rear axle temperature sensor or a problem with wiring to the sensor.
Table 84 Rear-Rear Axle Oil Temperature Gauge Preliminary Check

STEP KEY ACTION TEST SPEC. YES-IN SPEC. NO-OUT OF SPEC.
POINTS
1. Off/On Does the rear-rear Gauge Go to next Replace gauge
axle oil temperature performs step. and check jumper
gauge operate during during harness. If problem
the gauge sweep? gauge persists, replace
sweep. EGC circuit board.
Refer to Remove
and Install.
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Table 84 Rear-Rear Axle Oil Temperature Gauge Preliminary Check (cont.)

POINTS
2. On Check for rear-rear Read Rear-rear Go to fault Go to next step.
axle oil temperature display on axle detection
gauge diagnostic odometer. oil temperature management.
trouble codes. (See gauge (See Fault
Diagnostic Trouble diagnostic Detection/
Codes (DTC), page trouble Management,
271) codes are page 272)
active.
3. On There are no DTC’s Observe Rear-rear Go to fault Go to next step.
for an open in sensor gauge axle detection
circuits. temperature temperature management.
reading gauge reads (See Fault
Does gauge read when axle minimum Detection/
minimum when it is hot. when axle Management,
should obviously is hot. page 272)
be reading a higher
temperature.
software. Verify
gauge and
gauge inputs
are programmed
correctly.
"INTUNE" diagnostic "INTUNE" gauge sweep.
software. diagnostic Insure jumper
input. harness between
gauge and circuit
board is in correct
location. If jumper
is correct, replace
EGC circuit board.
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Table 85 Rear–Rear Axle Gauge Diagnostic Trouble Codes

612 14 32 1 Rear Axle Oil Temperature out of range low
Shorted to ground or open circuit.

612 14 32 2 Rear Axle Oil Temperature out of range high
Shorted high.
A short in the Rear—rear axle oil temperature sensor circuits will be apparent when the temperature gauge
points straight down. Transmission temperature sensor diagnostic trouble codes will also be present.
There is no DTC for this condition. A gauge with an open sensor circuit will always read minimum.
Problems in sensor circuits could be the result of open or shorted sensor, open circuits, shorted circuits
Refer to Rear–Rear Axle Temperature Sensor Circuits.
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Figure 136 Rear–Rear Axle Oil Temperature Sensor Circuits—Always Refer to Circuit Diagram Book
for Latest Circuit Information
LOCATED CHASSIS
(9812) REAR–REAR AXLE OIL TEMPERATURE
LOCATED ON REAR–REAR AXLE DIFFERENTIAL
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Table 86 Rear–Rear Axle Oil Temperature Gauge Diagnostic Trouble Codes

612 14 32 1 Rear Axle Oil Temperature out of range low

612 14 32 2 Rear Axle Oil Temperature out of range high
Shorted high.
Table 87 Rear–Rear Axle Oil Temperature Gauge Tests

Rear–Rear Axle Oil Temperature Gauge Voltage Checks
Check with ignition on and rear–rear axle oil temperature sensor (9812) disconnected.
(9812) cavity 1 to 10 ± 1 volts If voltage is missing, check for open or shorts in circuit
ground. R32, N32 or J32A to ESC connector (4004) cavity 1.

from ESC.
(9812) cavity 1 to 2. 10 ± 1 volts If voltage is missing, check for open in circuits R9X,
N9X, J9G or J9A to ESC connector (4004) cavity 26.

reference from ESC.
If voltage is present, circuits to temperature sensor are

good. Replace sensor.
The zero volt reference signal from the ESC is supplied from ESC connector (4004) terminal 26 to rear-rear
axle temperature sensor connector (9812) terminal 2.
10 volts from ESC connector (4004) terminal 1 is supplied to rear-rear axle temperature sensor connector
(9812) terminal 1. This voltage will drop across the sensor providing the ESC with temperature information.
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Component Locations
Figure 137 Axle Oil Temperature Sensor Location

(9812) REAR–REAR AXLE OIL TEMPERATURE SENSOR
4.43. FORWARD-REAR AXLE OIL TEMPERATURE GAUGE

Forward-Rear Axle Oil Temperature Gauge
Figure 138 Forward-Rear Axle Oil Temperature Gauge Function Diagram

1. FORWARD-REAR AXLE OIL TEMPERATURE SENSOR
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Information driving the forward-rear axle oil temperature gauge is provided on the Drivetrain 1939 data link
from the ESC. The ESC generates this information based on input from a sensor on the forward-rear axle.
Diagnostics
the gauge.
Problems with the forward-rear axle oil temperature gauge can be caused by a malfunctioning gauge, a
malfunction in EGC circuitry, an incorrect connection inside the EGC, a loss of programming, a problem in the
ESC, a problem with the forward-rear axle oil temperature sensor or a problem with wiring to the sensor.
Table 88 Forward-Rear Axle Oil Temperature Gauge Preliminary Check

POINTS SPEC.
1. Off/On Does the Gauge Go to next Replace gauge
forward-rear axle oil performs step. and check jumper
temperature gauge during gauge harness. If problem
operate during the sweep. persists, replace
gauge sweep? EGC circuit board.
Refer to Remove
and Install.
2. On Check for Read Forward—rear Go to fault Go to next step.
forward-rear axle display on axle oil detection
oil temperature odometer. temperature management.
gauge diagnostic gauge (See Fault
trouble codes. (See diagnostic Detection/
Diagnostic Trouble trouble Management,
Codes (DTC), page codes are page 278)
277) active.
3. On There are no DTC’s Observe Forward-rear Go to fault Go to next step.
for an open in sensor gauge axle oil detection
circuits. temperature temperature management.
reading gauge reads (See Fault
Does gauge read when axle minimum Detection/
minimum when it is hot. when axle Management,
should obviously is hot. page 278)
be reading a higher
temperature.
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Table 88 Forward-Rear Axle Oil Temperature Gauge Preliminary Check (cont.)

POINTS SPEC.
software. Verify
gauge and
gauge inputs
are programmed
correctly.
circuit board is in
jumper is correct,
replace EGC circuit
board.
Table 89 Forward-Rear Axle Gauge Diagnostic Trouble Codes

612 14 34 1 Forward-Rear Axle Oil Temperature out of range low

612 14 34 2 Forward-Rear Axle Oil Temperature out of range high
Shorted high.
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A short in the forward–rear oil temperature sensor circuits will be apparent when the temperature gauge points
straight down. Transmission temperature sensor diagnostic trouble codes will also be present.
There is no DTC for this condition. A gauge with an open sensor circuit will always read minimum.
Problems in sensor circuits could be the result of open or shorted sensor, open circuits, shorted circuits
Refer to Forward–Rear Axle Oil Temperature Sensor Circuits.
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Figure 139 Forward–Rear Axle Oil Temperature Sensor Circuits—Always Refer to Circuit Diagram
LOCATED CHASSIS
(9811) FORWARD–REAR AXLE OIL TEMPERATURE
LOCATED ON FORWARD–REAR AXLE DIFFERENTIAL
Table 90 Forward–Rear Axle Oil Temperature Gauge Diagnostic Trouble Codes

612 14 34 1 Forward–rear axle oil temperature sensor shorted to ground
612 14 34 2 Forward-Rear Axle Oil Temperature out of range high.
Shorted high.
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Table 91 Forward–Rear Axle Oil Temperature Gauge Tests

Forward–Rear Axle Oil Temperature Gauge Voltage Checks
Check with ignition on and forward–rear axle oil temperature sensor (9811) disconnected.
(9811) cavity 1 to ground. 10 ± 1 volts If voltage is missing, check for open or shorts
in circuit R32A, N32A or J32 to ESC connector
(4004) cavity 2.
If circuits check good, check for missing 10 volt

signal from ESC.
(9811) cavity 1 to 2. 10 ± 1 volts If voltage is missing, check for open in circuits
R9A, R9B, J9G, N9H, N9. J9G or J9A to ESC

reference from ESC.
If voltage is present, circuits to temperature sensor

are good. Replace sensor.
The zero volt reference signal from the ESC is supplied from ESC connector (4004) terminal 26 to forward-rear
axle oil temperature sensor connector (9811) terminal 2.
10 volts from ESC connector (4004) terminal 2 is supplied to forward-rear axle temperature sensor connector
(9811) terminal 1. This voltage will drop across the sensor providing the ESC with temperature information.
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Component Locations
Figure 140 Axle Oil Temperature Sensor Location

(9811) FORWARD-REAR AXLE OIL TEMPERATURE SENSOR
4.44. PRIMARY AIR PRESSURE GAUGE

Circuit Functions
Figure 141 Primary Air Pressure Gauge Function Diagram

1. PRIMARY AIR PRESSURE SENSOR
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Information driving the primary air pressure gauge is provided on the Drivetrain 1939 data link from the ESC.
The ESC generates this information based on input from a transducer connected to the air line.
Diagnostics
Problems with the primary air pressure gauge can be caused by a malfunctioning gauge, a malfunction in EGC
circuitry, an incorrect connection inside the EGC, a loss of programming, a problem in the ESC, a problem with
the air brake application transducer or a problem with wiring to the sensor.
Table 92 Primary Air Pressure Gauge Preliminary Check

POINTS SPEC.
1. Off/On Does the primary Gauge Go to next Replace gauge
air pressure gauge performs step. and check jumper
perform during the during gauge harness. If problem
gauge sweep? sweep. persists, replace
EGC circuit board.
Refer to Remove
and Install.
2. On Check for primary Read Primary air Go to fault Go to next step.
air pressure gauge display pressure detection
diagnostic trouble on gauge management.
codes. (See odometer. diagnostic (See Fault
Diagnostic Trouble trouble codes Detection/
Codes (DTC), page are active. Management,
283) page 284)
software. Verify
gauge and
gauge inputs
are programmed
correctly.
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Table 92 Primary Air Pressure Gauge Preliminary Check (cont.)

POINTS SPEC.
"INTUNE" diagnostic "INTUNE" gauge sweep.
software. diagnostic Insure jumper
input. harness between
gauge and circuit
board is in correct
location. If jumper
is correct, replace
EGC circuit board.
Table 93 Primary Air Pressure Gauge Diagnostic Trouble Codes

612 14 4 1 Primary air pressure out of range low
Short to ground, open circuit or missing 5 volts from ESC

612 14 4 2 Primary air pressure out of range high
Shorted high
1705 14 108 3 (EGC Version 8.7) EGC gauge location 8 (primary air pressure) out of range high
1705 14 108 4 (EGC Version 8.7) EGC gauge location 8 (primary air pressure) out of range low
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Table 93 Primary Air Pressure Gauge Diagnostic Trouble Codes (cont.)

1705 14 108 5 (EGC Version 8.7) EGC gauge location 8 (primary air pressure) sensor fault
this gauge.
1705 14 108 6 (EGC Version 8.7) EGC gauge location 8 (primary air pressure) data unavailable
at this time.
2023 14 108 5 or 2023 14 208 5 Primary air pressure gauge sensor fault to primary EGC (108)
this gauge.
2023 14 108 6 or 2023 14 208 6 Primary air pressure gauge data unavailable to primary EGC
at this time.
2023 14 108 7 or 2023 14 208 7 Primary air pressure gauge data missing to primary EGC (108)
the gauge.
Refer to Primary Air Pressure Transducer Circuits.
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Figure 142 Primary Air Pressure Transducer Circuits—Always Refer To Circuit Diagram Book For
(1600) ELECTRICAL SYSTEM CONTROLLER CONNECTOR
LOCATED IN DASH COMPARTMENT SIDE OF ESC
(1800) CAB/DCM CONNECTOR
LOCATED BEHIND CLUSTER
(1811) PRIMARY AIR PRESSURE TRANSDUCER CONNECTOR
LOCATED TO LEFT OF LOWER STEERING COLUMN
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Table 94 Primary Air Pressure Gauge Tests 286

612 14 4 1 Primary Air Pressure out of range low

612 14 4 2 Primary Air Pressure out of range high
Shorted to high.
1705 14 108 3 (EGC Version 8.7) EGC gauge location 8 (primary air pressure) out of range high
1705 14 108 4 (EGC Version 8.7) EGC gauge location 8 (primary air pressure) out of range low
1705 14 108 5 (EGC Version 8.7) EGC gauge location 8 (primary air pressure) sensor fault
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gauge.
1705 14 108 6 (EGC Version 8.7) EGC gauge location 8 (primary air pressure) data unavailable
at this time.
2023 14 108 5 or 2023 14 208 5 Primary air pressure gauge sensor fault to primary EGC (108) or
gauge.
2023 14 108 6 or 2023 14 208 6 Primary air pressure gauge data unavailable to primary EGC (108)
5 ELECTRONIC GAUGE CLUSTER AND AUXILIARY GAUGE SWITCH PACK
at this time.
Table 94 Primary Air Pressure Gauge Tests (cont.)
2023 14 108 7 or 2023 14 208 7 Primary air pressure gauge data missing to primary EGC (108)
Primary Air Pressure Gauge Voltage Checks
(1811) cavity B to 5 ± .5 volts If voltage is missing, check for open or shorts in circuit
ground. B6HB, B6H or A6H to ESC connector (1600) cavity 27.

from ESC.
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(1811) cavity B to 5 ± .5 volts If voltage is missing, check for open in circuits B9VC,
cavity A. B9V, A9V or A9H to ESC connector (1600) cavity 3.

reference from ESC.
(1811) cavity B to 5 ± .5 volts If voltage is incorrect, check for open or short to voltage
cavity C. in circuits B40, or A40 to ESC connector (1600) cavity 15.
If voltage is present, circuits to transducer are good.

Replace transducer
287
The 5 volt sensor supply signal is supplied to primary air pressure transducer connector (1811) pin B from
ESC connector (1600) pin 27.
The zero volt reference signal is supplied to air brake application transducer connector (1811) pin A from
The pressure transducer acts like a potentiometer. The transducer will provide a voltage to ESC connector
(1600) pin 15, which will vary with changes in applied pressure.
Component Locations
Figure 143 Primary Air Gauge Transducer Location (Steering Column Support View)
(1800) DRIVER CONTROL MODULE (DCM) CONNECTOR
(1811) PRIMARY AIR TRANSDUCER
(1812) SECONDARY AIR TRANSDUCER
(1822) AIR APPLICATION TRANSDUCER
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4.45. SECONDARY AIR PRESSURE GAUGE

Circuit Function
Figure 144 Secondary Air Pressure Gauge Function Diagram

1. SECONDARY AIR PRESSURE SENSOR
Information driving the secondary air pressure gauge is provided on the drivetrain 1939 data link from the ESC.
Diagnostics
Problems with the secondary air pressure gauge can be caused by a malfunctioning gauge, a malfunction
problem with the air brake application transducer or a problem with wiring to the sensor.
Table 95 Secondary Air Pressure Gauge Preliminary Check

POINTS SPEC.
1. Off/On Does the secondary Gauge Go to next Replace gauge
perform during the during gauge harness . If problem
gauge sweep? sweep. persists, replace
EGC circuit board.
Refer to Remove and
Install.
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Table 95 Secondary Air Pressure Gauge Preliminary Check (cont.)

POINTS SPEC.
2. On Check for secondary Read Secondary Go to fault Go to next step.
air pressure gauge display air pressure detection
290) page 291)
tool (EZ-Tech) to the and gauge step. gauge with the
diagnostic connector. inputs are “ICAP” software.
Turn key to accessory programmed Refer to the ICAP
position. Start the correctly. programming
"ICAP" programming software manual
software. Verify for details.
gauge and
gauge inputs
are programmed
correctly.
circuit board is in
jumper is correct,
replace EGC circuit
board.
5. Consider replacing ESC . (See ESC REPLACEMENT, page 123)
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Table 96 Secondary Air Pressure Gauge Diagnostic Trouble Codes

612 14 3 1 Secondary Air Pressure out of range low

612 14 3 2 Secondary Air Pressure out of range high
Shorted high
1705 14 110 3 (EGC Version 8.7) EGC gauge location 10 (secondary air pressure) out of range
high
For example: a value exceeding the gauge maximum scale
value.
1705 14 110 4 (EGC Version 8.7) EGC gauge location 10 (secondary air pressure) out of range low
1705 14 110 5 (EGC Version 8.7) EGC gauge location 10 (secondary air pressure) sensor fault
this gauge.
1705 14 110 6 (EGC Version 8.7) EGC gauge location 10 (secondary air pressure) data unavailable
at this time.
2023 14 110 5 or 2023 14 210 5 Secondary air pressure gauge sensor fault to primary EGC (110)
this gauge.
2023 14 110 6 or 2023 14 210 6 Secondary air pressure gauge data unavailable to primary EGC
at this time.
2023 14 110 7 or 2023 14 210 7 Secondary air pressure gauge data missing to primary EGC
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the gauge.
Refer to Secondary Air Pressure Transducer Circuits.
Figure 145 Secondary Air Pressure Transducer Circuits—Always Refer To Circuit Diagram Book
(1812) SECONDARY AIR PRESSURE TRANSDUCER CONNECTOR
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Table 97 Secondary Air Pressure Gauge Tests
612 14 3 1 Secondary Air Pressure out of range low

612 14 3 2 Secondary Air Pressure out of range high
Shorted to high
1705 14 110 3 (EGC Version 8.7) EGC gauge location 10 (secondary air pressure) out of range high
1705 14 110 4 (EGC Version 8.7) EGC gauge location 10 (secondary air pressure) out of range low
1705 14 110 5 (EGC Version 8.7) EGC gauge location 10 (secondary air pressure) sensor fault
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gauge.
1705 14 110 6 (EGC Version 8.7) EGC gauge location 10 (secondary air pressure) data unavailable
at this time.
2023 14 110 5 or 2023 14 210 5 Secondary air pressure gauge sensor fault to primary EGC (110)
gauge.
2023 14 110 6 or 2023 14 210 6 Secondary air pressure gauge data unavailable to primary EGC
at this time.
293
Table 97 Secondary Air Pressure Gauge Tests (cont.)
294

2023 14 110 7 or 2023 14 210 7 Secondary air pressure gauge data missing to primary EGC (110)
Secondary Air Pressure Gauge Voltage Checks
(1812) cavity B to ground. 5 ± .5 volts If voltage is missing, check for open or shorts in circuit
B6HA, B6H or A6H to ESC connector (1600) cavity 27.

from ESC.
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(1812) cavity B to cavity 5 ± .5 volts If voltage is missing, check for open in circuits B9VE,
A. B9V, A9V or A9H to ESC connector (1600) cavity 3.

reference from ESC.
(1812) cavity B to cavity 5 ± .5 volts If voltage is incorrect, check for open or short to voltage
C. in circuits B40A or A40A to ESC connector (1600) cavity
16.

Replace transducer
The 5 volt sensor supply signal is supplied to secondary air pressure transducer connector (1812) pin B from
The zero volt reference signal is supplied to air brake application transducer connector (1812) pin A from
The pressure transducer acts like a potentiometer. The transducer will provide a volage to ESC connector
Component Locations
Figure 146 Secondary Air Pressure Gauge Transducer Location (Steering Column Support View)
(1811) SECONDARY AIR PRESSURE TRANSDUCER
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4.46. AUXILIARY AIR PRESSURE GAUGE

Auxiliary Air Pressure Gauge
Figure 147 Auxiliary Air Pressure Gauge Function Diagram

1. AUXILIARY AIR PRESSURE SENSOR
Information driving the auxiliary air pressure gauge is provided on the Drivetrain 1939 data link from the ESC.
Diagnostics
Problems with the auxiliary air pressure gauge can be caused by a malfunctioning gauge, a malfunction in
EGC circuitry, an incorrect connection inside the EGC, a loss of programming, a problem in the ESC, a
problem with the auxiliary air pressure transducer or a problem with wiring to the sensor.
Table 98 Auxiliary Air Pressure Gauge Preliminary Check

POINTS SPEC.
1. Off/On Does the auxiliary Gauge Go to next Replace gauge
perform during the during gauge harness. If problem
gauge sweep? sweep. persists, replace EGC
circuit board. Refer to
Remove and Install.
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Table 98 Auxiliary Air Pressure Gauge Preliminary Check (cont.)

POINTS SPEC.
2. On Check for auxiliary Read Auxiliary air Go to fault Go to next step.
air pressure gauge display pressure detection
297) page 298)
tool (EZ-Tech) to and gauge step. with the “ICAP”
the diagnostic inputs are software. Refer to the
connector. Turn programmed ICAP programming
key to accessory correctly. software manual for
position. Start details.
the "ICAP"
programming
software. Verify
gauge and
gauge inputs
are programmed
correctly.
4. On Attempt to exercise Gauge Go to next Insure gauge operates
the gauge with responds to step. during gauge sweep.
the "INTUNE" "INTUNE" Insure jumper harness
diagnostic software. diagnostic between gauge and
jumper is correct,
replace EGC circuit
board.
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Table 99 Auxiliary Air Pressure Gauge Diagnostic Trouble Codes

612 14 4 1 Auxiliary Air Pressure out of range low

612 14 4 2 Auxiliary Air Pressure out of range high
Shorted high
1705 14 108 3 (EGC Version 8.7) EGC gauge location 8 (auxiliary air pressure) out of range high
Data for this gauge is above the value that the gauge can display. For
example: a value exceeding the gauge maximum scale value.
1705 14 108 4 (EGC Version 8.7) EGC gauge location 8 (auxiliary air pressure) out of range low
1705 14 108 5 (EGC Version 8.7) EGC gauge location 8 (auxiliary air pressure) sensor fault
gauge.
1705 14 108 6 (EGC Version 8.7) EGC gauge location 8 (auxiliary air pressure) data unavailable
this time.
2023 14 108 5 or 2023 14 208 5 Auxiliary air pressure gauge sensor fault to primary EGC (108) or
gauge.
2023 14 108 6 or 2023 14 208 6 Auxiliary air pressure gauge data unavailable to primary EGC (108)
this time.
2023 14 108 7 or 2023 14 208 7 Auxiliary air pressure gauge data missing to primary EGC (108) or
the gauge.
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Refer to Auxiliary Air Pressure Gauge Transducer Circuits.
Figure 148 Auxiliary Air Pressure Gauge Transducer Circuits—Always Refer To Circuit Diagram
Book For Latest Circuit Information
(4014) DASH PASS THRU CONNECTOR
LOCATED ABOVE ESC
(4301) FORWARD CHASSIS/DASH PASS CONNECTOR
(4820) J1708 & 5 VOLT REF SPLICE
LOCATED NEAR WIPER MOTOR BRACKET
(8505) AUXILIARY AIR TRANSDUCER CONNECTOR
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Table 100 Auxiliary Air Pressure Gauge Tests 300

612 14 4 1 Auxiliary Air Pressure out of range low

612 14 4 2 Auxiliary Air Pressure out of range high
Shorted to 12 volts.
1705 14 108 3 (EGC Version 8.7) EGC gauge location 8 (auxiliary air pressure) out of range high
1705 14 108 4 (EGC Version 8.7) EGC gauge location 8 (auxiliary air pressure) out of range low
1705 14 108 5 (EGC Version 8.7) EGC gauge location 8 (auxiliary air pressure) sensor fault
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gauge.
1705 14 108 6 (EGC Version 8.7) EGC gauge location 8 (auxiliary air pressure) data unavailable
at this time.
2023 14 108 5 or 2023 14 208 5 Auxiliary air pressure gauge sensor fault to primary EGC (108) or
gauge.
2023 14 108 6 or 2023 14 208 6 Auxiliary air pressure gauge data unavailable to primary EGC (108)
at this time.
Table 100 Auxiliary Air Pressure Gauge Tests (cont.)
2023 14 108 7 or 2023 14 208 7 Auxiliary air pressure gauge data missing to primary EGC (108) or
Auxiliary Air Pressure Gauge Voltage Checks
(8505) cavity B to 5 ± .5 volts If voltage is missing, check for open or shorts in circuit M6A,
ground. J6BA or J6A to ESC connector (4004) cavity 27.
If circuits check good, check for missing 5 volt signal from

ESC.
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(8505) cavity B to 5 ± .5 volts If voltage is missing, check for open in circuits M9A, J9EA
cavity A. or J9A to ESC connector (4004) cavity 26.
If circuits check good, check for missing zero volt reference

from ESC.
(8505) cavity B to 5 ± .5 volts If voltage is incorrect, check for open or short to voltage
cavity C. in circuits B40F, A40F or J40F to ESC connector (1600)
cavity 15.

Replace transducer
301
The 5 volt sensor supply signal is supplied to auxiliary air pressure transducer connector (8505) pin B from
The zero volt reference signal is supplied to auxiliary air pressure transducer connector (8505) pin A from
The pressure transducer acts like a potentiometer. The transducer will provide a volage to ESC connector
Component Locations
Figure 149 Auxiliary Air Pressure Gauge Transducer Location

1. AIR PRESSURE TRANSDUCER
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4.47. BOOST PRESSURE GAUGE

Circuit Function
Figure 150 Boost Pressure Gauge Function Diagram

1. BOOST PRESSURE SENSOR
Information driving the boost pressure gauge is provided on the Drivetrain 1939 data link from the ESC. The
ESC generates this information based on input from a sensor connected to the turbo charger.
Diagnostics
the gauge.
Problems with the turbo boost pressure gauge can be caused by a malfunctioning gauge, a malfunction in
EGC circuitry, an incorrect connection inside the EGC, a loss of programming, a problem in the ESC, a
problem with the boost sensor or a problem with wiring to the sensor.
S082504
Table 101 Boost Pressure Gauge Preliminary Check

POINTS SPEC.
1. Off/On Does the turbo Gauge Go to next Replace gauge
boost gauge operate performs step. and check jumper
during the gauge during gauge harness . If problem
sweep? sweep. persists, replace
EGC circuit board.
Refer toRemove and
Install.
software. Verify
gauge and
gauge inputs
are programmed
correctly.
circuit board is in
jumper is correct,
replace EGC circuit
board.
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4.48. AMMETER GAUGE

Circuit Function
Figure 151 Ammeter Gauge Diagram

1. AMMETER SENSE CIRCUITS
2. PYROMETER/AMMETER MODULE (PAM)
5. AUXILIARY GAUGE SWITCH PACK (AGSP)
Information driving the ammeter gauge is provided on the Drivetrain 1939 data link from the pyrometer/ammeter
module (PAM). The PAM determines the net battery current flow by measuring the differential voltage between
the starter ground stud and the negative battery stud.
Either of two ammeter gauges are available. The ranges are, -150/+150 amps and -300/+300 amps (high
resolution).
Diagnostics
gauge. A gauge pointing to 10 o’clock is connected to an unprogrammed connector on the Electronic Gauge
Cluster (EGC) circuit board, or the Auxiliary Gauge Switch Pack (AGSP).
The service tool (EZ-Tech) running the Diamond Logic® Builder (DLB) diagnostic software, can be used to
check operation of the gauge. See the diagnostic software manual for details on using the software.
Problems with the ammeter gauge can be caused by a malfunctioning gauge, a malfunction in EGC (or
AGSP) circuitry, an incorrect connection inside the EGC (or AGSP), a loss of programming, a problem in the
PAM or a problem with wiring to and from the PAM.
S082504
Table 102 Ammeter Gauge Preliminary Check

POINTS SPEC.
1. Off/On Does the ammeter Gauge Go to next Replace gauge and
gauge operate performs step. check jumper harness.
during the gauge during If problem persists,
sweep? gauge replace EGC (or
sweep. AGSP) circuit board.
Refer to Remove and
Install.
2. On Check for Read Ammeter Go to fault Go to next step.
Diagnostic Trouble display on gauge detection
Codes (DTC’s) odometer. diagnostic management.
related to the PAM, trouble (See Fault
the ammeter, or the codes are Detection/
gauge location in active. Management,
the gauge cluster. page 307)
Refer to DTC list

(See DIAGNOSTIC
TROUBLE CODE
(DTC) LIST, page
1039).
tool (EZ-Tech) to and gauge step. with the DLB software.
the diagnostic inputs are Refer to the DLB
connector. Turn programmed programming software
key to accessory correctly. manual for details.
position. Start the
DLB programming
software. Verify
gauge and
gauge inputs
are programmed
correctly.
4. On Attempt to exercise Gauge Go to next Insure gauge operates
the gauge with the responds step. during gauge sweep.
DLB diagnostic to DLB Insure jumper harness
software. diagnostic between gauge and
jumper is correct,
replace EGC (or
AGSP) circuit board.
5. Troubleshoot pyrometer/ammeter module and sensor inputs. Pyrometer/ Ammeter Module
(PAM)(See PYROMETER/AMMETER MODULE (PAM), page 804)
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Because the location of the ammeter is optional, some of the DTC’s that may be related to the ammeter are
described in the DTC list(See DIAGNOSTIC TROUBLE CODE (DTC) LIST, page 1039) by “gauge location”.
Table 103 Ammeter Gauge Diagnostic Trouble Codes

Refer to DTC list (See DIAGNOSTIC TROUBLE CODE (DTC) LIST, page 1039).
A short in the ammeter gauge circuits will be apparent when the ammeter gauge points straight down.
Problems in the ammeter circuits could be the result of an open or shorted gauge, open circuits, shorted
circuits, a failure in the ESC, a problem in the PAM or a problem with wiring to and from the PAM.
Refer to the Pyrometer/Ammeter Module Circuits (See PYROMETER/AMMETER MODULE (PAM), page 804).
Figure 152 Unused Figure
Table 104 Unused Table

This table is no longer used and was intentionally left blank.
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4.49. FUEL PRESSURE GAUGE

Circuit Function
Figure 153 Fuel Pressure Gauge Function Diagram

1. FUEL PRESSURE SENSOR
Information driving the fuel pressure gauge is provided on the Drivetrain 1939 data link from the ESC. The
ESC generates this information based on input from a sensor connected to the fuel system.
Diagnostics
Problems with the fuel pressure gauge can be caused by a malfunctioning gauge, a malfunction in EGC
circuitry, an incorrect connection inside the EGC, a loss of programming, a problem in the ESC, a problem
with the fuel pressure sensor or a problem with wiring to the sensor.
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Table 105 Fuel Pressure Gauge Preliminary Check

SPEC.
1. Off/On Connect diagnostic tool Gauge and Go to next Program the gauge with
(EZ-Tech) to the diagnostic gauge inputs step. the “ICAP” software.
connector. Turn key to are programmed Refer to the ICAP
accessory position. Start correctly. programming software
the "ICAP" programming manual for details.
2. On Attempt to exercise the Gauge responds Go to next Insure gauge operates
gauge with the "INTUNE" to "INTUNE" step. during gauge sweep.
diagnostic software. diagnostic input. Insure jumper harness
between gauge and
circuit board is in correct
location. If jumper is
correct, replace EGC
circuit board.
3. On Attempt to exercise the Gauge responds Consider Replace EGC.
gauge with the "INTUNE" to ESC replacing
diagnostic software. diagnostic input. ESC.(See
ESC
REPLACEMENT,
page 123)
the gauge.
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4.50. SUSPENSION AIR GAUGE

Circuit Function
Figure 154 Suspension Air Gauge Function Diagram

1. SUSPENSION AIR SENSOR
Information driving the suspension air gauge is provided on the Drivetrain 1939 data link from the ESC. The
ESC generates this information based on input from a sensor connected to the air suspension system.
Diagnostics
Problems with the air suspension gauge can be caused by a malfunctioning gauge, a malfunction in EGC
the suspension air transducer or a problem with wiring to the transducer.
Table 106 Air Suspension Gauge Preliminary Check

POINTS SPEC.
1. Off/On Does the air Gauge Go to next Replace gauge and
suspension gauge performs step. check jumper harness
perform during the during . If problem persists,
gauge sweep? gauge replace EGC circuit
sweep. board. Refer to
Remove and Install.
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Table 106 Air Suspension Gauge Preliminary Check (cont.)

POINTS SPEC.
2. On Check for air Read Suspension Go to fault Go to next step.
suspension gauge display on gauge detection
diagnostic trouble odometer. diagnostic management.
codes. (See trouble (See Fault
Diagnostic Trouble codes are Detection/
Codes (DTC), page active. Management,
311) page 312)
tool (EZ-Tech) to the and gauge step. with the “ICAP”
diagnostic connector. inputs are software. Refer to the
Turn key to accessory programmed ICAP programming
position. Start the correctly. software manual for
"ICAP" programming details.
software. Verify
gauge and
gauge inputs
are programmed
correctly.
circuit board is in
jumper is correct,
replace EGC circuit
board.
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Table 107 Air Suspension Gauge Diagnostic Trouble Codes

TBD Air Suspension Gauge out of range low

TBD Air Suspension Gauge out of range high
Shorted high
the gauge.
Refer to Air Suspension Solenoid Circuits in the Chassis Features section.
4.51. AIR APPLICATION GAUGE

Circuit Function
Figure 155 Air Application Gauge Function Diagram

1. AIR APPLICATION TRANSDUCER
Information driving the air application gauge is provided on the Drivetrain 1939 data link from the ESC. The
ESC generates this information based on input from a transducer connected to the air application system.
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Diagnostics
Problems with the air application gauge can be caused by a malfunctioning gauge, a malfunction in EGC
the air brake application transducer or a problem with wiring to the sensor.
Table 108 Air Application Gauge Preliminary Check

POINTS
1. Off/On Does the air Gauge Go to next step. Replace gauge
application gauge performs and check jumper
perform during the during harness. If problem
gauge sweep? gauge persists, replace
sweep. EGC circuit board.
Refer to Remove and
Install.
2. On Check for air Read Air Go to fault Go to next step.
application gauge display on application detection
diagnostic trouble odometer. gauge management.
codes. (See diagnostic (See Fault
Diagnostic Trouble trouble Detection/
Codes (DTC), page codes are Management,
314) active. page 314)
3. Off/On Connect diagnostic Gauge Go to next step. Program the gauge
tool (EZ-Tech) to and gauge with the “ICAP”
the diagnostic inputs are software. Refer to the
connector. Turn programmed ICAP programming
key to accessory correctly. software manual for
position. Start details.
the "ICAP"
programming
software. Verify
gauge and
gauge inputs
are programmed
correctly.
4. On Attempt to exercise Gauge Go to next step. Insure gauge
the gauge with responds to operates during
the "INTUNE" "INTUNE" gauge sweep. Insure
diagnostic diagnostic jumper harness
software. input. between gauge and
circuit board is in
jumper is correct,
replace EGC circuit
board.
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Table 109 Air Application Gauge Diagnostic Trouble Codes

612 14 35 1 Brake application air out of range low
Short to ground or open circuit.

612 14 35 2 Brake application air out of range high
Shorted high
the gauge.
Refer to Air Application Gauge Transducer Circuits.
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Figure 156 Air Application Gauge Transducer Circuits—Always Refer To Circuit Diagram Book For
(1822) AIR APPLICATION GAUGE TRANSDUCER CONNECTOR
LOCATED IN CAB SIDE OF ESC
(4014) DASH PASS THRU CONNECTOR
LOCATED ABOVE ESC
Table 110 Air Application Gauge Tests

612 14 35 1 Brake application air out of range low
Short to ground or open circuit.

612 14 35 2 Brake application air out of range high
Shorted high.
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Table 110 Air Application Gauge Tests (cont.)

Air Application Gauge Voltage Checks
(1822) cavity B to ground. 5 ± .5 volts If voltage is missing, check for open or shorts in circuit
B6HC, B6H or A6H to ESC connector (1600) cavity 27.

from ESC.
(1822) cavity B to cavity 5 ± .5 volts If voltage is missing, check for open in circuits B9VF,
A. B9V, A9V or A9H to ESC connector (1600) cavity 3.

reference from ESC.
(1822) cavity B to cavity 5 ± .5 volts If voltage is incorrect, check for open or short to
C. voltage in circuits B40F, A40F or J40F to ESC
If voltage is present, circuits to transducer are

good. Replace transducer
The 5 volt sensor supply signal is supplied to air application transducer connector (1822) pin B from ESC
connector (1600) pin 27.
The zero volt reference signal is supplied to air application transducer connector (1822) pin A from ESC
connector (1600) pin 3.
The pressure transducer acts like a potentiometer. The transducer will provide a voltage to ESC connector
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Component Locations
Figure 157 Air Application Gauge Transducer Location (Steering Column Support View)
(1811) PRIMARY AIR TRANSDUCER
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4.52. AUDIBLE ALARM

Circuit Function
Figure 158 Audible Alarm Function Diagram

The audible alarm is controlled by the EGC.
The EGC will activate the alarm based on the data communicated on the Drivetrain 1939 data link from the
ESC and the engine controller.
Diagnostics
An inoperative alarm can be caused by a malfunctioning alarm or a malfunction in EGC circuitry.
Table 111 Audible Alarm Preliminary Check

SPEC.
1. On Test alarm by disconnecting Alarm Alarm is Replace the alarm.
fuel sender connector. operates. working. If problem persists,
replace circuit board.
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4.53. SELECT/RESET SWITCH

Circuit Function
Figure 159 Select/Reset Switch Function Diagram

1. SELECT/RESET SWITCH
The Select/Reset switch controls the digital display.
The switch allows the user to select modes within each major functional area of the display and perform reset
functions. Each time the switch is momentarily depressed it will scan through a different mode. Depressing the
switch for three seconds or more will clear the display or toggle between options depending upon the current
mode. The reset function has no effect if the parameter cannot be reset.
Diagnostics
Problems with the Select/Reset switch can be caused by a faulty switch, loose connection between the
switch and the circuit board, or a faulty circuit board.
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Table 112 Select/Reset Switch Preliminary Check

SPEC.
1. On Verify operation of the Display changes Switch is Go to next step.
switch by observing when button is working
odometer display while pushed. correctly.
pushing button.
2. Off Remove the Select/Reset Switch contacts Replace Replace the
switch and test with an should close while circuit board. Select/Reset switch.
ohmmeter. switch is pushed.
A fault with Select/Reset switch operation will be apparent if the odometer display does not change when the
button is pushed.
Check continuity through switch while button it is pressed.
If continuity is good replace circuit board
If there is no continuity, replace switch.
4.54. HEAD LAMP/PARK LAMP SWITCH

See Headlight System in the Light Section of this manual. (See HEADLIGHT SYSTEM, page 872)
4.55. PANEL LIGHT SWITCH

See Panel Light in the Light Section of this manual. (See PANEL LIGHTS, page 889)
4.56. WORK LIGHT SWITCH

See Work Light in the Light Section of this manual. (See WORK LIGHTS, page 932)
4.57. DIGITAL DISPLAY

Circuit Function
The EGC has an integral liquid crystal display (LCD).
The three lines of the digital display provide a PRNDL display, a numeric display, and a line to indicate the
mode of the display.
Diagnostics
Problems with the digital display can be caused by loose connections between the display and the circuit
board, a failed display or a failed EGC circuit board.
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Table 113 Digital Display Preliminary Check

1. Off/On During the gauge sweep Display elements Digital display Replace LCD display.
all LCD elements of are active and is working.
the display should backlights work If problems
be activated and the during gauge continue,
backlighting should sweep. replace EGC
illuminate. circuit board.
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5. REMOVE AND INSTALL
Figure 160 EGC Exploded View

1. GAUGE CLUSTER BEZEL
2. GAUGE CLUSTER SHIELD
3. 3-SWITCH PACK
4. ETHER START SWITCH
5. GAUGE CLUSTER HOUSING
6. BUZZER LOCATION
7. WARNING LAMP LENS
8. OPTIONAL SMALL GAUGES
9. LCD DISPLAY
10 . STANDARD SMALL GAUGES
11. GAUGE CLUSTER CIRCUIT BOARD
12. GAUGE CLUSTER BACK PLATE
13. OPTIONAL (HARD WIRED) GAUGE CIRCUIT BOARD
14. STANDARD SMALL GAUGES
15. OPTIONAL SMALL GAUGES
16. OPTIONAL WARNING LAMP LENS
17. SET/RESET SWITCH LOCATION
18. ROCKER START SWITCH
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5.1. EGC FRONT BEZEL

Refer to EGC Exploded View. (See Figure 160, page 322)
Bezel removal is not required to remove or replace any other EGC components. Removal should only be
required to replace a damaged bezel.
The bezel can be removed by cutting the seven retaining clips off with a razor blade, being careful not to
scratch the gauge cluster housing. Installation of the bezel is accomplished by inserting the new bezel clips
into the notches on the housing.
The front bezel snaps to the EGC body. To remove the bezel, remove the EGC shroud from the instrument
panel. The bezel can be removed by gently pressing the seven clips on the bezel outer housing.
Installation of the bezel is accomplished by reversing the removal process.
5.2. REMOVE ELECTRONIC GAUGE CLUSTER

A. Remove EGC shroud from instrument panel.

B. Remove four screws which hold the EGC in place.
C. Tilt the EGC forward to gain access to the back of the EGC.
D. Remove the 12–way connector from the center of the EGC.
E. Remove any additional connectors from the EGC.
Installation of the gauge cluster is the reverse of the removal procedure.
5.3. FUEL, VOLTS, WATER OR ENGINE OIL GAUGES

The Fuel, Volts, Water and Engine Oil Gauges may be integral components of the EGC circuit board. If they
are not separate gauges they can be removed and replaced by scoring the perforated line between the gauges
and the main circuit board and snapping the circuit board. The replacement gauge is fastened to the EGC
body with two screws and connected to the main circuit board with the supplied cable with connectors.
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Figure 161 Typical EGC Circuit Board Gauge Connector Location

1. FUEL GAUGE CONNECTOR LOCATION
2. TOP OUTSIDE GAUGE LOCATION
3. TOP OUTSIDE GAUGE LOCATION
4. WATER TEMPERATURE GAUGE CONNECTOR LOCATION
5. OIL PRESSURE GAUGE CONNECTOR LOCATION
6. BOTTOM OUTSIDE GAUGE LOCATION
7. BOTTOM OUTSIDE GAUGE LOCATION
8. VOLTAGE GAUGE CONNECTOR LOCATION
The speedometer and tachometer cannot be individually replaced. If the speedometer or tachometer fail, the
entire circuit board must be replaced.
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5.4. OPTIONAL GAUGES

Refer to Typical EGC Circuit Board Gauge Connector Location (See Figure 161, page 324)
Optional Gauges
A. Remove the EGC from the instrument panel.

B. Remove six screws holding the back cover of the EGC in place.
C. Disconnect connectors for the optional gauge.
D. Remove two screws holding the gauge to EGC body and remove the gauge.
Installation of the optional gauge is accomplished by reversing the removal procedure.
NOTE – When adding a gauge that was not previously installed in the cluster, the electrical system
controller must be programmed to recognize the gauge before the gauge will function. Refer to the
ICAP programming software manual for details
5.5. CIRCUIT BOARD

A. Remove six screws holding the back of the EGC in place.

B. Disconnect all connectors connected to the circuit board.
C. Remove six screws holding circuit board to EGC body.
Installation of the circuit board is accomplished by reversing the removal procedure.
NOTE – The replacement circuit board will not have any of the standard smaller gauges attached to it.
It may be necessary to replace the smaller gauges when the circuit board is replaced.
5.6. LCD DISPLAY


B. Remove the center circuit board.
C. Remove four screws holding LCD to the EGC body and remove the display.
5.7. SELECT/RESET SWITCH


B. Remove the connector for the switch from the center circuit board.
C. Remove two screws holding the switch and remove the switch.
To install the switch, reverse the removal procedure.
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5.8. AUDIBLE ALARM


B. Remove the connector for the audible alarm from the center circuit board.
C. Remove two screws holding the audible alarm and remove the alarm.
5.9. EGC PANEL LAMPS AND GAUGE BACKLIGHTING LAMPS

The EGC panel lamps are twist in lamps. To replace the lamps the failed lamp must be removed and replaced
with a good lamp.

B. Remove six screws holding the back of the EGC in place and remove the back cover.
C. Locate the failed lamp and remove it by twisting it out of the circuit board.
D. Replace the removed lamp with a good twist in indicator lamp.
5.10. EGC WARNING LAMPS AND GAUGE WARNING LAMPS

The EGC warning lamps and warning lamps are integral parts of the EGC circuit board. To replace the lamps
the failed lamp must be cut out of the circuit board and a twist in lamp must be used to replace it.

B. Remove six screws holding the back of the EGC in place and remove the back cover.
C. Locate the failed lamp and cut it out of the circuit board.
D. Replace the removed lamp with a twist in indicator lamp.
5.11. EGC SWITCH PACK

After the instrument panel shroud around the EGC has been removed, The EGC switch pack can be removed
by using two DIN removal tools on each side of the switch pack. After the unit is removed from the cluster the
connector on the switch pack may be removed. Removal may be easier if the back cover of the switch pack is
removed. The back cover is removed by prying it off.
The switch pack is installed by simply reversing the removal process.
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5.12. EGC SWITCH PACK SWITCHES

Switches are removed through the front of the switch pack. To remove a switch:
A. Remove the back cover from the switch pack.

B. Squeeze the switch release tabs, behind the switch pack.
C. Push the switch out of the switch pack body.
To install a switch reverse the removal process.
5.13. EGC SWITCH PACK LAMPS

EGC switch pack lamps are accessed by removing the switch pack and the back cover of the switch pack. The
lamps that are replaceable are removed by twisting the lamp and pulling it out. The backlight lamps for the
headlight and dimmer switches are not replaceable. If these LED’s fail, the switch pack will need to be replaced.
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SERVICE MANUAL

TRUCK SERVICE MANUAL

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 3200, 4100, 4200,

2. VEHICLE ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3. ELECTRICAL CIRCUIT DIAGRAM BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5. ELECTRICAL TEST EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

6. BENCH TESTING RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

7. CIRCUIT BREAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

2. VEHICLE ELECTRICAL SYSTEM OVERVIEW

3. ELECTRICAL CIRCUIT DIAGRAM BOOK

3.1. CIRCUIT DIAGRAMS

Figure 1 Sample Circuit Diagram

Circuit Diagram Instructions

Figure 2 Sample Circuit Diagram Instructions

Figure 3 Sample Circuit Diagram Instructions and Abbreviations

Figure 4 Sample Schematic Symbol Chart

3.2. COMPONENT ILLUSTRATIONS

Figure 5 Sample Component Location Illustration

3.3. CONNECTOR BODY COMPOSITE

Figure 6 Sample Pin Configuration

4.1. VERIFY THE PROBLEM

1. Check the accuracy and completeness of the complaint.

3. Analyze what parts of the system are working.

4.2. IMPORTANT STEPS BEFORE TESTING

3. Check for and record any logged diagnostic trouble codes.

7. Perform the following preliminary steps:

4.3. READ "EXTENDED DESCRIPTION"

4.4. CHECK THE CIRCUIT DIAGRAM

4.5. CHECK FOR CAUSE OF THE PROBLEM

4.6. MAKE THE REPAIR

4.7. VERIFY THE REPAIR IS COMPLETE

5. ELECTRICAL TEST EQUIPMENT

5.2. ESC BREAKOUT BOX (ZTSE4477)

Figure 7 ESC Breakout Box

5.3. FLUKE 88 DIGITAL MULTIMETER (DMM)

Figure 8 Digital and Analog Meters

5.4. JUMPER WIRES AND TEST LEADS

Jumper wires allow "jumping" across a suspected open or break in a circuit.

Figure 9 Jumpers in Circuits

5.5. OHMS LAW REVIEW

Table 1 Ohms Law

Table 1 Ohms Law (cont.)

Figure 10 Typical Circuit

To find the current flow use the formula:

Filling in the numbers for the circuit in Figure 11 , we have:

I = 12V/2 ohms or I= 12 divided by 2 = 6 amperes of current flow.

In electrical diagnosis, the voltmeter is used to answer:

2. What is the voltage reading?

3. What is the voltage drop across a load device?

Figure 11 Voltmeter Lead Connections Diagram

Figure 12 Connecting the Meter in Series Diagram

Figure 13 Checking Voltage Drop Across a Load Device Diagram

Figure 14 Measuring Current Flow Diagram

Resistance measurements determine:

4. Operation of variable resistors.

Figure 15 Measuring Resistance Diagram

Figure 16 Placing Ohmmeter Leads Across a Component or Circuit Diagram

Checking For Open Circuits

Figure 17 Checking For Open Circuits