Fault Code Guide

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IMPORTANT: Always use ServiceLink when at-

tempting to diagnose problems with the AGS

(Automated Gear Shift) transmission.

How To Start

To gain a baseline for troubleshooting when there is

no deﬁnite problem, when the malfunction is erratic

or intermittent, or to determine the general health of

the electrical system, start with the electrical pre-test

in Subject 301.

In a few cases there will be a deﬁnite problem and

no J1587 fault code will be sent (engine will not

crank, no information on gear display, ﬂuid level

fault). For these problems, see the appropriate table

in Subject 301.

But in most cases, the J1587 fault code is the start-

ing point for the troubleshooting procedures. See

Table 1 to ﬁnd information for SID fault codes. See

Table 2 to ﬁnd information for PID fault codes.

Before starting any procedures, use ServiceLink to

depressurize the AGS hydraulic system. For detailed

procedures, see Subject 160.

Fault Code Guide

To troubleshoot a given fault code, look up the sub-

ject number in Table 1 (for SIDs) and Table 2 (for

PIDs). Follow the procedures for that fault code until

the fault is corrected.

Fault Code Guide (MID 130 SIDs)

SID FMI Text Message Failure Reason Procedure

18 02 Prim Selector Erratic The shift lever does not shift gears. See Subject 302.

33 03 MultiPress Ind Short Hi The hydraulic pressure sensor circuit is shorted to power. See Subject 303.

33 04 MultiPress Ind Short Lo The hydraulic pressure sensor circuit is shorted to ground. See Subject 303.

33 05 MultiPress Ind OPEN The hydraulic pressure sensor circuit is open. See Subject 303.

52 05 Hydraulic Sys OPEN The hydraulic pump circuit is open. See Subject 304.

52 07 Hydraulic Sys NoRESPONSE

The hydraulic pressure does not increase even though the

hydraulic pump is activated.

See Subject 304.

52 11 Clutch Act Not Known The hydraulic pump temperature is too high. See Subject 304.

55 00 Clutch Act HIGH The clutch is too hot. See Subject 305.

55 07 Clutch Act NoRESPONSE The clutch does not operate properly. See Subject 305.

55 13 Clutch Act Calibrate The clutch needs to be calibrated. See Subject 305.

231 02 SAE J1939 Datalink Erratic The J1939 datalink is not communicating properly. See Subject 306.

231 09 SAE J1939 Datalink UPDATE The J1939 datalink has timed out. See Subject 306.

231 12 SAE J1939 Datalink Bad

The J1939 datalink is not communicating with the

transmission.

See Subject 306.

251 00 POWER SUPPLY HIGH The power supply voltage is too high. See Subject 307.

251 01 POWER SUPPLY Low The power supply voltage is too low. See Subject 307.

251 05 POWER SUPPLY OPEN

There is no power to the transmission with the engine

running.

See Subject 307.

251 14 POWER SUPPLY RSRVD The power supply is not properly grounded. See Subject 307.

253 02 Calibration Memory Erratic The transmission needs to be recalibrated. See Subject 308.

253 12 Calibration Memory Bad The transmission needs to be recalibrated. See Subject 308.

253 13 Calibration Memory Calibrate The transmission needs to be recalibrated. See Subject 308.

253 14 Calibration Memory RSRVD The transmission needs to be recalibrated. See Subject 308.

Freightliner AMT

and Mercedes-Benz Automated-Manual

Transmissions

26.03

General Troubleshooting

Business Class M2 Workshop Manual, Supplement 20, September 2011 300/1

Summary of content (163 pages)

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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 General Troubleshooting IMPORTANT: Always use ServiceLink when attempting to diagnose problems with the AGS (Automated Gear Shift) transmission. But in most cases, the J1587 fault code is the starting point for the troubleshooting procedures. See Table 1 to find information for SID fault codes. See Table 2 to find information for PID fault codes.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 General Troubleshooting Fault Code Guide (MID 130 SIDs) SID FMI 254 04 Controller Short Lo Text Message The TCU is shorted to ground. Failure Reason See Subject 309. Procedure 254 05 Controller OPEN The TCU has an open circuit. See Subject 309. 254 11 Controller Not Known The TCU AUTO mode software module has an error. See Subject 309. 254 12 Controller Bad The TCU has a hardware problem. See Subject 309.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 General Troubleshooting Fault Code Guide (MID 130 PIDs) PID FMI Text Message Failure Reason Procedure 162 02 RANGE Selected Erratic The transmission is not properly calibrated. See Subject 316. 163 02 RANGE Attained Erratic The gears do not shift properly. See Subject 316. 191 02 OUTPUT SPEED Erratic One or both of the output shaft speed sensor circuits give invalid data. See Subject 317.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 Troubleshooting Without Fault Codes IMPORTANT: Always use ServiceLink when attempting to diagnose problems with the automated gear shift (AGS) transmission. Use the electrical pre-test instructions given in Table 1 as a baseline for troubleshooting when there is no definite problem, the malfunction is erratic or intermittent, or as an informational step to determine the general health of the electrical system.
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26.03 Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions Troubleshooting Without Fault Codes Electrical Pre-Test Procedure Check for resistance between pin 2 (ground) of the X3 connector and the battery ground terminal. Result Action Resistance is greater than 0.3 ohms. Repair or replace the wiring as needed. See Section 54.06, Subject 100. Resistance is 0.3 ohms or less. Go to the next row in the table.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 Troubleshooting Without Fault Codes Electrical Pre-Test Procedure Result Action Turn off the ignition switch. Check the ignition ground circuit. 9 6 3 20 17 14 11 8 5 2 19 16 13 10 7 4 1 21 18 15 12 X1 07/21/2004 With the ignition switch off, check for resistance between pins 18 and 21 (ground) of the X1 connector and the battery ground terminal. f544483d Resistance is greater than 0.3 ohms.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 Troubleshooting Without Fault Codes Electrical Pre-Test Procedure With the ignition switch off, remove the X1 connector from the TCU and check for resistance between pins 7 and 13 (J1939 datalink). Result Action Resistance is less than 55 or greater than 65 ohms. Troubleshoot the J1939 datalink. See Freightliner Service Bulletin 54-133. Resistance is between 55 and 65 ohms. The vehicle has passed the electrical pre-test.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 Transmission Range Faults (PID 162 and 163) Transmission Range Faults Transmission Range-Selected Faults (PID 162) There is one transmission range-selected fault covered in these procedures. Transmission Range-Attained Faults (PID 163) There is one transmission range-attained fault covered in these procedures. • For PID 163, FMI 02, see Table 2 for procedures. • For PID 162, FMI 02, see Table 1 for procedures.
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26.03 Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions Transmission Range Faults (PID 162 and 163) PID 163, FMI 02—The Gears Do Not Shift Properly Failure Reason: • There is a defect in the TCU. • There is a defect in the speed sensor. • There is a defect in the actuator. • The transmission software is not properly programmed. • The datalink does not recognize the transmission type. Problem Procedure There are other active transmission faults. Check for other MID 130 fault codes.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 Output Shaft Speed Sensor Faults (PID 191) • For PID 191, FMI 02, 05, and 08 see Table 1 for procedures and pin identification. Output Shaft Speed Sensor Faults (PID 191) • For PID 191, FMI 14, see Table 2 for procedures. There are four output shaft speed sensor faults covered in these procedures. One troubleshooting procedure is used to correct FMI 02, 05, and 08. A separate procedure is used for FMI 14.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 Output Shaft Speed Sensor Faults (PID 191) PID 191, FMI 02, 05, 08—The Output Shaft Speed Sensor Circuit Gives Invalid Data, Is Open, or Not Broadcasting a Signal Failure Reason: • The TCU has a hardware problem. • The sensor is mounted too loose (air gap too big). • The sensor connectors are dam- 1 4 7 10 13 2 5 8 11 14 3 6 9 12 15 aged or bent. • The wiring harness has had an electrical failure.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 Output Shaft Speed Sensor Faults (PID 191) PID 191, FMI 14—The Output Shaft Speed Sensor Is Providing Invalid Data Failure Reason • The antilock brake system (ABS) is not broadcasting wheel speed data. • There is a defective output shaft speed sensor. Procedure Check for active fault codes in MID 136 (ABS). Result Action Active MID 136 fault codes are found. Troubleshoot the ABS system (see the applicable section in Group 42).
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 Specifications For a schematic of the AGS transmission wiring behind the X2 (transmission) connector, see Fig. 1. For a schematic of the AGS transmission wiring behind the X1 (main vehicle) and X3 (electric motor) connectors, see drawing G06-49466. Input Shaft Speed Sensor Output Shaft Speed Sensor (9:00 position) 3 2 1 13 11 For a list of special tools, see Table 1.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.03 Specifications Special Tools for AGS Transmission Tool Description Manufacturer Part Number High-Pressure Line Disconnect Tool Kent-Moore J-47201 Shift Finger Alignment Fork Kent-Moore J-47204 Shift Mechanism End Guide Kent-Moore J-47203 f580379 f580380 f580382 Table 1, Special Tools for AGS Transmission For transmission installation torque values, see Table 2.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.
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26.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.
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Freightliner AMT3 and Mercedes-Benz Automated-Manual Transmissions 26.
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26.04 Mercedes-Benz Manual Transmission General Information General Information The Mercedes-Benz transmission (MBT) is offered in two 6-speed models: • MBT520S-6D, direct drive, 520 lb·ft torque rating • MBT660S-6O, overdrive, 660 lb·ft torque rating The gear case holds 9.5 quarts (9.0 liters) of oil. MobilTrans SHC® DC is the approved oil. Both models are fully synchronized for reduced shifting effort.
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26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation Removal 1. Park the vehicle on a level surface. Shut down the engine, set the parking brake, and chock the rear tires. 1 2. Drain the transmission fluid. See Fig. 1 for the location of the drain plug. 3 2 1 3 05/22/2001 2 f261102 NOTE: The transmission is shown from the left-hand side. 1. Transmission 2. Fill Plug 3. Drain Plug f261005 06/05/2001 1. Transmission 2. Output Yoke 3. Driveshaft Fig.
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26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 1 1 2 3 4 f261007 01/28/99 Fig. 4, Supporting the Driveshaft 06/06/2001 1. 2. 3. 4. f261108 Shift Lever Shift Lever Mounting Bolt Thick Washer Head of Shift Lever Fig. 6, Shift Lever Connection 6. Disconnect the electrical connectors for the reverse gear switch and the optional starter lock switch (if installed). Mark with a paint pen for ease of installation.
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26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 3 2 1 f261009 06/05/2001 1. Speedometer Sensor 2. Fuel Line 05/14/2001 3. Standoff Bracket f261105 Bend back the nut retainer (arrow). Fig. 7, Fuel Line Standoff Bracket and Speedometer Sensor 1 Fig. 9, Power Take-Off Unit (PTO) Nut Retainers 2 3 3 05/24/2001 1. M8 Bolts 2. Bleed Valve f261107 3. Slave Cylinder Fig. 8, Hydraulic Clutch Slave Cylinder 8.
PAGE 25
26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 1 01/29/99 f261011 Fig. 12, Capscrews Left in the Timing Case 3 2 flywheel. Taking these precautions will prevent damage to the input shaft, flywheel, and clutch. 15. After making sure that the transmission is firmly secured and well supported, remove the transmission from the vehicle. See Fig. 13. f261014 03/01/99 1. Transmission 2. Support Plate 3. Jack Fig. 11, Supporting the Transmission 13.
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.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 15.1 15.2 Pull the transmission and jack straight back until the transmission input shaft is clear of the clutch. Turn the left-hand front wheel to allow room for the transmission to pass. If necessary, lower the jack supporting the transmission. It might also be necessary to jack up the truck to get enough clearance to allow the transmission to pass.
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26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 6. Install the fuel line standoff bracket and connect the fuel lines to the bracket. 7. Connect the electrical connectors. Connect the electrical cable to the speedometer sensor. Connect the electrical connector(s) on the shift lever. 8. Install the shift lever. 8.1 8.2 8.3 Fit the shift lever over the cone of the transmission tower.
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26.04 Mercedes-Benz Manual Transmission Shift Mechanism Removal and Installation NOTE: These procedures are for the manual transmission with shift lever only. For the automated AGS transmission, see Section 26.03, Subject 200. Removal 1. Remove the transmission. For detailed procedures, see Subject 100. 2. Secure the transmission on a wooden pallet, or other device to keep it from moving. Installation NOTE: See the installation procedure in Section 26.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 Testing Wheel Speed Sensor Tests 6. Turn the ignition switch off. 7. If the voltage at the ECU is not within the specified range, check the battery voltage and test the wiring to the ECU and to ground. 8. Connect the X1 connector to the ECU and remove the chocks from the tires. ABS Pneumatic System Test To check for air leaks in the ABS pneumatic system, listen for the sound of escaping air at each valve.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.
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42.00 Meritor WABCO Pneumatic Antilock Braking System (ABS) Testing 4. Set a digital multimeter to the AC voltmeter mode. Connect the probes to the cable connector terminals for the sensor being tested. A 1 3 5. Rotate the wheel by hand at a speed of 30 rpm (one-half revolution per second) and read the voltage output. The wheel speed sensor must generate a minimum of 0.2 volt AC. • If the voltage is at least 0.2 volt AC, skip to the next step. B • If the voltage reading is less than 0.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 Testing 4. The resistance in each solenoid coil and cable circuit must be 4 to 8 ohms. • If the resistance in each solenoid circuit is 4 to 8 ohms, the cable and modulator valve are good. Install the connector on the ECU and remove the chocks from the tires. • If the resistance in either solenoid circuit is less than 4 ohms or greater than 8 ohms, go to the next test, "Modulator Valve Resistance.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 Testing 2. Disconnect the cable connector from the ATC valve. See Table 1. 3. Connect ohmmeter probes to the ATC valve terminals and read the resistance. See Fig. 4. 3 2 08/30/99 1 f430144 1. ATC Valve 2. Rear Modulator Valve Assembly 3. ATC Solenoid Terminals Fig. 4, ATC Valve Terminals 4. The resistance of the ATC solenoid coil and its wiring must be 6.4 to 12 ohms. • If the resistance is 6.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Troubleshooting Tables J1587 Fault Code Cross-Reference Using the following tables, troubleshoot the ABS system by MID-SID.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Left Front Wheel Sensor Troubleshooting (SID 001) MID SID FMI 136 001 04 Problem Short to ground Test 3. Measure the resistance between pin 7 of the X2 (black) connector and a good chassis ground. Repeat the test between pin 8 and ground. Test Result Resistance between either pin and ground is greater than 100,000 ohms 136 001 05 Open circuit 4.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Left Front Wheel Sensor Troubleshooting (SID 001) MID SID FMI 136 001 10 Problem Test Test Result Intermittent signal 7. Adjust the sensor. Using Signal output OK the wheel sensor output screen in Meritor PC Diagnostics, spin the Signal output wheel or drive the vehicle incorrect and check for intermittent or erratic signal.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Right Front Wheel Sensor Troubleshooting (SID 002) MID SID FMI 136 002 04 Problem Short to ground Test 3. Measure the resistance between pin 5 of the X2 (black) connector and a good chassis ground. Repeat the test between pin 6 and ground. Test Result Resistance between either pin and ground is greater than 100,000 ohms 136 002 05 Open circuit 4.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Right Front Wheel Sensor Troubleshooting (SID 002) MID SID FMI 136 002 10 Problem Test Test Result Intermittent signal 7. Adjust the sensor. Using Signal output OK the wheel sensor output screen in Meritor PC Diagnostics, spin the Signal output wheel or drive the vehicle incorrect and check for intermittent or erratic signal.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Left Rear Wheel Sensor Troubleshooting (SID 003) MID SID FMI 136 003 04 Problem Short to ground Test 3. Measure the resistance between pin 1 of the X3 (green) connector and a good chassis ground. Repeat the test between pin 2 and ground. Test Result Resistance between either pin and ground is greater than 100,000 ohms 136 003 05 Open circuit 4.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Left Rear Wheel Sensor Troubleshooting (SID 003) MID SID FMI 136 003 10 Problem Test Test Result Intermittent signal 7. Adjust the sensor. Using Signal output OK the wheel sensor output screen in Meritor PC Diagnostics, spin the Signal output wheel or drive the vehicle incorrect and check for intermittent or erratic signal.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Right Rear Wheel Sensor Troubleshooting (SID 004) MID SID FMI 136 004 04 Problem Short to ground Test 3. Measure the resistance between pin 3 of the X3 (green) connector and a good chassis ground. Repeat the test between pin 4 and ground. Test Result Resistance between either pin and ground is greater than 100,000 ohms 136 004 05 Open circuit 4.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Right Rear Wheel Sensor Troubleshooting (SID 004) MID SID FMI 136 004 10 Problem Test Test Result Intermittent signal 7. Adjust the sensor. Using Signal output OK the wheel sensor output screen in Meritor PC Diagnostics, spin the Signal output wheel or drive the vehicle incorrect and check for intermittent or erratic signal.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Right Front Modulator Valve Troubleshooting (SID 008) MID SID FMI 136 008 03 Problem Test Short to power Inlet or outlet circuit shorted to battery supply or another modulator valve wire. 1. Measure the voltage between pins 3, 4, and 9 of the X2 (black) connector and a good chassis ground. Test Result No voltage at either pin Action Repeat test.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Left Rear Modulator Valve Troubleshooting (SID 009) MID SID FMI 136 009 06 Problem Short to ground Inlet or outlet circuit shorted to ground. Test 3. Check the modulator valve inlet and outlet circuit resistance. Disconnect the connector from the valve and perform the modulator valve test. Test Result Action Resistance in both circuits is within 4 to 8 ohms.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Ground Faults Troubleshooting (SID 014) MID SID FMI 136 014 04 136 136 014 014 05 06 Problem Test Low voltage or open circuit 1. Disconnect the X1 (gray) connector at the ABS ECU. With the ignition ON, measure the voltage between pins 1 and 12. Central group open or high resistance 2. Disconnect the X1 (gray) connector at the ABS ECU.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Ground Faults Troubleshooting (SID 015) MID SID FMI Problem Test 136 015 07 Internal relay fault Test Result Action If fault repeats, replace the ABS ECU. Table 11, Ground Faults Troubleshooting (SID 015) ATC Valve Troubleshooting (SID 018) MID SID FMI 136 018 03 136 018 05 Problem Short to power. Open circuit Test 2. Disconnect the ATC Valve connector.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Auxiliary Output Troubleshooting (not currently used) (SID 019) MID SID FMI 136 019 03 Short to power. Problem Test Test Result This fault should not appear. Reconfigure the ECU. If fault continues to appear, check the wiring in the X2 (black) connector. This ABS ECU connector should be unused. Make sure there are no connections to these pins. If incorrect wiring is found, correct it and reconfigure the ECU.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting J1939 Datalink Troubleshooting (SID 231) MID SID FMI 136 231 07 Problem Test J1939 time out NOTE: Fault occurs if engine retarder sends message incorrectly. 136 231 08 J1939 time out NOTE: Fault occurs if engine retarder sends message incorrectly. 136 231 09 J1939 time out NOTE: Fault occurs if engine retarder sends message incorrectly.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Configuration Errors Troubleshooting (SID 253) MID SID FMI Problem 136 253 01 ATC configuration error Test Test Result Action Check J1939 for proper wiring. Check engine ECU for communication. Repair as necessary, then reconfigure ECU. NOTE: ATC valve is detected without engine datalink (J1939). 136 253 02 ABS configuration/ wheel parameter incorrect. Reconfigure ECU.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Miscellaneous Faults Troubleshooting (SID 254) MID SID FMI 136 254 14 Problem Test Test Result Action ECU Mounting Check ECU mounting. Replace the ECU if fault persists. Extreme banked road (measured acceleration not plausible) No correction required. This fault is for reporting only.
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42.00 Meritor WABCO Pneumatic Antilock Braking System (ABS) ABS System Troubleshooting 3. At the PLC filter, connect one lead of the DMM to the green wire (at the 2-pin connector with the green and yellow wires) and the other lead to one of the blue wires (at the 2-pin connector with the two blue wires). Measure the capacitance. • If the reading is 4.8 to 7.2 µF, go to the next step. • If the reading is less than 4.8 or more than 7.2 µF, one or more of the internal capacitors is faulty.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS System Troubleshooting Trailer ABS Warning Lamp Troubleshooting Symptom Possible Cause Action Trailer ABS lamp does not come on when the ignition is turned on. There is no trailer connected or the trailer is not equipped with PLC. The trailer ABS lamp will not illuminate at start-up unless a trailer equipped with PLC is connected to the vehicle. Trailers manufactured on or after March 1, 2001 are equipped with PLC.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS Lamp Troubleshooting ABS Warning Lamp Function The ABS warning lamp in the instrument cluster warns the driver of a malfunction in the anti-lock brake system. When the system is operating normally, the lamp should come on for a few seconds when the ignition is first turned on, then it should turn off. If a fault occurs in the system, the lamp will illuminate as long as the fault remains active.
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42.00 Meritor WABCO Pneumatic Antilock Braking System (ABS) ABS Lamp Troubleshooting 01/18/2002 Ref. Dia. G06−42022 f544040 Fig.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS Lamp Troubleshooting J1587 Fault Codes (MID 136 SID 023): ABS Warning Lamp Circuit FMI 05 Fault Description Open Circuit Test Test Result Action Test 1: 1. Disconnect the gray X1 connector at the ABS ECU. 2. Turn the ignition ON. 3. Check for voltage between pin 10 of the X1 connector (harness side) and a known good ground. 12V (approx.) Go to Test 3. 0V Go to Test 2. 12V (approx.) Go to Test 3. Test 2: 1.
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Meritor WABCO Pneumatic Antilock Braking System (ABS) 42.00 ABS Lamp Troubleshooting Diagnosing an ABS Lamp that Remains On Symptom Warning Lamp Stays On Test Test Result Test 1: Action Yes Go to Test 2. No Go to Test 3. Yes Refer to "Diagnosing Warning Lamp Fault Codes" in this section. No Go to Test 3. Use Servicelink or Meritor Toolbox to check for J1587 fault codes (MID 136).
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Meritor Cam-Master Q Plus Brakes 42.01 General Information General Information Principles of Operation Meritor Q Plus brakes are standard for both front and rear axles. These Cam-Master® brakes are airactuated, cam-operated, foundation brakes. The main components in each brake assembly (wheel end) include the following: When the brake pedal is depressed, compressed air enters the brake chamber, causing the diaphragm to move a pushrod assembly.
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42.01 Meritor Cam-Master Q Plus Brakes General Information 8 22 4 2 9 1 7 3 12 10 3 11 15 20 24 17 23 14 5 16 16 6 21 19 4 15 18 7 12/11/97 1. 2. 3. 4. 5. 6. 7. 8. 13 f421684 Anchor Pin Anchor Pin Bushing Retaining Spring Brake Shoe and Lining Assembly Cam Roller Roller Retainer Capscrew, Chamber Bracket Plug 9. Capscrew, Dust Shield 10. Dust Shield 11. Camshaft Snap Ring 12. Washer (spacer) 13. Automatic Slack Adjuster 14. Washer (thick spacer) 15. Camshaft Grease Seal 16.
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Meritor Cam-Master Q Plus Brakes 42.01 General Information A 07/19/95 f420156a A. Oversized Hole (10 or 2 o’clock position) for ABS bushing. Fig.
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Component Tests WARNING Sensor Voltage Output Test Before working on or around hydraulic brake systems and components, see Safety Precautions 100. Failure to do so may result in personal injury. IMPORTANT: Sensor output voltage must be at least 0.2 volts AC at 30 rpm. Voltage Check Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Component Tests 3. Measure resistance at the sensor connector. Disconnect the sensor from the chassis harness. 4. Measure the resistance across the two pins at the sensor connector. 5. If the measurement is not between 500 and 2000 ohms, replace the sensor. 6. Remove the chocks from the rear tires.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting Troubleshooting Meritor WABCO TOOLBOX Software The Meritor WABCO TOOLBOX Software can be used to diagnose hydraulic antilock brake system (ABS) faults. This software is packaged and launched from ServiceLink and provides J1587 fault codes and on-screen information to make the necessary repairs or replacements. TOOLBOX must be used to reset the ECU memory. See Meritor WABCO Maintenance Manual No. 39, Rev. 1/00.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting Erasing a Fault from the ECU Memory ON A OFF NOTE: An active fault cannot be erased until it has been corrected. A OFF ON B Meritor WABCO recommends that you erase all faults from the ECU memory after they have been noted and corrected. C Stored faults are erased from the ECU memory by clearing historic faults in ServiceLink or Meritor Toolbox.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting No Yes Yes 2 No Yes 1 No No No Yes Yes No Yes f040634a 09/27/2002 Fig. 3, Flow Chart: ABS Warning Lamp Troubleshooting ABS ignition power is located at pin B1/P on the BHM (Fig. 7). For more information about the BHM, see Section 54.12.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting 1 2 3 4 5 6 12 11 10 9 8 7 1 2 3 4 5 6 12 11 10 9 8 7 3 4 5 6 12 11 10 9 8 7 A B 1 C 09/30/2002 A. 12-Pin Black X2 Connector 2 B. 12-Pin Gray X1 Connector f543085 C. 12-Pin Green X3 Connector Fig.
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting 5 4 9 8 3 13 12 2 1 1 2 7 6 6 7 11 10 3 10 11 A 4 5 8 9 12 13 B E F C D 06/16/2000 f430158 A. Harness Connector Pinout B. Modulator Assembly Connector Pinout C. Main Ground D. Pump Connector E. Pin 2, Pump Power F. Pin 1, Pump Ground Fig.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting 1 08/20/2002 f543902a 1. Fuse 16, ABS Constant Battery Power Fig. 6, Cab Power Distribution Module 2 S R P N M L K J H G F E D C B A 1 09/06/2002 1. B1 Connector f430334 2. Frontwall Fig.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-001 Left Front Wheel Sensor MID SID FMI Problem Intermittent open circuit or incorrect sensor resistance 136 001 02 NOTE: This SAE J1587 fault code can also be caused by incorrect or mixed tire size. Also see test 4. Test Test Result 2. Measure the resistance across Pins 5 and 8 of the green X3 ECU connector (Circuits 377LF– and 377 LF+).
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting J1587 Fault 136-001 Left Front Wheel Sensor MID SID FMI Problem Test 5. Measure the resistance across Pins 5 and 8 of the green X3 ECU connector (Circuits 377LF– and 377LF+). 136 001 05 Open circuit Test Result Action Check for intermittent, loose or poor connections Resistance in Circuits 377LF+ and reading between 377LF– and repair as 500 and 2000 necessary. If the problem ohms persists, suspect the ECU is at fault.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-002 Right Front Wheel Sensor MID SID FMI Problem Test Test Result 2. Measure the resistance across Pins 4 and 9 of the green X3 ECU connector (Circuits 377RF– and 377RF+). 136 002 02 Intermittent open circuit or incorrect sensor resistance Action Check for intermittent, loose or poor connections Resistance in Circuits 377RF+ and reading between 377RF– and repair as 500 and 2000 necessary.
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting J1587 Fault 136-003 Left Rear Wheel Sensor MID 136 136 136 SID 003 003 003 FMI 01 02 05 Problem Incorrect sensor air gap Test 1. Adjust the sensor. Check the AC voltage across Pins 3 and 10 of the green X3 ECU connector (Circuits 377LR+ and 377LR–) while rotating the left rear wheel 30 rpm. Test Result Action Voltage greater than 0.2 VAC Sensor adjustment solved the problem.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-004 Right Rear Wheel Sensor MID 136 SID 004 FMI 01 Problem Incorrect sensor air gap Test Test Result 1. Adjust the sensor. Check the AC voltage across Pins 6 and 7 of the green X3 ECU connector (Circuits 377RR+ and 377RR–) while rotating the right rear wheel 30 rpm. 2. Measure the resistance across Pins 6 and 7 of the green X3 ECU connector (Circuits 377RR– and 377RR+).
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting J1587 Fault 136-013 Retarder MID 136 136 136 SID 013 013 013 FMI 03 05 06 Problem Test Short to power Open circuit Action 1. Disconnect the black X2 connector at the ECU. Voltage zero Disconnect the retarder relay. With the ignition ON, measure the voltage between Pin 7 of the black Voltage not zero X2 ECU connector and a good chassis ground. Check for an intermittent short to power in Circuit 376R.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-023 ABS Warning Light MID 136 SID 023 FMI 05 Problem Open circuit or low current Test Test Result Action ABS light illuminates Check circuit 376L for open circuit between splice S22 and X2/8 at the ABS connector. Repair as necessary. ABS light does not illuminate Check the bulb and wire (circuit 376L between splice S22 and ICU pin B11. If okay, replace the ICU. 1.
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting J1587 Fault 136-030 Recirculation Pump Relay MID SID FMI Problem Pump relay sticks, pump continues to run when ECU deactivates the relay 136 030 07 NOTE: The problem may be intermittent and a new relay may be required to correct the fault. Test Test Result Pump OFF 4. If the fault is active, disconnect the black X2 connector from the ECU. With the ignition ON, check to see if the recirculation pump is running.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-042 Left Front Inlet Solenoid Valve MID SID FMI Problem Test Test Result Resistance reading 6.5±0.5 ohms Resistance reading not 6.5±0.5 ohms Go to Test 2. 2. Check the ground circuit by measuring the resistance between Pin 2 of the gray X1 ECU connector and a good chassis ground. Resistance reading close to zero Go to Test 3. Resistance reading not close to zero Check and repair the ground circuit. 3.
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting J1587 Fault 136-043 Right Front Inlet Solenoid Valve MID SID FMI Problem Test Open circuit (inlet valve) 03 136 043 05 06 Shorted to ground (inlet valve) Action Resistance reading 6.5±0.5 ohms Check for intermittent wiring connections. If the wiring is OK, suspect the ECU is at fault. Resistance reading not 6.5±0.5 ohms Go to Test 2. 2.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-044 Left Rear Inlet Solenoid Valve MID SID FMI Problem Test Test Result Resistance reading 6.5±0.5 ohms Resistance reading not 6.5±0.5 ohms Go to Test 2. 2. Check the ground circuit by measuring the resistance between Pin 2 of the gray X1 ECU connector and a good chassis ground. Resistance reading close to zero Go to Test 3. Resistance reading not close to zero Check and repair the ground circuit. 3.
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting J1587 Fault 136-045 Right Rear Inlet Solenoid Valve MID SID FMI Problem Test Open circuit (inlet valve) 03 136 045 05 06 Shorted to ground (inlet valve) Action Resistance reading 6.5±0.5 ohms Check for intermittent wiring connections. If the wiring is OK, suspect the ECU is at fault. Resistance reading not 6.5±0.5 ohms Go to Test 2. 2.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-048 Left Front Outlet Solenoid Valve MID SID FMI Problem Test Test Result Resistance reading 3.5±0.5 ohms Resistance reading not 3.5±0.5 ohms Go to Test 2. 2. Check the ground circuit by measuring the resistance between Pin 2 of the gray X1 ECU connector and a good chassis ground. Resistance reading close to zero Go to Test 3. Resistance reading not close to zero Check and repair the ground circuit. 3.
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting J1587 Fault 136-049 Right Front Outlet Solenoid Valve MID SID FMI Problem Test Open circuit (outlet valve) 03 136 049 05 06 Shorted to ground (outlet valve) Action Resistance reading 3.5±0.5 ohms Check for intermittent wiring connections. If the wiring is OK, suspect the ECU is at fault. Resistance reading not 3.5±0.5 ohms Go to Test 2. 2.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-050 Left Rear Outlet Solenoid Valve MID SID FMI Problem Test Test Result Resistance reading 3.5±0.5 ohms Resistance reading not 3.5±0.5 ohms Go to Test 2. 2. Check the ground circuit by measuring the resistance between Pin 2 of the gray X1 ECU connector and a good chassis ground. Resistance reading close to zero Go to Test 3. Resistance reading not close to zero Check and repair the ground circuit. 3.
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting J1587 Fault 136-051 Right Rear Outlet Solenoid Valve MID SID FMI Problem Test Open circuit (outlet valve) 03 136 051 05 06 Shorted to ground (outlet valve) Action Resistance reading 3.5±0.5 ohms Check for intermittent wiring connections. If the wiring is OK, suspect the ECU is at fault. Resistance reading not 3.5±0.5 ohms Go to Test 2. 2.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-054 Recirculation Pump MID SID FMI Problem Recirculation pump on without being activated by ECU 136 054 03 Test Test Result 1. Remove the black X2 connector from the ECU. With the ignition ON, measure the voltage between Pin 10 and a good chassis ground.
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Meritor WABCO Hydraulic Antilock Braking System (ABS) 42.26 Troubleshooting J1587 Fault 136-055 ECU MID SID FMI Problem Test 1. With the ignition OFF, measure the voltage between Pin 2 of the gray X1 ECU connector (Circuit GND) and a good chassis ground. 136 055 02 Reference to ground interrupted 2. Measure the resistance between Pin 2 of the gray X1 ECU connector and a good chassis ground. Test Result Voltage zero volts Action Go to Test 2.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Troubleshooting J1587 Fault 136-253 Internal Tire Parameter MID 136 SID 253 FMI 02 Problem Incorrect internal tire parameter Test Test Result — — Action Contact Meritor WABCO (1-800-535-5560). Table 23, J1587 Fault 136-253 Internal Tire Parameter J1587 Fault 136-254 ECU Internal Fault MID SID FMI 136 254 12 Problem Internal ECU Fault Test Test Result — — Action Replace the ECU.
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42.26 Meritor WABCO Hydraulic Antilock Braking System (ABS) Specifications For a full view of the hydraulic ABS wheel sensor and modulator assembly (ECU green and gray connectors) wiring diagram, see Fig. 1. For partial (detailed) views of the hydraulic ABS wheel sensor and modulator assembly (ECU green and gray connectors) wiring diagram, see Fig. 2 and Fig. 3. For hydraulic ABS pump and dash wiring (ECU black connector) wiring, see Fig. 4.
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54.12 Bulkhead Module Troubleshooting Park Brake (pneumatic) Function Input to BHM from CHM via J1939 Park Brake Status Output from BHM to ICU via J1939 Park Brake Light Status Closed Engaged On Open Disengaged Off Input to CHM from Park Brake Pressure Switch Table 21, Park Brake (pneumatic) Function Park Brake (pneumatic) Function Fault Conditions* Description of Fault Action Taken by BHM CHM transmits J1939 park brake switch status unavailable or in error to the BHM.
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54.12 Bulkhead Module Troubleshooting Wake Circuits Troubleshooting Procedures Test No. 2 Test Procedure Test Result If everything works correctly after meeting the conditions in test no. 1, the system should go to sleep within 60 seconds. The template indicates this when all of the annunciators show an exclamation mark (!)*. Action Go to test no. 6.
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54.12 Bulkhead Module Troubleshooting Wake Circuits Troubleshooting Procedures Test No. 6 Test Procedure Test Result Starting with the system in the sleep state, activate one of the inputs that initiates a wake, such as opening the driver’s door. If the system is functioning properly, all of the annunciators on the template in the second column should be active (yellow) for ECUs equipped on the vehicle as long as the input remains active. For example, the door is open.
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54.12 Bulkhead Module Specifications See Fig. 1 for an illustration of the Bulkhead Module (BHM) Harness Connections. See Fig. 3 for an illustration of the BHM with pinout assignments and harness connections. 4 5 3 20A B5.F − Cigar Lighter Output 12A B3.E − Horn 12A Combined 12A 7 B5.H − Panel Lamps B7.A1 − Panel Lamps (Smart Switch) 12A Combined B4.F − SPARE (Left Heated Mirror) B4.E − SPARE (Right Heated Mirror) 6.7A Combined B6.A9 − Accessory (HVAC) B6.A10 − Accessory (Radio) 6.
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54.12 Bulkhead Module Specifications 4 A B C D E F G H J K L M A B C D H G F E A B C D E F G H A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 03/31/2004 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 S R P N M L K J H G F E D C B A A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 1 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 2 A B C D E F G H J K L M N P 3 5 6 7 f543868 NOTE: Pins shown are viewed toward the BHM or wire insertion end of the harness connector. 1. 2. 3. 4.
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54.12 Bulkhead Module Specifications Power Supply Fuses and Associated Outputs for the Bulkhead Module BHM Power Input BHM Power Input Pin Fuse Supplying BHM Power Input BHM Outputs Supplied Power In VBAT2 VBAT3 VBAT4 VBAT5 B4.G B1.N B4.K B1.J BHM Output Pin Power Out Fuse 20 (30A) Fuse 18 (30A) Fuse 15 (30A) Fuse 7 (30A) Accessory (HVAC) B6.A9 Accessory (radio) B6.A10 Wake Up (instrument cluster) B5.D Left High Beam B1.L Wiper High B3.F Horn B3.E Wiper Low B3.H Spare 8.
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54.12 Bulkhead Module Bulkhead Module Fault Code Information • Suspect Parameter Number (SPN) – Indicates what function on the ECU has failed. All J1939 SPNs for the BHM are listed in Table 2. General Information Subject 410 contains information on all proprietary Bulkhead Module (BHM) fault codes for J1587 and J1939 datalink protocols, how to view these codes, and what the codes mean. Each fault code contains three distinct pieces of information.
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54.12 Bulkhead Module Bulkhead Module Fault Code Information J1587 SIDs for Bulkhead Module (BHM) MID 164 SID Possible FMI Multifunction Turn Signal Switch Wiper Low Input Fault 2 016 Multifunction Turn Signal Switch Wiper High Input Fault 2 017 Wheel-Based Vehicle Speed CAN Message Error 2 018 Wake-up Hardware Fault–Modules are kept awake 7 019 Unknown Keep Awake Fault–Modules are kept awake.
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54.12 Bulkhead Module Bulkhead Module Fault Code Information J1587 SIDs for Bulkhead Module (BHM) MID 164 SID Description Possible FMI 053 BHM B1.K, B5.C—Tail/Clearance Lamp Output Fault 5, 6 054 BHM B1.L—Left High Beam Output Fault 5, 6 055 BHM B1.N—Main BHM Power VBAT3 Input Fault 3, 4 056 BHM B1.R—Left Low Beam Output Fault 5, 6 057 BHM B2.M—A/C Clutch Output Fault 5, 6 058 BHM B3.D—Main BHM Power VBAT1 Input Fault 3, 4 059 BHM B3.E—Horn Output Fault 060 BHM B3.
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54.12 Bulkhead Module Bulkhead Module Fault Code Information J1587 SIDs for Bulkhead Module (BHM) MID 164 SID Description Possible FMI 089 CHM C4.F—Left DRL Output Fault 5, 6 090 CHM C4.J—Main CHM Power VBAT3 Input Fault 3, 4 091 CHM C4.K—Right High Beam Output 5, 6 092 CHM C4.P—Main CHM Power VBAT1 Input Fault 3, 4 093 CHM C5.A—Solenoid #0 Pressure Feedback Fault 3, 4 094 CHM C5.B—Solenoid #1 Pressure Feedback Fault 3, 4 095 CHM C5.
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54.13 Chassis Module and Expansion Module General Information General Information The Chassis Module (CHM) and the Expansion Module (EXM) both serve the same function in the M2 electrical system by acting as slaves to the Bulkhead Module (BHM). The CHM and EXM respond to commands from the BHM and broadcast the status of the inputs and outputs that are sent to and delivered by the modules.
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54.13 Chassis Module and Expansion Module General Information Awake State and Sleep State Expansion Module The BHM, CHM, and instrumentation control unit (ICU) are, as a group, in an awake state or a sleep state depending on vehicle conditions. When any of these electronic components are awakened, the remaining components wake up if they are not already awake. When the BHM, CHM, and ICU are in an awake state, the odometer reading appears on the dash driver display screen.
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54.13 Chassis Module and Expansion Module General Information External strapping is the interconnection of specific pins on the module in order to select a desired feature. In the external strapping of the Expansion Module, the J1939 source address and the J1587 message ID are used to identify the module on the vehicle datalinks. Pins on the C4 connector of the Expansion Module are connected as specified in Table 2.
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54.37 Body Builder Transmission Interfaces Specifications 12/07/2005 Ref. Dia. G06−43860 Chg. Ltr. A f544742 Fig.
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54.38 PTO and Pump Electrical Controls General Information General Information Normally open AMU solenoid—Allows air to flow until power is applied to the solenoid coil. A PTO (power takeoff) and pump controls are options that can be ordered for a Business Class® M2 vehicle at the time the vehicle is ordered, after the vehicle is delivered, or when buying a used vehicle. Pump—Also called a split shaft PTO. The main driveshaft is "split" by the PTO. The PTO is actually a transfer case.
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54.38 PTO and Pump Electrical Controls Troubleshooting PTO and Fire Pump Controls Electrical Troubleshooting Use Table 1 or Table 2 to begin troubleshooting. For power takeoff (PTO) function electrical diagnosis, see Table 1. For fire pump controls function diagnosis, see Table 2.
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54.38 PTO and Pump Electrical Controls Troubleshooting PTO Function Electrical Diagnosis Test No. 4 Test Procedure Test Result In ServiceLink, open the "PTO Interlocks" Datalink Monitor template. Yes Using Table 4, determine which PTO interlocks are used based on the PTO reference parameter programmed in to the BHM. Engage the PTO using the switch in the dash. No Determine the cause for interlock drop out and repair as necessary. Check PTO solenoid output circuit amperage. If it exceeds 0.
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54.38 PTO and Pump Electrical Controls Troubleshooting Fire Pump Controls Function Electrical Diagnosis Test No. 1 Test Procedure In ServiceLink, use the Chassis Module (CHM) Configuration screen to determine which CHM solenoid output numbers control the two solenoids for the fire pump. Test Result Action Go to test no. 2. Yes Then open the "AMU Solenoids Circuits" or "AAVA Solenoids Circuits" in the appropriate Datalink Monitor template. Make sure the vehicle has full air pressure.
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54.38 PTO and Pump Electrical Controls Troubleshooting Fire Pump Controls Function Electrical Diagnosis Test No. 3 Test Procedure Test Result Make sure the vehicle has full air pressure. Turn the ignition on. Go to test no. 4. Yes Using the appropriate solenoids Datalink Monitor template, attempt to engage the fire pump using the smart switch in the dash while observing the status of the pressure switch under the "Inputs to BHM" heading for the two solenoids that control the fire pump. See Fig.
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54.38 PTO and Pump Electrical Controls Troubleshooting Fire Pump Controls Function Electrical Diagnosis Test No. 5 Test Procedure Test Result In ServiceLink, open the "Chassis Module Battery Inputs" Datalink Monitor template. Action The problem is in one or both of the fire pump solenoid output circuits. Is Battery Power Feed No. 3 at approximately battery voltage? Make sure the fire pump solenoids are wired to the correct CHM output pins per the ServiceLink CHM Configuration screen.
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54.38 PTO and Pump Electrical Controls Troubleshooting PTO and Fire Pump Control Switch and Interlocks Test Test No. Test Procedure 2 Are any of the five SSn ID#s equal to 0? 3 In ServiceLink, open the "Switch Expansion Module 1, Smart Switches" Datalink Monitor template. Test Result Yes No Go to test no. 3. Yes Go to test no. 4. If diagnosing the PTO, are any of the five SSn ID#s equal to 38? No If diagnosing the fire pump controls, are any of the five SSn ID#s.
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54.38 PTO and Pump Electrical Controls Troubleshooting PTO and Fire Pump Control Switch and Interlocks Test Test No. 7 Test Procedure Test Result Action Reapply the PTO or fire pump control reference parameter. In ServiceLink, open one of the following Datalink Monitor templates: • If testing the PTO controls, open the "PTO Interlocks" If the PTO or fire pump control continues to be inoperable, contact the Freightliner Customer Assistance Center at 1-800-FTLHELP or 1-800-385-4357.
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54.38 PTO and Pump Electrical Controls Troubleshooting Fire Pump Control Interlocks by Reference Parameter Interlocks Reference Parameter Description 26-01032-004 PTO Fire Pump Control (Smart Switch ID#104) 26-01032-010 PTO Fire Pump Control, w/Park Brake & Veh Spd Interlocks (Smart Switch ID#104) Indicated Vehicle Speed from Engine* Ignition (BHM input) Park Brake (from CHM) — On Set Approximately 5 mph (8 km/h) On Set * The fire pump is driven by a transfer case.
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54.38 PTO and Pump Electrical Controls Troubleshooting PTO and Fire Pump Control J1939 Fault Codes SA SPN FMI 33 6954 07 Description End of Frame (PTO and fire pump control)–no air pressure feedback Action Solenoid is not activated, but CHM senses that the pressure switch is in an unexpected state. For example, a normally closed solenoid is off, but air pressure is detected. Check the following: • Air system • Pressure feedback circuit including the ground.
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54.38 PTO and Pump Electrical Controls Troubleshooting You must enter Test Mode before using the test buttons to operate the outputs. Please exit Test Mode when finished. Enter Test Mode Test Mode Exit Test Mode ON Inputs to BHM: Outputs from BHM: (pin) Press. Switch (pin) Sol. Output (pin) Sol. Output (From CHM to BHM) AMU SOLENOID 0 C5.A Status (From BHM to CHM) C5.H AIR ON AMU SOLENOID 1 C5.B Status C5.F Status C5.J C5.G Status AIR ON C5.H Status C5.J OFF C5.
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54.38 PTO and Pump Electrical Controls Troubleshooting You must enter Test Mode before using the test buttons to operate the outputs. Please exit Test Mode when finished. Enter Test Mode Test Mode Exit Test Mode ON Inputs to BHM: Outputs from BHM: (pin) Press. Switch (pin) Sol. Output (pin) Sol. Output (From CHM to BHM) AMU SOLENOID 0 C5.A (From BHM to CHM) C5.H Status AIR ON AMU SOLENOID 1 C5.B C5.F C5.J Status C5.G C5.L Status Status C5.H Status C5.
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54.38 PTO and Pump Electrical Controls Troubleshooting 02/22/2012 f120223 Fig.
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54.38 PTO and Pump Electrical Controls Specifications See Fig. 1 for a typical wiring diagram of an Allison hydraulic PTO. See Fig. 2 for a typical wiring diagram of an Allison hydraulic PTO with a 4th generation TCU. See Fig. 3 for a typical wiring diagram of a pneumatic PTO. See Fig. 4 for a typical wiring diagram of a split shaft PTO.
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54.38 PTO and Pump Electrical Controls Specifications 2 200 GRD 1 497D3 81C +12V IGN 5 4 3 87A 200E 43 PTO REG. 30 87 497C1 85 86 30 PTO ENABLE f545341 07/11/2008 1. CHM 2. Hydraulic Pressure Switch 3. TCU 4. PTO Relay 5. PTO Solenoid Fig.
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54.38 PTO and Pump Electrical Controls Specifications AMU/AAVA Solenoid 1 Smart Switch 399A J1939 Bulkhead Module 399 Pressure Feedback Switch Chassis Module Solenoid Coil PUMP AMU/AAVA Solenoid 2 399C 399B Pressure Feedback Switch Solenoid Coil f544724 02/22/2012 NOTES: • Pump functions require two solenoids to shift the transfer case. Solenoid 1 provides air when power is applied to the solenoid coil (normally closed).
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54.39 Optional Power Switches and Connection General Information Introduction feed from the CHM. See Section 54.35 for information on the junction block marker light feed. Optional power switches are factory-installed, switchcontrolled power provisions that can be ordered for a Business Class® M2 vehicle. Optional switches can be ordered in a one-, two-, or four-switch configuration. All optional switches mount on the dash, provide fuse-protected battery power, and route to a customer access point.
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54.39 Optional Power Switches and Connection General Information Optional-Switch Current Capacity PDM Fuse F25 No.
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Optional Power Switches and Connection 54.39 Optional Switch Connections Connecting to One Switch With a Junction Block 7. Using capscrews, attach the junction block cover to the junction block. 1. Turn off the engine, apply the parking brakes, and chock the tires. 2. Disconnect the negative leads from the batteries or, if the vehicle is equipped with a battery disconnect switch, turn the switch to the off position. 3. Locate the junction block attached to the frame rail near the Chassis Module (CHM.
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54.39 Optional Power Switches and Connection Optional Switch Connections 11. Allow the solder sleeve to cool for a few minutes. 12. Place the heat shrink over the splice and center it as best you can. Then apply 250°F (121°C) to the heat shrink until it has shrunk completely over the wire insulation. Some of the sealant material should be bubbling out of the ends of the heat shrink. 5 4 3 13. When routing additional electrical wiring, make sure all circuits are properly protected and secured. 2 14.
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54.39 Optional Power Switches and Connection Troubleshooting Troubleshooting For electrical troubleshooting, see Table 1. Electrical Troubleshooting Description of Fault Possible Cause No power at an optional switch output. Switch is on. Check appropriate power distribution module (PDM) fuse to see if it is open or missing. F25 supplies switches 1 and 2. F26 supplies switches 3 and 4. No power at an optional switch output. Switch is on and power supply fuse is proven good.
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54.39 Optional Power Switches and Connection Specifications Wiring Diagrams For a wiring diagram of the four-switch configuration, see Fig. 3. For a wiring diagram of the one-switch configuration, see Fig. 1. Circuit Identification For a wiring diagram of the two-switch configuration, see Fig. 2. For a pinout chart of a typical optional switch connector, see Table 1.
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54.39 Optional Power Switches and Connection Specifications Optional Switch Connector Connector Pin Signal Name Signal Type Circuit Color Circuit Number 8 6 5B 5A 4 7 10 3 2B 2A 1 9 1 — — f544751 — — 2B Fused Battery Power Input T 399 for optional switches 1 and 2. 399B for optional switches 3 and 4. 3 Optional Switch Output Output T 399A for optional switch 1. 399C for optional switch 2. 399E for optional switch 3. 399G for optional switch 4.
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54.40 Chassis Electrical Control Systems General Information Background Information axles spin equally and improve traction by turning all rear wheels at the same speed. Chassis electrical control systems are optional features on a Business Class® M2 vehicle. These features include: NOTE: Operating the vehicle with the interaxle lock activated under normal driving conditions increases driveline and tire wear. The interaxle lock should be used only when improved traction is needed.
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54.40 Chassis Electrical Control Systems General Information grounded feedback circuit from the closed pressure switch indicates that the interaxle lock is activated and pressure is being supplied to the interaxle lock. An open feedback circuit indicates that the interaxle lock is not activated, or there is a malfunction; the interlock switch is turned on but the pressure switch is still open. mission.
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54.40 Chassis Electrical Control Systems General Information ECM. For other engine configurations, the system controls a relay that provides a ground input as the ECM feedback. With the system set for low range, the relay coil receives no power and a ground input is provided to the ECM through the closed switch contacts of the relay. The operating power for this relay is provided by a splice connection into the CHM output that also controls the the AMU/AAVA solenoid.
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54.40 Chassis Electrical Control Systems General Information amps. The 2010 CHM does not have the current sourcing ability to drive these solenoids, so a relay in the chassis PDM is added to the circuit. The energized solenoid opens and directs air flow by means of a three-port valve. An open solenoid removes the air supply to the rear suspension and vents the existing suspension pressure, allowing the rear of the vehicle to be lowered.
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54.40 Chassis Electrical Control Systems General Information 4 3 2 5 1 02/24/2006 1. Lock Plunger 2. Return Spring f310477a 3. Control Linkage 4. Air Cylinder 5. Slide Rail Fig. 5, Fifth Wheel Slide Assembly switch is in the air line. A grounded feedback circuit from the closed pressure switch indicates that the fifth wheel slide is activated and pressure is being supplied to the fifth wheel slide air cylinder.
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting If a leak exists in the system and it cannot be traced to other parts or fittings, suspect damage to one of the evaporator coils. Temperature Blend Door Actuator Circuit Tests Condenser The temperature blend door actuator controls the amount of air that is routed through the heater core. The temperature blend door actuator is controlled by the temperature control switch on the control head (climate control panel).
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting Temperature Blend Door Actuator Circuit Tests Test actuator motor drive circuit Conditions Test Point Good Result What to Do if Test Fails key on, engine off Measure across pins 5 and 6 9V+ for Check wiring between control of the temperature blend about 1 head and temperature blend temperature blend door actuator door actuator connector. second* door actuator.
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting and the actuator still does not operate properly, check for mechanical problems with the actuator. To quickly check for normal operation, feel for air flowing from the correct outlet in each air selection setting.
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting sumes full recirculation mode for 20 minutes. This cycle repeats as long as the system remains in recirculation mode. The control head senses the recirculation door position by reading the feedback voltage from the actuator position sensor. The feedback voltage will be less than the 5V reference voltage sent by the control head to the sensor. The target position is based on the recirculation button setting and internal control head algorithms.
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting Recirculation Door Actuator Circuit Tests Test Conditions Test Point actuator key on, engine off position sensor feedback signal all connectors connected circuit Backprobe pins A11 and B5 at control head connector. Good Result 0.8V (recirc. on) to 4.7V (recirc. off) What to Do if Test Fails Check wiring between control head and recirculation door actuator.† If wiring is okay, replace the actuator.
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting Blower Motor Circuit Tests Test blower motor ground circuit Conditions Test Point battery switch on (if equipped) key off Measure between pin 3 of blower motor connector and the positive battery post. Good Result 12V* What to Do if Test Fails Check for an open in blower motor ground circuit.
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting Evaporator Probe Circuit Tests Test evaporator temperature probe Conditions Good Result Test Point key off, engine off sensor probe removed and disconnected Measure across pins on the temperature probe. fill a cup with ice then add water to make an ice-water bath for pre- Replace temperature probe.
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting • make sure that the engine speed is available (make sure it registers on the tachometer). • The fan switch is on any setting other than off. • The evaporation sensor temperature is above 40.1°F (4.5°C). When these conditions exist, the control head sends the A/C request signal to the bulkhead module. See Fig. 2. NOTE: The A/C signal will remain active until the evaporator sensor reaches 38.3°F (3.
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting A/C Clutch Circuit Tests for Diagnosing No A/C Clutch Engagement Test A/C request input A/C clutch circuit* Conditions Test Point/Method key on, engine on ServiceLink/Datalink Monitor air selection switch in one of A/C NOTE: Make sure the settings Datalink Monitor template is not in Test Mode. The fan (blower) speed on any control head should request setting but off A/C.
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83.00 Cab Heater and Air Conditioner, Valeo Troubleshooting Backlighting Circuit Tests Test backlighting power test Conditions Test Point battery switch on (if equipped) key off, engine off control head connector disconnected headlight switch on backlighting pulse width modulated (PWM) signal test battery switch on (if equipped) key off, engine off Good Result What to Do if Test Fails Check circuit 29A for an open/ short.
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83.00 Cab Heater and Air Conditioner, Valeo Specifications Refrigerant Refrigerant Oil Specification WARNING R–134a is the only refrigerant that is approved for use on Freightliner vehicles. Several companies offer less expensive, hydrocarbon-based refrigerant, such as propane and methane. Use of these refrigerants will void the warranty on the air conditioning system, cause damage to the air conditioning system, and possibly result in personal injury or property damage.
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83.00 Cab Heater and Air Conditioner, Valeo Specifications • Small Cooling Package: The condenser is mounted below the charge air cooler and does not cover the entire face of the radiator. See Fig. 2. 2 1 2 3 01/21/2008 f831792 1. Condenser 2. Charge Air Cooler 3. Radiator Fig. 3, Large Cooling Package phased out and replaced with a 19-fpi condenser. The 14-fpi condenser may still be found on vehicles built through March 2003.
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83.00 Cab Heater and Air Conditioner, Valeo Specifications 3. Place the sheet of paper on a clean, flat surface and place a ruler on the impression. Line the ruler up with one of the fin marks. counted by 2 to obtain the approximate number of fins per inch. For example, 29 fins divided by 2 equals 14.5 or approximately 14 fins per inch. 4. Count the number of fin marks from the zeroinch (zero-mm) mark to the two-inch (51-mm) mark on the ruler.
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83.00 Cab Heater and Air Conditioner, Valeo Specifications Temperature/Pressure Specifications for a Vehicle With a Small Cooling Package* and a 19-fpi Condenser† Dash Outlet Service Port Pressures A/C Ambient Humidity Temperature Compressor A/C Compressor Status Comments Air High Side Low Side (approximate) (approximate) Status Temp.
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83.00 Cab Heater and Air Conditioner, Valeo Specifications Temperature/Pressure Specifications for a Vehicle With a Large Cooling Package and a Behr Condenser but No Auxiliary HVAC Unit* Dash Outlet Service Port Pressures A/C Ambient Humidity Temperature Compressor A/C Compressor Status Comments Air High Side Low Side (approximate) (approximate) Status Temp.
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83.00 Cab Heater and Air Conditioner, Valeo Specifications Temperature/Pressure Specifications for a Vehicle With a Large Cooling Package, a Behr Condenser, and an Auxiliary HVAC Unit* Auxiliary Service Port Pressures Dash Outlet A/C Ambient Unit Lower A/C Compressor Status Humidity Temperature Compressor Air High Side Low Side Louver Comments (approximate) (approximate) Status Temp.
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83.00 Cab Heater and Air Conditioner, Valeo Specifications Temperature/Pressure Specification Tables (EPA07 compliant vehicles) Condenser Identification: EPA07 Compliant Vehicles Before using the temperature/pressure specifications in Table 7, Table 8, Table 9, and Table 10, determine what condenser is installed on the vehicle. To do so, identify the vehicle rating, or measure the condenser. See Table 6 for condenser identification. Vehicle Rating Condenser Width: in. (cm) Height: in.
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