SERVICE MANUAL

SERVICE MANUAL SECTION

INSTRUMENTS (Data Link Driven Instrument Cluster)

Model: FE 300
Start Date: 03/01/2004
Model: IC Bus
Start Date: 03/01/2000
End Date: 03/01/2004

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01/29/2007

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Copyright © 01/29/2007 International Truck and Engine Corporation
 INSTRUMENTS (Data Link Driven Instrument Cluster) i

Table of Contents

1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2. SPEEDOMETER GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3. ODOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.4. TACHOMETER GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.5. HOUR-METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.6. VOLTMETER GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.7. ENGINE OIL PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.8. DUAL AIR PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.9. FUEL LEVEL GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.10. ENGINE WATER TEMPERATURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.11. TRANSMISSION OIL TEMPERATURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.12. AMMETER GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.13. INDICATOR AND WARNING LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
OIL/WATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
((P)) BRAKE PRESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
STOP ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
CHANGE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
WARN ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TRAC CNTL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
CHECK TRANS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
LEFT TURN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
(ABS) ANTI-LOCK BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
HIGH BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
RIGHT TURN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
WAIT-TO-START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
PDL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
((P)) PARK BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
((P)) LOW AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
WSHLD WASH FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
FRONT AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
DIFF LOCK ENGAGED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
SUSP LOW AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
WATER-IN-FUEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
LOW BRAKE FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
RETARD ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
CHANGE TRANS FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
RETARD OVER HEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.1. SPEEDOMETER GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.2. ODOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.3. TACHOMETER GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.4. HOUR-METER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

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2.5. VOLTMETER GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.6. ENGINE OIL PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.7. DUAL AIR PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.8. FUEL LEVEL GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.9. ENGINE WATER TEMPERATURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.10. TRANSMISSION OIL TEMPERATURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.11. AMMETER GAUGE (SHUNT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.12. INDICATOR AND WARNING LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
OIL/WATER: FE 300 With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
OIL/WATER: FE 300 With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Oil/Water: IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
BRAKE PRESS: FE 300 With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
BRAKE PRESS: FE 300 With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Brake Pressure: IC With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Brake Pressure: IC With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
STOP ENGINE: FE 300 AND IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
CHANGE OIL: FE 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
CHANGE OIL: IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
WARN ENGINE: FE 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
WARN ENGINE: IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
TRAC CTRL: FE 300 With Anti-lock Brake System (ABS) — Hydraulic Brakes. . . . . . . . . . .15
TRAC CTRL: FE 300 With WTEC or Allison 2000 ICT Anti-lock Brake System (ABS) —
Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
TRAC CTRL: IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
CHECK TRANS: FE 300 With Allison WTEC III With Hydraulic Brakes . . . . . . . . . . . . . . . . . . . .16
CHECK TRANS: FE 300 With Allison WTEC III GEN 4 With Hydraulic Brakes . . . . . . . . . . . .16
CHECK TRANS: FE 300 With Allison WTEC III With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
CHECK TRANS: FE 300 With Allison WTEC III GEN 4 With Air Brakes . . . . . . . . . . . . . . . . . . . .16
CHECK TRANS: FE 300 With Allison 2000 (LCT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
CHECK TRANS: FE 300 With Allison 1000/2000 GEN 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
CHECK TRANS: IC With Allison MD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
LEFT TURN: FE 300 With International Turn Signal Switch (Stationary Column). . . . . . . .17
LEFT TURN: FE 300 With Douglas Turn Signal Switch (Tilt Column). . . . . . . . . . . . . . . . . . . . . . .17
LEFT TURN: IC With International Turn Signal Switch (Stationary Column and Tilt
Column). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
(ABS) ANTI-LOCK BRAKE: FE 300 With WTEC or Allison 2000 ICT Air Brakes. . . . . . . . . .17
(ABS) ANTI-LOCK BRAKE: FE300 With Hydraulic Brakes GEN 4. . . . . . . . . . . . . . . . . . . . . . . . . . .18
(ABS) ANTI-LOCK BRAKE: IC Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
(ABS) ANTI-LOCK BRAKE: IC Hyd Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HI BEAM: FE 300 With Douglas Turn Signal Switch (Tilt Column). . . . . . . . . . . . . . . . . . . . . . . . . .18
HI BEAM: FE 300 With International Turn Signal Switch (Stationary Column). . . . . . . . . . . .18
HI BEAM: IC With International Turn Signal Switch (Stationary Column). . . . . . . . . . . . . . . . . .18
RIGHT TURN: FE 300 With International Turn Signal Switch (Stationary Column). . . . . . .19
RIGHT TURN: FE 300 With Douglas Turn Signal Switch (Tilt Column). . . . . . . . . . . . . . . . . . . . .19
RIGHT TURN: IC With International Turn Signal Switch (Stationary Column and Tilt
Column). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
WAIT-TO-START: FE 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
WAIT-TO-START: IC With International T 444E Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
PDL: FE 300 AND IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
((P)) PARK BRAKE: FE 300 With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
((P)) PARK BRAKE: FE 300 With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
((P)) PARK BRAKE: IC With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
((P)) LOW AIR: FE 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

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 INSTRUMENTS (Data Link Driven Instrument Cluster) iii

((P)) LOW AIR: IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

WINDSHIELD WASHER FLUID: FE 300 AND IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
FRONT AXLE: FE 300 AND IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
DIFF. LOCK ENGAGED: FE 300 AND IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
SUSP LOW AIR: FE 300 AND IC With Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
WATER-IN-FUEL: FE 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
WATER-IN-FUEL: IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
FUEL FILTER: FE 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
FUEL FILTER: IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
PTO: FE 300 AND IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
LOW BRAKE FLUID: FE 300 With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
LOW BRAKE FLUID: IC With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
RETARD ON: FE 300 With Allison WTEC III XMSN GEN 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
RETARD ON: IC With Allison MD and International Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
CHANGE TRANS FILTER: FE 300 With Allison WTEC III XMSN GEN 4. . . . . . . . . . . . . . . . . . . . .22
CHANGE TRANS FILTER: IC With Allison “AT”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
RETARD OVER HEAT: FE 300 With Allison WTEC III XMSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
RETARD OVER HEAT: FE 300 With Allison WTEC III XMSN GEN 4. . . . . . . . . . . . . . . . . . . . . . . . . .23
RETARD OVER HEAT: IC With Allison MD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
ALTERNATOR: FE 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
ALTERNATOR: IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

3. REMOVE AND INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

3.1. INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.2. INSTRUMENT CLUSTER COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.3. PRINTED CIRCUIT BOARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.4. SPEEDOMETER SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4. INSTRUMENT CLUSTER JUMPER USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5. CLUSTER FAILURE DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

5.1. CLUSTER HARNESS CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Left Side Harness Connector Pinouts (Yellow) (10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Center Harness Connector Pinouts (Green) (11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Right Side Harness Connector Pinouts (Natural) (12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.2. CLUSTER CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.3. AIR GAUGE FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.4. FUEL LEVEL SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.5. FUEL GAUGE, OPTIONAL ELECTRICALLY OPERATED TEMPERATURE GAUGE, OR
AMMETER FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Instrument Gauge Tester Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Gauge Tester Resistance Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Thermistor Resistance Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Restricted Needle Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Open or Shorted Gauge Winding Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Cluster Pinouts 16.73in8.0in72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Harness Continuity and Voltage Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

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iv INSTRUMENTS (Data Link Driven Instrument Cluster)

5.6. VOLTMETER DISPLAY FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.7. EXHAUST TEMPERATURE DISPLAY FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Exhaust Temperature Display Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Pyrometer Sensor Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Internal Voltage Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5.8. SPEEDOMETER, ODOMETER, TACHOMETER, HOUR-METER, VOLTMETER, OIL
PRESSURE GAUGE, AND WATER TEMPERATURE GAUGE FAILURE ISOLATION. . . . . . . . . . .41
Pass Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Fail Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Electronic Service Tool (EST) Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
5.9. SPEEDOMETER, ODOMETER, TACHOMETER, HOUR-METER, VOLTMETER, OIL
PRESSURE GAUGE, AND WATER TEMPERATURE GAUGE FAILURE CHART. . . . . . . . . . . . . . . .42

6. TROUBLESHOOTING (INDICATOR AND WARNING LIGHT DIAGNOSTICS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.1. OIL/WATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
FE 300 With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
FE 300 With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.2. BRAKE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
FE 300 With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
FE 300 With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
IC With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
IC With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.3. STOP ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
FE 300 and IC SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
6.4. CHANGE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
FE 300 With International Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
IC With International Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
6.5. WARN ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
FE 300 With International Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
IC With International Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
6.6. TRAC CTRL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
FE 300 With Anti-lock Brake System (ABS) — Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . .60
FE 300 With WTEC or Allison 2000 ICT Anti-lock Brake System (ABS) — Air Brakes. . .61
6.7. TRAC CTRL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
6.8. CHECK TRANS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
FE 300 With Allison WTEC III Transmission With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . .62
FE 300 With Allison WTEC III GEN 4 Transmission With Hydraulic Brakes. . . . . . . . . . . . . . . .63
FE 300 With Allison WTEC III Transmission With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
FE 300 With Allison WTEC III GEN 4 Transmission With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . .65
FE 300 With Allison 2000 (LCT) Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
FE 300 With Allison 1000/2000 GEN 4 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
IC With Allison MD Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
6.9. LEFT TURN INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
FE 300 With International Turn Signal Switch (Stationary Column). . . . . . . . . . . . . . . . . . . . . . . . .69
FE 300 With Douglas Turn Signal Switch (Tilt Column). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
IC With International Turn Signal Switch (Stationary Column and Tilt Column). . . . . . . . . .70
6.10. (ABS) ANTI-LOCK BRAKE WARNING LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
FE 300 With WTEC or Allison 2000 ICT Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
FE 300 With Hydraulic Brakes GEN 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
IC With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
IC With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

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 INSTRUMENTS (Data Link Driven Instrument Cluster) v

6.11. HIGH BEAM INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

FE 300 With Douglas Turn Signal Switch (Tilt Column). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
FE 300 With International Turn Signal Switch (Stationary Column). . . . . . . . . . . . . . . . . . . . . . . . .78
IC With International Turn Signal Switch (Stationary Column). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
6.12. RIGHT TURN INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
FE 300 With International Turn Signal Switch (Stationary Column). . . . . . . . . . . . . . . . . . . . . . . . .81
FE 300 With Douglas Turn Signal Switch (Tilt Column). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
IC With International Turn Signal Switch (Stationary Column and Tilt Column). . . . . . . . . .82
6.13. WAIT-TO-START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
FE 300 With International Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
IC With International T444E Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
6.14. PDL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
FE 300 AND IC SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
6.15. PARK BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
FE 300 With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
FE 300 With Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
IC With Hydraulic Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
6.16. ((P)) LOW AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
FE 300 SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
6.17. ((P)) LOW AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
6.18. WINDSHIELD WASHER FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
FE 300 AND IC SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
6.19. FRONT AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
FE 300 AND IC SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
6.20. DIFF LOCK ENGAGED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
FE 300 AND IC SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
6.21. SUSP LOW AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
FE 300 AND IC (With Hyd Brakes) SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . .90
6.22. WATER-IN-FUEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
FE 300 (I6 ENGINE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
IC With International Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
6.23. FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
FE 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
IC Series With International Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
6.24. POWER TAKE OFF (PTO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
FE 300 AND IC SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
6.25. LOW BRAKE FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
FE 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
6.26. RETARD ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
FE 300 With Allison WTEC III XMSN GEN 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
IC With Allison MD Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
6.27. CHANGE TRANS FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
FE 300 With Allison WTEC III XMSN GEN 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
IC With Allison AT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
6.28. RETARD OVER HEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
FE 300 With Allison WTEC III XMSN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
FE 300 With Allison WTEC III XMSN GEN 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
IC With Allison MD Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
6.29. ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
FE 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
6.30. ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

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vi INSTRUMENTS (Data Link Driven Instrument Cluster)

IC SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

6.31. ((P)) LOW AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
SE item not covered at this time.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 1

1. DESCRIPTION
1.1. GENERAL
All instruments are located on the instrument panel in a demountable instrument cluster (Figure 1) directly in
front of the driver. Gauges and panel lights of the cluster are connected to the vehicle electrical system by
three connectors mounted to the back side of the cluster.

Figure 1 Instrument Cluster

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2 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 1
1. LEFT WARNING LIGHTS: 8. HIGH BEAM INDICATOR 12. RIGHT PACK WARNING
LIGHTS:
A. OIL/WATER 9. RIGHT TURN INDICATOR A. WATER-IN-FUEL
B. ((P)) BRAKE PRESS 10. RIGHT WARNING LIGHTS B. FUEL FILTER
C. STOP ENGINE A. WAIT-TO-START C. PTO
D. CHANGE OIL B. PDL D. LOW BRAKE FLUID
E. WARN ENGINE C. ((P)) PARK BRAKE 13. VOLTMETER GAUGE
F. TRAC CTRL C. ((P)) LOW AIR 14. ODOMETER
G. CHECK TRANS D. WSHLD WASH FLUID 15. HOURMETER
2. LEFT TURN INDICATOR E. FRONT AXLE 16. ENGINE OIL PRESSURE
GAUGE
3. (ABS) ANTI-LOCK BRAKE F. DIFF LOCK ENGAGED 17. LEFT PACK WARNING
WARNING LIGHT LIGHTS:
4. ENGINE WATER G. SUSP LOW AIR A. RETARD ON
TEMPERATURE GAUGE
5. TACHOMETER GAUGE 11. DUAL AIR PRESSURE B. CHANGE TRANS FILTER
GAUGE (WITH AIR BRAKES
ONLY)
6. SPEEDOMETER GAUGE C. RETARD OVER HEAT
7. FUEL LEVEL GAUGE D. ALTERNATOR
18. AMMETER
19. TRANSMISSION OIL
TEMPERATURE GAUGE

The speedometer, odometer, tachometer, hour-meter, voltmeter, oil pressure gauge, and water temperature
gauge are microprocessor driven. All other gauges are directly driven by either a sensor or mechanical
connection. Gauges and meters are free floating at power off (key switch turned off) and may not return to a
"zero" position when electrical power is removed.

1.2. SPEEDOMETER GAUGE

An electronic speedometer gauge (Figure 2) is located in the instrument cluster and it indicates miles and
kilometers per hour. The electronic speedometer system consists of the dash mounted air core gauge,
microprocessor, transmission mounted vehicle speed sensor (VSS), engine ECM2, data link and circuits
that connect the units.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 3

Figure 2 Speedometer Gauge

1.3. ODOMETER
The odometer (Figure 3) is a solenoid activated mechanical counter unit driven by the cluster microprocessor
to log mileage traveled by the vehicle.

Figure 3 Odometer

1.4. TACHOMETER GAUGE

The electronic tachometer gauge (Figure 4) is located in the instrument cluster to record engine RPM
(Revolutions Per Minute). The instrument enables drivers to keep engine speed within an efficient operating
range. The electronic tachometer system consists of a dash mounted air core gauge and microprocessor,
engine mounted camshaft position sensor, engine ECM2, data link and circuits that connect the units.

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4 INSTRUMENTS (Data Link Driven Instrument Cluster)

Figure 4 Tachometer Gauge

1.5. HOUR-METER
The hour-meter (Figure 5) is a solenoid activated mechanical counter type unit driven by the cluster
microprocessor.

Figure 5 Hour-meter

1.6. VOLTMETER GAUGE

An electronic voltmeter gauge (Figure 6) is located in the instrument cluster. It is used to indicate the battery
voltage available for the vehicle systems.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 5

Figure 6 Voltmeter Gauge

1.7. ENGINE OIL PRESSURE GAUGE

An electronic engine oil pressure gauge (Figure 7) is located in the instrument cluster. It is used to indicate
the engine oil pressure.

Figure 7 Engine Oil Pressure Gauge

1.8. DUAL AIR PRESSURE GAUGE

A dual readout pressure gauge (Figure 8) is located in the instrument cluster. It is used to indicate the air
pressure in both the primary and secondary systems.

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6 INSTRUMENTS (Data Link Driven Instrument Cluster)

Figure 8 Dual Air Pressure Gauge

1.9. FUEL LEVEL GAUGE

An electric fuel level gauge (Figure 9) is located in the instrument cluster. It is used to indicate the amount of
fuel contained in the vehicle’s fuel tank(s).

Figure 9 Fuel Level Gauge

1.10. ENGINE WATER TEMPERATURE GAUGE

An electronic engine water temperature gauge (Figure 10) is located in the instrument cluster. It is used to
indicate the operating temperature of the engine.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 7

Figure 10 Engine Water Temperature Gauge

1.11. TRANSMISSION OIL TEMPERATURE GAUGE

An electronic transmission oil temperature gauge (Figure 11) is located in the instrument cluster. It is used to
indicate the operating transmission oil temperature of the transmission.

Figure 11 Transmission Oil Temperature Gauge

1.12. AMMETER GAUGE

The ammeter gauge (150 AMP) (Figure 12) is connected between the batteries ("B" terminal of cranking motor
solenoid) and the alternator "B" terminal which has connected to it the vehicle loads (less the cranking motor).
Thus when the alternator is charging the batteries, current flows through the ammeter and registers a positive
reading. When the vehicle loads are greater than the output of the alternator, power flows from the batteries
through the ammeter in the opposite direction, registering a negative reading.

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8 INSTRUMENTS (Data Link Driven Instrument Cluster)

Figure 12 Ammeter Gauge

1.13. INDICATOR AND WARNING LIGHTS

OIL/WATER

The "OIL/WATER" warning light (Figure 1, Item 1.A) and red lens provide a warning, to driver of the vehicle,
that the engine’s oil pressure is running low, that its coolant temperature is running high, or the coolant level is
low (with electronic engines). Thus the driver can take the necessary actions to protect the engine. This light is
also used with International engines to signal that the engine is going to shut down in 30 seconds due to either
idle shutdown counter or engine protection system.

((P)) BRAKE PRESS

The "BRAKE PRESS" warning light (Figure 1, Item 1.B) and red lens provide a warning, to the driver of the
vehicle, that one of the following conditions is present: the air pressure has dropped below an acceptable level
to keep the brakes fully released with an air brake system, or that there is an abnormal condition detected
by the hydraulic brake monitor module.

STOP ENGINE

The "STOP ENGINE" warning light (Figure 1, Item 1.C) and red lens, used with International engines, provide
a warning, to the driver of the vehicle, that the engine is going to shut down in 30 seconds due to either the
idle shutdown timer or engine protection circuits.

CHANGE OIL

The "CHANGE OIL" warning light (Figure 1, Item 1.D) and yellow lens provide an indication, to the driver of
the vehicle, that it is time to get the vehicle in for an oil change. This feature, available on vehicles with
the International consolidated engine controller (CEC), keeps track of mileage and engine hours by using
a programmed service interval counter to determine that it is time to change the engine oil and turn on the
warning light.

WARN ENGINE

The "WARN ENGINE" warning light (Figure 1, Item 1.E) and yellow lens provide a warning, to the driver of the
vehicle, that a sensor or system of the engine is not performing as it should. This condition could be affecting
performance and or emissions, and indicates that the driver should get the vehicle into a shop for servicing.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 9

This light is also used in conjunction with the (STI) Self Test Initialization switch and "STOP ENGINE" light
to display active and inactive engine fault codes.

TRAC CNTL

The "TRAC CNTL" warning light (Figure 1, Item 1.F) and green lens provide a warning, to the driver of the
vehicle, that the optional traction control circuitry has been engaged, and that the anti-lock braking has been
switched off.

CHECK TRANS

The "CHECK TRANS" warning light (Figure 1, Item 1.G) and yellow lens provide a warning, to the driver of the
vehicle, that the transmission is overheating (with Allison nonelectronic transmissions), or that the transmission
is overheating, or the ECU senses a problem with the Allison WTEC III electronic transmissions or with
the Allison 2000 (LCT) transmissions.

LEFT TURN

The left turn arrow indicator light (Figure 1, Item 2) and green lens provide an indication, to the driver of the
vehicle, that the turn signal switch is in the left turn position by blinking in unison with the turn signal lights.

(ABS) ANTI-LOCK BRAKE

The "ABS" indicator light (Figure 1, Item 3) and yellow lens provide an indication, to the driver of the vehicle,
that the anti-lock brake system is activating and overriding the engine retarder. The light will also illuminate
when a fault in the ABS system is detected by the ABS controller.

HIGH BEAM

The high beam indicator light (Figure 1, Item 8) and blue lens provide an indication, to the driver of the vehicle,
that the headlights are on and switched to the bright position.

RIGHT TURN

The right turn arrow indicator light (Figure 1, Item 9) and green lens provide an indication, to the driver of the
vehicle, that the turn signal switch is in the right turn position by blinking in unison with the turn signal lights.

WAIT-TO-START

The "WAIT-TO-START" warning light (Figure 1, Item 10.A) and yellow lens signals the driver to hold off on
cranking over the engine until the glow plugs have heated up.

PDL

The power divider lock "PDL" warning light (Figure 1, Item 10.B) and yellow lens provide an indication, to the
driver of the vehicle, that the power divider lock is engaged. Thus the driver can remember to unlock the power
divider when acceptable road surfaces are reached.

((P)) PARK BRAKE

The "((P)) PARK BRAKE" warning light (Figure 1, Item 10.C) and red lens provide an indication, to the driver of
the vehicle, that the parking brake is applied. This light is utilized with both air and hydraulic brake systems.

((P)) LOW AIR

The "((P))"ark brake "LOW AIR" warning light (Figure 1, Item 10.C) and red lens warns the driver that the air
park brake system has either not yet pumped up to a pressure that will reliably release the park brake, or that
the system is losing pressure and the park brake is going to apply. The light is used only with SE code orders.

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10 INSTRUMENTS (Data Link Driven Instrument Cluster)

WSHLD WASH FLUID

The "WSHLD WASH FLUID" warning light (Figure 1, Item 10.D) and yellow lens provide an indication, to the
driver of the vehicle, that the windshield washer reservoir tank is low on windshield washer fluid.

FRONT AXLE

The "FRONT AXLE" warning light (Figure 1, Item 10.E) and yellow lens provide an indication, to the driver of
the vehicle, that the transfer case has shifted to transfer power to the front drive shaft and axle, thus indicating
that the vehicle is in four wheel drive.

DIFF LOCK ENGAGED

The "DIFF LOCK ENGAGED" warning light (Figure 1, Item 10.F) and yellow lens provide an indication, to
the driver of the vehicle, that the differential lock is engaged. Thus the driver can remember to unlock the
differential when acceptable road surfaces are reached.

SUSP LOW AIR

The "SUSP LOW AIR" warning light (Figure 1, Item 10.G) and red lens warn the driver that the air suspension
system has not yet pumped up to a safe level for operation, or that a leak has developed in the system
and that it is deflating.

WATER-IN-FUEL

The "WATER-IN-FUEL" warning light (Figure 1, Item 12.A) and yellow lens provide an indication, to the driver
of the vehicle, that there is water up to the probe in the fuel filter. Thus the driver knows that the filter must
be drained or changed to prevent water from getting into the engine.

FUEL FILTER

The "FUEL FILTER" warning light (Figure 1, Item 12.B) and yellow lens provide an indication, to the driver of
the vehicle, that the fuel filter is becoming excessively plugged or restricted. Thus the filter should be changed
to prevent hard starting, power limiting, or stalling.

PTO

A location for a bodybuilder to install a "Power Take Off (PTO)" warning light (Figure 1, Item 12.C) is supplied
in the instrument cluster, and a red lens is also provided.

LOW BRAKE FLUID

A "LOW BRAKE FLUID" warning light (Figure 1, Item 12.D) and red lens is used to warn the driver of the
vehicle that the brake master cylinder is low on fluid.

RETARD ON

The "RETARD ON" indicator light (Figure 1, Item 17.A) and green lens provide an indication, to the driver
of the vehicle, that the transmission retarder has been enabled. Thus the driver will be reminded to turn
off the retarder when road surfaces are slippery.

CHANGE TRANS FILTER

The "CHANGE TRANS FILTER" warning light (Figure 1, Item 17.B) and yellow lens provide a warning, to the
driver of the vehicle, that the transmission fluid filter has become restricted.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 11

RETARD OVER HEAT

The "RETARD OVER HEAT" warning light (Figure 1, Item 17.C) and red lens provide an indication, to the
driver of the vehicle, that the transmission retarder has reached an unsafe operating temperature. At this point
the driver should switch off the retarder and allow it to cool before turning it back on.

ALTERNATOR

An "ALTERNATOR" warning light (Figure 1, Item 17.D) and yellow lens provide an indication, to the driver of
the vehicle, that the charging voltage to the battery is low.

2. OPERATION
2.1. SPEEDOMETER GAUGE
The sensor (Figure 13) is a magnetic pick up that senses the rotation of a speedometer gear mounted in the
transmission. A permanent magnet located in the sensor establishes a magnetic field at the tip of the sensor.
The field is repeatedly interrupted by the teeth of the speedometer gear in the transmission, creating voltage
impulses from the vehicle speed sensor (VSS). When Fuller manual transmission, these are transmitted
through connector (303), on circuits K47 and K47A, to connector (6021) on the ECM2. When Allison WTEC
automatic transmission, these are transmitted from connector (7983), on circuits K139 and K148, to connector
(7203) on the ECU, and these are transmitted from the control module connector (7204), on circuits K157, to
connector (6021) on the ECM2. Or, Allison 2000 (LCT) automatic transmission, these are transmitted from
connector (7600), on circuits K215 and K216, to connector (7304) on the TCM, and these are transmitted
from the control module connector (7305), on circuits K126/K126W, to connector (6021) on the ECM2. The
ECM2 converts the sensor signal to a digital data signal. This signal is transferred over the data link on
circuits A98E(+) and A98F(-) to pins 7 and 9 of connector (11), into the instrument cluster. The instrument
cluster’s microprocessor drives the speedometer.

Figure 13 Speedometer Operation

1. SENSOR OUTPUT VOLTAGE
2. SENSOR
3. MAGNETIC FIELD
4. SPEEDOMETER GEAR
5. TRANSMISSION

A permanent magnet located in the sensor establishes a magnetic field at the tip of the sensor. The magnetic
field is repeatedly interrupted by the teeth of the speedometer gear in the transmission, creating voltage
impulses that are transmitted to the ECM2 which converts the analog signal to a digital data signal and feeds
it to the speedometer.

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2.2. ODOMETER
The electronic odometer system consists of a dash mounted, solenoid activated, mechanical counter and
microprocessor. The microprocessor’s internal counter advances the odometer 1/10 mile after counting the
appropriate distance based on vehicle speed sensor information. In addition, the microprocessor’s internal
counter advances 1/20 mile every time the ignition is turned on to minimize odometer error by replacing the
accumulated mileage that is less than 1/10 mile (lost when key switch is turned off) with an average value of
1/2 of 1/10 mile or 1/20 mile. This provides for a very accurate odometer.

NOTE – Tire revolutions per mile are the greatest variable in determining speedometer accuracy. Factors
which can affect tire revolutions per mile are tire manufacturing tolerances, tire load, tire pressure,
vehicle speed and tire wear.

2.3. TACHOMETER GAUGE

The camshaft position sensor is a magnetic pickup that senses the rotation of the engine’s camshaft timing
disk. The sensor’s permanent magnet establishes a magnetic field at the tip of the sensor. This magnetic field
is interrupted regularly by the windows in the camshaft timing disk. This interruption creates voltage impulses
that are transmitted to the engine ECM2. The ECM2 converts the sensor signal to a digital data signal. This
signal is transferred over the data link on circuits A98E(+) and A98F(-) to pins 7 and 9 of connector (11), into
the instrument cluster. The instrument cluster’s microprocessor drives the tachometer. Refer to the appropriate
engine service manual for camshaft position sensor operation, adjustment and repair.

2.4. HOUR-METER
The electronic hour-meter system consists of a dash mounted, solenoid activated, mechanical counter and
microprocessor. The microprocessor internal timer advances the hour-meter 1/10 hour for every 6 minutes that
the engine is running (above 300 rpm). In addition, the microprocessor’s internal timer advances its counter 3
minutes every time the ignition is turned on to minimize hour-meter error by replacing the accumulated time
that is less than 1/10 hour (lost when key switch is turned off) with an average value of 1/2 of 1/10 hour or 3
minutes. This provides for a very accurate engine hour-meter.

2.5. VOLTMETER GAUGE

The battery voltage is measured by the engine ECM2, converted to a data signal, and transferred over the
data link to the instrument cluster’s microprocessor. This signal is transferred over the data link on circuits
A98E(+) and A98F(-) to pins 7 and 9 of connector (11), into the instrument cluster. The instrument cluster’s
processor then drives the voltmeter display gauge.

2.6. ENGINE OIL PRESSURE GAUGE

The engine oil pressure is measured by an electrical sending unit, and fed to the engine ECM2. The ECM2
converts the electrical voltage into a data signal, and transfers it over the data link to the instrument cluster’s
microprocessor. This signal is transferred over the data link on circuits A98E(+) and A98F(-) to pins 7
and 9 of connector (11), into the instrument cluster. The instrument cluster’s processor then drives the oil
pressure display gauge.

2.7. DUAL AIR PRESSURE GAUGE

The dual read out pressure gauge is plumbed, with air lines, to both the primary and secondary air systems of
the vehicle, thus displaying the pressure in PSI of both systems (a pointer for each system) at the same time.

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2.8. FUEL LEVEL GAUGE

The battery voltage is to circuit A13/A13F, fuse F22, circuit A28/A28B, the green instrument cluster (11), pin 10
to the fuel gauge. The level of fuel in the vehicle fuel tank is sensed by the fuel sending unit (37). The sending
unit feeds an electrical voltage through circuit K36, pin A of connector (37), circuit K36, pin D of connector (2)
and circuit A36, pin 3 of connector (11) to the fuel gauge, which displays the fuel level. The fuel sender (37) pin
B is grounded through circuits K36–G/K11–GJ to the (J10) engine ground. The fuel gauge is grounded through
pin 2 of connector (11) circuits A28–G/A11–GB/A11–G to the (J1) platform ground.

2.9. ENGINE WATER TEMPERATURE GAUGE

The engine water temperature is measured by an electrical sending unit and is fed to the engine ECM2. The
ECM2 converts the electrical voltage into a data signal, and transfers it over the data link to the instrument
cluster’s microprocessor. This signal is transferred over the data link on circuits A98E(+) and A98F(-) to
pins 7 and 9 of connector (11), into the instrument cluster. The instrument cluster’s processor then drives
the water temperature display gauge.

2.10. TRANSMISSION OIL TEMPERATURE GAUGE

The battery voltage is to circuit A13/A13F, fuse F22, circuit A28/A28A, the yellow instrument cluster connector
(10), pin 1 to the transmission oil temperature gauge. The transmission temperature is sensed by the
transmission temperature sending unit (38). The sending unit feeds an electrical voltage through pin A of
connector (38), circuit K31, pin F of connector (2) and circuit A31, pin 17 of the yellow instrument cluster
connector (10) to the transmission oil temperature gauge, which displays the transmission oil temperature.
The transmission temperature sending unit (38) pin B is grounded through circuits K31–G/K11–GJ to the (J10)
engine ground. The transmission oil temperature gauge is grounded through pin 6 of connector (10) circuits
A28–GA/A11–GB/A11–G to the (J1) platform ground.

2.11. AMMETER GAUGE (SHUNT)

The ammeter gauge current flows through the circuit K26, pin L of connector (15) and circuit A26, pin 16 of the
yellow instrument cluster connector (10) to the ammeter gauge, which displays the positive or negative current
flow. The ammeter gauge is grounded through pin 7 of connector (10) circuits A26A, pin M of connector (15),
circuits K26A and K26A-FL to the "B" terminal of cranking motor solenoid.

2.12. INDICATOR AND WARNING LIGHTS

OIL/WATER: FE 300 With Air Brakes

The alarm receives power from fuse F24 over circuit A13B, and the oil/water warning light receives power
from fuse F22, circuits A28 and A28A, and yellow instrument cluster connector (10), pin 5. The warning light
illuminates when a ground path is applied to yellow instrument cluster connector (10), pin 10 by circuits
A29A/35 and A97AF by the MSM1 (3111M), pin 1. The alarm will also sound at a slow rate when a ground
path is applied by the MSM1 in response to low oil pressure, high water temperature, or low coolant level.

The battery voltage is through circuits A13/A13F, fuse F22, circuits A28/A28A, yellow instrument cluster
connector (10), pin 5 to the “OIL/WATER" indicator. The “OIL/WATER" indicator is controlled by the ECM2
(6020). The control from ECM2 connector (6020), pins 12 and 13, is transferred over the data link on circuits
K5AA(+) and K5AA(-) through pins A and C of connector (3084K), to the MSM1, circuits A5DMS(+) and
A5DMS(-) to connector (3111) pins 5 and 6. A ground is sent from the MSM1 connector (3111M) through pin 1,
circuit A97AF, to pin 1 of the audible alarm connector (211). This causes the indicator to illuminate.

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OIL/WATER: FE 300 With Hydraulic Brakes

The alarm receives power from fuse F24 over circuit A13B, and the oil/water warning light receives power
from fuse F22, circuits A28 and A28A, and yellow instrument cluster connector (10), pin 5. The warning light
illuminates when a ground path is applied to yellow instrument cluster connector (10), pin 10 by circuits
A29A/35 and A97AF by the MSM1 (3111M), pin 1. The alarm will also sound at a slow rate when a ground
path is applied by the MSM1 in response to low oil pressure, high water temperature, or low coolant level.

The battery voltage is through circuits A13/A13F, fuse F22, circuits A28/A28A, yellow instrument cluster
connector (10), pin 5 to the “OIL/WATER" indicator. The “OIL/WATER" indicator is controlled by the ECM2
(6020). The control from ECM2 connector (6020), pins 12 and 13, is transferred over the data link on circuits
K5AA(+) and K5AA(-) through pins A and C of connector (3084K), to the MSM1, circuits A5DMS(+) and
A5DMS(-) to connector (3111) pins 5 and 6. A ground is sent from the MSM1 connector (3111M) through pin 1,
circuit A97AF, to pin 1 of the audible alarm connector (211). This causes the indicator to illuminate.

Oil/Water: IC

The engine ECM monitors the oil pressure, coolant temperature, and coolant level sensors, and when the
oil pressure or coolant level drops below a programmed value or the water temperature climbs above a
programmed value, the ECM will set its connector (379)/pin 54 to a low state (ground). This activates the
warning alarm (20) at a slow rate by allowing current to flow from circuit 28D through the alarm (R1), through
circuit 97AF, connector (2), circuit 97AF to the ECM (379).

The battery voltage is through fuse F24, circuits A28/28D at the alarm is fed to the oil/water warning light
connector (26)/pin 5. When the ECM (379) sets pin 54 to a low state (applies a ground), the oil/water light
will illuminate and the alarm (R1) will sound at a slow rate as current flows through it, connector (26)/pin 10,
circuits 29/35 and 97AF, connector (2), circuits 97AF.

BRAKE PRESS: FE 300 With Hydraulic Brakes

When the hydraulic brake pressure system monitor module (86) detects a problem with the brake system, it
applies a ground to circuit A90M, connector and blocking diode (25), and circuit A90NA to the alarm (211).
Power will then flow from fuse F24 through circuit A13B and alarm connector (211), causing the alarm to sound
at a fast rate. When a problem is detected, a ground is also applied by circuit A90M, connector (25), circuit
A90N, and yellow instrument cluster connector (10), pin 3 to the brake warning light, causing it to illuminate.
The brake warning light, the battery voltage is through circuits A13/A13F, fuse F22, circuits A28 and A28C,
and yellow instrument cluster connector (10), pin 1.

BRAKE PRESS: FE 300 With Air Brakes

The brake press warning light, the battery voltage is through circuits A13/A13F, fuse F22, circuits A28 and
A28A, and natural instrument cluster connector (10), pin 1. When the air pressure drops below 60 psi, the
pressure switch will close, and power will flow through the warning light, natural instrument cluster connector
(10), pin 3, circuits A40A and A40, connector (2), pin A4, circuit K40 and the low air pressure switch (717) to
ground (1LA). This will cause the brake press warning light to illuminate, and the warning alarm (211) to sound
at a fast rate. The warning alarm receives power from fuse F24 over circuit A13B.

Brake Pressure: IC With Hydraulic Brakes

When the hydraulic brake system monitor module (49) detects a problem with the brake system, it applies
a ground to circuits 90S and 90T. The alarm (20) receives power from fuse F24 over circuit 28D, and when
circuit 90S is switched to ground, the alarm will sound at a fast rate. The brake pressure warning light is
supplied power from fuse F24, circuits 28 and 28A, and connector (26)/pin 1. When circuit 90T is switched to
ground, power will flow through the brake pressure warning light (causing it to illuminate), connector (26)/pin 3,
and circuit 90T to the brake monitor module (49).

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 15

Brake Pressure: IC With Air Brakes

The brake pressure warning light is fed power by fuse F24, circuits 28 and 28A, and connector (26)/pin 1.
When the air pressure drops below 60 psi, the pressure switch will close, and power will flow through the
warning light, connector (26)/pin 3, circuits 40, 40B, and 40A, connector (2), and circuit 40 through the low air
pressure switch to ground. This will cause the brake pressure warning light to illuminate, and the warning
alarm (20) to sound at a fast rate. The alarm receives power from fuse F24 over circuit 28D.

STOP ENGINE: FE 300 AND IC

SE item not covered at this time.

CHANGE OIL: FE 300

The engine ECM2 is programmed to track engine hours and vehicle miles, and when the programmed values
are achieved, the ECM2 will turn on the “CHANGE OIL" indicator. The battery voltage is through circuits
A13/A13F, fuse F22, circuits A28/A28K, yellow instrument cluster connector (10), pin 4 to the “CHANGE OIL"
indicator. The “CHANGE OIL" indicator is controlled by the ECM2 (6020). The control from ECM2 connector
(6020), pins 12 and 13, is transferred over the data link on circuits K5AA(+) and K5AA(-) through pins A
and C of connector (3084K), to the MSM1 connector (3111) pins 5 and 6. A ground is sent from the MSM2
connector (3111) through pin 2, circuit A97AA, to pin 11 of the yellow instrument cluster connector (10).
This causes the indicator to illuminate.

NOTE – The Change Oil/Service interval light default setting is off. The customer can use the service tool
to activate the light and enter their own parameters into the ECM2 memory. The STI button (diagnostics
flash button) is used to reset the service interval reminder light.

CHANGE OIL: IC

The engine ECM is programmed to track engine hours and vehicle miles, and when the programmed values
are achieved, the ECM will apply a ground to connector (379)/pin 45, circuit 97AA, connector (2), and circuit
97AA to the change oil warning light connector (26)/pin 11. This will cause the change oil warning light, which
is fed power from fuse F24 and circuits 28 and 28D through connector (26)/pin 4 to illuminate.

WARN ENGINE: FE 300

When the ECM2 detects a faulty sensor or circuit, it will set a fault code and turn on the “WARN ENGINE"
indicator. The battery voltage is through circuits A13/A13F, fuse F22, circuits A28/A28K, green instrument
cluster connector (10), pin 4 to the “WARN ENGINE" indicator. The “WARN ENGINE" indicator is controlled by
the ECM2 (6020). The control from ECM2 connector (6020), pins 12 and 13, is transferred over the data link
on circuits K5AA(+) and K5AA(-) through pins A and C of connector (3084K), to the MSM1 connector (3111)
pins 5 and 6. A ground is sent from the MSM1 connector (3111) through pin 9, circuit A97T, to pin 12 of the
yellow instrument cluster connector (10). This causes the indicator to illuminate.

WARN ENGINE: IC

When the ECM detects a faulty sensor or circuit, it will set a fault code and turn on the engine warn light by
switching connector (379)/pin 55 to ground. This allows power to flow from fuse F24 through circuits 28 and
28D, connector (26)/pin 4, the engine warn light, connector (26)/pin 12, circuit 97T, connector (2), circuit 97T,
and ECM connector (379/pin 55. This will cause the engine warn light to illuminate.

TRAC CTRL: FE 300 With Anti-lock Brake System (ABS) — Hydraulic Brakes

The battery voltage is through circuits A13/A13F, fuse F27, circuits A13J and A94T, to the “TRAC CTRL”
warning light, connector (1500), pin A, connector (1500), pin B, circuit A94U, connector (2), pin F6, circuit
N94U, to the full power HCV connector (9808), pin 13. When the traction control switch (1101) is placed (on)

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16 INSTRUMENTS (Data Link Driven Instrument Cluster)

position, the “TRAC CTRL” warning light to grounded through the full power HCV connector (9808), pin 8,
circuit N94W, connector (2), pin A2, circuit A94W, the traction control switch (1101), circuits A94-GT and A11-G
to the platform ground (1PG). The ABS module (ECU) (279) will enable the traction control mode and when
the wheel sensors sense wheel slip, the module will apply 12 volts to the modulator valve for the brake to
apply to the wheel that is slipping.

TRAC CTRL: FE 300 With WTEC or Allison 2000 ICT Anti-lock Brake System (ABS) — Air Brakes

The battery voltage is through circuits A13/A13C, fuse F27, circuits A13J and A94BT/A94DT, to the traction
control switch (1101) and is placed (on) position, circuit N94FT, connector (2), pin A7, circuit N94FT, to the
ABS module (ECU) connector (288), pin F2. Also, the battery voltage is to circuits A94BT/A94GT, to the
“TRAC CTRL” warning light, connector (3127), pin B, connector (3127), pin A, circuit A94CT, connector (2),
pin A5, circuit N94CT, to the ABS module (ECU) connector (288), pin C2. The “TRAC CTRL” warning light
and the traction control switch are grounded through the coil of the ABS power relay (283), circuits A94–GB
and A11-GB to the platform ground (4PG). The ABS module (ECU) (288) will enable the traction control
mode and when the wheel sensors sense wheel slip, the module will apply 12 volts to the modulator valve
for the brake to apply to the wheel that is slipping.

TRAC CTRL: IC

SE item not covered at this time.

CHECK TRANS: FE 300 With Allison WTEC III With Hydraulic Brakes

When the Allison ECU detects that the transmission is overheating or that there is a problem with the WTEC
III system, it will apply a ground to circuit K115 at connector (7204), pin 31. The battery voltage is through
circuits A13/A13F, fuse F22, circuits A28 and A28A, and yellow instrument cluster connector (10), pin 2, the
“CHECK TRANS” warning light, connector (10), pin 1, circuit A125, connector (377), circuit A115, connector
(644), circuit N125, connector (523), circuit K115, and ECU connector (7204), pin 31, to ground. This will cause
the “CHECK TRANS” warning light to illuminate.

CHECK TRANS: FE 300 With Allison WTEC III GEN 4 With Hydraulic Brakes

When the Allison ECU detects that the transmission is overheating or that there is a problem with the WTEC III
GEN 4 system, it will apply a ground to circuit K129 at connector (7150), pin 29. The battery voltage is through
circuits A13/A13F, fuse F22, circuits A28 and A28A, and yellow instrument cluster connector (10), pin 2, the
“CHECK TRANS” warning light, connector (10), pin 1, circuit A125, connector (377), circuit A115, connector
(644), circuit N129, connector (523), circuit K129, and ECU connector (7150), pin 29, to ground. This will
cause the “CHECK TRANS” warning light to illuminate.

CHECK TRANS: FE 300 With Allison WTEC III With Air Brakes

When the Allison ECU detects that the transmission is overheating or that there is a problem with the WTEC
III system, it will apply a ground to circuit K115 at connector (7204), pin 31. The battery voltage is through
circuits A13/A13F, fuse F22, circuits A28 and A28A, and yellow instrument cluster connector (10), pin 2, the
“CHECK TRANS” warning light, connector (10), pin 1, circuit A125, connector (377), circuit A125, connector
(644), circuit N125, connector (523), circuit K115, and ECU connector (7204), pin 31, to ground. This will cause
the “CHECK TRANS” warning light to illuminate.

CHECK TRANS: FE 300 With Allison WTEC III GEN 4 With Air Brakes

When the Allison ECU detects that the transmission is overheating or that there is a problem with the WTEC
III GEN 4 system, it will apply a ground to K129 at connector (7150), pin 29. The battery voltage is through
circuits A13/A13F, fuse F22, circuits A28 and A28A, and yellow instrument cluster connector (10), pin 2, the
“CHECK TRANS” warning light, connector (10), pin 1, circuit A125, connector (377), circuit A125, connector

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 17

(644), circuit N129, connector (523), circuit K129, and ECU connector (7150), pin 29, to ground. This will
cause the “CHECK TRANS” warning light to illuminate.

CHECK TRANS: FE 300 With Allison 2000 (LCT)

When the Allison ECU detects that the transmission is overheating or that there is a problem with the 2000
(LCT) system, it will apply a ground to circuit K125 at connector (7305), pin 25. The battery voltage is through
circuits A13/A13F, fuse F22, circuits A28 and A28A, and yellow instrument cluster connector (10), pin 2, the
“CHECK TRANS” warning light, connector (10), pin 1, circuit A125, connector (377), circuit A125, connector
(644), circuit N125, connector (9875), circuit K125, and ECU connector (7305), pin 25, to ground. This will
cause the “CHECK TRANS” warning light to illuminate.

CHECK TRANS: FE 300 With Allison 1000/2000 GEN 4

When the Allison ECU detects that the transmission is overheating or that there is a problem with the
1000/2000 GEN 4 system, it will apply a ground to circuit K129 at connector (7150), pin 29. The battery
voltage is through circuits A13/A13F, fuse F22, circuits A28 and A28A, and yellow instrument cluster connector
(10), pin 2, the “CHECK TRANS” warning light, connector (10), pin 1, circuit A125, connector (377), circuit
A125, connector (644), circuit N129, connector (9875), circuit K129, and ECU connector (7150), pin 29, to
ground. This will cause the “CHECK TRANS” warning light to illuminate.

CHECK TRANS: IC With Allison MD

When the Allison ECU detects that the transmission is overheating or that there is a problem with the Allison
MD system, it will apply a ground to circuit 115 at connector (634)/pin 31. This will allow power to flow through
fuse F24, circuits 28 and 28A, connector (26)/pin 1, the Check Trans. warning light, connector (26)/pin 2,
circuit 92A, connector (377), circuit 115, connector (418), circuit 115, and ECU connector (634)/pin 31 to
ground. This will cause the Check Transmission warning light to illuminate.

LEFT TURN: FE 300 With International Turn Signal Switch (Stationary Column)

When the turn signal switch is placed in the left turn position, power flows through the turn signal switch and
violet wire, connector (13)/pin D, circuits A56 and A56B to the left turn indicator connector (11)/pin 6. This will
cause the left turn indicator, grounded through connector (11)/pin 2 and circuits A28-G and A11-G to (1PG)
platform ground, to illuminate as the turn signal flasher blinks the turn signal lights.

LEFT TURN: FE 300 With Douglas Turn Signal Switch (Tilt Column)

When the turn signal switch is placed in the left turn position, power flows through the turn signal switch and
yellow wire, connector (13)/pin E, circuits A56 and A56B to the left turn indicator connector (11)/pin 6. This will
cause the left turn indicator, grounded through connector (11)/pin 2 and circuits A28-G and A11-G to (1PG)
platform ground, to illuminate as the turn signal flasher blinks the turn signal lights.

LEFT TURN: IC With International Turn Signal Switch (Stationary Column and Tilt Column)

When the turn signal switch is placed in the left turn position, power flows through the turn signal switch and
orange wire, connector (193) pin D, circuits 56, 56S, and 56C to the left turn indicator connector (27)/pin 6.
This will cause the left turn indicator, grounded through connector (27)/pin 2 and circuits 28-GA and 11-G to
cab ground, to illuminate as the turn signal flasher blinks the turn signal lights.

(ABS) ANTI-LOCK BRAKE: FE 300 With WTEC or Allison 2000 ICT Air Brakes

When the air anti-lock brake control module performs a bulb check or logs a fault code, it will set connector
(288), pin E3, low (to ground). The battery voltage is through circuits A13/A13C, fuse F27, circuits A13J
connector (168) and A13E/A13K, the coil of the warning light relay (284), circuit A94B, connector (297),
circuit A94E, A94H, connector (451), and a gray wire to the ABS module (288),pin E3. This energizes the

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warning light relay (284), and allows power to flow through fuse (F27), circuits A28, A94B, the anti-lock brake
warning light (297), circuit A94E, the warning light relay (284). This will cause the warning light (297), which
is grounded through circuit A94E, normally open contacts of the warning light relay (284), circuits A94-GA
and A11-GB to platform ground (4PG), to illuminate.

(ABS) ANTI-LOCK BRAKE: FE300 With Hydraulic Brakes GEN 4

When the hydraulic anti-lock brake control module performs a bulb check or logs a fault code, it will set
connector (279), pin 1, low (to ground). The battery voltage is through circuits A13/A13C, fuse F27, circuits
A94D, the coil of the warning light relay (R1), circuit A94H, connector (2), circuit K94H, connector (261), circuit
A94H, and a gray wire to the ABS module (279), pin 7. This energizes the warning light relay (R1), and allows
power to flow through fuse (F22), circuits A28, A94B, the anti-lock brake warning light (422), circuit A94E, the
warning light relay (R1), circuit A94H, connector (2), circuit K94A, to the hydraulic ABS module (279), pin 1.
This will cause the warning light (422), which is grounded through circuit A94E, normally open contacts of the
warning light relay (R1), circuits A94-GB and A11-G to platform ground (4PG), to illuminate.

(ABS) ANTI-LOCK BRAKE: IC Air Brakes

When the antilock brake control module performs a bulb check or logs a fault code, it will set connector
(288)/pin E3 low (to ground). This will allow power to flow from fuse F24 through circuits 28, 94D, the coil of
the warning light relay (R4), circuit 94H, connector (2), and a gray wire to the ABS module (288)/pin E3. This
energizes the warning light relay (R4), and allows power to flow through fuse F24, circuits 94F, connector (422),
and the antilock brake warning light. This will cause the warning light, which is grounded through circuit 94E,
normally open contacts of the warning light relay (R4), circuits 94-GC and 11-G to cab ground, to illuminate.

(ABS) ANTI-LOCK BRAKE: IC Hyd Brakes

When the antilock brake control module performs a bulb check or logs a fault code, it will set connector
(279)/pin 1 low (to ground). This will allow power to flow from fuse F24 through circuits 28, 94D, the coil of
the warning light relay (R4), circuit 94H, connector (2), and a gray wire to the ABS module (279)/pin 1. This
energizes the warning light relay (R4), and allows power to flow through fuse F24, circuits 94F, connector (422),
and the antilock brake warning light. This will cause the warning light, which is grounded through circuit 94E,
normally open contacts of the warning light relay (R4), circuits 94-GC and 11-G to cab ground, to illuminate.

HI BEAM: FE 300 With Douglas Turn Signal Switch (Tilt Column)

When the headlight switch (23) is moved to the on position and the dimmer switch (4) is placed in the high beam
position, power will flow through circuit A51, dimmer switch connector (4), a green wire, the switch contacts, a
brown wire, connector (4), circuits A52 and A52A, and the high beam indicator lamp and connector (11)/pin
4. Thus the lamp, grounded through connector (11)/pin 2 and circuits A28-G and A11-G to platform ground
(1PG), will illuminate, indicating that the headlights are on and the dimmer switch is in the high beam position.

HI BEAM: FE 300 With International Turn Signal Switch (Stationary Column)

When the headlight switch (23) is moved to the on position and the dimmer switch (6) is placed in the high
beam position, power will flow through circuit A51, circuit A51A, the normally closed contacts of lift-to-dim
headlight relay (100), circuits A52C and A52A, and the high beam indicator lamp and connector (11)/pin 4.
Thus the lamp, grounded through connector (11)/pin 2 and circuits A28-G and A11-G to platform ground (1PG),
will illuminate, indicating that the headlights are on and the dimmer switch is in the high beam position.

HI BEAM: IC With International Turn Signal Switch (Stationary Column)

When the headlight switch (23) is moved to the on position and the dimmer switch (6) is placed in the high
beam position, power will flow through circuit 51, circuit 51A, the normally closed contacts of lift-to-dim
headlight relay (100), circuits 52C and 52A, and the high beam indicator lamp and connector (27)/pin 4. Thus

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 19

the lamp, grounded through connector ((27)/pin 2 and circuits 28-G and 11-G to platform ground (1PG), will
illuminate, indicating that the headlights are on and the dimmer switch is in the high beam position.

RIGHT TURN: FE 300 With International Turn Signal Switch (Stationary Column)

When the turn signal switch is placed in the right turn position, power flows through the turn signal switch and
orange/red wire, connector (13)/pin F, circuits A57 and A57B to the right turn indicator connector (11)/pin 12.
This will cause the right turn indicator, grounded through connector (11)/pin 2 and circuits A28-G and A11-G to
(1PG) platform ground, to illuminate as the turn signal flasher blinks the turn signal lights.

RIGHT TURN: FE 300 With Douglas Turn Signal Switch (Tilt Column)

When the turn signal switch is placed in the right turn position, power flows through the turn signal switch and
light blue wire, connector (13)/pin F, circuits A57 and A57B to the right turn indicator connector (11)/pin 12.
This will cause the right turn indicator, grounded through connector (11)/pin 2 and circuits A28-G and A11-G to
(1PG) platform ground, to illuminate as the turn signal flasher blinks the turn signal lights.

RIGHT TURN: IC With International Turn Signal Switch (Stationary Column and Tilt Column)

When the turn signal switch is placed in the right turn position, power flows through the turn signal switch and
blue wire, connector (193)/pin F, circuits 57, 57S, and 57C to the right turn indicator connector (27)/pin 12. This
will cause the right turn indicator, grounded through connector (27)/pin 2 and circuits 28-GA and 11-G to cab
ground, to illuminate as the turn signal flasher blinks the turn signal lights.

WAIT-TO-START: FE 300

When the key switch is initially moved to the ignition position, the engine controller ECM2 (6020) will activate
the glow plugs and the “WAIT-TO-START" indicator. The battery voltage is through circuits A13/A13F, fuse
F22, circuits A28/A28C, natural instrument cluster connector (12), pin 8 to the “WAIT-TO-START" indicator.
The “WAIT-TO-START" indicator is controlled by the ECM2 (6020). The control from ECM2 connector (6020),
pins 12 and 13, is transferred over the data link on circuits K5AA(+) and K5AA(-) through pins A and C of
connector (3084K), to the MSM1 connector (3111) pins 5 and 6. A ground is sent from the MSM1 connector
(3111) through pin 10, circuit A97AE, to pin 5 of the natural instrument cluster connector (12). This causes the
indicator to illuminate.

WAIT-TO-START: IC With International T 444E Engine

When the key switch is initially moved to the ignition position on vehicles equipped with T 444E engines, the
engine controller (379) will activate the glow plugs and apply a ground to pin 53. This will illuminate the wait to
start warning light, which is fed battery power through connector (28)/pin 8, as a ground is applied to the light
by connector (28) pin 5, circuit 18-G, connector (2), circuit 18-G, and ECM and connector (379) pin 53.

PDL: FE 300 AND IC

SE item not covered at this time.

((P)) PARK BRAKE: FE 300 With Hydraulic Brakes

Power is fed by the battery voltage is through circuits A13/A13F, fuse F22 to circuits A28 and A28C and the
“((P)) PARK BRAKE” warning light and connector (12)/pin 8. When the parking brake is applied, power will
flow through the warning light and connector (12)/pin 17, circuits A44A and K44A, the park brake switch
(218), and circuits K44-G and K11-GD to start motor ground. This will cause the park brake warning light to
illuminate, indicating that the parking brake is applied. The lamp will also illuminate when the key switch
(20) is moved to the start position, and a ground is applied through circuit A44, a brake diode (82), and
circuit A90X, performing a bulb check.

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20 INSTRUMENTS (Data Link Driven Instrument Cluster)

((P)) PARK BRAKE: FE 300 With Air Brakes

Power is fed by the battery voltage is through circuits A13/A13F, fuse F22 to circuits A28 and A28C and the
“((P)) PARK BRAKE” warning light and connector (12)/pin 8. When the parking brake is applied, power will flow
through the warning light and connector (12)/pin 17, circuits A44 to the park brake switch (218), and circuits
A44GA to platform ground. This will cause the park brake warning light to illuminate, indicating that the parking
brake is applied. The lamp will also illuminate when the key switch (20) is moved to the start position, and a
ground is applied through circuit A44GB, a brake diode (64), and circuit A44, performing a bulb check.

((P)) PARK BRAKE: IC With Hydraulic Brakes

Power is applied by fuse 24 to circuits 28 and 28C and the park brake warning light and connector (28)/pin 8.
When the parking brake is applied, power will flow through the warning light and connector (28)/pin 17, circuits
44 and 44A, connector (214), a black wire, connector (218), the park brake switch, connector (218), a white
wire, connector (214), and circuit 44-G to ground. This will cause the park brake warning light to illuminate,
indicating that the park brake is applied. With US and Canadian DRL, additional circuitry is connected between
connector (214). The lamp will also illuminate when the key switch is moved to the start position, and a ground
is applied through circuit 44A or 44B, performing a bulb check.

((P)) LOW AIR: FE 300

SE item not covered at this time.

((P)) LOW AIR: IC

The "((P))"ark brake "LOW AIR" warning light is fed power by fuse F24, circuits 28 and 28C, and connector
(28)/pin 8. When the air pressure drops below 60 psi, the pressure switch will close, and power will flow
through the warning light, connector (28)/pin 9, circuits 40D, connector (1151), and circuit 40D through the low
air pressure switch to ground. This will cause the "((P))"ark brake "LOW AIR" warning light to illuminate, and
the warning alarm (3098) to sound at a fast rate. The alarm receives power from fuse F20 over circuit 40.

WINDSHIELD WASHER FLUID: FE 300 AND IC

SE item not covered at this time.

FRONT AXLE: FE 300 AND IC

SE item not covered at this time.

DIFF. LOCK ENGAGED: FE 300 AND IC

SE item not covered at this time.

SUSP LOW AIR: FE 300 AND IC With Hydraulic Brakes

SE item not covered at this time.

WATER-IN-FUEL: FE 300

The I6 engine ECM2 will turn on the “WATER-IN-FUEL” warning light. The battery voltage is through circuits
A13/A13A, fuse F20, circuits A97AC/A97AB, to the MSM1 connector (3111) pin 7 and to the WIF connector
(3116), pin G, circuit A19K, to the WIF connector (3116), pin C, circuit A19–G, to the “WATER-IN-FUEL”
warning light (9), pin B. The “WATER-IN-FUEL” indicator is controlled by the ECM2 (6020). The control from
ECM2 connector (6020), pins 12 and 13, is transferred over the data link on circuits K5AA(+) and K5AA(-)
through pins A and C of connector (3084K), to the MSM1 connector (3111) pins 5 and 6. A ground is sent
from the MSM2 connector (3111) through pin 3, circuit A19–GD, to the WIF connector (3116), pin H, circuit

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 21

A19F, to the WIF connector (3116), pin B, to the “WATER-IN-FUEL” warning light (9), pin A, thus causing
the “WATER-IN-FUEL” warning light to illuminate.

WATER-IN-FUEL: IC

With the key switch in the ignition or start position, the water-in-fuel module receives power at connector
(470)/pin A from fuse F22, circuit 13A, connector (3), and circuits 13A and 19A. When the key switch is moved
to the start position, a ground is applied to circuit 19A, connector (1150), circuit 19C, connector (2), circuit
19C, going to the water-in-fuel module (470)/pin C. This initiates a bulb check by causing the module to apply
power to connector (470)/pin B, circuit 19B, connector (2), circuit 19B, connector (1150), circuit 19B, and the
water-in-fuel warning light and connector (433). This causes the warning light, grounded through connector
(433) and circuit 19-G to cab ground, to illuminate. When water is detected in the fuel filter by the water probe,
a ground path is completed to the water-in-fuel module (470)/pin D by circuit 19E, connector (401), circuit 19C,
thus causing the water-in-fuel warning light to illuminate.

FUEL FILTER: FE 300

When the fuel filter becomes restricted, the contacts of the fuel filter vacuum switch will close and the ECM2
will turn on the “FUEL FILTER" indicator. The battery voltage is through circuits A28/A19J, fuse F22, circuits
A19J, to the “FUEL FILTER" warning light (69), pin A, in the instrument cluster. The “FUEL FILTER" indicator
is controlled by the ECM2 (6020). The control from ECM2 connector (6020), pins 12 and 13, is transferred
over the data link on circuits K5AA(+) and K5AA(-) through pins A and C of connector (3084K), to the MSM1
connector (3111) pins 5 and 6. A ground is sent from the MSM2 connector (3111) through pin 1, circuit A19K, to
the “FUEL FILTER" warning light (69), pin B, in the instrument cluster. This causes the indicator to illuminate.

FUEL FILTER: IC

With the key switch in the on or start position, power is applied to fuse F24, circuits 28/19F, connector (1150),
and circuit 19F to the fuel filter warning light (434). When the fuel filter becomes restricted, the contacts of the
fuel filter vacuum switch will close and the fuel filter warning light will illuminate as a ground path is applied
through circuit 19D, connector (1150), circuit 19D, connector (2), circuit 19D, connector (401), and circuit
19B to the switch and chassis ground.

PTO: FE 300 AND IC

Refer to information provided by body builder.

LOW BRAKE FLUID: FE 300 With Hydraulic Brakes

With the key switch in the on or start position, battery voltage is through circuits A13/A13F, fuse F22, circuits
A28 and A90R to the “LOW BRAKE FLUID” warning light (89–A). With the key switch held in the start position,
the low brake fluid warning light will illuminate (bulb check is performed) as a ground is applied through
circuits A90V and A90W, brake diode assy (82), and circuit A44-G (also A31-GD with pall transmission
filter) to the key switch ground.

LOW BRAKE FLUID: IC With Hydraulic Brakes

With the key switch in the on or start position, power is applied to fuse F19, and circuits 13E and 90U to
the low brake fluid warning light. With the key switch held in the start position, the low brake fluid warning
light will illuminate (bulb check is performed) as a ground is applied through circuits 90U and 90E, blocking
diode (47), and circuit 90-G/11-G to the cab ground.

RETARD ON: FE 300 With Allison WTEC III XMSN GEN 4

When the key switch is in the ignition or start position, power from fuse F1C–1 flows through circuit V146A,
connector (7101), pin U, circuit K146A, to the ECU “S” connector (7204), pin 4, and the spliced circuit

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22 INSTRUMENTS (Data Link Driven Instrument Cluster)

V146A/V146D, to the retard on warning light relay connector (7807), pin 1. When the retard on on/off switch
(919) is moved to the on position, the switch (919), pin 1, circuit A163A, connector (644), pin F, circuit N163A,
connector (523), pin L, circuit K163A, spliced circuit K163, to the ECU “S” connector (7204), pin 27, and
through the switch (919), pin 2, circuit A143H, connector (644), pin H, circuit N143H, spliced circuit N143A,
connector (523), pin J, circuit K143A, to the ECU “S” connector (7204), pin 32, and the retarder enable function
is completed. The retarder warning light relay circuit V146B to its coil and circuit V146D to its contacts, will
become de-energized when the ECU removes its ground to circuit K125 at connector (7202), pin 18, through
spliced circuit K125A, connector (7101), pin Q, circuit V125A, relay (7807), pin 5. This will allow power to flow
through the contacts of the de-energized warning light relay (7807), circuit V92H, connector (7100), pin L,
circuit K92H, connector (523), pin V, circuit N92H, connector (1601), pin A and circuit A92H to the “RETARD
ON” warning light (926), pin A. This will cause the warning light (926), pin B, which is grounded through circuits
A92-GA/A186, connector (377), pin A, circuits A186/A11-G to the platform ground (1PG), to illuminate.

RETARD ON: IC With Allison MD and International Engines

When the key switch is in the ignition or start position, power from fuse F24 flows through circuit 97K,
connector (3), circuits 97K and 24B, connector (372), circuit 24B, connector (789), circuit 24B, and the retarder
enable relay coil (790). When the retarder on/off switch (917) is moved to the on position, a ground is applied
to ECM connector (379)/pin 15 by circuit 24, connector (3), circuit 24, connector (377), circuit 24, connector
(377), circuit 24V, switch (917), circuits 92-G, 92-GY, 94-GC, connector (377), and circuits 94-GC and 11-G to
cab ground. This causes the ECM (379) to switch pin 47 low (to apply a ground), and power to flow through
the enable relay coil and circuit 24A, connector (789), circuit 24A, connector (372), circuit 24A, and the ECM
at connector (379)/pin 47. This will activate the retarder enable relay, and complete a ground circuit from
connector (632)/pin 31, circuits 161 and 161D, the relay’s normally open contacts, and circuit 163 to ECU
connector (634)/pin 27. The retarder warning light relay (791), which receives power from fuse F24 through
the same circuits as the retarder enable relay (790) [listed above] and circuit 146H to its coil and also circuit
146F to its contacts, will become de-energized when the ECU removes its ground to circuit 125 at connector
(632)/pin 18. This will allow power to flow through the contacts of the de-energized warning light relay (791),
circuit 92H, connector (499), and circuit 92H to the retarder on warning light. This will cause the warning
light, which is grounded through circuits 92-GZ, 92-GY, and 94-GC, connector (337), and circuits 94-GC
and 11-G to cab ground, to illuminate.

CHANGE TRANS FILTER: FE 300 With Allison WTEC III XMSN GEN 4

For vehicles equipped with the automatic transmission filter warning light, power is supplied to fuse F10, circuit
A31D, and the filter warning light (94). When the key switch (20) is held in the start position, power will flow
through the filter warning light (94), circuit A31-GA, connector (344), a blue wire, and the pigtail of the filter
pressure differential switch. This power will flow through the normally closed contacts of the pressure switch
and its connector, a green wire, connector (344), circuit A31-GB, blocking diode (64), circuits A31-GC and
A31-GD, and the key switch ground, thus causing the warning light to illuminate for a bulb check. When the
transmission filter becomes restricted, the pressure differential switch’s normally open contacts will close and
power will flow through the warning light to the switch as above, but the power will flow through the normally
open contacts of the switch and its connector, a brown wire, connector (344) and circuit A11-GE to platform
ground, thus illuminating the change trans filter warning light.

CHANGE TRANS FILTER: IC With Allison “AT”

For vehicles equipped with the automatic transmission filter warning light, power is supplied to fuse F24,
circuits 28/19F, connector (1150), 31B and the filter warning light (837). When the key switch (63) is held in the
start position, power will flow through the filter warning light (837), circuit 31-GA, connector (760A), a blue
wire, and the pigtail of the filter pressure differential switch. This power will flow through the normally closed
contacts of the pressure switch and its connector, a green wire, connector (760B), circuit 31-GA, blocking diode
(47), circuits 31D, and the key switch ground, thus causing the warning light to illuminate for a bulb check.
When the transmission filter becomes restricted, the pressure differential switch’s normally open contacts will

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 23

close and power will flow through the warning light to the switch as above, but the power will flow through
the normally open contacts of the switch and its connector, a brown wire, connector (760B) and circuit 31-G
to cab ground, thus illuminating the change trans filter warning light.

RETARD OVER HEAT: FE 300 With Allison WTEC III XMSN

The battery voltage is through circuits A13/A13F, fuse F22, circuits A28 and A13J, connector (377), pin F,
circuit A13J, to the “RETARD OVER HEAT” warning light, connector (925), pin B, connector (925), pin A, circuit
A105B, connector (1601), pin B, circuit N105B, connector (523), pin U, circuit K105B/K105, to the ECU
connector (7202), pin 19. When the transmission ECU detects that the transmission retarder is overheating, it
will apply a ground (switch to low state) to illuminate the “RETARD OVER HEAT” warning light.

RETARD OVER HEAT: FE 300 With Allison WTEC III XMSN GEN 4

The battery voltage is through circuits A13/A13F, fuse F22, circuits A28 and A13J, connector (377), pin F,
circuit A13J, to the “RETARD OVER HEAT” warning light, connector (925), pin B, connector (925), pin A, circuit
A164B, connector (1601), pin B, circuit N164B, connector (523), pin U, circuit K164B/K164, to the TCM
connector (7150), pin 64. When the transmission TCM detects that the transmission retarder is overheating, it
will apply a ground (switch to low state) to illuminate the “RETARD OVER HEAT” warning light.

RETARD OVER HEAT: IC With Allison MD

When the transmission ECU detects that the transmission retarder is overheating, it will apply a ground
(switch to low state) to (632)/pin 19 and circuit 105, connector (499), circuit 105 and the retarder overheat
warning light. Thus the light that receives power from the key switch (63), circuit 13E, connector (377),
circuit 13E, will illuminate.

ALTERNATOR: FE 300

When the voltage output of the alternator is low, a ground will be provided on terminal (G) of the alternator, and
through the I6 circuit filters. This ground will be present on circuit A26 to pin 16, of the yellow instrument cluster
connector (10) and will cause the “ALTERNATOR” warning light, to illuminate. The battery voltage is through
circuit A26A, the yellow instrument cluster (10), pin 7 to the alternator warning light.

ALTERNATOR: IC

SE item not covered at this time.

3. REMOVE AND INSTALL

3.1. INSTRUMENT CLUSTER
The cluster is a reliable, quick-disconnect package for the most commonly used instruments. Should the need
arise, the cluster body can be quickly detached from the instrument panel for quick access to any of its
components. Either the complete cluster assembly or any of its components can be replaced.

Always place the ignition in the OFF position (not ACC) prior to working on the cluster, due to potential shorting
between the ground and ignition pins, which will damage the circuit board and gauges.

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24 INSTRUMENTS (Data Link Driven Instrument Cluster)

CAUTION – Static electricity can cause permanent damage to the cluster. Before working on the
cluster, be sure you have removed all static electricity from your body by touching metal that is
grounded. Do not wear clothing that causes static build up (such as nylon). Do not touch any pin
connectors during removal and installation of gauges. Work on the cluster in a clean environment
to avoid dust.

Remove

1. Protect the bezel during removal by placing a soft cloth on the forward side of the steering column.

2. Remove the two cluster mounting screws (Item 1, Figure 14) located on the lower front face of the cluster.

Figure 14 Instrument Cluster Assembly

1. CLUSTER MOUNTING SCREWS
2. INSTRUMENT CLUSTER BEZEL
3. CLUSTER
4. WIRING HARNESS CONNECTOR
5. DASH PANEL
6. RETAINING TABS

3. Depress the two gray retaining tabs (Item 6, Figure 14) located on the top corners of the bezel.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 25

4. Holding the tabs depressed, pull the cluster forward and gently release it from the dash panel. If the cluster
does not come loose easily, put more pressure on the tabs and continue to pull gently. Do not attempt to
pry the cluster from the dash panel as damage will result.

5. Disconnect the three wiring harness connectors from the back of the cluster assembly (Figure 15).

Figure 15 Disconnect Wiring Harness Connectors

WARNING – Whenever any component is serviced or removed from the air system, be sure to
set the parking brake and/or block the vehicle to prevent it from moving while the service is being
performed. Also drain air from the system to prevent dirt or debris from being propelled into one’s
eyes.

6. After bleeding the air system, disconnect the air lines from the fittings on the back of the air gauge. A
double needle air pressure gauge is used with vehicles with air brakes (Figure 16).

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26 INSTRUMENTS (Data Link Driven Instrument Cluster)

Figure 16 Disconnect Air Lines From Fittings on Back of Air Gauge

NOTE – Note the color of the air lines being removed from the gauge. The green line is for the primary
system and the orange line is for the secondary system.

7. The instrument cluster assembly is now free to be removed from the instrument panel.

Install

1. Connect the air lines to the air pressure gauge. The green line is for the primary system and the orange for
the secondary system.

NOTE – Do not exceed 36 in-lbs. (4.0 Nm) of torque when tightening air lines.

2. Connect the three wiring harness connectors to the back of the cluster. These connectors are color-coded
for proper orientation.

3. Align the cluster in the instrument panel frame and push the cluster gently until the retaining tabs snap
into place.

4. Install the two cluster mounting screws on the lower front face of the cluster.

3.2. INSTRUMENT CLUSTER COMPONENTS

Remove

1. With the cluster released from the dash panel (refer to INSTRUMENT CLUSTER, Remove), remove the
three (3) bezel screws that fasten the bezel to the cluster housing (Figure 17). Place the instrument cluster
face up on a clean, horizontal surface to prevent loss of unused gauge covers, gauges, etc.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 27

Figure 17 Remove Bezel Screws Fastening Bezel to Cluster Housing

2. Remove the bezel lens assembly from the housing and put it in a safe place to prevent scratching. Take
care not to damage the gauge pointers with the bezel.

CAUTION – Individual gauge dials are not protected by a lens. When removing or installing
gauges, handle them by the edge of the dial face only. Do not touch the gauge pointer.

3. All gauges, with the exception of the air pressure, hourmeter and odometer, are plug-in gauges. To
remove, locate the hole in the back of the cluster behind the gauge and using a small, blunt tool such
as a small screwdriver handle, push the gauge out of the housing. Once the gauge has cleared the
housing, it may be removed from the front.

CAUTION – After a gauge is removed from the cluster, it is important that the exposed terminals
attached to the circuit board are not touched or shorted across. Static electricity or shorting
between power and ground terminals can damage the cluster.

4. To remove the hourmeter and/or odometer, disconnect the wiring plugs from the circuit board at the back of
the cluster. At the front of the cluster, remove the adhesive-backed mask covering the gauge, then retract
the two fingers that hold the gauges in the cluster and lift the gauge out of the cluster.

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28 INSTRUMENTS (Data Link Driven Instrument Cluster)

CAUTION – When removing or installing the hourmeter or odometer, do not touch the metal
portion of the leads that fasten to the circuit board. A static discharge could damage the cluster.

5. The mechanical type air gauge is front serviceable after the air line fittings and the retaining nuts have
been removed from the rear of the gauge.

6. The panel lamp bulbs are the push-in type and are mounted in a twist lock receptacle. They are
serviceable from the rear of the instrument cluster by twisting to remove (Figure 18).

Figure 18 Twist Panel Lamp Bulbs to Remove

The gauge back lights are #936 bulbs and the turn signals, high beam and warning lights are #37.

3.3. PRINTED CIRCUIT BOARDS

Replacement

Since printed circuit boards are fastened to and integral with the instrument cluster body, the boards and
cluster are available for replacement as a complete assembly only. Where replacement is required, obtain
a new gaugeless instrument cluster assembly and transfer all gauges, warning light masks and light bulbs
from old cluster body to the new.

3.4. SPEEDOMETER SENSOR

IMPORTANT – Turn the key switch to OFF before removing or installing the speedometer sensor.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 29

Remove

1. Disconnect the sensor connector from the wiring harness connector (Figure 19).

Figure 19 Disconnect Sensor Connector From Wiring Harness Connector

1. SENSOR BODY
2. LOCKNUT
3. HOUSING
4. TRANSMISSION SPEEDOMETER GEAR
5. SENSOR CONNECTOR

2. Loosen the sensor locknut and remove the sensor from the back of the transmission housing.

IMPORTANT – Allison automatic transmissions use a non-adjustable speedometer sensor, but its electrical
operation is similar to the standard International sensor.

Install

1. Install the new sensor by turning into the housing until it bottoms out against the speedometer gear.
Back off one (1) turn.

2. Tighten the lock nut using two wrenches to keep the sensor from turning while tightening the locknut.
Tighten to 15 ft-lbs. (20 Nm).

3. Reconnect the sensor connector to the wiring harness connector.

4. Test drive the vehicle to test the speedometer.

4. INSTRUMENT CLUSTER JUMPER USAGE

The speedometer jumper pins are used to set up the cluster for MPH or KPH as the primary speedometer
readout, and to select axle ratios. They are located at the top edge of the cluster and can be accessed by
pulling the cluster out of the instrument panel (Item 3, Figure 20). All other speedometer and tachometer
parameters are programmed electronically through the data link into the engine ECM2.

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30 INSTRUMENTS (Data Link Driven Instrument Cluster)

Figure 20 Jumper Pin Location

1. CLUSTER
2. WIRING HARNESS CONNECTORS
3. RECEPTACLE PINS FOR JUMPERS
4. ENGLISH-METRIC CONVERSION SPEEDOMETER AND ODOMETER JUMPER PINS
(MPH/KPH)
5. ONE AXLE RATIO SETTING JUMPER PINS

There may be two jumpers visible. The left jumper is for setting the odometer from English to metric readings
(Item 4, Figure 20). For miles per hour (MPH), the jumper is not installed. For a kilometers per hour (KPH)
speedometer, the jumper is installed.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 31

The right jumper (Item 5, Figure 20) is for calibration of the two available two-speed axle ratios. These are
1.36:1 (jumper not installed) and 1.39:1 (jumper installed). If the vehicle does not have a two-speed axle, the
jumper setting is inactive and a jumper is not needed.

IMPORTANT – For the speedometer and tachometer to function properly when tire sizes and/or rear axle
ratios are changed, the engine ECM2 must be reprogrammed so that it will send the correct data to the
instrument cluster.

5. CLUSTER FAILURE DIAGNOSIS

CAUTION – Be sure to turn the key switch to OFF when the cluster or any cluster part is inserted
or removed. Shorting across the meter pins could cause permanent damage to the cluster.

CAUTION – Static electricity can cause permanent damage to the cluster. Before working on the
cluster, be sure you have removed all static electricity from your body by touching metal that is
grounded. Do not wear clothing that causes static build up (such as nylon). Do not touch any pin
connectors during removal and installation of gauges. Work on the cluster in a clean environment
to avoid dust.

After a cluster failure or suspected malfunction, turn off electrical power to the cluster by switching off
accessory voltage. Remove the cluster from the dash. Refer to INSTRUMENT CLUSTER, Remove.

5.1. CLUSTER HARNESS CONNECTORS

Connecting the instrument panel to the vehicle are three vehicle harness connectors fastened to the back of
cluster. The left or driver’s side connector is yellow, the center is green, and the right or passenger’s side
connector is natural in color.

Each harness connector has seventeen (17) pins numbered right to left. The bottom row contains pins 1
through 9 and the top row, pins 10 through 17. There is a space between pins 13 and 14 (Figure 21).

Figure 21 Harness Connector Pins

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32 INSTRUMENTS (Data Link Driven Instrument Cluster)

Left Side Harness Connector Pinouts (Yellow) (10)

BOTTOM ROW
1. Ignition Voltage (+) Cir A28A

2. Check Trans (-) Cir A92

3. Brake Pressure (-) Cir A40A Air Brakes or A90N With Hydraulic Brakes)

4. Stop Engine/Change Oil and Engine Warning (+) Cir A28K

5. Oil/Water (+) Cir A28D

6. Gauge Ground (-) Cir A28-GA

7. Ammeter (-) Cir A26A

8. Gauge Backlighting (+) Cir A62B

9. (No Connection)

TOP ROW
10. Oil/Water (-) Cir A29/A35

11. Stop Engine/Change Oil (-) Cir A97AA

12. Engine Warning (-) Cir A97T

13. (No Connection)

14. ABS Warning Cir A94BD

15. Gauge Backlighting (-) Cir A62-GA

16. Ammeter (+) Cir A26

17. Transmission Oil Temperature Cir A31A

Center Harness Connector Pinouts (Green) (11)

BOTTOM ROW
1. Gauge Backlighting (+) Cir A62C

2. Electronic Ground (-) Cir A28-G

3. Fuel Sensor Cir A36

4. High Beam (+) Cir A52A

5. (No Connection)

6. Left Turn (+) Cir A56B

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 33

7. J1587/J1708 Data Link (+) Cir A98E(+)

8. (No Connection)

9. J1587/J1708 Data Link (-) Cir A98F(-)

TOP ROW
10. Ignition Voltage (+) Cir A28B

11. Gauge Backlighting (-) Cir A62-GB

12. Right Turn (+) Cir A57B

13. (No Connection)

14. (No Connection)

15. (No Connection)

16. (No Connection)

17. (No Connection)

Right Side Harness Connector Pinouts (Natural) (12)

BOTTOM ROW
1. Gauge Backlighting (+) Cir A62D

2. (No Connection)

3. Gauge Ground (-) Cir A28-GB

4. (No Connection)

5. Wait To Start (-) Cir A97AE

6. (No Connection)

7. (No Connection)

8. Ignition Voltage (+) Cir A28C

9. (No Connection)

TOP ROW
10. Gauge Backlighting (-) Cir A62-GC

11. (No Connection)

12. (No Connection)

13. Windshield Washer Fluid (+) Cir A28H

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14. (No Connection)

15. (No Connection)

16. (No Connection)

17. Parking Brake (-) Cir A44A With Hydraulic or Air Brakes

5.2. CLUSTER CONNECTORS

Looking at the rear of the cluster (Figure 20), the three connectors (Figure 22) will be the reverse of the plug-in
harness connectors (Figure 21). The right connector is yellow, the center is green and the left is natural.

Figure 22 Cluster Connectors

The connector pins are numbered from left to right. The bottom row has pins 1 through 9. The top row has
pins 10 through 17. There is a space between pins 13 and 14 in the top row.

5.3. AIR GAUGE FAILURE

If either air gauge pressure reading is outside a ± 5 psi range of the shop gauge reading, replace the cluster
air gauge.

5.4. FUEL LEVEL SENSOR

If the electric fuel gauge shows a reading and it is suspected of being in error and the steps defined in FUEL
GAUGE, OPTIONAL ELECTRICALLY OPERATED TEMPERATURE GAUGE, OR AMMETER FAILURE, do
not locate the problem, the fuel level sensor must be checked. The fuel level sensor used is a float/resistive
potentiometer type with the following output characteristics at different fuel levels.

IMPORTANT – Before checking the fuel gauge, be sure the vehicle has been parked long enough on a level
surface for the fuel to settle out, and in cold weather be sure the cab interior is warmed up.

Table 2 Fuel Tank Level to Sensor Output Ohms

Fuel Tank Levels Sensor Output Ohms
Full 88±3
3/4 66±3
1/2 44±2

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Table 2 Fuel Tank Level to Sensor Output Ohms (cont.)

Fuel Tank Levels Sensor Output Ohms
1/4 22±2
Empty 1±1

When the sensor wire is shorted to ground, the gauge should read "E"mpty. When the sensor wire is
disconnected, the gauge should read "F"ull.

Locate the fuel level sensor circuit pin in the cluster harness [connector (11)/pin 3] and measure resistance
to ground. If the resistance reading and the fuel level agrees with the above listing and the gauge does not
match, replace the fuel gauge.

If readings and fuel level do not match, disconnect harness at sensor and measure resistance at the sensor. If
correct readings are obtained, repair harness. If readings are out of specification, replace fuel level sensor.

5.5. FUEL GAUGE, OPTIONAL ELECTRICALLY OPERATED TEMPERATURE GAUGE,

OR AMMETER FAILURE
If any of the five possible electrical temperature gauges or the fuel gauge is suspected of displaying incorrectly,
the vehicle circuits that affect the suspected gauge must be checked for clean, tight, unbroken and non-shorted
connections. If the wiring and connector are OK, the thermistor type temperature sensor’s electrical resistance
must be checked with a quality ohmmeter at the cluster harness connector. Refer to CLUSTER HARNESS
CONNECTORS for the pin locations.

NOTE – The following tests are for the three pin electric gauges and circuitry only. These tests do not
apply to the four pin data link driven electronic gauges and circuitry.

Instrument Gauge Tester Operation

The Instrument Gauge Tester (Special Tool Catalog #ZE-2781) (Figure 23) permits testing of electric gauges
without removing them from the vehicle. This tester will provide up to 2050 ohms required for making low
scale readings on temperature gauges.

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Figure 23 Instrument Gauge Tester

1. INSTRUMENT GAUGE TESTER
2. ELECTRIC GAUGE
3. WIRE TO GAUGE
4. SENDER
5. GROUND

To test an electric gauge:

1. With key off, disconnect the sensor wire at the sensor.

2. Connect one lead of the Instrument Gauge Tester to the sensor wire.

3. Connect the other tester lead to a good vehicle ground.

4. Set the resistance to the values shown in Gauge Tester Resistance Settings.

5. Turn key switch to ON.

6. Note gauge needle positions.

If gauge responds correctly to the tests:

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 37

• Gauge is OK.
• Sender unit may be faulty, or
• Sender unit ground may be faulty.

NOTE – Sealant or dirt on the sender unit or engine threads may prevent good electrical ground. Check
for this condition before replacing sender unit.

If gauge does not respond to the tester:

• Check continuity of gauge wiring circuits for opens or shorts.

• Check connectors for clean, tight fits.
• Check gauge cluster ground circuit. Make sure circuit is grounded.
• If wiring is OK, replace gauge.

Gauge Tester Resistance Settings

Table 3 Gauge Tester Resistance Settings (Ohms) — For Use With ZE-2781 Gauge Tester)
Type of Gauge Gauge Reading (Within Two Needle Widths ±)
Low Scale Half Scale Full Scale
Fuel Level 1 44 88
Oil Temperature: Engine 1365 63 28
Oil Temperature: 1365 63 28
Transmission
Oil Temperature: Rear 1365 63 28
Axle

Thermistor Resistance Check

To check thermistor type temperature sensors, the approximate temperature of the component being checked
must be known to determine the amount of resistance that will be read at the cluster harness connector.

Table 4 Component Temperature to Thermistor Resistance

Component Temperature Thermistor
Resistance (Ohms)
Fahrenheit Centigrade
32 0 8,335
50 10 4,945
68 20 3,010
86 30 1,871
104 40 1,185
140 60 505
158 70 341
194 90 169.8
212 100 125.6

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Table 4 Component Temperature to Thermistor Resistance (cont.)

Component Temperature Thermistor
Resistance (Ohms)
Fahrenheit Centigrade
230 110 95.2
248 120 73.5
266 130 57.5

The thermistor type sensor is used in the following electrical gauge applications:

• Engine Coolant Temperature

• Engine Oil Temperature
• Transmission Oil Temperature
• Forward Rear Axle Temperature
• Rear Rear Axle Temperature.

NOTE – The two axle gauges and the transmission oil temperature gauge may not indicate a gauge
reading due to a low/short run time condition. If there is no gauge reading and any of these gauges is
suspected of having a faulty reading, short out the appropriate leads at the sensor. When the sensor
leads are shorted together, the gauge should read full scale.

Restricted Needle Movement

If the sensor electrical resistance checks OK, the gauge should be checked for restricted needle movement.
Very gently move the needle between the minimum and maximum dial positions. If the needle moves freely,
the gauge must be checked for an open or shorted winding. Make sure the key is in the "OFF" position.

Open or Shorted Gauge Winding Check

CAUTION – Static electricity can cause permanent damage to the cluster. Before working on the
cluster, be sure you have removed all static electricity from your body by touching metal that is
grounded. Do not wear clothing that causes static build up (such as nylon). Do not touch any pin
connectors during removal and installation of gauges. Work on the cluster in a clean environment
to avoid dust.

After it has been determined that an individual gauge is defective by using the substitution of a known good
gauge method, the gauge can be further quick tested as follows:

Remove the gauge and use an ohmmeter to check for an open or shorted winding between the two terminals
that connect to that winding. Refer to Cluster Pinouts Table.

• Below 20 ohms - SHORT - Replace Gauge

• Above 1000 ohms - OPEN - Replace Gauge
• Between 20 and 1000 ohms - OK - Refer to Harness Continuity and Voltage Tests.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 39

Cluster Pinouts 16.73in8.0in72

Refer to Figure 24 and Figure 25.

Figure 24 Cluster Pinouts

Figure 25 Gauge Position

Table 5 Cluster Pinouts Table

Gauge Position
1 2 3 4
Speedometer SIN- SIN+ COS- COS+
Tachometer SIN- SIN+ COS- COS+
Voltmeter SIN- SIN+ COS- COS+
Oil Pressure SIN- SIN+ COS- COS+
Water Temp. Gauge SIN- SIN+ COS- COS+
Temp. Gauges (N/Water +12V Ground Sender Not used
Temp.)
Fuel Level +12V Ground Sender Not used
Pyrometer Reference Ground Sender Not used
voltage*
Ammeter Positive Not used Negative Not used
* Stewart Warner (round amplifier) 3.5 to 3.9 volts; Isspro (square amplifier) 7.7 to 8.7 volts

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40 INSTRUMENTS (Data Link Driven Instrument Cluster)

Harness Continuity and Voltage Tests

1. Turn the key switch to OFF.

2. Unplug the wiring harness connector servicing the gauge in question from the cluster. Refer to CLUSTER
HARNESS CONNECTORS and GROUP 08 - ELECTRICAL, Circuit Diagrams.

3. Using an ohmmeter, check the resistance of the harness ground circuit and sensor circuit affecting the
gauge in question. The resistance should read less than one (1) ohm.

4. Turn the key switch to accessories position and using a voltmeter, check the harness power circuit. It
should read just under battery voltage.

5. If all three harness circuits check OK, install a new cluster that does not yet contain plug-in gauges.

6. If the voltage measurement or either of the two electrical resistances is incorrect, a faulty sensor,
connector, wiring harness or other failure is indicated and further testing is required.

5.6. VOLTMETER DISPLAY FAILURE

If the voltmeter display is indicating a problem, the circuits that serve it must be checked for clean, tight,
unbroken and non-shorted connections. If the circuits check OK, measure the appropriate voltage at the
appropriate cluster harness connector (refer to CLUSTER HARNESS CONNECTORS and GROUP 08 -
ELECTRICAL, Circuit Diagrams). Turn the key switch to ACC and read across the accessory voltage and
ground with a good test voltmeter. Replace the voltmeter display gauge if it does not read near the test
accessory voltage.

5.7. EXHAUST TEMPERATURE DISPLAY FAILURE

Exhaust Temperature Display Gauge

1. If the exhaust temperature display gauge indicates a problem, check the circuits serving the pyrometer for
clean, tight, unbroken and non-shorted connections (refer to CLUSTER HARNESS CONNECTORS and
GROUP 08 - ELECTRICAL, Circuit Diagrams).

2. If the circuits are OK, measure the appropriate voltages through the cluster harness connector that
services the pyrometer. The pyrometer is supplied with two driving voltages. ALL VOLTAGES ARE
MEASURED WITH RESPECT TO THE ELECTRONIC GROUND PIN:
a. Pyrometer power voltage for Isspro is 8.2 ± 0.5 volts, for Stewart Warner 3.7 ± 0.2 volts (Connector
10-Yellow, Terminal 16).
b. Sensor voltage that varies according to the exhaust gas temperature and will range from .15 to 6.1
(vdc) (Connector 10-Yellow, Terminal 7).
c. Ground is at Connector 10-Yellow, Terminal 6.

Pyrometer Sensor Voltage

Table 6 Pyrometer Sensor Voltage

Temperature Voltage (DC)
Fahrenheit Centigrade
300 149 0.15

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Table 6 Pyrometer Sensor Voltage (cont.)

Temperature Voltage (DC)
Fahrenheit Centigrade
600 315 1.60
900 482 3.10
1200 649 4.60
1500 816 6.10

1. If voltages are not within limits, a faulty sensor, connector or wiring harness is indicated and further
testing is required.

2. If the voltages are within limits, the pyrometer gauge should be checked for a sticky needle (refer to
Restricted Needle Movement).
a. The needle sticks, replace the pyrometer gauge.
b. The needle moves freely, check internal voltage.

Internal Voltage Check

1. Turn key switch to OFF, remove the pyrometer gauge from cluster and make sure the cluster harness
connectors are properly installed on the cluster (refer to CLUSTER HARNESS CONNECTORS).

2. Turn the key switch to ACC and measure the voltage across the gauge’s cluster socket pins. Refer to
GROUP 08 - ELECTRICAL, Circuit Diagrams. Pyrometer reference voltage is at Terminal 1, Sensor
voltage at Terminal 3 and Ground at Terminal 2.
a. If the proper voltages are not present, replace cluster with a new gaugeless cluster and re-install
gauges.
b. If the voltages are correct, turn the key switch to OFF and re-install the pyrometer gauge. Turn the key
switch to ACC and if the gauge does not operate, replace the gauge.

5.8. SPEEDOMETER, ODOMETER, TACHOMETER, HOUR-METER, VOLTMETER, OIL

PRESSURE GAUGE, AND WATER TEMPERATURE GAUGE FAILURE ISOLATION
If the speedometer, odometer, tachometer, hour-meter, voltmeter, oil pressure, or water temperature gauge
indicates a failure, the circuits serving the instrument in question must be checked for clean, tight, unbroken
and non-shorted connections.

IMPORTANT – Be sure all relays in the vehicle are the suppressed type.

IMPORTANT – Make sure the accessory voltage to the cluster is within a range of 11 to 16 volts.

The instrument cluster has self testing capabilities that will identify various failures in the electronic portions of
the unit. The self testing diagnostics provide a strong indication of exactly what is wrong with the unit, without
removing the cluster from the vehicle or spending a large amount of time troubleshooting.

Pass Indications

The cluster will test itself each time the vehicle is powered up. If all tests pass, the unit will drive the
speedometer, tachometer, voltmeter, oil pressure gauge, and water temperature gauge needles through one

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complete sweep. This indicates that all input circuits are good and tells the driver that all output circuits
driving the gauges are good.

Fail Indications

The cluster will provide failure indications in two ways:

1. Does not provide a proper gauge sweep on power up.

2. The speedometer, tachometer, voltmeter, oil pressure gauge, and water temperature gauge needles
"wave" on power up.

If the unit senses a circuit problem at power up, the speedometer, tachometer, voltmeter, oil pressure gauge,
and water temperature gauge needles will simultaneously wave from 0 and one of the numbers on the
speedometer and tachometer dial faces three times. Corrective action is defined in the following failure chart.

Electronic Service Tool (EST) Diagnostics

Operation and accuracy of the speedometer, tachometer, fuel, oil pressure, water temperature and voltmeter
can be verified with an EST, without removing the cluster. The EZ-Tech, with the instrument cluster software,
can be used to exercise the speedometer/tachometer, through the J1708 data link . Refer to the instrument
cluster software manual for instructions.

5.9. SPEEDOMETER, ODOMETER, TACHOMETER, HOUR-METER, VOLTMETER, OIL

PRESSURE GAUGE, AND WATER TEMPERATURE GAUGE FAILURE CHART
Table 7 Speedometer, Odometer, Tachometer, Hour-meter, Voltmeter, Oil Pressure Gauge, and Water
Temperature Gauge Failure Chart
FAILURE MODE FIRST ACTION SECOND ACTION
1. Speedometer, tachometer, Verify that ignition voltage and ground Replace cluster.
voltmeter, oil pressure gauge, are provided to cluster. Refer to
and water temperature gauge CLUSTER HARNESS CONNECTORS
needles do not move on power and GROUP 08 - ELECTRICAL, Circuit
up. Diagrams.
2. Speedometer, tachometer, Swap the speedometer and tachometer If the defect stays at the same
voltmeter, oil pressure or water in the cluster, or water temperature meter location, replace the
temperature gauge needle gauge for another temperature gauge, cluster.
moves erratically on power up etc. in the cluster. If the defect follows
sweep. the meter, replace the meter.
3. Speedometer and J1587/J1708 Data Link failure. Insure Verify data from the ECM2 by
tachometer sweep in unison that the vehicle Data Link is not shorted using an electronic service tool
and the tachometer needle or wired incorrectly. With the ignition on, (EST), such as the EZ-Tech™
points to three (3) times. voltage from Positive data link circuit to or Pro-Link® 9000, with the
ground should be approximately 4 volts. applicable engine software. If
Voltage from Negative data link circuit data is present replace cluster.
to ground should be approximately 1
volt. Refer to CLUSTER HARNESS
CONNECTORS and GROUP 08 -
ELECTRICAL, Circuit Diagrams.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 43

Table 7 Speedometer, Odometer, Tachometer, Hour-meter, Voltmeter, Oil Pressure Gauge, and Water
Temperature Gauge Failure Chart (cont.)
FAILURE MODE FIRST ACTION SECOND ACTION
4. Speedometer and Cluster electronics failed. Replace
tachometer sweep in unison cluster.
and the tachometer needle
points to three (3) times.
5. Speedometer and Odometer drive circuit failed, odometer Disconnect odometer
tachometer sweep in unison is disconnected, or odometer coil is connector, swap with
and the tachometer needle open. Insure odometer connector is hour-meter or connect
points to three (3) times. properly seated to the printed wiring to hour-meter connector,
board connector. start engine, and note if
odometer advances once
every 6 minutes. If odometer
advances, replace cluster. If
odometer does not advance,
replace odometer.
6. Speedometer and Check speedometer sensor wiring Verify signal to ECM2 by using
tachometer go through a continuity and sensor output signal an electronic service tool
good power up sweep, but levels. Refer to CLUSTER HARNESS (EST), such as the EZ-Tech™
speedometer does not work CONNECTORS and GROUP 08 - or Pro-Link® 9000.
when driving. ELECTRICAL, Circuit Diagrams.
7. Speedometer and Verify signal to ECM2 by using an
tachometer go through a electronic service tool.
good power up sweep, but
tachometer does not work
when driving.
8. Speedometer and Remove odometer and swap with If odometer does not advance,
tachometer go through a hour-meter or connect to hour-meter replace odometer.
good power up sweep, but connector, start engine, and note if
odometer does not work odometer advances every 6 minutes. If
when driving. odometer advances, replace the cluster.
9. Speedometer and Swap hour-meter with odometer, drive If the hour-meter does
tachometer go through a truck and note if the hour-meter (placed not advance, replace the
good power up sweep, but in odometer location) advances every hour-meter.
hour-meter does not work tenth of a mile. If the hour-meter
when driving. operates, replace the cluster.

6. TROUBLESHOOTING (INDICATOR AND WARNING LIGHT

DIAGNOSTICS)
Before beginning these test procedures, do the following:

A. 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.

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44 INSTRUMENTS (Data Link Driven Instrument Cluster)

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.

6.1. OIL/WATER
FE 300 With Air Brakes

Table 8 FE 300 With Air Brakes

Step Key Action Test Points Spec. Yes - In Spec. No - Out of
Spec.
1. Off/ On 1. Turn key to RUN Are both the Go to step 2. Go to step 4.
engine (0x00)
2. Connect J1939 and the MSM
sniffer (aka ESC) on
the data-link?
2. Off/ On 1. Disconnect J1939 Does the Go to step 3. ECM2 is
sniffer. "Oil/Water" not updating
output "Oil/Water"
2. Connect Master change? output.
Diagnostics See engine
troubleshooting
3. Monitor the guide.
"Oil/Water" output.
3. Off/ On 1. Disconnect MSM1 (3111), pin Does the Replace MSM Go to next step.
connector (3111). 1 to gnd. "Oil/Water" and retest
lamp turn on
2. Connect pin 1 to and alarm
ground. sounds?
4. Off 1. Remove instrument Across <100 ohms. Re-install bulb. Replace
cluster. warning Go to next step. defective bulb
light bulb. and reconnect
2. Remove connector.
OIL/WATER indicator Repeat all
bulb. tests if problem
persists.
3. Test bulb for
continuity.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 45

Table 8 FE 300 With Air Brakes (cont.)

Step Key Action Test Points Spec. Yes - In Spec. No - Out of
Spec.
5. Off 1. Instrument cluster (10), pin <1 ohm. Go to next step. Locate open or
removed. 10, cir. poor connection
A97AF, in circuit A97AF,
2. Measure resistance A29A/35 A29A/35 or
from disconnected to (3111) cluster, then
conn. (10), pin 10, pin 1. repair.
circuit A97AF, A29A/35
to MSM1 disconnected
conn. (3111) pin 1.
6. Off/ On 1. Instrument cluster (10), pin 12±1.5 volts. Install cluster. Locate cause
removed. 5, cir. Go to next step. of no or low
A28A/A28 voltage in circuit
2. Move key switch to to gnd. A28A/A28 from
ignition. fuse F22, then
repair.
3. Measure voltage
from conn. (10), pin
5, circuit A28A/A28 to
ground.
7. Off/ On 1. Leave J1939 sniffer Is the engine Go to step 8. Go to step 11.
connected (0x00) on the
data-link?

8. Off/ On 1. Turn the key to OFF. (3111), Is the Go to step 9. Fix data-link
pins 5 and resistance wiring, cir
2. Disconnect MSM1 6. approx. 60 A5DMS(-) and
connector (3111). ohms? A5DMS(+),
retest
3. Measure resistance
across data-link pins 5
& 6, in wiring harness
9. Off/ On 1. Turn the key to (3111), Is the voltage Go to step 7. Fix wiring cir
Ignition. pin 7, cir 12-16 volts? A13MS or fuse
A13MS to F31, retest.
2. Measure the voltage gnd.
at the MSM1’s harness
ignition pin 7 to ground.

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46 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 8 FE 300 With Air Brakes (cont.)

Step Key Action Test Points Spec. Yes - In Spec. No - Out of
Spec.
10. Off/ On 1. Measure the (3111), Is the Replace MSM Fix ground
resistance between pin 8, cir resistance and retest wiring cir
the MSM1’s harness A11–GM/ less than 10 A11–GM/
ground pin 8 and A11–G to ohms? A11–G and cab
ground gnd. ground, retest.
11. Off/ On 1. Leave J1939 sniffer Is the MSM Check the Verify sniffer
connected (aka ESC) on engine’s power is working
the data-link? connections and properly
NOTE: This assumes data link wiring.
the "Oil/Water" output
can be monitored
using MD.

FE 300 With Hydraulic Brakes

Table 9 FE 300 With Hydraulic Brakes

Step Key Action Test Points Spec. Yes - In Spec. No - Out of
Spec.
1. Off/ On 1. Turn key to RUN Are both Go to step 2. Go to step 4.
the engine
2. Connect J1939 (0x00) and
sniffer the MSM
(aka ESC)
on the
data-link?
2. Off/ On 1. Disconnect J1939 Does the Go to step 3. ECM2 is
sniffer. "Oil/Water" not updating
output "Oil/Water"
2. Connect Master change? output.
Diagnostics See engine
troubleshooting
3. Monitor the guide.
"Oil/Water" output.
3. Off/ On 1. Disconnect MSM1 (3111), pin 1 Does the Replace MSM Go to next step.
connector (3111). to gnd. "Oil/Water" and retest
lamp turn
2. Connect pin 1 to on and
ground. alarm
sounds?

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 47

Table 9 FE 300 With Hydraulic Brakes (cont.)

Step Key Action Test Points Spec. Yes - In Spec. No - Out of
Spec.
4. Off 1. Remove instrument Across <100 ohms. Re-install bulb. Replace
cluster. warning Go to next step. defective bulb
light bulb. and reconnect
2. Remove connector.
OIL/WATER indicator Repeat all
bulb. tests if problem
persists.
3. Test bulb for
continuity.
5. Off 1. Instrument cluster (10), pin 10, <1 ohm. Go to next step. Locate open or
removed. cir. A97AF, poor connection
A29/35 to in circuit A97AF,
2. Measure resistance (3111) pin 1. A29/35 or
from disconnected cluster, then
conn. (10), pin 10, repair.
circuit A97AF, A29/35
to MSM1 disconnected
conn. (3111) pin 1.
6. Off/ On 1. Instrument cluster (10), pin 12±1.5 Install cluster. Locate cause
removed. 5, cir. volts. Go to next step. of no or low
A28D/A28 voltage in circuit
2. Move key switch to to gnd. A28D/A28 from
ignition. fuse F22, then
repair.
3. Measure voltage
from conn. (10), pin
5, circuit A28D/A28 to
ground.
7. Off/ On 1. Leave J1939 sniffer Is the Go to step 8. Go to step 11.
connected engine
(0x00)
on the
data-link?
8. Off/ On 1. Turn the key to OFF. (3111), pins Is the Go to step 9. Fix data-link
5 and 6. resistance wiring, cir
2. Disconnect MSM1 approx. 60 A5DMS(-) and
connector (3111). ohms? A5DMS(+),
retest
3. Measure resistance
across data-link pins 5
& 6, in wiring harness

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48 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 9 FE 300 With Hydraulic Brakes (cont.)

Step Key Action Test Points Spec. Yes - In Spec. No - Out of
Spec.
9. Off/ On 1. Turn the key to (3111), Is the Go to step 7. Fix wiring cir
Ignition. pin 7, cir voltage A13MS or fuse
A13MS to 12-16 volts? F31, retest.
2. Measure the voltage gnd.
at the MSM1’s harness
ignition pin 7 to ground.
10. Off/ On 1. Measure the (3111), Is the Replace MSM Fix ground
resistance between pin 8, cir resistance and retest wiring cir
the MSM1’s harness less than 10
A11–GM/A11–G A11–GM/A11–G
ground pin 8 and to gnd. ohms? and cab
ground ground, retest.
11. Off/ On 1. Leave J1939 sniffer Is the MSM Check the Verify sniffer
connected (aka ESC) engine’s power is working
on the connections and properly
NOTE: This assumes data-link? data link wiring.
the "Oil/Water" output
can be monitored
using MD.

IC

Table 10 IC
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ECM Warning light Go to next step.
On connector (379) and circuits test good.
use a test jumper to Turn key off,
connect pin 54/circuit reconnect conn.
97AF to ground. (379), and turn
Move key switch key on. If warning
to ignition position. light does not
Does warning light illuminate during
illuminate? bulb check,
reprogram/
replace defective
ECM.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove oil/water warning ohms. Go to next step. bulb and reconnect
warning light bulb. light bulb. connector. Repeat all
Test for continuity. tests if problem persists.
Clear fault codes from
ECM.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 49

Table 10 IC (cont.)
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
3. Off Disconnect connector (26), <1 Go to next step. Locate open or poor
(26), and with jumper 29/35 to ohm. connection in circuit
still attached at gnd. 29/35, 97AF, connector
connector (379), (2), circuit 97AF, then
measure resistance repair. Reconnect
from connector (26) connector and clear
circuit 29/35 to ground. fault codes.
4. On Move key switch to (26), 28D 12±1.5 Go to next step. Locate cause of no or
ignition position and to gnd. volts. low voltage in circuit
measure voltage from 28D from fuse F24,
connector (26) circuit then repair. Reconnect
28D to ground. connectors and clear
fault codes.
5. On With jumper still Warning light Replace defective
installed at connector circuits test cluster assembly.
(379), reconnect good. Reconnect Reconnect connector
connector (26). connector. and clear fault codes.
Does warning light
illuminate?

6.2. BRAKE PRESSURE

FE 300 With Hydraulic Brakes

Table 11 FE 300 With Hydraulic Brakes

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect hydraulic Warning light Go to next step.
On brake booster monitor circuits test
module connector (86) good. Turn key
and use a test jumper off, reconnect
to connect pin C/circuit conn. (86),
A90M to ground. Move and turn key
key switch to ignition on. If warning
position. Does warning light does
light illuminate? not illuminate
during bulb
check, replace
brake monitor
module.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove BRAKE PRESS warning ohms. Go to next bulb and reconnect
light bulb. Test for light bulb. step. connector. Repeat all
continuity. tests if problem persists.

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50 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 11 FE 300 With Hydraulic Brakes (cont.)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
3. Off Disconnect connector (25), <1 Go to next Locate open or poor
(25), and with jumper A90N to ohm. step. connection in circuit
still attached at gnd. A90N or A90M, then
connector (86), repair. Reconnect
measure resistance connectors.
from connector (25)
circuit A90N to ground.
4. On Move key switch to (25), 12±1.5 Go to next Locate cause of no or
ignition position and A28C to volts. step. low voltage in circuit A28
measure voltage from gnd. or A28C from fuse F22,
connector (25) circuit then repair. Reconnect
A28C to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (86), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(25). Does warning light Reconnect
illuminate? connector (86).

FE 300 With Air Brakes

Table 12 FE 300 With Air Brakes

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect air pressure Warning Go to next step.
On switch connector (1LA) light circuits
and use a test jumper to test good.
connect circuit K40 Reconnect
to ground. Move conn. (1LA),
key switch to ignition and drain air
position. Does warning from brake
light illuminate? system. If
warning light
does not
illuminate
when press.
<60 psi,
replace
pressure
switch.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove BRAKE PRESS warning ohms. Go to next bulb and reconnect
light bulb. Test for light bulb. step. connector. Repeat all
continuity. tests if problem persists.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 51

Table 12 FE 300 With Air Brakes (cont.)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
3. Off Disconnect connector (2), A40A <1 Go to next Locate open or poor
(2), and with jumper to gnd. ohm. step. connection in circuits
still attached at A40A, A40, connector
connector (1LA), (2), circuit N40,
measure resistance connector (9850) or
from connector (2) circuit K40, then repair.
circuit A40A to ground. Reconnect connectors.
4. On Move key switch to (2), A28D 12±1.5 Go to next Locate cause of no or
ignition position and to gnd. volts. step. low voltage in circuit A28
measure voltage from or A28D from fuse F22,
connector (2) circuit then repair. Reconnect
A28D to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (1LA), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(2). Does warning light Reconnect
illuminate? connector
(1LA).

IC With Hydraulic Brakes

Table 13 IC With Hydraulic Brakes

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect hydraulic Warning Go to next step.
On brake booster monitor light circuits
module (49) and test good.
use a test jumper to Turn key off,
connect pin C/circuit reconnect
90T to ground. Move conn. (49),
key switch to ignition and turn key
position. Does warning on. If warning
light illuminate? light does
not illuminate
during bulb
check, replace
brake monitor
module.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove brake pressure warning ohms. bulb. Go to bulb and reconnect
light bulb. Test for light bulb. next step. connector. Repeat all
continuity. tests if problem persists.

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52 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 13 IC With Hydraulic Brakes (cont.)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
3. Off Disconnect connector (26), 90T <1 Go to next Locate open or poor
(26), and with jumper to gnd. ohm. step. connection in circuit 90T,
still attached at then repair. Reconnect
connector (49), connectors.
measure resistance
from connector (26)
circuit 90T to ground.
4. On Move key switch to (26), 28A 12±1.5 Go to next Locate cause of no or
ignition position and to gnd. volts. step. low voltage in circuit
measure voltage from 28A from fuse F24,
connector (26) circuit then repair. Reconnect
28A to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (49), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(26). Does warning light Reconnect
illuminate? connector
(49).

IC With Air Brakes

Table 14 IC With Air Brakes

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Remove warning buzzer Warning Go to next step.
On at relay socket (20), light circuits
move key switch to test good.
ignition position, and Re-install
at relay socket and warning
circuit 40A, connect a buzzer. To
jumper to ground. Does test sensor
warning light illuminate? circuits, go to
Step 6.
2. Off Loosen cluster and Across <100 Re-install Replace defective bulb
remove brake pressure warning ohms. bulb. Go to and re-install warning
warning light bulb. Test light bulb. next step. buzzer.
for continuity.
3. Off Disconnect connector (26), 40A <1 Go to next Locate open or poor
(26), and with jumper still to gnd. ohm. step. connection in circuit
attached at socket (20), 40A, then repair.
measure resistance
from connector (26)
circuit 40A to ground.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 53

Table 14 IC With Air Brakes (cont.)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
4. On Move key switch to (26), 28D 12±1.5 Go to next Locate cause of no or
ignition position and to gnd. volts. step. low voltage in circuit 28
measure voltage from or 28D from fuse F24,
connector (26) circuit then repair.
28D to ground.
5. On With jumper still installed Warning Replace defective
at socket (20), reconnect light circuits cluster assembly.
connector (26). Does test good. Re-install warning
warning light illuminate? Re-install buzzer.
warning
buzzer. To
test sensor
circuits, go to
next step.
6. On Disconnect low air Go to next Locate open or poor
press. sensor connector step. connection in circuit 40B
and install a jumper or 40A, connector (2),
wire from circuit 40 to or circuit 40, then repair.
ground. Does warning Go to next step.
light illuminate?
7. On Remove jumper and Circuits check Replace defective air
reconnect air pressure good. Turn pressure sensor.
sensor connector. Drain key switch off.
air pressure from brake
system until <60 psi.
Does warning light
illuminate?

6.3. STOP ENGINE

FE 300 and IC SE item not covered at this time.

6.4. CHANGE OIL

FE 300 With International Engines

Table 15 FE 300 With International Engines

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
1. Off/ On 1. Turn key to RUN Are both the Go to step 2. Go to step 4.
engine (0x00)
2. Connect J1939 and the MSM
sniffer (aka ESC) on the
data-link?

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54 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 15 FE 300 With International Engines (cont.)

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
2. Off/ On 1. Disconnect J1939 Does the "Change Go to step 3. ECM2 is
sniffer. Oil" output not updating
change? "Change
2. Connect Master Oil" output.
Diagnostics See engine
troubleshooting
3. Monitor the guide.
"Change Oil" output.
3. Off/ On 1. Disconnect (3111), Does the "Change Replace MSM Go to next step.
MSM2 connector pin 2 to Oil" lamp turn on? and retest
(3111). gnd.

2. Connect pin 2 to
ground.
4. Off 1. Remove Across <100 ohms. Re-install Replace
instrument cluster. warning bulb. Go to defective bulb
light next step. and reconnect
2. Remove bulb. connector.
CHANGE OIL Repeat all
indicator bulb. tests if problem
persists.
3. Test bulb for
continuity.
5. Off 1. Instrument cluster (10), pin <1 ohm. Go to next Locate open
removed. 11, cir. step. or poor
A97AA connection in
2. Measure to circuit A97AA
resistance from (3111) or cluster, then
disconnected conn. pin 2. repair.
(10), pin 11, circuit
A97AA to MSM2
disconnected conn.
(3111) pin 2.
6. Off/ On 1. Instrument cluster (10), pin 12±1.5 volts. Install cluster. Locate cause
removed. 4, cir. Go to next of no or low
A28K to step. voltage in
2. Move key switch gnd. circuit A28,
to ignition. A28K from
fuse F22, then
3. Measure voltage repair.
from conn. (10), pin
4, circuit A28K to
ground.
7. Off/ On 1. Leave J1939 Is the engine Go to step 8. Go to step 11.
sniffer connected (0x00) on the
data-link?

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 55

Table 15 FE 300 With International Engines (cont.)

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
8. Off/ On 1. Turn the key to (3111), Is the resistance Go to step 9. Fix data-link
OFF. pins 5 approx. 60 ohms? wiring, cir
and 6. A5DMS(-) and
2. Disconnect A5DMS(+),
MSM1 connector retest
(3111).

3. Measure
resistance across
data-link pins 5 & 6,
in wiring harness
9. Off/ On 1. Turn the key to (3111), Is the voltage Go to step 7. Fix wiring cir
Ignition. pin 7, cir 12-16 volts? A13MS or fuse
A13MS. F31, retest.
2. Measure the
voltage at the
MSM1 conn. (3111)
harness ignition pin
7 to ground.
10. Off/ On 1. Measure the (3111), Is the resistance Replace MSM Fix ground
resistance between pin 8, cir less than 10 and retest wiring cir
the MSM1 conn. A11–GM, ohms? A11–GM,
(3111) harness A11–G A11–G and
ground pin 8 and to gnd. platform
ground ground, retest.
11. Off/ On 1. Leave J1939 Is the MSM (aka Check the Verify sniffer
sniffer connected ESC) on the engine’s is working
data-link? power properly
NOTE: This connections
assumes the and data link
"Change Oil" output wiring.
can be monitored
using MD.

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56 INSTRUMENTS (Data Link Driven Instrument Cluster)

IC With International Engines

Table 16 IC With International Engines

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ECM Warning light Go to next step.
On connector (379) and circuits test
use a test jumper to good. Turn key
connect pin 45/circuit off, reconnect
97AA to ground. Move conn. (379),
key switch to ignition and turn key
position. Does warning on. If warning
light illuminate? light does
not illuminate
during bulb
check,
reprogram/
replace ECM.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove change oil warning ohms. Go to next step. bulb and reconnect
warning light bulb. Test light bulb. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (26), <1 Go to next step. Locate open or poor
(26), and with jumper 97AA to ohm. connection in circuit
still attached at gnd. 97AA, connector (2), or
connector (379), circuit 97AA, then repair.
measure resistance Reconnect connectors.
from connector (26)
circuit 97AA to ground.
4. On Move key switch to (26), 28D 12±1.5 Go to next step. Locate cause of no or
ignition position and to gnd. volts. low voltage in circuit 28
measure voltage from or 28D from fuse F24,
connector (26) circuit then repair. Reconnect
28D to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (379), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(26). Does warning light Reconnect
illuminate? connector
(379).

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 57

6.5. WARN ENGINE

FE 300 With International Engines

Table 17 FE 300 With International Engines

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
1. Off/ On 1. Turn key to RUN Are both the Go to step 2. Go to step 4.
engine (0x00)
2. Connect J1939 and the MSM
sniffer (aka ESC) on the
data-link?
2. Off/ On 1. Disconnect J1939 Does the "Warn Go to step 3. ECM2 is not
sniffer. Engine" output updating "Warn
change? Engine" output.
2. Connect Master See engine
Diagnostics troubleshooting
guide.
3. Monitor the "Warn
Engine" output.
3. Off/ On 1. Disconnect (3111), Does the "Warn Replace MSM Go to next step.
MSM1 connector pin 9 to Engine" lamp turn and retest
(3111). gnd. on?

2. Connect pin 9 to
ground.
4. Off 1. Remove Across <100 ohms. Re-install bulb. Replace
instrument cluster. warning Go to next defective bulb
light step. and reconnect
2. Remove WARN bulb.. connector.
ENGINE indicator Repeat all
bulb. tests if problem
persists.
3. Test bulb for
continuity.
5. Off 1. Instrument cluster (10), pin <1 ohm. Go to next Locate open or
removed. 12, cir. step. poor connection
A97T to in circuit A97T
2. Measure (3111) or cluster, then
resistance from pin 9. repair.
disconnected conn.
(10), pin 12, circuit
A97T to MSM1
disconnected conn.
(3111) pin 9.

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58 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 17 FE 300 With International Engines (cont.)

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
6. Off/ On 1. Instrument cluster (11), pin 12±1.5 volts. Install cluster. Locate cause
removed. 4, cir. Go to next of no or low
A28K to step. voltage in circuit
2. Move key switch gnd. A28, A28K or
to ignition. fuse F22, then
repair.
3. Measure voltage
from conn. (11), pin
4, circuit A28K to
ground.
7. Off/ On 1. Leave J1939 Is the engine Go to step 8. Go to step 11.
sniffer connected (0x00) on the
data-link?
8. Off/ On 1. Turn the key to (3111), Is the resistance Go to step 9. Fix data-link
OFF. pins 5 approx. 60 ohms? wiring, cir
and 6. A5DMS(-) and
2. Disconnect A5DMS(+),
MSM1 connector retest
(3111).

3. Measure
resistance across
data-link pins 5 & 6,
in wiring harness
9. Off/ On 1. Turn the key to (3111), Is the voltage Go to step 7. Fix wiring cir
Ignition. pin 7, cir 12-16 volts? A13MS or fuse
A13MS. F31, retest.
2. Measure the
voltage at the
MSM1 conn. (3111)
harness ignition pin
7 to ground.
10. Off/ On 1. Measure the (3111), Is the resistance Replace MSM Fix ground
resistance between pin 8, cir less than 10 and retest wiring cir
the MSM1 conn. A11–GM, ohms? A11–GM,
(3111) harness A11–G A11–G and
ground pin 8 and to gnd. platform
ground ground, retest.
11. Off/ On 1. Leave J1939 Is the MSM (aka Check the Verify sniffer
sniffer connected ESC) on the engine’s power is working
data-link? connections properly
NOTE: This and data link
assumes the "Warn wiring.
Engine" output can
be monitored using
MD.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 59

IC With International Engines

Table 18 IC With International Engines

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ECM Warning Go to next step.
On connector (379) and light circuits
use a test jumper to test good.
connect pin 55/circuit Turn key off,
97T to ground. Move reconnect
key switch to ignition conn. (379),
position. Does warning and turn key
light illuminate? on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECM.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove engine warn warning ohms. bulb. Go to bulb and reconnect
warning light bulb. Test light bulb. next step. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (26), 97T <1 Go to next Locate open or poor
(26), and with jumper to gnd. ohm. step. connection in circuit
still attached at 97T, connector (2),
connector (379), circuit 97T, then repair.
measure resistance Reconnect connectors.
from connector (26)
circuit 97T to ground.
4. On Move key switch to (26), 28D 12±1.5 Go to next Locate cause of no or
ignition position and to gnd. volts. step. low voltage in circuit 28
measure voltage from or 28D from fuse F24,
connector (26) circuit then repair. Reconnect
28D to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (379), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(26). Does warning light Reconnect
illuminate? connector
(379).

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60 INSTRUMENTS (Data Link Driven Instrument Cluster)

6.6. TRAC CTRL

FE 300 With Anti-lock Brake System (ABS) — Hydraulic Brakes

Table 19 FE 300 With Anti-lock Brake System (ABS) — Hydraulic Brakes

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off/ Disconnect traction control Go to Step Go to next step.
On switch conn. (1101), and 6.
connect a jumper wire from
circuit A94W to ground.
Move key switch to ignition
position. Does warning
light illuminate?
2. Off Loosen cluster and remove Across <100 Re-install Replace defective
TRAC CTRL warning light warning ohms. bulb. Go to bulb and reconnect
bulb. Test for continuity. light bulb. next step. connector. Repeat all
tests if problem persists.
3. Off With jumper still in place, (1500), <1 Go to next Locate open or poor
disconnect connector A94U, to ohm. step. connection in circuit
(1500) and at pin B, circuit gnd. A94U, conn. (2), pin F6
A94U, measure resistance or N94U, then repair.
to ground.
4. On With jumper still in place, (1500), 12±1.5 Go to next Locate cause of no or
move key switch to ignition A94U to volts. step. low voltage in circuit
position, and at connector A94T. A28 or A94T from fuse
(1500) and at pin A, circuit F22, then repair.
A94T, measure voltage
from pin A, circuit A94U, to
pin B, circuit A94T.
5. On With jumper still installed, Go to next Replace defective
reconnect connector step. cluster assembly.
(1500). Does warning light Reconnect connector
illuminate? and clear fault codes.
6. Off With traction control switch Across <1 Go to next Replace defective
conn. (1101) applied, switch ohm. step. traction control switch.
measure resistance across (1101).
traction control switch
conn. (1101).
7. Off At traction control switch (1101), <1 Warning Locate open or poor
conn. (1101), measure A94-GT ohm. light circuits connection in circuits
resistance from circuit to gnd. test good. A94W, conn. (2), pin
A94-GT to ground. Reconnect A2, N94W, A94-GT
circuits. or A11-G to platform
ground, then repair.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 61

FE 300 With WTEC or Allison 2000 ICT Anti-lock Brake System (ABS) — Air Brakes

Table 20 FE 300 With WTEC or Allison 2000 ICT Anti-lock Brake System (ABS) — Air Brakes
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off Disconnect ABS ECU Warning light Go to next step.
connector (288) and circuits test good.
use a test jumper to Turn key off,
connect pin C2 to +12 reconnect conn.
volts. Does warning (288), and turn key
light illuminate? on. If warning light
does not illuminate
during bulb check,
reprogram/ replace
ECU.
2. Off Loosen cluster and Across <100 Re-install bulb. Go Replace defective
remove TRAC CTRL warning ohms. to next step. bulb and reconnect
warning light bulb. Test light bulb. connector. Repeat
for continuity. all tests if problem
persists.
3. On Disconnect connector (3127), 12±1.5 Go to next step. Locate cause of no
(3127), and with A94CT to volts. or low voltage in,
jumper still attached gnd. N94CT connector (2),
at connector (288), or circuit A94CT then
measure voltage from repair. Reconnect
connector (3127), pin A, connectors.
circuit A94CT to ground.
4. Off At connector (3127), (3127), 12±1.5 Go to next step. Locate open or poor
measure voltage from A94GT to volts. connection in circuits
connector (3127), pin B, gnd. A11-GB, A94–GB, coil
circuit A94GT to ground. of relay (283), circuits
A94BT, A94GT or
A13M, from fuse F27,
then repair. Reconnect
connectors.
5. On With jumper still installed Warning light Replace defective
at connector (288), circuits test cluster assembly.
reconnect connector good. Reconnect Reconnect connector.
(3127). Does warning connector (288).
light illuminate?
6. Off With traction control Across <1 Locate open or Replace defective
switch connector (1101) switch ohm. poor connection traction control switch.
applied, measure (1101). in circuits N94DT,
resistance across conn. (2), pin A7, or
traction control switch N94FT, then repair.
connector (1101).

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62 INSTRUMENTS (Data Link Driven Instrument Cluster)

6.7. TRAC CTRL

SE item not covered at this time.

6.8. CHECK TRANS

FE 300 With Allison WTEC III Transmission With Hydraulic Brakes

Table 21 FE 300 With Allison WTEC III Transmission With Hydraulic Brakes
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect Allison ECU Warning Go to next step.
On connector (7204) and light circuits
use a test jumper to test good.
connect pin 31, circuit Turn key off,
K115 to ground. Move reconnect
key switch to ignition conn. (7204),
position. Does warning and turn key
light illuminate? on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove CHECK TRANS warning ohms. bulb. Go to bulb and reconnect
warning light bulb. Test light bulb. next step. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (10), <1 Go to next Locate open or poor
(10), and with jumper A125 to ohm. step. connection in connector
still attached at gnd. (7204), pin 31, circuit
connector (7204), K115, connector (523),
measure resistance circuit N125, connector
from connector (10), (644), circuit A115,
pin 2, circuit A125 to connector (377), circuit
ground. A125 or connector
(10), pin 2, then repair.
Reconnect connectors.
4. On Move key switch to (10), 12±1.5 Go to next Locate cause of no or
ignition position and A28A to volts. step. low voltage in circuit A28
measure voltage from gnd. or A28A from fuse F22,
connector (10), pin1, then repair. Reconnect
circuit A28A to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (7204), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(10). Does warning light Reconnect
illuminate? connector
(7204).

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 63

FE 300 With Allison WTEC III GEN 4 Transmission With Hydraulic Brakes

Table 22 FE 300 With Allison WTEC III GEN 4 Transmission With Hydraulic Brakes
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect Allison ECU Warning Go to next step.
On connector (7150) and light circuits
use a test jumper to test good.
connect pin 29, circuit Turn key off,
K129 to ground. Move reconnect
key switch to ignition conn. (7150),
position. Does warning and turn key
light illuminate? on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove CHECK TRANS warning ohms. bulb. Go to bulb and reconnect
warning light bulb. Test light bulb. next step. connector. Repeat all
for continuity. tests if problem persists.

3. Off Disconnect connector (10), <1 Go to next Locate open or poor

(10), and with jumper A125 to ohm. step. connection in connector
still attached at gnd. (7150), pin 29, circuit
connector (7150), K129, connector (523),
measure resistance circuit N125, connector
from connector (10), (644), circuit A115,
pin 2, circuit A125 to connector (377), circuit
ground. A125 or connector
(10), pin 2, then repair.
Reconnect connectors.
4. On Move key switch to (10), 12±1.5 Go to next Locate cause of no or
ignition position and A28A to volts. step. low voltage in circuit A28
measure voltage from gnd. or A28A from fuse F22,
connector (10), pin 1, then repair. Reconnect
circuit A28A to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (7150), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(10). Does warning light Reconnect
illuminate? connector
(7150).

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64 INSTRUMENTS (Data Link Driven Instrument Cluster)

FE 300 With Allison WTEC III Transmission With Air Brakes

Table 23 FE 300 With Allison WTEC III Transmission With Air Brakes
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect Allison ECU Warning light Go to next step.
On connector (7204) and circuits test
use a test jumper to good. Turn key
connect pin 31, circuit off, reconnect
K115 to ground. Move conn. (7204),
key switch to ignition and turn key
position. Does warning on. If warning
light illuminate? light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove CHECK TRANS warning ohms. Go to next step. bulb and reconnect
warning light bulb. Test light bulb. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (10), <1 Go to next step. Locate open or poor
(10), and with jumper A125 to ohm. connection in connector
still attached at gnd. (7204), pin 31, circuit
connector (7204), K#115, connector (523),
measure resistance circuit N125, connector
from connector (10), (644), circuit A125,
pin 2, circuit A125 to connector (377), circuit
ground. A125 or connector
(10), pin 2, then repair.
Reconnect connectors.
4. On Move key switch to (10), 12±1.5 Go to next step. Locate cause of no or
ignition position and A28A to volts. low voltage in circuit A28
measure voltage from gnd. or A28A from fuse F22,
connector (10), pin 1, then repair. Reconnect
circuit A28A to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (7204), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(10). Does warning light Reconnect
illuminate? connector
(7204).

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 65

FE 300 With Allison WTEC III GEN 4 Transmission With Air Brakes

Table 24 FE 300 With Allison WTEC III GEN 4 Transmission With Air Brakes
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect Allison ECU Warning Go to next step.
On connector (7150) and light circuits
use a test jumper to test good.
connect pin 29, circuit Turn key off,
K129 to ground. Move reconnect
key switch to ignition conn. (7150),
position. Does warning and turn key
light illuminate? on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove CHECK TRANS warning ohms. bulb. Go to bulb and reconnect
warning light bulb. Test light bulb. next step. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (10), <1 Go to next Locate open or poor
(10), and with jumper A125 to ohm. step. connection in connector
still attached at gnd. (7150), pin 29, circuit
connector (7150), K129, connector (523),
measure resistance circuit N129, connector
from connector (10), (644), circuit A125,
pin 2, circuit A125 to connector (377), circuit
ground. A125 or connector
(10), pin 2, then repair.
Reconnect connectors.
4. On Move key switch to (10), 12±1.5 Go to next Locate cause of no or
ignition position and A28A to volts. step. low voltage in circuit A28
measure voltage from gnd. or A28A from fuse F22,
connector (10), pin 1, then repair. Reconnect
circuit A28A to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (7150), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(10). Does warning light Reconnect
illuminate? connector
(7150).

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66 INSTRUMENTS (Data Link Driven Instrument Cluster)

FE 300 With Allison 2000 (LCT) Transmission

Table 25 FE 300 With Allison 2000 (LCT) Transmission

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect Allison ECU Warning light Go to next step.
On connector (7305) and circuits test
use a test jumper to good. Turn key
connect pin 25, circuit off, reconnect
K125 to ground. Move conn. (7305),
key switch to ignition and turn key
position. Does warning on. If warning
light illuminate? light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove CHECK TRANS warning ohms. Go to next bulb and reconnect
warning light bulb. Test light bulb. step. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (10), <1 Go to next Locate open or poor
(10), and with jumper A125 to ohm. step. connection in connector
still attached at gnd. (7305), pin 25, circuit
connector (7305), K125, connector (9875),
measure resistance circuit N125, connector
from connector (10), (644), circuit A125,
pin 2, circuit A125 to connector (377), circuit
ground. A125 or connector
(10), pin 2, then repair.
Reconnect connectors.
4. On Move key switch to (10), 12±1.5 Go to next Locate cause of no or
ignition position and A28A to volts. step. low voltage in circuit A28
measure voltage from gnd. or A28A from fuse F22,
connector (10), pin 1, then repair. Reconnect
circuit A28A to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (7305), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(10). Does warning light Reconnect
illuminate? connector
(7305).

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 67

FE 300 With Allison 1000/2000 GEN 4 Transmission

Table 26 FE 300 With Allison 1000/2000 GEN 4 Transmission

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect Allison ECU Warning light Go to next step.
On connector (7150) and circuits test
use a test jumper to good. Turn key
connect pin 29, circuit off, reconnect
K129 to ground. Move conn. (7150),
key switch to ignition and turn key
position. Does warning on. If warning
light illuminate? light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove CHECK TRANS warning ohms. Go to next bulb and reconnect
warning light bulb. Test light bulb. step. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (12), <1 Go to next Locate open or poor
(10), and with jumper A125 to ohm. step. connection in connector
still attached at gnd. (7150), pin 29, circuit
connector (7150), K129, connector (9875),
measure resistance circuit N129, connector
from connector (10), (644), circuit A125,
pin 2, circuit A125 to connector (377), circuit
ground. A125 or connector
(10), pin 2, then repair.
Reconnect connectors.
4. On Move key switch to (10), 12±1.5 Go to next Locate cause of no or
ignition position and A28A to volts. step. low voltage in circuit A28
measure voltage from gnd. or A28A from fuse F22,
connector (10), pin 1, then repair. Reconnect
circuit A28A to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (7150), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(10). Does warning light Reconnect
illuminate? connector
(7150).

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68 INSTRUMENTS (Data Link Driven Instrument Cluster)

IC With Allison MD Transmission

Table 27 IC With Allison MD Transmission

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect Allison ECU Warning light Go to next step.
On connector (634) and circuits test
use a test jumper to good. Turn key
connect pin 31/circuit off, reconnect
115 to ground. Move conn. (634),
key switch to ignition and turn key
position. Does warning on. If warning
light illuminate? light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove Check Trans warning ohms. Go to next bulb and reconnect
warning light bulb. Test light bulb. step. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (26), 115 <1 Go to next Locate open or poor
(26), and with jumper to gnd. ohm. step. connection in circuit 92,
still attached at connector (377), circuit
connector (634), 115, connector (418), or
measure resistance circuit 115, then repair.
from connector (26) Reconnect connectors.
circuit 115/pin 2 to
ground.
4. On Move key switch to (26), 28A 12±1.5 Go to next Locate cause of no or
ignition position and to gnd. volts. step. low voltage in circuit 28
measure voltage from or 28A from fuse F24,
connector (26) circuit then repair. Reconnect
28A to ground. connectors.
5. On With jumper still installed Warning Replace defective
at connector (634), light circuits cluster assembly.
reconnect connector test good. Reconnect connector.
(26). Does warning light Reconnect
illuminate? connector
(634).

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 69

6.9. LEFT TURN INDICATOR

FE 300 With International Turn Signal Switch (Stationary Column)

Table 28 FE 300 With International Turn Signal Switch (Stationary Column)

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off Move turn signal switch Go to next Refer to Electrical
(62) to left turn position. step. Troubleshooting
Does left turn signal light Manual (ETM) for
illuminate? troubleshooting of turn
signal lights and switch.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove LEFT TURN indicator ohms. bulb. Go to bulb and reconnect
signal indicator light light bulb. next step. connector. Repeat all
bulb. Test for continuity. tests if problem persists.
3. Off Disconnect connector (11), Pulsating Go to next Locate cause of no or
(11), and measure A56B to 12±1.5 step. low voltage in circuit
voltage from circuit gnd. volts. A56B, then repair.
A56B to ground. Reconnect connectors.
4. Off At connector (11), (11), Pulsating Go to next Locate open or poor
measure voltage from A56B to 12±1.5 step. connection in circuit
circuit A56B to circuit A28-G. volts. A28-G or A11-G to
A28-G with turn signal in platform ground, then
left turn position. repair.
5. Off Reconnect connector Left turn Replace defective
(11). Does turn signal indicator cluster assembly.
indicator blink with turn and circuits
signal lights? test good.

FE 300 With Douglas Turn Signal Switch (Tilt Column)

Table 29 FE 300 With Douglas Turn Signal Switch (Tilt Column)

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off Move turn signal switch Go to next Refer to Electrical
(95) to left turn position. step. Troubleshooting
Does left turn signal light Manual (ETM) for
illuminate? troubleshooting of turn
signal lights and switch.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove LEFT TURN indicator ohms. bulb. Go to bulb and reconnect
signal indicator light light bulb. next step. connector. Repeat all
bulb. Test for continuity. tests if problem persists.
3. Off Disconnect connector (11), Pulsating Go to next Locate cause of no or
(11), and measure A56B to 12±1.5 step. low voltage in circuit
voltage from circuit gnd. volts. A56B, then repair.
A56B to ground. Reconnect connectors.

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70 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 29 FE 300 With Douglas Turn Signal Switch (Tilt Column) (cont.)
Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
4. Off At connector (11), (11), Pulsating Go to next Locate open or poor
measure voltage from A56B to 12±1.5 step. connection in circuit
circuit A56B to circuit A28-G. volts. A28-G or A11-G to
A28-G with turn signal in platform ground, then
left turn position. repair.
5. Off Reconnect connector Left turn Replace defective
(11). Does turn signal indicator cluster assembly.
indicator blink with turn and circuits
signal lights? test good.

IC With International Turn Signal Switch (Stationary Column and Tilt Column)

Table 30 IC With International Turn Signal Switch (Stationary Column and Tilt Column)
Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off Move turn signal switch Go to next Refer to Electrical
to left turn position. step. Troubleshooting
Does left turn signal light Manual (ETM) for
illuminate? troubleshooting of turn
signal lights and switch.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove left turn signal indicator ohms. bulb. Go to bulb and reconnect
indicator light bulb. Test light bulb. next step. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (27), 56C Pulsating Go to next Locate cause of no or
(27), and measure to gnd. 12±1.5 step. low voltage in circuit
voltage from circuit 56C volts. 56C, then repair.
to ground. Reconnect connectors.
4. Off At connector (27), (27), 56C Pulsating Go to next Locate open or poor
measure voltage from to 28-GA. 12±1.5 step. connection in circuit
circuit 56C to circuit volts. 28-GA, or 11-G to cab
28-GA with turn signal in ground, then repair.
left turn position.
5. Off Reconnect connector Left turn Replace defective
(27). Does turn signal indicator cluster assembly.
indicator blink with turn and circuits
signal lights? test good.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 71

6.10. (ABS) ANTI-LOCK BRAKE WARNING LIGHT

FE 300 With WTEC or Allison 2000 ICT Air Brakes

Table 31 FE 300 With WTEC or Allison 2000 ICT Air Brakes

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ABS ECU Warning light Go to next step.
On connector (288) and use circuits test
a test jumper to connect good. Turn key
pin E3 to ground. Move off, reconnect
key switch to ignition conn. (288),
position. Does ABS and turn key
warning light illuminate? on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove (ABS) anti-lock warning ohms. Go to next step. bulb and reconnect
brake warning light bulb. light bulb. connector. Repeat all
Test for continuity. tests if problem persists.
3. Off/ Disconnect connector (297), 12±1.5 Go to next step. Locate cause of no or
On (297), move key switch A94B to volts. low voltage in circuits
to ignition position, and gnd. A13K, A13E or A94B
measure voltage from from fuse (F27), then
circuit A94B to ground. repair.
4. On Remove warning light (284), 12±1.5 Go to next step. Locate cause of no or
relay (284), and at relay A94E to volts. low voltage in circuit
socket, measure voltage gnd. A94E, then repair.
from circuit A94E to
ground.
5. On At relay socket (284), (284), 12±1.5 Go to next step. Locate open or poor
measure voltage from A94E to volts. connection in circuits
circuit A94E to A94-GA. A94-GA. A94-GA, A94-GB or
A11-GB, then repair.
6. On With jumper still (284), 12±1.5 Go to next step. Locate open or poor
connected at ECU, A94E to volts. connection in circuits
at relay socket (284), A94H. A94H, conn. (451) or
measure voltage from gray wire, then repair.
circuit A94E to A94H.
7. Off Bench test warning Relay, pin <1 Go to next step. Replace defective
light relay (284) by 30 to 87A. ohm. warning light relay.
measuring resistance
from pin 30 to 87A.

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72 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 31 FE 300 With WTEC or Allison 2000 ICT Air Brakes (cont.)
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
8. Off Bench test warning light Energized <1 Go to next step. Replace defective
relay (284) by applying relay, pin ohm. warning light relay.
+12V to pin 86, gnd. to 30 to 87.
pin 85, and measuring
resistance from pin 30
to 87.
9. Off/ Re-install warning ABS warning Locate open or poor
On light relay, and with light circuits connection in circuit
jumper still installed at test good. A94E, then repair.
connector (288), move Turn key off.
key switch to ignition Reconnect
position. Does warning conn. (288)
light illuminate? and turn key
on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECU.

FE 300 With Hydraulic Brakes GEN 4

Table 32 FE 300 With Hydraulic Brakes GEN 4

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ABS ECU Warning light Go to next step.
On connector (279) and use circuits test good.
a test jumper to connect Turn key off,
pin 1 to ground. Move reconnect conn.
key switch to ignition (279), and turn key
position. Does ABS on. If warning light
warning light illuminate? does not illuminate
during bulb check,
reprogram/ replace
ECU.
2. Off Loosen cluster and Across <100 Re-install bulb. Go Replace defective
remove (ABS) anti-lock warning ohms. to next step. bulb and reconnect
brake warning light bulb. light bulb. connector. Repeat
Test for continuity. all tests if problem
persists.
3. Off/ Disconnect connector (422), 12±1.5 Go to next step. Locate cause of no or
On (422), move key switch A94B to volts. low voltage in circuits
to ignition position, and gnd. A28, A13N or A94B
measure voltage from from fuse (F22), then
circuit A94B to ground. repair.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 73

Table 32 FE 300 With Hydraulic Brakes GEN 4 (cont.)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
4. On Remove warning light (R1), 12±1.5 Go to next step. Locate cause of no or
relay (R1), and at relay A94E to volts. low voltage in circuit
socket, measure voltage gnd. A94E, then repair.
from circuit A94E to
ground.
5. On At relay socket (R1),, (R1), 12±1.5 Go to next step. Locate open or poor
measure voltage from A94E to volts. connection in circuit
circuit A94E to A94-GB. A94-GB. A94-GB or A11-G,
then repair.

6. On With jumper still (R1,, 12±1.5 Go to next step. Locate open or poor
connected at ECU, A94E to volts. connection in circuits
at relay socket (R1),, A94H. A94H, conn. (2),
measure voltage from K94H, conn. (261),
circuit A94E to A94H. K94H, or gray wire,
then repair.
7. Off Bench test warning light Relay, pin <1 Go to next step. Replace defective
relay (R1), by measuring 30 to 87A. ohm. warning light relay.
resistance from pin 30
to 87A.
8. Off Bench test warning light Energized <1 Go to next step. Replace defective
relay (R1), by applying relay, pin ohm. warning light relay.
+12V to pin 86, gnd. to 30 to 87.
pin 85, and measuring
resistance from pin 30
to 87.
9. Off/ Re-install warning ABS warning Locate open or poor
On light relay, and with light circuits test connection in circuit
jumper still installed at good. Turn key off. A94E, then repair.
connector (279), move Reconnect conn.
key switch to ignition (279) and turn key
position. Does warning on. If warning light
light illuminate? does not illuminate
during bulb check,
reprogram/ replace
ECU.

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74 INSTRUMENTS (Data Link Driven Instrument Cluster)

IC With Air Brakes

Table 33 IC With Air Brakes

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ABS ECU Warning light Go to next step.
On connector (288) and use circuits test
a test jumper to connect good. Turn key
pin E3 to ground. Move off, reconnect
key switch to ignition conn. (288),
position. Does ABS and turn key
warning light illuminate? on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove antilock brake warning ohms. Go to next bulb and reconnect
warning light bulb. Test light bulb. step. connector. Repeat all
for continuity. tests if problem persists.
3. Off/ Disconnect connector (297), 12±1.5 Go to next Locate cause of no or
On (297), move key switch 94D to volts. step. low voltage in circuit 28
to ignition position, and gnd. or 94D from fuse (F24),
measure voltage from then repair.
circuit 94D to ground.
4. On Remove warning light (R4), 94F 12±1.5 Go to next Locate cause of no or
relay (R4), and at relay to gnd. volts. step. low voltage in circuit
socket, measure voltage 94F, then repair.
from circuit 94F to
ground.
5. On At relay socket (R4), (R4), 94E 12±1.5 Go to next Locate open or poor
measure voltage from to 94-GC. volts. step. connection in circuit
circuit 94E to 94-GC. 94-GB, circuit 94-GC or
11-G, then repair.
6. On With jumper still (R4), 12±1.5 Go to next Locate open or poor
connected at ECU, 94H. volts. step. connection in circuit
at relay socket (R4), 94H, conn. (2), 94H or
measure voltage from gray wire, then repair.
circuit 94H.
7. Off Bench test warning light Relay, pin <1 Go to next Replace defective
relay (R4) by measuring 30 to 87A. ohm. step. warning light relay.
resistance from pin 30
to 87A.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 75

Table 33 IC With Air Brakes (cont.)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
8. Off Bench test warning light Energized <1 Go to next Replace defective
relay (R4) by applying relay, pin ohm. step. warning light relay.
+12V to pin 86, gnd. to 30 to 87.
pin 85, and measuring
resistance from pin 30
to 87.
9. Off/ Re-install warning ABS warning Locate open or poor
On light relay, and with light circuits connection in circuit
jumper still installed at test good. 94E, then repair.
connector (288), move Turn key off.
key switch to ignition Reconnect
position. Does warning conn. (288)
light illuminate? and turn key
on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECU.

IC With Hydraulic Brakes

Table 34 IC With Hydraulic Brakes

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ABS ECU Warning Go to next step.
On connector (279) and use light circuits
a test jumper to connect test good.
pin 1 to ground. Move Turn key off,
key switch to ignition reconnect
position. Does ABS conn. (279),
warning light illuminate? and turn key
on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECU.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove antilock brake warning ohms. bulb. Go to bulb and reconnect
warning light bulb. Test light bulb. next step. connector. Repeat all
for continuity. tests if problem persists.

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76 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 34 IC With Hydraulic Brakes (cont.)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
3. Off/ Disconnect connector (R4), 94D 12±1.5 Go to next Locate cause of no or
On (R4), move key switch to gnd. volts. step. low voltage in circuit 28
to ignition position, and or 94D from fuse (F24),
measure voltage from then repair.
circuit 94D to ground.
4. On Remove warning light (R4), 94F 12±1.5 Go to next Locate cause of no or
relay (R4), and at relay to gnd. volts. step. low voltage in circuit
socket, measure voltage 94F, then repair.
from circuit 94F to
ground.
5. On At relay socket (R4), (R4), 94E 12±1.5 Go to next Locate open or poor
measure voltage from to 94-GC. volts. step. connection in circuit
circuit 94E to 94-GC. 94-GB, circuit 94-GC or
11-G, then repair.
6. On With jumper still (R4), 12±1.5 Go to next Locate open or poor
connected at ECU, 94H. volts. step. connection in circuit
at relay socket (R4), 94H, conn. (2), 94H or
measure voltage from gray wire, then repair.
circuit 94H.
7. Off Bench test warning light Relay, pin <1 Go to next Replace defective
relay (R4) by measuring 30 to 87A. ohm. step. warning light relay.
resistance from pin 30
to 87A.
8. Off Bench test warning light Energized <1 Go to next Replace defective
relay (R4) by applying relay, pin ohm. step. warning light relay.
+12V to pin 86, gnd. to 30 to 87.
pin 85, and measuring
resistance from pin 30
to 87.
9. Off/ Re-install warning ABS warning Locate open or poor
On light relay, and with light circuits connection in circuit
jumper still installed at test good. 94E, then repair.
connector (279), move Turn key off.
key switch to ignition Reconnect
position. Does warning conn. (279)
light illuminate? and turn key
on. If warning
light does
not illuminate
during bulb
check,
reprogram/
replace ECU.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 77

6.11. HIGH BEAM INDICATOR

FE 300 With Douglas Turn Signal Switch (Tilt Column)

Table 35 FE 300 With Douglas Turn Signal Switch (Tilt Column)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off Loosen cluster, remove Across <100 Re-install Replace defective
HIGH BEAM indicator light bulb. ohms. bulb. Go to bulb and repeat test if
bulb, and test for next step. problem persists.
continuity
2. Off Disconnect connector (11), pin 4 12±1.5 Go to next Go to Step 4.
(11), move headlight to gnd. volts. step.
switch to on, and
dimmer switch to high
beam position. Measure
voltage from connector
(11) pin 4, circuit A52A
to ground.
3. Off With switches still set, (11), pin 4 12±1.5 High beam Locate open or poor
measure voltage at to pin 2. volts. circuits connection in circuit
connector (11) from pin check good. A28-G or A11-G, then
4, circuit A52A to pin 2, Reconnect repair.
circuit A28-G. conn. (11) and
replace cluster
if warning
light fails to
illuminate.
4. Off Remove connector (4) (4), A51B 12±1.5 Go to next Locate cause of no or
and with switches still to gnd. volts. step. low voltage in circuit
set, measure voltage A50C, switch and conn.
from circuit A51B to (23) or circuit A51B,
ground. then repair.
5. Off On switch half of (4), green <1 Go to next Replace defective
connector (4), measure to brown. ohm. step. dimmer switch.
resistance from green
wire to brown wire with
switch in high beam
position.
6. Off Reconnect connector (11), 12±1.5 Circuits Locate cause of low or
(4), and with switches A52A to volts. test good. no voltage in circuit A52
still set, at connector gnd. Reconnect or 52A, then repair.
(11), measure voltage conn. (11) and
from circuit A52A to replace cluster
ground. if warning
light fails to
illuminate.

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78 INSTRUMENTS (Data Link Driven Instrument Cluster)

FE 300 With International Turn Signal Switch (Stationary Column)

Table 36 FE 300 With International Turn Signal Switch (Stationary Column)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off Loosen cluster, remove Across <100 Re-install Replace defective
HIGH BEAM indicator light bulb. ohms. bulb. Go to bulb and repeat test if
bulb, and test for next step. problem persists.
continuity
2. Off Disconnect connector (11), pin 4 12±1.5 Go to next Go to Step 4.
(11), move headlight to gnd. volts. step.
switch to on, and
dimmer switch to high
beam position. Measure
voltage from connector
(11) pin 4, circuit A52A
to ground.
3. Off With switches still set, (11), pin 4 12±1.5 High beam Locate open or poor
measure voltage at to pin 2. volts. circuits check connection in circuit
connector (11) from pin good. If light A28-G or A11-G, then
4, circuit A52A to pin 2, fails to turn off, repair.
circuit A28-G. check relay or
switch.
4. Off Remove lift-to-dim relay Socket 12±1.5 Go to next Locate cause of no or
(100) and with switches (100), volts. step. low voltage in circuit
still set, measure voltage A51A to A50C, switch and conn.
from circuit A51A to gnd. (23) or circuit A51A,
ground. then repair.
5. Off With switches still set, Socket 12±1.5 Go to next Locate cause of low
at relay socket (100), (100), volts. step. or no voltage in circuit
measure voltage from A51F to A51F, then repair.
circuit A51F to ground. gnd.
6. Off With switches still set, Socket 12±1.5 Go to next Locate open or poor
at relay socket (100), (100), volts. step. connection in circuit
measure voltage from A51F to A51D, switch and conn.
circuit A51F to A51D. A51D. (6), circuit A51-G or
A11-GBA to cab ground,
then repair.
7. Off Bench test lift-to-dim Relay, pin <1 Go to next Replace defective
relay (100) by 30 to 87A. ohm. step. lift-to-dim relay.
measuring resistance
from pin 30 to 87A.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 79

Table 36 FE 300 With International Turn Signal Switch (Stationary Column) (cont.)
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
8. Off Bench test lift-to-dim Energized <1 Go to next Replace defective
relay (100) by applying relay, pin ohm. step. lift-to-dim relay.
+12V to pin 85, gnd. to 30 to 87.
pin 86, and measuring
resistance from pin 30
to 87.
9. Off Re-install relay. With (11), pin 4 12±1.5 Circuits Locate cause of low
headlight switch in on to gnd. volts. to cluster or no voltage in circuit
position and dimmer check good. A52C or A52A, then
switch in high beam Reconnect repair.
position, at connector cluster. If
(11) measure voltage warning
from pin 4, circuit A52A light fails to
to ground. illuminate,
replace
defective
cluster.

IC With International Turn Signal Switch (Stationary Column)

Table 37 IC With International Turn Signal Switch (Stationary Column)

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off Loosen cluster, remove Across <100 Go to next Replace defective
high beam indicator bulb. ohms. step. bulb and repeat test if
bulb, and test for open problem persists.
condition.
2. Off Re-install bulb, disconnect (27), pin 4 12±1.5 Go to next Go to Step 4.
connector (27), move to gnd. volts. step.
headlight switch to on,
and dimmer switch to high
beam position. Measure
voltage from connector
(27) pin 4/circuit 52A to
ground.
3. Off With switches still set, (27), pin 4 12±1.5 High beam Locate open or poor
measure voltage at to pin 2. volts. circuits connection in circuit
connector (27) from pin check good. 28-GA or 11-G, then
4/circuit 52A to pin 2/circuit If light fails repair.
28-GA. to turn off,
check relay
or switch.

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80 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 37 IC With International Turn Signal Switch (Stationary Column) (cont.)

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
4. Off Remove lift-to-dim relay Socket 12±1.5 Go to next Locate cause of no or
(100) and with switches (100), volts. step. low voltage in circuit 50,
still set, measure voltage 51A to 50B, switch and conn.
from circuit 51A to ground. gnd. (35) or circuit 51A, then
repair.
5. Off With switches still set, Socket 12±1.5 Go to next Locate cause of low or
at relay socket (100), (100), volts. step. no voltage in circuit 51C,
measure voltage from 51C to then repair.
circuit 51C to ground. gnd.
6. Off With switches still set, Socket 12±1.5 Go to next Locate open or poor
at relay socket (100), (100), volts. step. connection in circuit
measure voltage from 51A to 51D, switch and conn.
circuit 51A to 51D. 51D. (100), circuit 51-G or
11-G to cab ground,
then repair.
7. Off Bench test lift-to-dim Relay, pin <1 Go to next Replace defective
relay (100) by measuring 30 to 87A. ohm. step. lift-to-dim relay.
resistance from pin 30 to
87A.
8. Off Bench test lift-to-dim relay Energized <1 Go to next Replace defective
(100) by applying +12V relay, pin ohm. step. lift-to-dim relay.
to pin 85, gnd. to pin 86, 30 to 87.
and measuring resistance
from pin 30 to 87.
9. Off Re-install relay. With (27), pin 4 12±1.5 Circuits Locate cause of low or
headlight switch in on to gnd. volts. to cluster no voltage in circuit 52C
position and dimmer check good. or 52A, then repair.
switch in high beam Reconnect
position, at connector (27) cluster. If
measure voltage from pin warning
4/circuit 52A to ground. light fails to
illuminate,
replace
defective
cluster.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 81

6.12. RIGHT TURN INDICATOR

FE 300 With International Turn Signal Switch (Stationary Column)

Table 38 FE 300 With International Turn Signal Switch (Stationary Column)

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off Move turn signal switch Go to next Refer to Electrical
(62) to right turn position. step. Troubleshooting
Does right turn signal Manual (ETM) for
light illuminate? troubleshooting of turn
signal lights and switch.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove RIGHT TURN indicator ohms. bulb. Go to bulb and reconnect
signal indicator light light bulb. next step. connector. Repeat all
bulb. Test for continuity. tests if problem persists.
3. Off Disconnect connector (11), Pulsating Go to next Locate cause of no or
(11), and measure A57B to 12±1.5 step. low voltage in circuit
voltage from circuit gnd. volts. A57B, then repair.
A57B to ground. Reconnect connectors.
4. Off At connector (11), (11), Pulsating Go to next Locate open or poor
measure voltage from A57B to 12±1.5 step. connection in circuit
circuit A57B to circuit A28-G. volts. A28-G, or A11-G to cab
A28-G with turn signal in ground, then repair.
right turn position.
5. Off Reconnect connector Right turn Replace defective
(11). Does turn signal indicator cluster assembly.
indicator blink with turn and circuits
signal lights? test good.

FE 300 With Douglas Turn Signal Switch (Tilt Column)

Table 39 FE 300 With Douglas Turn Signal Switch (Tilt Column)

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off Move turn signal switch Go to next Refer to Electrical
(95) to right turn position. step. Troubleshooting
Does right turn signal Manual (ETM) for
light illuminate? troubleshooting of turn
signal lights and switch.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove RIGHT TURN indicator ohms. bulb. Go to bulb and reconnect
signal indicator light light bulb. next step. connector. Repeat all
bulb. Test for continuity. tests if problem persists.
3. Off Disconnect connector (11), Pulsating Go to next Locate cause of no or
(11), and measure A57B to 12±1.5 step. low voltage in circuit
voltage from circuit gnd. volts. A57B, then repair.
A57B to ground. Reconnect connectors.

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82 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 39 FE 300 With Douglas Turn Signal Switch (Tilt Column) (cont.)
Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
4. Off At connector (11), (11), Pulsating Go to next Locate open or poor
measure voltage from A57B to 12±1.5 step. connection in circuit
circuit A57B to circuit A28-G. volts. A28-G or A11-G to
A28-G with turn signal in platform ground, then
right turn position. repair.
5. Off Reconnect connector Right turn Replace defective
(11). Does turn signal indicator cluster assembly.
indicator blink with turn and circuits
signal lights? test good.

IC With International Turn Signal Switch (Stationary Column and Tilt Column)

Table 40 IC With International Turn Signal Switch (Stationary Column and Tilt Column)
Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off Move turn signal switch Go to next Refer to Electrical
to right turn position. step. Troubleshooting
Does right turn signal Manual (ETM) for
light illuminate? troubleshooting of turn
signal lights and switch.
2. Off Loosen cluster and Across <100 Re-install Replace defective
remove right turn signal indicator ohms. bulb. Go to bulb and reconnect
indicator light bulb. Test light bulb. next step. connector. Repeat all
for continuity. tests if problem persists.
3. Off Disconnect connector (27), 57C Pulsating Go to next Locate cause of no or
(27), and measure to gnd. 12±1.5 step. low voltage in circuit
voltage from circuit 57C volts. 57C, then repair.
to ground. Reconnect connectors.
4. Off At connector (27), (27), 57C Pulsating Go to next Locate open or poor
measure voltage from to 28-GA. 12±1.5 step. connection in circuit
circuit 57C to circuit volts. 28-GA, or 11-G to cab
28-GA with turn signal in ground, then repair.
right turn position.
5. Off Reconnect connector Right turn Replace defective
(27). Does turn signal indicator cluster assembly.
indicator blink with turn and circuits
signal lights? test good.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 83

6.13. WAIT-TO-START
FE 300 With International Engines

Table 41 FE 300 With International Engines

Step Key Action Test Spec. Yes - In Spec. No - Out of Spec.
Points
1. Off/ On 1. Turn key to RUN Are both the Go to step 2. Go to step 4.
engine (0x00)
2. Connect J1939 and the MSM
sniffer (aka ESC) on the
Data-link?
2. Off/ On 1. Disconnect J1939 Does the "Wait Go to step 3. ECM2 is not
sniffer. to Start" output updating "Wait
change? to Start" output.
2. Connect Master See engine
Diagnostics troubleshooting
guide.
3. Monitor the "Wait
to start" output.
3. Off/ On 1. Disconnect (3111), Does the "Wait to Replace MSM Go to next step.
MSM1 connector pin 10 to Start" lamp turn and retest
(3111). gnd. on?

2. Connect pin 10 to
ground.
4. Off 1. Remove Across <100 ohms. Re-install Replace defective
instrument cluster. light bulb. Go to bulb. Repeat all
bulb. next step. tests if problem
2. Remove WAIT- persists.
TO- START indicator
bulb.

3. Test bulb for

continuity.
5. Off 1. Instrument cluster (12), pin <1 ohm. Go to next Locate open or
removed. 5, cir. step. poor connection
A97AE in circuit A97AE
2. Measure to (3111) or cluster, then
resistance from pin 10. repair.
disconnected conn.
(12), pin 5, circuit
A97AE to MSM1
disconnected conn.
(3111) pin 10.

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84 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 41 FE 300 With International Engines (cont.)

Step Key Action Test Spec. Yes - In Spec. No - Out of Spec.
Points
6. Off/ On 1. Instrument cluster (12), pin 12±1.5 volts. Install cluster. Locate cause of
removed. 8, cir. Go to next no or low voltage
A28C to step. in circuits A28C,
2. Move key switch gnd. A28 or fuse F22,
to ignition. then repair.

3. Measure voltage
from conn. (12), pin
8, circuit A28C to
ground.
7. Off/ On 1. Leave J1939 Is the engine Go to step 8. Go to step 11.
sniffer connected (0x00) on the
Data-link?
8. Off/ On 1. Turn the key to (3111), Is the resistance Go to step 9. Fix data-link
OFF. pins 5 approx. 60 ohms? wiring, cir
and 6. A5DMS(-) and
2. Disconnect A5DMS(+), retest
MSM1 connector
(3111).

3. Measure
resistance across
data—link pins 5 &
6, in wiring harness
9. Off/ On 1. Turn the key to (3111), Is the voltage Go to step 7. Fix wiring cir
Ignition. pin 7, cir 12-16 volts? A13MS. or fuse
A13MS. F31, retest.
2. Measure the
voltage at the
MSM1 conn. (3111)
harness ignition pin
7 to ground.
10. Off/ On 1. Measure the (3111), Is the resistance Replace MSM Fix ground wiring
resistance between pin 8, cir less than 10 and retest cir A11–GM,
the MSM1 conn. A11–GM, ohms? A11–G and
(3111) harness A11–G platform ground,
ground pin 8 and to gnd. retest.
ground
11. Off/ On 1. Leave J1939 Is the MSM (aka Check the Verify sniffer is
sniffer connected ESC) on the engine’s working properly
data-link? power
NOTE: This connections
assumes the "Wait and data link
to Start" output can wiring.
be monitored using
MD.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 85

IC With International T444E Engine

Table 42 IC With International T444E Engine

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ECM Warning Go to next step.
On connector (379) and use light circuits
a test jumper to connect test good.
circuit 18-G to ground. If warning
Move key switch to light fails to
ignition position. Does illuminate
warning light illuminate? during bulb
check,
reprogram/
replace ECM.
2. On Remove wait-to-start Across <100 Go to next Replace defective
indicator bulb and check bulb. ohms. step. bulb and repeat test if
for open condition. problem persists.
3. Off With jumper still in place, (28), 18-G <1 Go to next Locate open or poor
disconnect connector to gnd. ohm. step. connection in circuit
(28) and measure 18-G, conn. (2), or
resistance from pin circuit 18-G, then repair.
5/circuit 18-G to ground.
4. On With jumper still in (28), 28D 12±1.5 Go to next Locate cause of no or
place, move key switch to 18-G. volts. step. low voltage in circuit 28
to ignition position, or 28D from fuse F24,
and at connector (28), then repair.
measure voltage from
pin 8/circuit 28D to pin
5/circuit 18-G.
5. On With jumper still installed Warning light Replace defective
at connector (379), circuits test cluster assembly.
reconnect connector good. Test Reconnect connector
(28). Does warning light complete. and clear fault codes.
illuminate? Reconnect
conn.

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86 INSTRUMENTS (Data Link Driven Instrument Cluster)

6.14. PDL
FE 300 AND IC SE item not covered at this time.

6.15. PARK BRAKE

FE 300 With Hydraulic Brakes

Table 43 FE 300 With Hydraulic Brakes

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off/ Disconnect park brake Go to Step Go to next step.
On switch conn. (218), and 6.
connect a jumper wire
from circuit K44A to
ground. Move key switch
to ignition position. Does
park brake warning light
illuminate?
2. On Remove instrument Across <100 Re-install Replace defective
cluster and remove PARK warning ohms. bulb. Go to bulb and reconnect
BRAKE indicator bulb. light bulb. next step. connector. Repeat all
Test bulb for continuity. tests if problem persists.
3. Off With jumper still in place, (12), A44 <1 Go to next Locate open or poor
disconnect connector (12) to gnd. ohm. step. connection in circuit A44
and at pin 17, circuit A44, or K44A, then repair.
measure resistance to
ground.
4. On With jumper still in place, (12), 12±1.5 Go to next Locate cause of no or
move key switch to ignition A28C to volts. step. low voltage in circuit
position, and at connector A44. A28 or A28C from fuse
(12), measure voltage F22, then repair.
from pin 8, circuit A28C to
pin 17, circuit A44.
5. On With jumper still installed, Go to next Replace defective
reconnect connector step. cluster assembly.
(12). Does warning light Reconnect connector
illuminate? and clear fault codes.
6. Off With parking brake Across <1 Go to next Replace defective park
applied, measure switch ohm. step. brake switch.
resistance across park (218).
brake switch (218).
7. Off At park brake switch (218), (218), <1 Warning Locate open or poor
measure resistance from K44-G to ohm. light circuits connection in K44-G,
circuit K44-G to ground. gnd. test good. K11-GD to start ground,
Reconnect then repair.
circuits.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 87

FE 300 With Air Brakes

Table 44 FE 300 With Air Brakes

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.

1. Off/ Disconnect park brake air Go to Step Go to next step.

On switch conn. (218), and 6.
connect a jumper wire
from circuit A44 to ground.
Move key switch to ignition
position. Does park brake
warning light illuminate?
2. On Remove instrument Across <100 Re-install Replace defective
cluster and remove PARK warning ohms. bulb. Go to bulb and reconnect
BRAKE indicator bulb. light bulb. next step. connector. Repeat all
Test bulb for continuity. tests if problem persists.
3. Off With jumper still in place, (12), A44 <1 Go to next Locate open or poor
disconnect connector (12) to gnd. ohm. step. connection in circuit
and at pin 17, circuit A44, A44, then repair.
measure resistance to
ground.
4. On With jumper still in place, (12), 12±1.5 Go to next Locate cause of no or
move key switch to ignition A28C to volts. step. low voltage in circuit
position, and at connector A44. A28 or A28C from fuse
(12), measure voltage F22, then repair.
from pin 8, circuit A28C to
pin 17, circuit A44.
5. On With jumper still installed, Go to next Replace defective
reconnect connector step. cluster assembly.
(12). Does warning light Reconnect connector
illuminate? and clear fault codes.
6. Off With parking brake Across <1 Go to next Replace defective park
applied, measure switch. ohm. step. brake air switch.
resistance across park
brake air switch (218).
7. Off At connector (218), (218), <1 Warning Locate open or poor
measure resistance from A44GA to ohm. light circuits connection in A44GA to
circuit A44GA to ground. gnd. test good. cab ground, then repair.
Reconnect
circuits.

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88 INSTRUMENTS (Data Link Driven Instrument Cluster)

IC With Hydraulic Brakes

Table 45 IC With Hydraulic Brakes

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off/ Disconnect park brake Go to Step Go to next step.
On switch conn. (218), and 6.
connect a jumper wire
from black wire, going to
warning light, to ground.
Move key switch to ignition
position. Does warning
light illuminate?
2. On Loosen cluster, remove Across <100 Go to next Replace defective
indicator bulb and test for bulb. ohms. step. bulb and repeat test if
open condition. problem persists.
3. Off Re-install bulb. With (28), 44 to <1 Go to next Locate open or poor
jumper still in place, gnd. ohm. step. connection in circuit 44,
disconnect connector (28) 44A [circuit 44A, diode
and at pin 17/circuit 44, (212), and circuit 44B
measure resistance to with DRL], a black wire,
ground. or another black wire,
then repair.
4. On With jumper still in place, (28), 28C 12±1.5 Go to next Locate cause of no or
move key switch to ignition to 44. volts. step. low voltage in circuit 28
position, and at connector or 28C from fuse F24,
(28), measure voltage then repair.
from pin 8/circuit 28C to
pin 17/circuit 44.
5. On With jumper still installed, Go to next Replace defective
reconnect connector step. cluster assembly.
(28). Does warning light Reconnect connector
illuminate? and clear fault codes.
6. Off With parking brake Across <1 Go to next Replace defective park
applied, measure switch. ohm. step. brake switch.
resistance across park
brake switch.
7. Off At park brake switch, Near <1 Warning Locate open or poor
measure resistance from switch, ohm. light circuits connection in white wire,
white wire to ground. white wire test good. conn. (214), circuit
to gnd. Reconnect 44-GA with DRL), or
circuits. 44-G, then repair.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 89

6.16. ((P)) LOW AIR

FE 300 SE item not covered at this time.

6.17. ((P)) LOW AIR

IC

Table 46 IC
Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. Off Disconnect low air Go to Step Go to next step.
pressure switch (230), 6.
and use a test jumper to
connect circuit 40-GB to
ground. Does warning
light illuminate?
2. On Loosen cluster, remove Across <100 Go to next Replace defective
indicator bulb and test for bulb. ohms. step. bulb and repeat test if
open condition. problem persists.
3. Off Re-install bulb. With (28), <1 Go to next Locate open or poor
jumper still in place, 44-GC to ohm. step. connection in circuit
disconnect connector (28) gnd. 40-GC or 40-GB, then
and measure resistance repair.
from pin 7/circuit 40-GC
to ground.
4. On With jumper still in place, (28), 28C 12±1.5 Go to next Locate cause of no or
move key switch to to 40-GC. volts. step. low voltage in circuit 28
ignition position, and at or 28C from fuse F24,
connector (28), measure then repair.
voltage from pin 8/circuit
28C to pin 7/circuit
40-GC.
5. On With jumper still installed, Go to next Replace defective
reconnect connector step. cluster assembly.
(28). Does warning light Reconnect connector.
illuminate?
6. Off Drain air from suspension Across <1 Go to next Replace defective air
system and measure switch. ohm. step. pressure switch.
resistance across low
air pressure switch (230)
terminals.
7. Off At air pressure switch (230), <1 Warning Locate open or poor
connector (230) and 61-GA to ohm. light circuits connection in circuit
circuit 61-GA, measure gnd. test good. 61-GA, then repair.
resistance to ground. Reconnect
circuits.

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90 INSTRUMENTS (Data Link Driven Instrument Cluster)

6.18. WINDSHIELD WASHER FLUID

FE 300 AND IC SE item not covered at this time.

6.19. FRONT AXLE

FE 300 AND IC SE item not covered at this time.

6.20. DIFF LOCK ENGAGED

FE 300 AND IC SE item not covered at this time.

6.21. SUSP LOW AIR

FE 300 AND IC (With Hyd Brakes) SE item not covered at this time.

6.22. WATER-IN-FUEL
FE 300 (I6 ENGINE)

Table 47 FE 300 (I6 ENGINE)

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
1. Off/ On 1. Turn key to RUN Are both the Go to step 2. Go to step 4.
engine (0x00)
2. Connect J1939 and the MSM
sniffer (aka ESC) on the
data-link?
2. Off/ On 1. Disconnect J1939 Does the Go to step 3. ECM2 is
sniffer. "Water-In-Fuel" not updating
output change? "Water-In-Fuel"
2. Connect Master output.
Diagnostics See engine
troubleshooting
3. Monitor the guide.
"Water-In-Fuel"
output.
3. Off/ On 1. Disconnect (3111), Does the Replace MSM Go to next step.
MSM2 connector pin 3 to "Water-In-Fuel" and retest
(3111). gnd. lamp turn on?

2. Connect pin 3 to
ground.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 91

Table 47 FE 300 (I6 ENGINE) (cont.)

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
4. Off 1. Remove Across <100 ohms. Re-install Replace
instrument cluster. warning bulb. Go to defective bulb
light next step. and reconnect
2. Remove bulb. connector.
WATER-IN-FUEL Repeat all
indicator bulb. tests if problem
persists.
3. Test bulb for
continuity.
5. Off 1. Instrument cluster (9), pin <1 ohm. Go to next Locate open
removed. A, cir. step. or poor
A19F to connection in
2. Measure (3111) circuit A19F,
resistance from pin 3. conn. (3111),
disconnected conn. pin 3, circuit
(9), pin A, circuit A19F or cluster,
A19F to MSM2 then repair.
disconnected conn.
(3111) pin 3.
6. Off/ On 1. Instrument cluster (9), pin 12±1.5 volts. Install cluster. Locate cause
removed. B, cir. Go to next of no or low
A19E to step. voltage in
2. Move key switch gnd. circuit A19E,
to ignition. Heated Fuel
Relay (R5),
3. Measure voltage circuit A11–GA,
from conn. (9), pin circuit A19D or
B, circuit A19E to fuse F20, then
ground. repair.
7. Off/ On 1. Leave J1939 Is the engine Go to step 8. Go to step 11.
sniffer connected (0x00) on the
data-link?
8. Off/ On 1. Turn the key to (3111), Is the resistance Go to step 9. Fix data-link
OFF. pins 5 approx. 60 ohms? wiring, cir
and 6. A5DMS(-) and
2. Disconnect A5DMS(+),
MSM1 connector retest
(3111).

3. Measure
resistance across
data-link pins 5 & 6,
in wiring harness

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92 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 47 FE 300 (I6 ENGINE) (cont.)

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
9. Off/ On 1. Turn the key to (3111), Is the voltage Go to step 7. Fix wiring cir
Ignition. pin 7, cir 12-16 volts? A13MS or fuse
A13MS. F31, retest.
2. Measure the
voltage at the
MSM1 conn. (3111)
harness ignition pin
7 to ground.
10. Off/ On 1. Measure the (3111), Is the resistance Replace MSM Fix ground
resistance between pin 8, cir less than 10 and retest wiring cir
the MSM1 conn. A11–GM, ohms? A11–GM,
(3111) harness A11–G A11–G and
ground pin 8 and to gnd. platform
ground ground, retest.
11. Off/ On 1. Leave J1939 Is the MSM (aka Check the Verify sniffer
sniffer connected ESC) on the engine’s is working
data-link? power properly
NOTE: This connections
assumes the and data link
"Water-In-Fuel" wiring.
output can be
monitored using
MD.

IC With International Engines

Table 48 IC With International Engines

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
1. On Disconnect circuit 19C Warning Go to next step.
from water probe, and light circuits
connect it with a jumper test good.
wire to ground. Does
warning light illuminate?
2. On Remove water-in-fuel Across <100 Go to next Replace defective bulb
indicator bulb and check bulb. ohms. step. and repeat tests if
for open condition. problem persists.
3. Off With jumper still in place, (470), <1 Go to next Locate open or poor
disconnect water-in-fuel 19C to ohm. step. connection in circuit
module connector (470) gnd. 19C, conn. (401), or
and measure resistance circuit 19E, then repair.
from circuit 19C to ground.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 93

Table 48 IC With International Engines (cont.)

Step Key Action Test Spec. Yes-In No-Out of Spec
Points Spec.
4. On Move key switch to (470), 12±1.5 Go to next Locate cause of no or
ignition position, and 19E to volts. step. low voltage in circuit
with jumper still in place, 19C. 19E, conn. (401) or
measure voltage at 92C, then repair.
connector (470) from
circuit 19E to 19C.
5. On At warning light bulb (433), <1 Go to next Locate open or poor
socket (433), measure 19-G to ohm. step. connection in circuit
resistance from circuit gnd. 19-G, then repair.
19-G to ground.
6. On Re-install warning light Go to next Locate cause of low or
bulb and use a jumper step. no voltage in circuit 19B,
wire to connect circuit 19B then repair.
to 19B. Does warning light
illuminate?
7. On Reconnect water-in-fuel Warning Replace defective
module (470) and leave light circuits water-in-fuel module
jumper at circuit 19C test good. (470).
connected. Does warning Remove
light illuminate? jumper and
reconnect
circuit 19C.

6.23. FUEL FILTER

FE 300

Table 49 FE 300
Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
1. Off/ On 1. Turn key to RUN Are both the Go to step 2. Go to step 4.
engine (0x00)
2. Connect J1939 and the MSM
sniffer (aka ESC) on the
data-link?
2. Off/ On 1. Disconnect J1939 Does the "FUEL Go to step 3. ECM2 is
sniffer. FILTER" output not updating
change? "FUEL FILTER"
2. Connect Master output.
Diagnostics See engine
troubleshooting
3. Monitor the guide.
"FUEL FILTER"
output.

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94 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 49 FE 300 (cont.)

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
3. Off/ On 1. Disconnect (3111), Does the "FUEL Replace MSM Go to next step.
MSM2 connector pin 1 to FILTER" lamp turn and retest
(3111). gnd. on?

2. Connect pin 1 to
ground.
4. Off 1. Remove Across <100 ohms. Re-install Replace
instrument cluster. warning bulb. Go to defective bulb
light next step. and reconnect
2. Remove FUEL bulb. connector.
FILTER indicator Repeat all
bulb. tests if problem
persists.
3. Test bulb for
continuity.
5. Off 1. Instrument cluster (69), pin <1 ohm. Go to next Locate open
removed. B, cir. step. or poor
A19K to connection in
2. Measure (3111) circuit A19K,
resistance from pin 1. conn. (69), pin
disconnected conn. B or cluster,
(69), pin B, circuit then repair.
A19K to MSM2
disconnected conn.
(3111) pin 1.
6. Off/ On 1. Instrument cluster (69), pin 12±1.5 volts. Install cluster. Locate cause
removed. A, cir. Go to next of no or low
A19J to step. voltage in
2. Move key switch gnd. circuit A19J,
to ignition. conn. (69), pin
A or fuse F22,
3. Measure voltage then repair.
from conn. (69), pin
A, circuit A19J to
ground.
7. Off/ On 1. Leave J1939 Is the engine Go to step 8. Go to step 11.
sniffer connected (0x00) on the
data-link?

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 95

Table 49 FE 300 (cont.)

Step Key Action Test Spec. Yes - In Spec. No - Out of
Points Spec.
8. Off/ On 1. Turn the key to (3111), Is the resistance Go to step 9. Fix data-link
OFF. pins 5 approx. 60 ohms? wiring, cir
and 6. A5DMS(-) and
2. Disconnect A5DMS(+),
MSM1 connector retest
(3111).

3. Measure
resistance across
data-link pins 5 & 6,
in wiring harness
9. Off/ On 1. Turn the key to (3111), Is the voltage Go to step 7. Fix wiring cir
Ignition. pin 7, cir 12-16 volts? A13MS or fuse
A13MS. F31, retest.
2. Measure the
voltage at the
MSM1 conn. (3111)
harness ignition pin
7 to ground.
10. Off/ On 1. Measure the (3111), Is the resistance Replace MSM Fix ground
resistance between pin 8, cir less than 10 and retest wiring cir
the MSM1 conn. A11–GM, ohms? A11–GM,
(3111) harness A11–G A11–G and
ground pin 8 and to gnd. platform
ground ground, retest.
11. Off/ On 1. Leave J1939 Is the MSM (aka Check the Verify sniffer
sniffer connected ESC) on the engine’s is working
data-link? power properly
NOTE: This connections
assumes the "FUEL and data link
FILTER" output can wiring.
be monitored using
MD.

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96 INSTRUMENTS (Data Link Driven Instrument Cluster)

IC Series With International Engines

Table 50 IC With International Engines

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect connector Warning Go to next step.
On (401) from fuel filter light circuits
vacuum switch, and test good.
connect circuit 19B to Reconnect
ground with a jumper conn. (401).
wire. Move key switch to If warning
ignition position. Does light fails to
warning light illuminate? illuminate
when filter
becomes
restricted,
replace
vacuum
switch.
2. On Remove fuel filter Across <100 Go to next Replace defective bulb
indicator bulb and test bulb. ohms. step. and repeat tests if
for open condition. problem persists.
3. Off With jumper still in place, (434), <1 Go to next Locate open or poor
at bulb socket (434), 19B to ohm. step. connection in circuit
measure resistance gnd. 19D, conn. (1150),
from circuit 19B to circuit 19D, conn. (2), or
ground. circuit 19B, then repair.
4. Off/ Re-install bulb and Warning Locate cause of low or
On move key switch to light circuits no voltage in circuit 19D,
ignition position. Does test good. conn. (1150), circuit 19B
warning light illuminate? Reconnect or 19D, then repair.
conn. (401).
If warning
light fails to
illuminate
when filter
becomes
restricted,
replace
vacuum
switch.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 97

6.24. POWER TAKE OFF (PTO)

FE 300 AND IC SE item not covered at this time.

6.25. LOW BRAKE FLUID

FE 300

Table 51 FE 300
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect connector Warning Go to next step.
On (90) from brake fluid light circuits
level sensor, and test good.
connect circuit N90P, Reconnect
going to warning light, conn. (90).
to ground with a jumper If warning
wire. Move key switch to light fails to
ignition position. Does illuminate
warning light illuminate? when reservoir
level is low,
replace level
sensor.
2. Off Loosen cluster and Across <100 Re-install bulb. Replace defective
remove LOW BRAKE warning ohms. Go to next bulb and reconnect
FLUID warning light light bulb. step. connector. Repeat all
bulb. Test for continuity. tests if problem persists.
3. Off With jumper still in place, (89), <1 Go to next Locate open or poor
at bulb socket (89), A90V to ohm. step. connection in circuits
measure resistance gnd. A90V, N90P, conn. (2),
from circuit A90V to circuits N90P, N11–GF,
ground. or N11–GB, then repair.
4. Off/ Re-install bulb and Warning Locate cause of low or
On move key switch to light circuits no voltage in circuit A28,
ignition position. Does test good. or A90R from fuse F22,
warning light illuminate? Reconnect then repair.
conn. (90).
If warning
light fails to
illuminate
when reservoir
level is low,
replace level
sensor.

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98 INSTRUMENTS (Data Link Driven Instrument Cluster)

IC

Table 52 IC
Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect connector Warning Go to next step.
On (90) from brake fluid light circuits
level sensor, and test good.
connect circuit 90U, Reconnect
going to warning light, conn. (90).
to ground with a jumper If warning
wire. Move key switch to light fails to
ignition position. Does illuminate
warning light illuminate? when
reservoir level
is low, replace
level sensor.
2. On Remove brake fluid Across <100 Go to next Replace defective bulb
indicator bulb and test bulb. ohms. step. and repeat tests if
for open condition. problem persists.
3. Off With jumper still in place, (89), 90U <1 Go to next Locate open or poor
at bulb socket (89), to gnd. ohm. step. connection in circuit
measure resistance 90U, conn. (84), circuit
from circuit 90U to 90U, conn. (88), or
ground. circuit 90U, then repair.
4. Off/ Re-install bulb and Warning Locate cause of low or
On move key switch to light circuits no voltage in circuit 13E,
ignition position. Does test good. conn. (47) or 90U from
warning light illuminate? Reconnect fuse F19, then repair.
conn. (90).
If warning
light fails to
illuminate
when
reservoir level
is low, replace
level sensor.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 99

6.26. RETARD ON
FE 300 With Allison WTEC III XMSN GEN 4

Table 53 FE 300 With Allison WTEC III XMSN GEN 4

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ECU (7202), 12±1.5 Warning light Go to next step.
On connector (7202), pin pin 18, volts. circuitry tests
18, connect a test K125. to good. Refer
jumper from circuit gnd. to Electrical
K125 to ground, and Troubleshooting
move key switch to Manual to locate
ignition position. Does problem with
RETARD ON warning transmission
light illuminate? circuitry.
2. Off Remove RETARD ON Across <100 Re-install bulb. Replace defective bulb
warning light bulb conn. warning ohms. Go to next step. and repeat all tests if
(926). Test for continuity. light bulb. problem persists.
3. Off/ Remove retard on relay Relay 12±1.5 Go to next step. Locate cause of no or
On (7807), move key switch socket volts. low voltage in circuit
to ignition position, and (7807), V146C or V146D from
measure voltage from V146D to fuse F4, then repair.
circuit V146D to ground. gnd.
4. On With key switch still in Relay 12±1.5 Go to next step. Locate cause of no or
ignition position, at relay socket, volts. low voltage in circuit
socket, measure voltage V146D to V146D then repair.
from circuit V146D to gnd.
ground.
5. On With key switch still in Relay 12±1.5 Go to next step. Locate open or poor
ignition position and socket, volts. connection in circuit
jumper still installed, at V146D to K125., then repair.
relay socket, measure K125.
voltage from circuit
V146D to K125.
6. Off Bench test retard on Relay, pin <1 Go to next step. Replace defective relay.
relay by measuring 30 to 87A. ohm.
resistance from pin 30
to 87A.
7. Off Bench test retard on Energized <1 Go to next step. Replace defective relay.
relay by applying +12V relay, pin ohm.
to pin 85, gnd. to pin 30 to 87.
86, and measuring
resistance from pin 30
to 87.

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100 INSTRUMENTS (Data Link Driven Instrument Cluster)

Table 53 FE 300 With Allison WTEC III XMSN GEN 4 (cont.)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
8. Off/ Re-install retard on Socket, 12±1.5 Go to next step. Locate cause of low
On relay, and with jumper A92H to volts. or no voltage in circuit
still installed, move gnd. A92H, conn. (1601–A),
key switch to ignition circuit N92H, conn.
position. Remove (523–V), circuit K92H,
warning light bulb and conn. (7100–L), or
measure voltage from circuit V92H, then repair.
circuit A92H to ground.
9. On With jumper still retard on Locate open or poor
installed, re-install warning light connection in circuit
warning light bulb. Does circuits test A92-GA, A186, conn.
warning light illuminate? good. Turn key (377–A), circuit A186 or
off. Reconnect A11-G to ground, then
conn. (7202). If repair.
problems persist,
reprogram/
replace ECU
after checking
input circuits.

IC With Allison MD Transmission

Table 54 IC With Allison MD Transmission

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ECU Warning light Go to next step.
On connector (632), circuitry tests
connect a test jumper good. Refer
from circuit 125 to to Electrical
ground, and move Troubleshooting
key switch to ignition Manual
position. Does retarder to locate
on warning light problem with
illuminate? transmission
circuitry.
2. Off Remove retarder on Across <100 Re-install Replace defective bulb
warning light bulb. Test warning ohms. bulb. Go to and repeat all tests if
for continuity. light bulb. next step. problem persists.
3. Off/ Remove retarder on Relay 12±1.5 Go to next Locate cause of no or
On relay, move key switch socket, volts. step. low voltage in circuit
to ignition position, and 146E to 97K, conn. (3), circuit
measure voltage from gnd. 97K, 24B, conn. (789),
circuit 146E to ground. circuit 24B or 146E from
fuse F24, then repair.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 101

Table 54 IC With Allison MD Transmission (cont.)

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
4. On With key switch still in Relay 12±1.5 Go to next Locate cause of no or
ignition position, at relay socket, volts. step. low voltage in circuit
socket, measure voltage 146F to 146F, then repair.
from circuit 146F to gnd.
ground.
5. On With key switch still in Relay 12±1.5 Go to next Locate open or poor
ignition position and socket, volts. step. connection in circuit
jumper still installed, at 146F to 125, then repair.
relay socket, measure 125.
voltage from circuit 146F
to 125.
6. Off Bench test retarder Relay, pin <1 Go to next Replace defective relay.
on relay by measuring 30 to 87A. ohm. step.
resistance from pin 30
to 87A.
7. Off Bench test retarder Energized <1 Go to next Replace defective relay.
on relay by applying relay, pin ohm. step.
+12V to pin 85, gnd. to 30 to 87.
pin 86, and measuring
resistance from pin 30
to 87.
8. Off/ Re-install retarder on Socket, 12±1.5 Go to next Locate cause of low or
On relay, and with jumper 92H to volts. step. no voltage in circuit 92H,
still installed, move gnd. conn. (499), or circuit
key switch to ignition 92H, then repair.
position. Remove
warning light bulb and
measure voltage from
circuit 92H to ground.
9. On With jumper still Retarder Locate open or poor
installed, re-install on warning connection in circuit
warning light bulb. Does light circuits 92-GZ, 92-GY, 94-GC,
warning light illuminate? test good. conn. (377), circuit
Turn key off. 94-GC or 11-G to
Reconnect ground, then repair.
conn. (632).
If problems
persist,
reprogram/
replace ECU
after checking
input circuits.

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102 INSTRUMENTS (Data Link Driven Instrument Cluster)

6.27. CHANGE TRANS FILTER

FE 300 With Allison WTEC III XMSN GEN 4

Table 55 FE 300 With Allison WTEC III XMSN GEN 4

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect black wire Warning light Go to next step.
On from transmission filter circuits test
and connect to ground good. Turn
with a test jumper. Move key off and
key switch to ignition reconnect
position. Does warning black wire.
light illuminate?
2. Off Remove CHANGE Across <100 Re-install Replace defective bulb
TRANS FILTER warning warning ohms. bulb. Go to and reconnect black
light bulb. Test for light bulb. next step. wire to filter. Repeat all
continuity. tests if problem persists.
3. Off Disconnect connector (94), <1 Go to next Locate open or poor
(94), and with jumper still A31-GA ohm. step. connection in circuit
attached at black wire, to gnd. A31-GA, connector
measure resistance (344), a blue wire, conn.
from connector (94) (N/L), or a black wire,
circuit A31-GA to then repair. Reconnect
ground. connectors.
4. On Move key switch to (94), 12±1.5 Go to next Locate cause of no or
ignition position and A31D to volts. step. low voltage in circuit
measure voltage from gnd. A31D from fuse F10,
connector (94) circuit then repair. Reconnect
A31D to ground. connectors.
5. Off With jumper still installed Warning Replace defective
at black wire, reconnect light circuits socket assembly.
connector (94). Does test good. Reconnect conn. (94)
warning light illuminate? Reconnect and black wire.
conn. (94)
and black
wire.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 103

IC With Allison AT

Table 56 IC With Allison AT

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect black wire Warning light Go to next step.
On from transmission filter circuits test
and connect to ground good. Turn
with a test jumper. Move key off and
key switch to ignition reconnect
position. Does warning black wire.
light illuminate?
2. Off Remove transmission Across <100 Re-install Replace defective bulb
filter warning light bulb. warning ohms. bulb. Go to and reconnect black
Test for continuity. light bulb. next step. wire to filter. Repeat all
tests if problem persists.
3. Off Disconnect connector (760B), <1 Go to next Locate open or poor
(760B), and with 31-GA to ohm. step. connection in circuit
jumper still attached gnd. 31-GA, connector (837),
at black wire, measure a blue wire, conn. (N/L),
resistance from or a black wire, then
connector (760) circuit repair. Reconnect
31-GA to ground. connectors.
4. On Move key switch to (760), 12±1.5 Go to next Locate cause of no or
ignition position and 31D to volts. step. low voltage in circuit
measure voltage from gnd. 31D from fuse F24,
connector (760) circuit then repair. Reconnect
31D to ground. connectors.
5. Off With jumper still installed Warning Replace defective
at black wire, reconnect light circuits socket assembly.
connector (760). Does test good. Reconnect conn. (760)
warning light illuminate? Reconnect and black wire.
conn. (94)
and black
wire.

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104 INSTRUMENTS (Data Link Driven Instrument Cluster)

6.28. RETARD OVER HEAT

FE 300 With Allison WTEC III XMSN

Table 57 FE 300 With Allison WTEC III XMSN

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ECU (7202), 12±1.5 Warning light Go to next step.
On connector (7202) and pin 19, volts. circuits test good.
use a test jumper to K105. to Turn key off and
connect pin 19 circuit gnd. reconnect conn.
K105. to ground. Move (7202). Turn key
key switch to ignition on. If warning light
position. Does warning does not illuminate
light illuminate? during bulb check,
reprogram/ replace
ECU.
2. Off Remove RETARDER Across <100 Re-install bulb. Go Replace defective
OVER HEAT warning warning ohms. to next step. bulb and reconnect
light bulb conn. (925). light bulb. connector. Repeat
Test for continuity. all tests if problem
persists.
3. Off With jumper still Socket, <1 Go to next step. Locate open or poor
attached at conn. K105. to ohm. connection in circuit
(7202), measure gnd. A105B, connector
resistance at socket (1601), circuit N105B,
from circuit K105. to connector (523), circuit
ground. K105B, connector
(7999), or circuits
K105B/K105A, K105,
then repair. Reconnect
connector and bulb.
4. On Move key switch to Socket, 12±1.5 Warning light Locate cause of no or
ignition position and A13J to volts. circuits test good. low voltage in circuit
measure voltage from gnd. Reconnect conn. A13J, conn. (377),
circuit A13J to ground. (7202). circuits A13J, or A28,
from fuse F22, then
repair. Reconnect
connector.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 105

FE 300 With Allison WTEC III XMSN GEN 4

Table 58 FE 300 With Allison WTEC III XMSN GEN 4

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ECU (7150), 12±1.5 Warning light Go to next step.
On connector (7150) and pin 64, volts. circuits test good.
use a test jumper to K164. to Turn key off and
connect pin 64 circuit gnd. reconnect conn.
K164. to ground. Move (7150). Turn key
key switch to ignition on. If warning
position. Does warning light does not
light illuminate? illuminate during
bulb check,
reprogram/
replace ECU.
2. Off Remove RETARDER Across <100 Re-install bulb. Replace defective
OVER HEAT warning warning ohms. Go to next step. bulb and reconnect
light bulb conn. (925). light bulb. connector. Repeat
Test for continuity. all tests if problem
persists.
3. Off With jumper still Socket, <1 Go to next step. Locate open or poor
attached at conn. K164. to ohm. connection in circuit
(7150), measure gnd. A164B, connector
resistance at socket (1601), circuit N164B,
from circuit K164. to connector (523), circuit
ground. K164B, connector
(7999), or circuits
K164B/K164A, K164,
then repair. Reconnect
connector and bulb.
4. On Move key switch to Socket, 12±1.5 Warning light Locate cause of no or
ignition position and A13J to volts. circuits test good. low voltage in circuit
measure voltage from gnd. Reconnect conn. A13J, conn. (377),
circuit A13J to ground. (7150). circuits A13J, or A28,
from fuse F22, then
repair. Reconnect
connector.

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106 INSTRUMENTS (Data Link Driven Instrument Cluster)

IC With Allison MD Transmission

Table 59 IC With Allison MD Transmission

Step Key Action Test Spec. Yes-In Spec. No-Out of Spec
Points
1. Off/ Disconnect ECU Warning light Go to next step.
On connector (632) and circuits test good.
use a test jumper to Turn key off and
connect pin 19 circuit reconnect conn.
105 to ground. Move (632). Turn key
key switch to ignition on. If warning light
position. Does warning does not illuminate
light illuminate? during bulb check,
reprogram/ replace
ECU.
2. Off Remove retarder Across <100 Go to next step. Replace defective
overheat warning light bulb. ohms. bulb and reconnect
bulb. Test for continuity. connector. Repeat
all tests if problem
persists.
3. Off With jumper still Socket, <1 Go to next step. Locate open or poor
attached at conn. (632), 105 to ohm. connection in circuit
measure resistance at gnd. 105, connector (499),
socket from circuit 105 or circuit 105, then
to ground. repair. Reconnect
connector and bulb.
4. On Move key switch to Socket, 12±1.5 Warning light Locate cause of no or
ignition position and 13E to volts. circuits test good. low voltage in circuit
measure voltage from gnd. Reconnect conn. 13E, conn. (377) or
circuit 13E to ground. (632) and bulb. circuit 13E, then repair.
Reconnect connector
and bulb.

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 INSTRUMENTS (Data Link Driven Instrument Cluster) 107

6.29. ALTERNATOR
FE 300

Table 60 FE 300
Step Key Action Test Spec. Yes - In Spec. No - Out of Spec.
Points
1. On Disconnect circuit Warning Warning light Go to next step.
1C from lug 1 of light circuits test good.
alternator. Connect illuminates. Troubleshoot
a jumper between alternator.
wire from lug
1 and ground.
Does warning light
illuminate?
2. Off Remove cluster Across <100 Re-install bulb. Replace defective
and remove indicator ohms. Go to next step. bulb or replace
ALTERNATOR light bulb. cluster, repeat
indicator light tests if problem
bulb. Test bulb persists.
for continuity.
3. Off Disconnect conn. Conn. <1 ohm. Go to next step. Locate open or
(12). With jumper (12), pin poor connection
still in place, 16, cir. 1C in circuit 1C, then
measure resistance to gnd. repair.
from pin 16 of wire
harness conn. (12),
circuit 1C to ground.
4. On Move key switch to Conn. 12±1.5 Go to next step. Locate cause of
ignition position and (11), pin volts. no or low voltage
measure voltage 10, cir. in circuit A28B,
at pin 10 of wiring A28B. conn. (11), fuse
harness conn. (11), F22, then repair.
circuit A28B.
5. On With jumper still Warning Warning light Replace defective
installed at circuit light circuits test good. cluster assembly
1C, reconnect illuminates. Reconnect circuit and reconnect all
connector (12). 1C to alternator connectors.
Does indicator light? lug 1.

6.30. ALTERNATOR
IC SE item not covered at this time.

6.31. ((P)) LOW AIR

SE item not covered at this time.

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