Module 7 – Troubleshooting

1
Student Guide Page
Class Name – Version Date 1
Module 7 Troubleshooting 7

A. Use of ServicePro and ServiceLink to troubleshoot electronic problems

B. Understand correct procedures to diagnose potential problems
C. Understand the proper tools to use when diagnosing a concern
▸ Exercise 7.1 Calibration Mode .................................................................... 7-5
▸ Exercise 7.2 HVAC Template ...................................................................... 7-6
▸ Exercise 7.3 HVAC Fault Codes .................................................................. 7-7
▸ Troubleshooting HVAC Problems ............................................................... 7-13
▸ Troubleshooting Headlight Problems ......................................................... 7-14
▸ Troubleshooting Worksheet ....................................................................... 7-15
▸ Troubleshooting Adding Fog lights or Aux High beams .............................. 7-21
▸ Module 7 Review ....................................................................................... 7-24

Student Guide Page 7-1

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HVAC Controller Network Topology 7

Student Guide Page 7-2

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HVAC Front Unit Component Locations 7

1. Panel/Defrost vent door actuator

2. Floor vent door actuator

3. Temperature mix door actuator
4. Evaporator core

5. Cab air filter

6. Blower

motor

10. Duct Temperature probe 7. Recirc/Fresh air door actuator

9. Heater core 8. Evaporator Temperature probe

Note: Located right hand side under dash and partly under Cab SAM.
Student Guide Page 7-3
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HVAC Auxiliary Unit Component Locations 7

6. Temperature mix 1. Heater Core

door actuator
5. Temperature
probe
2. Blower Motor
4. Evaporator
3. Sleeper
air filter

 Valeo - Blend air

 Direct drive actuator (No external drive gears)
 Blower motor same unit for Front, Aux and M2

• Located behind driver’s seat away from rear of cab to prevent possible damage if truck is
jack knifed
Student Guide Page 7-4
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Exercise 7.1 Calibration Mode 7

It is necessary to calibrate the actuators if they are removed or replaced. To do this,

perform the following steps:
1. Turn ignition ON (engine OFF)
2. Set blower speed control to Off (counterclockwise)
3. Set the mode control knob to the full counter-clockwise position (FACE)
4. Set the temperature control knob to the full clockwise position (HOT)
5. Press the A/C and RECIRC buttons simultaneously until the A/C and RECIRC
indicators begin flashing simultaneously
6. Thecalibration process will begin and will continue until the A/C and RECIRC LEDs
stop flashing

Student Guide Page 7-5

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Exercise 7.2 HVAC Template 7
Go to a truck/simulator and connect ServiceLink. Open the appropriate HVAC
template.
1. What do you have to do on this template to see all the data?
Check button press to see all data
____________________________________________
Turn on the front blower motor and observe the indicators.
2. What do you think the Protect button represents?
Blower is in protection mode
__________________________________________
Move the temperature knob to half way and observe the indicators. Now push the
bunk override button.
3. Did you see the bunk indicators respond? (Circle one) Yes or No
Push the override button again and turn off the front blower. With the park brake set,
turn the bunk blower switch to half way.
4. Did the front unit indicators respond? (Circle one) Yes or No

Student Guide Page 7-6

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Exercise 7.2 HVAC Template 7
Move the bunk temperature knob from one extreme to the other.
5. Did the front unit indicators respond? (Circle one) Yes or No
Turn on the front blower switch and push the recirc button.
6. Did you see the recirc indicators respond? (Circle one) Yes or No
Turn the front mode switch to various positions.
7. Did the AC mode ever become active? (Circle one) Yes or No
If no, why not?
No engine RPM
_________________________________________________________
8. Are the door indicators indicating real door position? ( Circle one) Yes or No
9. Record the following:
Eng Temp _____ Ambient Temp _____ HS Press _____% HS Press _____PSI
Disconnect ServiceLink, turn ignition off, turn load cut-off switch to off.

Student Guide Page 7-6

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Exercise 7.3 HVAC Fault Codes 7
Go to a truck/simulator and locate following components, once located follow the instruction
below for each component.
▸ unhook the harness at the component and record the fault display on the instrument display.
▸ The system or controls may need to be operated for a code to be set.
▸ Reconnect harness and clear the fault code
▸ Continue steps above with all components listed until all fault codes are recorded in the tables
Note; Use drawing on page 7-3, 7-4 of front and rear HVAC unit to help locate components

Note: the following information will be researched after attaining the fault code using Service
Information
The Fault Description / Fault Trigger / Vehicle Behavior / Possible causes / Actions

Student Guide Page 7-7

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Exercise 7.3 HVAC Fault Codes 7
Ambient Air Temperature Sensor

SA SPN FMI Fault Description Fault Trigger or Subject

33 522116 2 Temperature sensor,

C06.05 — Heated Mirrors
outside air, feedback –
Data erratic, intermittent G02.04 — SAM Cab
or incorrect.

Vehicle Behavior:
A/C clutch will not engage (Truck) (simulator has no engine RPM)
Possible Causes:
Defect sensor or Open in sensor wiring
Actions: Test sensor, Table 34, Outside Air Temperature Sensor Resistance
Test wiring at conn X20, pin 16
707 — Logic Controlled Unfused Outputs
Student Guide Page 7-8
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Exercise 7.3 HVAC Fault Codes 7
High Pressure Sensor

SA SPN FMI Fault Description Fault Trigger or Subject

Data valid, but above

25 522510 0 Pressure above 530 psi.
normal operating range

HVAC pressure
33 522010 2 transducer, feedback – C02.01 — HVAC System
Data erratic, intermittent G02.04 — SAM Cab
or incorrect
Vehicle Behavior:
Engine fan on all the time
A/C clutch will not engage (Truck) (simulator has no engine RPM)
Possible Causes:
Defect sensor or Open in sensor wiring
Actions

Defect sensor or Open in sensor wiring

Test sensor wiring at conn X19, pin 10

Student Guide Page 7-9

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Exercise 7.3 HVAC Fault codes 7
Blend Door Actuator

SA SPN FMI Fault Description Fault Trigger or Subject

Voltage below normal

25 523330 shorted low N/A
4
Open circuit

Vehicle Behavior:

A/C clutch engages (Truck) A/C may be inop depending on door position
A/C clutch will not engage (Truck) (simulator has no engine RPM)
Possible Causes:
Defect actuator or Open in actuator wiring
Actions
Test wiring by another actuator (all same part #)
Test wiring at FCU 26-Pin Connector,
Actuator Stepper Motor 6-Pin Connector
601 — Component Details Electrical Connectors
Student Guide Page 7-10
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Exercise 7.3 HVAC Fault codes 7
COTC Sensor

SA SPN FMI Fault Description Fault Trigger or Subject

Open circuit,
25 current below normal, N/A
1547 5 Short to Battery

Vehicle Behavior:
A/C clutch engages (Truck) (simulator has no engine RPM)
COTC Temp read defaults to approx.32 degrees
Temp control open /close blend air by knob position (convert to not CDTC)
Possible Causes:
Defect sensor or Open in sensor wiring
Actions
Test sensor Table 33, COTC Temperature Sensor Resistance
Test wiring at FCU 26-Pin Connector,
Pin 10 wire # 338L and Pin 11 Wire# 338G2
601 — Component Details Electrical Connectors
Student Guide Page 7-11
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Exercise 7.3 HVAC Fault codes 7
HVAC Blower Motor

SA SPN FMI Fault Description Fault Trigger or Subject

Mechanical System Not

Responding properly
25 523318 7 Blower motor protection N/A
mode (speed mismatch or
blocked rotor).

Vehicle Behavior:
Front HVAC blower inop
A/C clutch engages (Truck) Sleeper A/C operates
A/C clutch will not engage (Truck) (simulator has no engine RPM)
Possible Causes:

Open F10 HVAC motor fuse motor or Open in wiring or Defect motor
Actions
Locate blower operation information on C02.01/29
Locate and test F10 fuse
Test wiring at blower motor,
Test Motor
Student Guide Page 7-12
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Troubleshooting HVAC Problem 7
Your instructor will assign a vehicle serial number. SN AJ1791
______________
A/C In - Opt
Complaint: ______________________________ Verify Complaint: Yes / No

Any Symptom/Observation / Fault codes:___________________________________

Cause: _____________________________________________________________

Correction: __________________________________________________________
____________________________________________________________________

Area below is used to keep track of resources used during this exercise like;
Workshop Manuals / Sections:___________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
ServiceLink (ECU’s / templates):__________________________________________
PartsPro Modules # / Sub # and any parameters with in:_______________________
____________________________________________________________________
Drawing:____________________________________________________________
Useful information:_____________________________________________________
Student Guide Page 7-13
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Troubleshooting HVAC Problem 7
Cascadia TM C02.01 / 5
Fig. 2, HVAC System
Electrical Control Topology

Source: Student Guide Page 7-13

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Troubleshooting HVAC Problem 7

Your instructor will assign a vehicle serial number. AJ1791

SN ______________
A/C In - Opt
Complaint: ______________________________ Verify Complaint: Yes / No

Any Symptom/Observation / Fault codes:_________________________________

A/C clutch not engaging, No fault code

Ambient air temperature inaccurate

Cause: ____________________________________________________________
Used ServiceLink observer A/C template,
Correction:_________________________________________________________
Compared sensor with TM spec.
that sensor spec. Replace Ambient air temperature sensor
__________________________________________________________________
Determined
Area below is used to keep track of resources used during this exercise like;
Workshop Manuals / Sections:___________________________________________
Cascadia TM C02.01 / 5- 8
Is there a template in ServiceLink to be used with this complaint: Yes /No
ServiceLink (ECU’s / templates):________________________________________
Cascadia HVAC: (that applies to your truck)
__________________________________________________________________
PartsPro Modules # / Sub # and any parameters with in:_____________________
70B 70C
_________________________________________________________________
70B, G07-53571-000 70C, G07-56341-000
Drawing:___________________________________________________________
Template show low temp reading on the air temp sensor
Useful information:_____________________________________________________
Student Guide Page 7-13
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Troubleshooting Headlight Problem 7

Your instructor will assign a vehicle serial number. SN AJ1791

______________
Headlight on all the time
Complaint: ______________________________ Verify Complaint: Yes / No

Any Symptom/Observation / Fault codes:__________________________________

Cause:_____________________________________________________________

Correction:__________________________________________________________
___________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
Workshop Manuals / Sections:__________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
ServiceLink (ECU’s / templates):_________________________________________
PartsPro Modules # / Sub # and any parameters with in:______________________
Drawing:____________________________________________________________
Useful information:____________________________________________________

Student Guide Page 7-14

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Complaint: Headlight on all the time 7

Low Air Ambient

Pressure Temp
Switches Sensor

J1708/J1587
junction block

Terminating Terminating
Resister #2 Resister #1

Source: Student Guide Page 7-14

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Headlight on all the time 7

Cascadia TM C04.02 / 3
Fig. 2, Headlight System
Diagram

Source: Student Guide Page 7-14

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Headlight on all the time 7

Cascadia TM C04.02 / 6
Fig. 3, Datalink Network
Topology

Source: Student Guide Page 7-14

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Troubleshooting Headlight Problem 7

Your instructor will assign a vehicle serial number. SN AJ1791

______________
Headlight on all the time
Complaint: ______________________________ Verify Complaint: Yes / No

Warning Chime sound when headlight

Any Symptom/Observation / Fault codes:_________________________________
switch is on. / 49 523543 2
Open circuit 474B05 (MSF connector E pin 3)
Cause: ____________________________________________________________

Used ServiceLink to get fault code, Follow fault proceed TM .

Correction:_________________________________________________________
Determined that open circuit 474B05 at MSF connector E at pin 3 Replace wire
__________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
Cascadia TM C02.06 / 24
Workshop Manuals / Sections:___________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
MSF / Switches and Headlight templates
ServiceLink (ECU’s / templates):________________________________________
__________________________________________________________________
311
PartsPro Modules # / Sub # and any parameters with in:_____________________
G06-54729
Drawing:___________________________________________________________
Template shows N/A in the off and marker lamp positions
Useful information:_____________________________________________________
Student Guide Page 7-14
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Troubleshooting Utility Lamp Problem 7

Your instructor will assign a vehicle serial number. SN AJ1791

______________
Utility light flash on / off
Complaint: ______________________________ Verify Complaint: Yes / No

Any Symptom/Observation / Fault codes:__________________________________

Cause:_____________________________________________________________

Correction:__________________________________________________________
___________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
Workshop Manuals / Sections:___________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
ServiceLink (ECU’s / templates):_________________________________________
___________________________________________________________________
PartsPro Modules # / Sub # and any parameters with in:______________________
Drawing:____________________________________________________________
Useful information:____________________________________________________
Student Guide Page 7-15
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Troubleshooting Utility Problem 7

Low Air Ambient

Pressure Temp
Switches Sensor

J1708/J1587
junction block

Terminating Terminating
Resister #2 Resister #1

Source: Student Guide Page 7-13

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Troubleshooting Utility Problem 7

Your instructor will assign a vehicle serial number. SN AJ1791

______________
Utility light flash on / off
Complaint: ______________________________ Verify Complaint: Yes / No

Utility light flash on / off

Any Symptom/Observation / Fault codes:__________________________________

Two Mux Utility light switches installed on the Sub-bus

Cause:______________________________________________________________

Remove the 2nd Mux Utility light switches installed on the Sub-bus
Correction:__________________________________________________________
___________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
N/A
Workshop Manuals / Sections:___________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
MSF switch screen / monitor switch on/off
ServiceLink (ECU’s / templates):_________________________________________
___________________________________________________________________
N/A
PartsPro Modules # / Sub # and any parameters with in:______________________
N/A
Drawing:___________________________________________________________
MSF Master can not recognize two switches
Useful information:____________________________________________________
with the same ID on the Su-bus
Student Guide Page 7-15
Troubleshooting Tail light Problem 7

Your instructor will assign a vehicle serial number. SN AJ1791

______________
Rear Turn light In - Opt
Complaint: ______________________________ Verify Complaint: Yes / No

Any Symptom/Observation / Fault codes:_________________________________

Cause:____________________________________________________________

Correction:__________________________________________________________
___________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
Workshop Manuals / Sections:__________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
ServiceLink (ECU’s / templates):_________________________________________
___________________________________________________________________
PartsPro Modules # / Sub # and any parameters with in:______________________
Drawing:____________________________________________________________
Useful information:____________________________________________________
Student Guide Page 7-16
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Troubleshooting Tail light Problem 7

Low Air Ambient

Pressure Temp
Switches Sensor

J1708/J1587
junction block

Terminating Terminating
Resister #2 Resister #1

Source: Student Guide Page 7-14

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Troubleshooting Tail light Problem 7

Your instructor will assign a vehicle serial number. SN AJ1791

______________
Rear Turn light In - Opt
Complaint: ______________________________ Verify Complaint: Yes / No

Turn light not working

Any Symptom/Observation / Fault codes:_________________________________

Wrong parameter
Cause: ____________________________________________________________

Used ServiceLink Observer Stop, Turn Hazard lamp template,

Correction:_________________________________________________________
Compared parameter on vehicle to TM spec. / ServiceLink Host information
__________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
Stop, Turn, and Hazard Lights C04.04
Workshop Manuals / Sections:___________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
SAM Chassis
ServiceLink (ECU’s / templates):________________________________________
Stop / Turn / Hazard Lamps
__________________________________________________________________
301
PartsPro Modules # / Sub # and any parameters with in:_____________________
G06-66939
Drawing:___________________________________________________________
Note on parameter combination /separate turn lamp
Useful information:_____________________________________________________
Student Guide Page 7-14
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Complaint: Cruise Control kick out when raining 7

Low Air Ambient

Pressure Temp
Switches Sensor

J1708/J1587
junction block

Terminating Terminating
Resister #2 Resister #1

Source: Student Guide Page 7-15

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Troubleshooting Cruise Control Problem 7

Your instructor will assign a vehicle serial number. SN AJ1791

______________
Cruise Control kick out when
Complaint: ______________________________ Verify Complaint: Yes / No
Raining
Any Symptom/Observation / Fault codes:__________________________________

Cause:_____________________________________________________________

Correction:__________________________________________________________
___________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
Workshop Manuals / Sections:__________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
ServiceLink (ECU’s / templates):_________________________________________
___________________________________________________________________
PartsPro Modules # / Sub # and any parameters with in:______________________
Drawing:___________________________________________________________
Useful information:___________________________________________________
Student Guide Page 7-17
31
Troubleshooting Cruise Control Problem 7
Cascadia TM C04.04 / 2
Fig. 3, Datalink Network
Topology

Source: Student Guide Page 7-15

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Troubleshooting Cruise Control Problem 7

Your instructor will assign a vehicle serial number. SN AJ1791

______________
Complaint: Cruise Control kick out when
______________________________ Verify Complaint: Yes / No
Raining
Cruise not working when wiper are on
Any Symptom/Observation / Fault codes:__________________________________

Cruise Control parameter is set to disconnect when wiper are on

Cause:_____________________________________________________________

Change parameter or educate owner/drivers

Correction:__________________________________________________________
___________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
P04.01/8 800 — Parameters
Workshop Manuals / Sections:___________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
Sam Cab / Cascadia Cruise Control
ServiceLink (ECU’s / templates):_________________________________________
___________________________________________________________________
149
PartsPro Modules # / Sub # and any parameters with in:______________________
G06-61995
Drawing:____________________________________________________________
Cascadia Cruise Control show input for cruise disconnect
Useful information:____________________________________________________
Student Guide Page 7-15
33
Troubleshooting Worksheet 7

Your instructor will assign a vehicle serial number. SN ______________

Complaint: ______________________________ Verify Complaint: Yes / No

Any Symptom/Observation / Fault codes:__________________________________

Cause:_____________________________________________________________

Correction:__________________________________________________________
___________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
Workshop Manuals / Sections:__________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
ServiceLink (ECU’s / templates):_________________________________________
___________________________________________________________________
PartsPro Modules # / Sub # and any parameters with in:______________________
Drawing:___________________________________________________________
Useful information:___________________________________________________
Student Guide Page 7-21
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Troubleshooting Worksheet 7

Your instructor will assign a vehicle serial number. SN ______________

Complaint: ______________________________ Verify Complaint: Yes / No

Any Symptom/Observation / Fault codes:__________________________________

Cause:_____________________________________________________________

Correction:__________________________________________________________
___________________________________________________________________
Area below is used to keep track of resources used during this exercise like;
Workshop Manuals / Sections:__________________________________________
Is there a template in ServiceLink to be used with this complaint: Yes /No
ServiceLink (ECU’s / templates):_________________________________________
___________________________________________________________________
PartsPro Modules # / Sub # and any parameters with in:______________________
Drawing:___________________________________________________________
Useful information:___________________________________________________
Student Guide Page 7-22
35
Troubleshooting Worksheet – Adding Fog lights or 7
Aux High Beams
Your instructor will assign a vehicle serial number.
Truck Model _Cascadia____________ SN ______________

The following activities involve work in or near vehicles. Be sure to follow all
safety precautions and be alert to prevent accidents .
Customer wants add Fog lights to his truck
Complaint:___________________________________________________________
1. What is Parts Technical Bulletins that would be used to add this feature?
54-062
____________________________________________________________________
2. In the Parts Technical Bulletins locate and write down the following:
What the part numbers of the harness needed complete this insulation?
A06-53360-000, A06-62970-001, A06-62971-001
__________________________________________________________________
What parameters will need to changed and to which ECUs
__________________________________________________________________
003 447 20 58, SAM Cab
3. What drawing number should be use to locate connector / terminal positions
__________________________________________________________________
G06-53364-000

Student Guide Page 7-19

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Troubleshooting Worksheet – Adding Fog lights or 7
Aux High Beams
Your instructor will assign a vehicle serial number.
Truck Model _Cascadia____________ SN ______________

The following activities involve work in or near vehicles. Be sure to follow all
safety precautions and be alert to prevent accidents .
Customer wants to have Auxiliary High Beams installed on the truck
Complaint:___________________________________________________________
1. What is Parts Technical Bulletins that would be used to add this feature?
54-062
____________________________________________________________________
2. In the Parts Technical Bulletins locate and write down the following:
What the part numbers of the harness needed complete this insulation?
A06-53360-001, A06-62972-001, A06-62973-001
__________________________________________________________________
What parameters will need to changed and to which ECUs
__________________________________________________________________
000 447 78 23, MSF and 002 447 37 58, SAM Cab
3. What drawing number should be use to locate connector / terminal positions
__________________________________________________________________
G06-53365-000

Student Guide Page 7-20

37
Electrical Connector and Terminal 7
Installing terminals in connectors:
▸ locate the proper terminal for each connector
▸ locate the secondary lock open it or remove it from each connector
▸ Install terminal into each connector as the following diagram shows

Purple black
Black Black Gray
connector red lock blue lock connector
Wire # 1 Wire # 2
Cavity
5 Cavity Cavity Cavity
11 11 6

Source: 7-16
38

Student Guide Page

Electrical Connector and Terminal 7
Using the proper tools to remove terminals from the connectors:
▸ locate the secondary lock and open it
▸ Use tool as shown to remove terminal from the connector

Purple
connector
Wire # 1
Cavity
5

Source: Student Guide Page 7-16

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Electrical Connector and Terminal 7
Using the proper tools to remove terminals from the connectors:
▸ locate the secondary lock and remove it from the connector
▸ Use tool as shown to remove terminal from the connector

black
Black
Wire # 1 red lock

Source: Student Guide Page 7-17

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New Electrical Connector and Terminal 7
Using the proper tools to remove terminals from the connectors:
▸ locate the secondary lock and remove it from the connector
▸ Use tool as shown to remove terminal from the connector

Black
blue lock Wire # 2

Source: Student Guide Page 7-17

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New Electrical Connector and Terminal 7
Using the proper tools to remove terminals from the connectors:
▸ locate the secondary lock and remove it from the connector
▸ Use tool as shown to remove terminal from the connector

Gray
connector
Wire # 2

Source: Student Guide Page 7-18

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New Electrical Connector and Terminal 7
Upon removing all the terminal from the connector.
▸ Locate the secondary locks and install them in the connectors
▸ Place the tools, terminals, connector, and wires in the plastic zip lock bag

Purple black
Black Black Gray
connector red lock blue lock connector
Wire # 1 Wire # 2

Source: Student Guide Page 7-18

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Class Electronic Survey 7
Survey Directions:

1. Using the classroom computers open the Internet Explorer Browser

2. Enter the following into the browser address and click the GO button or Enter

www.tinyurl.com/Lepschat

Student Guide Page

44
Class Electronic Survey 7

3. Using drop down box to select class and then click the next button and complete the survey

Student Guide Page

45
 THANKS!

46
Student Guide Page
Class Name – Version Date 46