IK0800547 ­ Batt2 Load Shed Relay Failure

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CANADA, UNITED STATES, MEXICO Document ID: IK0800547

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ELECTRICAL SYSTEM

Created:

8/25/2017

Current Language: English

Last Modified: 10/30/2017

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Title : Batt2 Load Shed Relay Failure
Applies To : LT's Without 16UZL

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
08/25/2017 - Initial Article Release

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

DESCRIPTION
This document will guide the user through identifying a failed relay and possibly a spread terminal resulting in loss of power to the sleeper.

SYMPTOM(s)
Load shed type faults being set. No change in truck performance. The check electrical warning may be illuminated.
See if the unit is in active load shed. The standard load shed voltage is 12.1 vdc. If the voltage on the J8 (Gen 4 BMC) power stud of the Body Controller is
12.1 vdc or less, there is a good possibility the truck is in load shedding. If you find the unit is in load shedding, no troubleshooting needs to be performed for
these faults.
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
DTC/Light

Description

SPN 3979 FMI 05 (link to FCAP)

Cab Floor Light Relay Undercurrent or Open
Circuit

SPN 2362 FMI 05 (link to FCAP)

Tractor Rear High Mounted Work Lights

SPN 2058 FMI 14 (link to FCAP)

Rear HVAC Data LInk Communication Failure

Customer Observations or Concerns:
Sleeper dome lights and power outlets are not working properly. Check electrical warning message displayed.

SPECIAL TOOL(s) / SOFTWARE
Not Applicable

SERVICE PARTS INFORMATION
Part Description

Part Number

Quantity
Required

BATT2 LOAD SHED RELAY CONTROL HARNESS

2518071c91

1

5 PIN MICRO RELAY

3571998C1

1

Notes

DIAGNOSTIC STEP(s)

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IK0800547 ­ Batt2 Load Shed Relay Failure

Step Action
DIAGNOSTIC: Verify that there is no power to the sleeper. Follow the FCAP for load shed.
1

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Decision
Yes: Charge batteries and repair
charging circuit if necessary than
retest.

Is the unit actively load shedding?
No: Go to next step

Step Action

Decision

1. Gain access to the
PDM located on the
passenger side of the
unit.
2

2. Locate the batt2 load
shed relay in the
PDM.
3. Proceed to next step

Step Action

Decision

3
1. Remove relay and inspect
for signs of discoloration in
the PDM like the photo.
Apply power to pin 85 of
the relay and ground to pin
86 and listen for a click.
Replace the relay if no
audible noise heard.
2. Inspect the terminal for
signs of spreading or
damage from heat.
3. Remove the wire at pin 87
(A14N) ­ proceed to next
step.

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IK0800547 ­ Batt2 Load Shed Relay Failure

Step Action

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Decision
1. At the PDM verify
voltage on pin 30
(A14AB) via load
testing. If voltage is
correct proceed to
next decision. If
not, repair prior to
continuing.

4

2. Jump power from
pin 30 to pin 87 at
the PDM and
determine if your
sleeper powers up
and functions
correctly. If after
you jumper the wire
and everything is
operational proceed
to the repair steps.
If you still don't
have power to your
sleeper proceed to
the next decision.
3. Double check your
wiring following the
schematics book for
the LT. LT
Schematics
4. Refer to the LT
service manual.
Service and
Diganostics

REPAIR STEP(s)
REMOVAL PROCEDURE:

Always refer to the Technician manual for complete removal,
assembly, safety warnings, cautions, and torque specifications.
LT/RH Technician Manual (Service and Diagnostic)
1. Disconnect and isolate the negative ground cables at the batteries.

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2. Remove Driver's side kickpanels for access to the bulkehead and wiring.

3. Remove dog house outer cover.

4. If needed, remove cluster for easier access to route the new harness.

5. Loosen and set aside the PDM.

INSTALLATION PROCEDURE:

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Figure 1: Current vs. Change over Wiring Schematic
Once the harness is routed properly you will need to splice into the circuist according to the schematic.
Please refer to this document for proper wire repair IK0800269
1. With the instrument panel and rear engine cover area accesible obtain the new harness. The new relay in the harness will be mounted to the engine cover.

2. Feed the 3 blunt cut wires up labeled (A14XS, A14X
and A 14Y) up through the center console above the
rear engine cover up to the fuse panel.

It may be helpful to insert a long screwdriver or
some kind of stick from the top of the fuse panel so
it would be possible to see it from underneath to
help guide the routing of the wires up to the fuse
block area.

3. On the left side of the dog house cover, feed the red wire (A14A) with ring terminal and the grey ground wire (A11-G) with ring terminal behind the HVAC duct work and alo
and airline bundle over the steering column.

4. Route the red wire (A14A) and grey ground wire (A11-G) along the cab dash in front of the other harness bundles in order allow routing of these wires to the cab pass-thru
cab ground stud, respectively.

Care should be taken to avoid unnecessary contact of these wires to sharp edges of the steering column or the cab ground studs themselves.
5. Drill a series of slightly increasing diameter, pilot
holes into the grommet above the existing BCM power
feed to carefully expand a hole thru the grommet to feed
the red wire (A14A). Avoid contact between the drill bit
and the BCM power feed cable. Center the drill bit so it
is approximately 3/8” above the closest point of the
BCM power feed cable.

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6. Feed the red wire (A14A) with ring terminal end thru
the drilled hole in the grommet being careful not to tear
the grommet. Pull approximately (1 to 1.5) feet of the
red wire (A14A) thru the grommet.
7. Reinsert the grommet back into the cab opening.
Make sure that grommet is fully seated into the opening.
It may be necessary to check the seating of the
grommet from inside the cab as well.
8. Connect the ring terminal to the same terminal that
the body controller is currently receiving power from.
Torque 15 +/­ 1.5 N/M
9. Install conduit and zip ties. Make sure there is a slight
drip loop made with the body controller power and new
harness power feed.

10. On the inside of the cab, connect the ground ring
terminal (A111­g) to the cab ground stud.
11. Install the plastic cap on the ground stud and ensure
that the harness will not rub on the ground stud.
12. Using the double sided adhesive and zip ties mount
the fuse to the bulkhead and secure in place with the zip
ties provided on any convienient location near the
ground stud.

13. Locate the wires A14X and A14Y within the main
instrument panel that are spliced with wires A14R and
A14N. The splice # is GS33. Wires A14X and A14Y will
be coming from fuse block B8 (R/D 1017) cavities 9 and
17, respectively.
14. Cut wires A14X and A14Y approximately midway
between the fuse block connector (R/D 1017) and splice
GS33. Apply heatshrink to the end of wire A14Y that is
coming from GS33 splice.
15. Splice wire A14X coming from GS33 splice with wire
A14XS that was fed from the new jumper harness that
was routed. Listed as “New Splice 1” on the below
circuit diagrams. Use butt splice (item # 004) and
heatshrink

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16. Splice the other end of wire A14X coming from the
fuse block connector (R/D 1017) cavity 9 with wire A14X
that was fed from the new jumper harness that was
routed. Listed as “New Splice 2” on the below circuit
diagrams. Use butt splice and heatshrink.
17. Splice the other end of wire A14Y coming from the
fuse block connector (R/D 1017) cavity 17 with wire
A14Y that was fed from the new jumper harness that
was routed. Listed as “New Splice 3” on the below
circuit diagrams. Use butt splice (item # 003) and
heatshrink (item # 005).
18. Replace the batt2 relay in the PDM.

19. Verify proper operation of bunk electrical components
20. Re-install all previously removed components
21. Use a pen or paint marker to cover the discolored area under the relay to prevent the next tech from mistakenly thinking they need to do the repair.

WARRANTY INFORMATION
Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.

Standard Repair Time(s):
Refer to the SRT Manual for Repair Times

OTHER RESOURCES
Master Service Information Site
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