NHTSA ID Number: 10131136
Manufacturer Communication Number: IK0400057
TSB/Document Date: 2018-04-02
Summary
2007 and Newer Brake Light Operation; only equipped with Air Brakes
IK0400057 - 07 and Newer Brake Light Operation on HPV, ProStar and LoneStar with A... Page 1 of 3
Countries :
AUSTRALIA, BRAZIL, CANADA,
Document
IK0400057
UNITED STATES, SOUTH AFRICA ID:
Availability :
ISIS, Bus ISIS, FleetISIS
Revision:
4
Major
System:
Created:
2/11/2009
Current
Language:
English
Last
Modified:
10/16/2013
Other
Languages:
Français, Español,
Author:
Joe
Christopher
Viewed:
4628
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Title: 07 and Newer Brake Light Operation on HPV, ProStar and LoneStar with Air Brakes
Applies To: 07 and newer HPV ProStar LoneStar with Air Brakes
DESCRIPTION
On vehicles with air brakes, the zero volt reference signal is supplied to brake switch 1 HPV(1823) ProStar/LoneStar
(1806) terminal D from body controller connector (1602) terminal E5. (Only one switch is used in tractor applications).
When the key is in the ignition position, 12 volts will be applied to stop light switch 1 HPV(1823) ProStar/LoneStar
(1806) terminal C. When the key is in the off position 5 volts is supplied to terminal C of the switch instead of 12 volts.
A 6.8 volt Zener diode, inside the switch body is wired in parallel with the switch contacts. The diode allows current to
pass through it when the key is in the ignition position and 12 volts is applied to the switch. The diode prevents
current from passing through it when the key is off and 5 volts is applied to the switch. When the key is on and the
brake is not applied, the BC monitors the voltage drop across the diode and resistor in the switch. If there is an open
in the brake switch circuits there will be no voltage drop and the BC will set a fault. The diode is required to block
current flow when the key is off, preventing the circuits from putting a drain on the battery.
A 150 ohm resistor, inside the switch body, is wired in series with the switch. The BC senses the voltage drop across
this resistor to check for a short to ground in the brake switch circuits between the brake switch and the BC. If there is
a short, 12 volts from the BC will be pulled to ground and the BC will set a fault.
When the brake switch is closed the voltage drop will change and the BC will sense that the brake is applied.
SYMPTOMS
Brake Lights Stay On
Brake Lights Not Working
POSSIBLE DIAGNOSTIC TROUBLE CODES
DTC
597 0
597 1
597 2
597 7
MODULE
Body Controller
Body Controller
Body Controller
Body Controller
DESCRIPTION
Brake Switch reading above normal range
Brake Switch reading below normal range
Brake Switch inputs do not match
Brake Switch stuck open or closed
For instructions on retrieving fault codes with DLB please follow IK2600036
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/1/2013
IK0400057 - 07 and Newer Brake Light Operation on HPV, ProStar and LoneStar with A... Page 2 of 3
SIGNALS TO WATCH
SIGNAL
Brake_Analog_Switch_Raw_Signal
Brake_Switch_Signal
Brake_Switch
Brake_Analog_Switch_Raw_Signal
Brake_Switch_Signal
Brake_Switch
BRAKE PEDAL STATE
Applied
Applied
Applied
Released
Released
Released
VALUE
0.28v
Checked
Brake On
1.6v
No Check
Brake Off
TROUBLESHOOTING
Medium Duty Vehicles
Air brake switch harness connector 1823 voltage checks - Check with ignition switch on and brake switch
disconnected.
Harness connector 1823 cavity C to ground - 12 volts +/- 1.5 volts - If voltage is missing check for open or
shorts in circuits A70A and B70A.
Harness connector 1823 cavity D to ground - 0 volts - Zero volt reference signal to switch, if voltage found on
circuit check circuits A9AA, A9V, B9V and B9VG for shorts to voltage.
Harness connector 1823 Cavity C to D - 12 volts +/- 1.5 volts - If voltage is missing check for shorts or opens
on circuits A70A, B70A, A9AA, A9V, B9V and B9VG.
For tractor applications same tests as steps 1, 2 and 3 are done for connector 1824 refer to circuit diagram for
those circuit numbers.
ProStar and LoneStar
Air brake switch harness connector 1806 voltage checks - check with ignition switch on and brake switch
disconnected.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/1/2013
IK0400057 - 07 and Newer Brake Light Operation on HPV, ProStar and LoneStar with A... Page 3 of 3
Harness connector 1806 Cavity C to ground - 12 volts +/- 1.5 volts - If voltage is missing check for opens or
shorts in circuits A70 and BA70.
Harness connector 1806 Cavity D to ground - 0 volts - Zero volt reference signal to switch, if voltage found on
circuit check circuits A9A, B9 and BA9K, check for shorts to voltage.
Harness connector 1806 Cavity C to D - 12 volts +/- 1.5 volts - If voltage is missing check for shorts or opens
on circuits A70, BA70, A9A, B9 and BA9K.
CIRCUIT DIAGRAMS
Medium Duty Diagram
LoneStar and ProStar Diagram
Master Service Information Page
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Copyright © 2013 Navistar
, Inc.
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11/1/2013
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TSB/Document ID: IK0400057
Replacement Service Bulletin Number:
MFR Communication Date: 2013-10-16
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SERVICE BRAKES, AIR
MFR Component System:
MFR Component Subsystem:
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