NHTSA ID Number: 11017808

Manufacturer Communication Number: IK2300041

TSB/Document Date: 2025-05-05


Summary

Title: 6090/6091 Connector Damage Applies To: IC Bus® Electric CE Series, International® eMV™ Series


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TSB/Document ID: IK2300041
- Identifier the manufacturer uses to identify the communication and the way it can be located by those searching for it.

Replacement Service Bulletin Number:
- Replacement service bulletin number.

MFR Communication Date: 2025-04-21
- Date the communication was disseminated by the manufacturer.

MFR Internal Campaign ID/Software Version: IK2300041
- Manufacturer's unique identifier for the service campaign if this communication is a related one.

Communication Type: Service Bulletin/Repair Instructions

- Service Bulletin / Repair Instructions
- Service Campaign
- Warranty Program / Extension
- Over The Air
- Emissions
- Other

NHTSA Components: ELECTRICAL SYSTEM
- NHTSA Component(s) of the products involved in communications.

MFR Component System:
- Manufacturer's top-level component of the products involved in communications.

MFR Component Subsystem:
- Manufacturer's component subsystem of the top-level component identified above.



Countries:

CANADA, MEXICO, UNITED
STATES

Document ID: IK2300041

Availability:

ISIS, Bus ISIS, NotSIR

Revision:

0

Major System:
Current
Language:

ELECTRIC VEHICLE

Created:
Last
Modified:

4/21/2025

Author:

Josh
Bowman

English

Other Languages: NONE
Viewed:

4/22/2025

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Title : 6090/6091 Connector Damage
Applies To : IC Bus® Electric CE Series, International® eMV™ Series

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
04/22/2025 - Initial Article Release

DESCRIPTION
This document will guide the user through identifying a possible damaged 6090/6091 connector due to improper harness
routing/clipping.
Each scernio may vary depending on which terminal(s) and/or circuit wire(s) being affected.

SYMPTOMS
Diagnostic Trouble Codes & Dashboard Indicator Lights:
DTC/Light

Description

SPN 2128 FMI 9

Source Address 128 : Abnormal Update Rate

SPN 2176 FMI 9

VCU Communication with DCDC2 : Abnormal Update Rate

SPN 2179 FMI 9

VCU Communication with DCDC1 : Abnormal Update Rate

SPN 2186 FMI 9

VCU Communication with HVDM-TPIM : Abnormal Update Rate

SPN 2187 FMI 9

VCU Communication with HVDM-HVDU : Abnormal Update Rate

SPN 2188 FMI 9

VCU Communication with HVDM-DC Fast Charger : Abnormal Update Rate

SPN 2189 FMI 9

VCU Communication with HVDM-Front A/C Compressor Inverter Module : Abnormal Update Rate

SPN 2190 FMI 9

VCU Communication with HVDM-Rear A/C Compressor Inverter Module : Abnormal Update Rate

SPN 2239 FMI 9

VCU Communication with TPIM : Abnormal Update Rate

SPN 2243 FMI 9

VCU Communication with BMS : Abnormal Update Rate

SPN 517200 FMI 2

J1939 Lost : Data Erratic, Intermittent Or Incorrect

SPN 517207 FMI 4

Under-Voltage (High Voltage) : Voltage Below Normal, Or Shorted To Low Source

SPN 517300 FMI 11
SPN 520450 FMI 0
SPN 520450 FMI 0
SPN 523545 FMI 7
SPN 523546 FMI 7

A/C control module: Rear A/C module to A/C control module communication fault : Root Cause Not
Known
DCDC2 Input Voltage Under Limit : Data Valid But Above Normal Operational Range - Most Severe
Level
DCDC1 Input Voltage Under Limit : Data Valid But Above Normal Operational Range - Most Severe
Level
VCU - HVDM Smart Connection Element for - TPIM Faulty : Mechanical System Not Responding Or
Out Of Adjustment
VCU - HVDM Smart Connection Element for - HVDU Faulty : Mechanical System Not Responding Or
Out Of Adjustment

SPN 523548 FMI 7

A/C Compressor Inverter Module Faulty : Mechanical System Not Responding Or Out Of Adjustment

SPN 523559 FMI 9

Supervisory Control Unit communication with OCI : Abnormal Update Rate

SPN 523561 FMI 9

Supervisory Control Unit communication with BMS : Abnormal Update Rate

SPN 523643 FMI 5

HVDM/S-BOX High Voltage Interlock : Current Below Normal Or Open Circuit

SPN 523644 FMI 6

TPIM/Drive Motor High Voltage Interlock : Current Below Normal Or Open Circuit

SPN 523645 FMI 5

2-in-1 High Voltage Interlock : Current Below Normal Or Open Circuit

SPN 523646 FMI 5

DCDC1/DCDC2/HVDU HV Interlock : Current Below Normal Or Open Circuit

SPN 523649 FMI 2

Charge Plug : Data Erratic, Intermittent Or Incorrect

SPN 523650 FMI 7

DDC to DC Converter 1 : Mechanical System Not Responding Or Out Of Adjustment

SPN 523651 FMI 7

DC to DC Converter 2 : Mechanical System Not Responding Or Out Of Adjustment

SPN 523655 FMI 14 HVESS Initialization : Special Instructions
SPN 523657 FMI 2

HVESS Battery Switch State : Data Erratic, Intermittent Or Incorrect

SPN 5919 FMI 1

HVESS Voltage Level : Data Valid But Below Normal Operational Range - Most Severe Level

SPN 5919 FMI 2

HVESS Voltage Level : Data Erratic, Intermittent Or Incorrect

Customer Observations or Concerns:
Lights on the cluster
Intermittent derate
High-voltage drive concerns

SPECIAL TOOLS / SOFTWARE
Tool Description

Tool Number

Comments

Instructions

N/A

N/A

N/A

N/A

SERVICE PARTS INFORMATION

Kit Description

Part Number

Quantity
Notes
Required

Refer to Connector Body Composite

ID from failure

as needed 6090/6091, underhood left side of cowl

DIAGNOSTIC STEPS
Step Action
DIAGNOSTIC:
Are any of the faults listed above active alongside any of the symptoms?

Decision
Yes. Perform visual inspection on
6090/6091 connector located
underhood at left side of cowl.
Look for:
- Damaged wiring
- Missing connector lock
- Connector pulled apart
- Pulled back terminals

1

Repair accordingly
To prevent re-occurence, cut clipping
points to allow slack and re-secure.

No. No further action needed.

Failure Examples

Figure 1: Wire Tension

Figure 2: Missing Lock - Connector Pulled Apart

Figure 3: Pulled Back Pin

After repairing connector, terminals or wiring; to prevent re-occurence cut
clipping points to allow slack to the 6090/6091. Resecure as needed.

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

Standard Repair Times:
Refer to the SRT Manual for Repair Times

OTHER RESOURCES
Master Service Information Site

Hide Details

Feedback Information
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Copyright © 2025 Navistar, Inc.


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