SERVICE BULLETIN
Contents
1. facility using INSITE Software 268601a Figure 2 J1939 Multiplexing 2 Screen SB 221 032 Page 6 of 8 with attachment a iv 23 Instrument Cluster lt a a 4 Figure 3 J1939 Multiplexing 3 Screen F Activate Top2 with Cruise Con Figure 4 Features and Parameters Screen SB 221 032 Page 7 of 8 with attachment Cummins Engine Codes In chassis equipped with a Cummins engine the engine control module ECU uses specific codes that identify it as an engine in a MACK chassis The following table lists these specific codes These codes can be viewed by an authorized Cummins facility using INSITE software Engine Model ECM ECM ECM code code code ECM ECM ECM part No part No part No 3681405 3408426 3408501 ISX 530 N11341 N11333 N11337 ISX 565 N10358 N10350 N11251 ISX 600 N10357 N10349 N11249 Signature 600 STX N10356 N10348 N11246 Signature 600 N10355 N10347 N11244 ISX 500 1650 N11268 N11231 N11239 ISX 500 1850 N11267 N11230 N11238 ISX 500 ST2 N11266 N11229 N11237 NOTE On CL and CV model chassis equipped with a Cummins engine verify that the terminating resistor part No 598AX197 is installed at the ECM The labor code and maximum labor allowance for the procedures outlined in this bulletin are as follows 230 CA 21802 ssich biti iei bite T 3 5 hrs Time allowed to perform diagnostic and2. repair procedures relating to a logged 9 2 fault code SB 221 032 Page 8 of 8 with attachment VOLTAGE DROP TEST BATTERY LOAD TEST RESULTS CHASSIS INFORMATION Model VIN Mileage Customer Dealer Code Contact Name FAX completed form to Vehicle Electronic Service Engineering at 610 709 3800 Battery Positive Side Circuit Voltage Drop Test Measurement Points First Measurement Second Measurement Battery positive post to battery positive cable end Battery positive post to starter solenoid B terminal Battery positive post to starter relay B terminal Battery positive post to power relay No 1 Battery positive post to power relay No 2 Battery positive post to power relay No 3 Battery positive post to power relay No 4 Battery positive post to alternator B terminal First measurement taken before cleaning Second measurement taken after cleaning Battery Negative Side Circuit Voltage Drop Test Measurement Points First Measurement Second Measurement Battery negative post to battery negative cable end Battery negative post to starter ground terminal Battery negative post to frame ground Battery negative post to master ground circuit breaker Battery negative post to left hand side dashboard ground terminal Battery negative post to right hand side dashboard ground terminal Battery negative post to alternator ground G terminal Battery negative post to engine left hand side gro
3. tightened Install the ground wire ring terminals onto the ground bolt then install the bolt into the bolt hole in the engine block Fan the ring terminals around the ground bolt so that the wire lugs are not on top of each other Tighten the ground bolt to 120 lb ft 163 N m gt 4 Inspect the left side frame ground a Remove the bolt that secures the ground cables and wires to the left side frame rail note the tightness of the bolt prior to removal After removing the bolt discard the star washer if equipped Inspect the bolt and the wire ring terminals for signs of arcing or corrosion Clean both sides of the ring terminals making sure to remove all traces of the heat shrink sealant that may have oozed out during the heat sealing process Clean around the ground bolt hole on both sides of the frame rail Install the ground bolt ground cables and wires flat washer and nut Fan the ring terminals around the ground bolt so that the wire lugs are not on top of each other Tighten the nut to 37 5 lb ft 51 N m NOTE DO NOT use a star washer Spray paint the area of the frame rail around the ground bolt to prevent rust from forming 5 Inspect the ground circuit breaker a Remove the retaining nuts that secure the cables to the terminals of the ground circuit breaker note the tightness of the nuts prior to removal Discard the nuts with the captured star washers Clean both sides of the ring terminals b
4. BULLETIN NUMBER SB 221 032 DATE 12 4 03 MODEL All Not applicable to Mack Trucks Australia Supersedes bulletin SB 221 032 dated 3 20 03 9 2 FAULT CODE DIAGNOSTICS AND REPAIR PROCEDURES A 9 2 fault code Power reset without Key Switch Failure Mode Identifier FMI 4 Parameter Identifier PID S254 and Message Identification MID 128 142 will set with a MID 142 if the Vehicle Electronic Control Unit VECU senses a loss of battery without the key switch being turned off A 9 2 fault code will set with a MID 128 if the Engine Electronic Control Unit EECU senses a loss of switched power without the key switch being turned off Fault code 9 2 generally indicates a loss of power or ground connection to the VECU or EECU Complete electronic diagnostic procedures for troubleshooting a 9 2 fault code are outlined in the V MAC III Service Manual 8 211 dated October 2001 or later In addition to the diagnostic procedures outlined in the V MAC Ill service manual when troubleshooting the cause of a 9 2 fault code the investigation should include the following NOTE The following procedures cover all chassis equipped with MACK engines and CL and CV model chassis equipped with Cummins engines NOTE To avoid a repeat failure do not stop performing the procedures outlined in this bulletin at the point where it appears that the problem may have been corrected All steps steps 1 through 8 plus the voltage drop tests must
5. battery post terminal then place the negative meter lead at the following test points a e EE 5 g h Battery negative post to battery negative cable end Battery negative post to starter ground terminal Battery negative post to frame ground Battery negative post to master ground circuit breaker Battery negative post to left hand side dashboard ground terminal Battery negative post to right hand dashboard ground terminal Battery negative post to alternator ground G terminal Battery negative post to left hand side engine ground connection 5 Record the voltage drop measurements obtained at the above locations in the form provided with this bulletin If voltage drop measurements are higher than specified clean the connectors terminals etc as required and retest In addition to the above voltage drop tests also perform an open circuit voltage test and load test of all the batteries Include this information on the form provided with this bulletin NOTE For information concerning voltage drop tests battery open circuit voltage tests and battery load tests refer to the MACK Electrical Troubleshooting Manual 8 212 SB 221 032 Page 5 of 8 with attachment Multiplexing MUX Settings CL and CV Model Chassis Equipped with Cummins Engines On CL and CV model chassis equipped with Cummins engines the following multiplexing MUX settings must be verified These settings must be verified by an authorized Cummins
6. be performed to ensure that the cause of the 9 2 fault code has been repaired 1 Inspect the batteries a Load test each battery b Check tightness of each battery connection Clean and tighten as necessary c If the vehicle is equipped with a battery disconnect switch check the connections for corrosion and tightness Clean and tighten as necessary 2 Inspect the battery cable connections at the starter motor a Before proceeding disconnect the negative battery cables from the battery b Remove the positive and negative battery cables from the starter motor Note the tightness of the cable connections while they are being removed c Note any corrosion on the cable ends then clean both sides of the cable terminal Reinstall the battery cables and tighten the retaining nuts to 270 Ib in 31 N m SB 221 032 Page 1 of 8 with attachment SERVICE PUBLICATIONS ALLENTOWN PA 18105 MACK TRUCKS INC 2003 3 Inspect the left side engine ground a Remove the bolt that secures the ground cable to the engine block note the tightness of the ground bolt prior to removal After removing the ground bolt discard the star washer Clean the ring terminals of all the ground wires and also clean the ground bolt boss on the side of the engine block Measure the length of the ground bolt then measure the depth of the bolt hole in the engine block Compare the measurements to be sure the bolt will not bottom in the bolt hole when
7. e male terminals SB 221 032 Page 3 of 8 with attachment 9 If the 9 2 code is logged in the EECU proceed as follows a Remove fuse or circuit breaker No 40 from the Engine Power Distribution Module EPDM b Insert the purple male test lead adapter included in the Kent Moore V MAC Test Lead Adapter Kit tool No J 38581 into the female terminal to check tightness of the terminal c If the drag felt on the test lead is not sufficient replace the female terminal end part No 6031 12110844 d Disconnect connector B from the EPDM e Inspect the connector terminals for corrosion and other damage and check to make sure that each terminal is fully seated and locked in the connector body f Disconnect the engine to transmission transition connector g Inspect the terminals for corrosion and other damage and check to make sure that each terminal is fully seated and locked in the connector bodies Testing Voltage Drop Measuring voltage drop across a cable or a cable connection is useful in determining the integrity of the circuit Cables or connectors should have no measurable or only a fractional voltage drop For a wire cable or connector voltage drop should be 0 1 volt or less and for an insulated or ground circuit voltage drop should be 0 5 volt or less Voltage drop measurements greater than 0 1 volt for a cable or connector indicate the presence of high resistance that could be caused by a loose conn
8. ection dirt or corrosion When diagnosing a 9 2 fault code the following voltage drop tests should be performed and the information gathered from these tests should be recorded on the Voltage Drop Test Battery Load Test Results form included at the end of this service bulletin The completed form can then be faxed to the Mack Trucks Electronic Service Engineering Department for analysis Voltage Drop Test Procedures Voltage drop is measured by placing a digital multimeter volt ohm meter in parallel with the component wire connection etc as follows 1 Set the multimeter to the VDC function 2 Turn the vehicle ignition switch to the ON position SERVICE HINT Long jumper wires with alligator clips on both ends may be used to facilitate performing the following tests SB 221 032 Page 4 of 8 with attachment 3 Measure voltage drop on the positive side of the battery by placing the positive meter lead on the positive battery post terminal then place the negative meter lead at the following test points a b C d e Battery positive post to battery positive cable end Battery positive post to starter solenoid battery B terminal Battery positive post to starter relay battery B terminal Battery positive post to power relays 1 2 3 and 4 Battery positive post to alternator positive B terminal 4 Measure voltage drop on the negative side of the battery by placing the positive meter lead on the negative
9. eing sure to remove all traces of heat shrink sealant that may have oozed out during the heat sealing process Install the wire ring terminals onto the terminal stud on the ground circuit breaker Install a new nylock nut part No 21AX938 onto the terminal Fan the ring terminals around the terminal stud so that the wire lugs are not on top of each other Tighten the nut to 65 Ib in 6 16 N m SB 221 032 Page 2 of 8 with attachment 6 Inspect the left hand side dashboard ground wire a b C d Remove the instrument cluster and note the tightness of the ground bolt Remove the ground bolt discard the star washer and clean all the ring terminals Sand or scrape to remove the paint from around the ground bolt hole Install a flat washer over the ground bolt then insert the bolt through the cross bar from the front side Install another flat washer and secure with a prevailing torque nut Install a flat washer over the bolt then install the ground wire ring terminals a flat washer and secure with a prevailing torque nut Tighten the nut to 108 Ib in 12 N m 7 Inspect the right hand side dashboard ground a 25 Remove the D panel from the dashboard then check the tightness of the ground bolt Remove the ground bolt discard the star washer and clean all the ring terminals Sand or scrape to remove the paint from around the ground bolt hole Install a flat washer over the ground bolt then insert the bolt
10. through the cross bar from the front side Install another flat washer and secure with a prevailing torque nut Install a flat washer over the bolt then install the ground wire ring terminals a flat washer and secure with a prevailing torque nut Tighten the nut to 108 Ib in 12 N m 8 If the 9 2 code is logged in the VECU proceed as follows a b Remove fuse or circuit breaker No 16 from the electrical equipment panel Insert the purple male test lead adapter included in the Kent Moore V MAC Test Lead Adapter Kit tool No J 38581 into the female terminal to check the tightness of the terminal If the drag felt on the test lead is not sufficient replace the female terminal end part No 925AM173 Remove power relay Nos 1 and 2 from the electrical equipment panel Check the terminal blades of the relays for deep scratches which indicated good contact between the female terminals and the male terminal blades of the relays If deep scratches are not present inspect the female terminals for damage or spreading Replace the female terminals as required part Nos 2967 2807554 Amp Industries part No 280755 4 and 2967 422811 Amp Industries part No 42281 1 NOTE Although the power relays may seem tight when being removed from the electrical equipment panel this does not indicate sufficient contact between the male and female terminals The only way of determining sufficient contact is by looking for deep scratches on th
11. und connection First measurement taken before cleaning Second measurement taken after cleaning Battery Open Circuit Test Load Test Results Cold Cranking Amp CCA Rating of Batteries Open Circuit Voltage Test Battery Load Test Voltage Voltage Amperage Battery 1 Battery 2 Battery 3 Battery 4 FormSB221032 3 20 03
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