8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING 2007 Ford F650 : Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Listen

DIAGNOSIS AND TESTING

SECTION 413­01: Instrumentation and Warning Chimes 2007 F­Super Duty 650­750 Workshop Manual

DIAGNOSIS AND TESTING Procedure revision date: 10/09/2009

INSTRUMENTATION AND WARNING CHIMES Refer to Wiring Diagrams Cell 59 , Multifunction Control Modules for schematic and connector information. Refer to Wiring Diagrams Cell 60 , Instrument Cluster for schematic and connector information.

Special Tool(s)

Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

IC4COM (418­D553A) and MD Truck software with appropriate hardware

73 III Automotive Meter 105­R0057 or Equivalent

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Anti­Lock Brake Adapter 418­063 (T97P­50­ALA)

Instrument Gauge System Tester 014­R1063 or Equivalent

Flex Probe Kit 105­R025C or equivalent

Principles of Operation

Instrument Cluster (IC) Instrument Cluster (IC) Prove­Out The instrument cluster (IC) carries out a display prove out to verify that all warning/indicator lamps and monitored systems are functioning correctly. When the ignition switch is in the ON position with the engine off, the following indicators will illuminate:

SERVICE ENGINE SOON warning indicator Charge system warning indicator Red brake warning indicator Amber brake­E­motor (hydraulic brake) WATER IN FUEL indicator WAIT TO START indicator ENGINE PROTECT indicator STOP ENGINE indicator Anti­lock brake system (ABS) warning indicator (if so equipped) CHECK TRANS indicator

Gauge Indication Systems The gauge indication systems use magnetic gauges mounted in the instrument cluster (IC). No adjustment, calibration or maintenance is required for any gauges. The gauges cannot be installed separately. Fuel Gauge Unit The fuel sending unit is a variable resistor controlled by the action of a tube and float. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI0… 2/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Water Temperature Indicator Sender Unit When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and resulting in a corresponding movement of the pointer. Oil Pressure Indicator Sender Unit The oil pressure indicator sender unit consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Charge Indicator System The battery voltage gauge measures the voltage potential at the battery. Speedometer The electronic speedometer receives a speed signal from the GEM module (if equipped with 4 wheel anti­lock brake system [ABS]) or the GEM/CTM (if equipped with rear wheel ABS). Odometer A million­mile tamper­resistant odometer is standard. New speedometers have a resettable odometer. NOTE: Some state laws require that the odometer in any new speedometer must register the same as on the removed odometer. New speedometers and odometer modules with the mileage preset are available through Ford electronic repair centers. If the actual vehicle mileage cannot be determined, the repair centers are able to supply odometers set to "0" miles. An odometer mileage sticker is supplied with the new odometer. This sticker must display the estimated vehicle mileage and be affixed to the driver door jamb. Trip Odometer The trip odometer indicates how many miles the vehicle has been driven since the last reset. Tachometer The tachometer is a 4500­rpm tachometer. Diesel vehicles receive the tachometer signal from the engine control module (ECM). Warning Indicators — Brake System All vehicles use a brake system warning indicator in the instrument panel to warn of system malfunctions. The red brake warning light (BRAKE) is used to indicate a low fluid level, brake malfunction or a parking brake that is not fully released. The brake fluid level switch is located in the brake fluid reservoir. The yellow ABS warning indicator is used to indicate a malfunction or deactivation of the ABS. It illuminates when triggered by the ABS control module and stays illuminated as long as the malfunction remains in the system. Service Engine Soon Warning Indicator The SERVICE ENGINE SOON warning indicator is illuminated when a diagnostic trouble code (DTC) is sensed in the closed loop by the powertrain control module (PCM). Water­In­Fuel The water­in­fuel indicator will be illuminated when the fuel system water collector is full. Stop Engine The stop engine warning indicator will be illuminated when a critical engine control system parameter is out of range. Engine Protect The engine protect warning indicator (Cummins only) will be illuminated when one of the following engine fluid parameters is out of range:

Coolant level low Oil pressure low Coolant temperature high Intake manifold temperature high

Check Trans The Allison electronic automatic transmission ECU activates a CHECK TRANS warning indicator lamp to alert the operator http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI0… 3/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING that a problem has been detected. When a problem has been detected, downshifts and upshifts can be restricted. Wait­To­Start The WAIT­TO­START warning indicator illuminates to advise the operator to wait until the light goes out before attempting to start the vehicle. High Beam This indicator is illuminated when the high beams are on.

Warning Chimes Generic Electronic Module (GEM) The following distinct chime rates are used to indicate warning:

Key­in­ignition warning is 2 chimes per second Headlamp­on warning is 4 chimes per second Door ajar warning is a single chime Low air warning is a single chime Hydro­Max® warning is one chime per second

Door Ajar Warning Chime The door ajar warning chime sounds when all of the following conditions are met:

Any door is ajar The ignition switch is in the RUN position

Key­In­Ignition Warning Chime The key­in­ignition chime sounds when all of the following conditions are met:

Driver door is ajar Ignition switch is in the OFF/LOCK or ACC position Key is in the ignition

The key­in­ignition warning chime will stop sounding when any one of the conditions above are removed. Hydro­Max® Warning Chime The Hydro­Max® warning chime sounds when any one of the following conditions exist:

The brake pedal is pressed and the vehicle is not running The Hydro­Max® flow switch closes with the ignition in the RUN position The GEM does not see a change in the state of the flow switch (closed or open) once the vehicle has been started The GEM provides output to the Hydro­Max® relay to activate the Hydro­Max® motor, but 12­volt feedback is not provided to the GEM, confirming Hydro­Max® operation A 12­volt feedback is provided to the GEM, but the GEM did not request Hydro­Max® motor operation

Headlamps Warning Chime The headlamps warning chime sounds when all of the following conditions are met:

The driver door is ajar The headlamp switch is in the park or head position The ignition switch state is in the OFF/LOCK position Key is out of ignition

The headlamps warning chime will stop sounding when any one of the conditions above are removed. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI0… 4/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Low Pressure Warning Chime The GEM alerts the driver if there is low air pressure in the primary or secondary air brake reservoir. When the ignition switch is in the RUN position, the GEM will monitor the normally open primary and secondary low pressure switch. If the air pressure drops below 4482 kPa (65 psi) in the primary or secondary reservoir, the low air pressure switch closes. The GEM will illuminate a red brake warning lamp on the instrument panel cluster and sound a warning chime. When the air pressure rises above 4482 kPa (65 psi), the primary or secondary low air pressure switches open and the GEM will turn the warning chime and warning lamp off.

Inspection and Verification

1. Verify the customer concern by operating the system in question.

2. Visually inspect the components listed in the following chart:

Visual Inspection Chart

Mechanical Electrical

Damaged engine oil filter Damaged oil pump Central junction box (CJB) fuse: Damaged water thermostat 29 (10A) Door ajar switch 13 (20A) Engine coolant level Damaged miniature bulb(s) Key­in­ignition warning switch Damaged wiring harness Low engine oil level Loose or corroded connectors Stuck coolant temperature gauge Damaged instrument cluster (IC) Stuck oil pressure gauge needle

3. Verify the following systems are working correctly:

Brakes air hydraulic Charging Fuel Cooling Turn signals Headlamps

If the system(s) is not working correctly, refer to the appropriate section of the workshop manual.

4. If the concern remains after the inspection, connect the diagnostic tool or engine specific data line (CAT/Cummins) to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check the connections to the vehicle. check the ignition switch position.

5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.

6. Carry out the DATA LINK DIAGNOSTIC TEST. If the diagnostic tool responds with: http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI0… 5/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING SCP+, SCP­ or UBP circuits fault = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. NO RESP/NOT EQUIP for generic electronic module (GEM), GO to Pinpoint Test A. NOTE: The following criteria must be met when carrying out the GEM On­Demand Self­Test: headlamps and parklamps must be on. Failure to meet this criteria will result in DTC B1575 being set. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self­test diagnostics for the GEM.

7. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics.

8. If no DTCs related to the concern are retrieved, GO to Symptom Chart ­ Instrument Cluster (IC) or GO to Symptom Chart ­ Warning Chimes.

GEM Diagnostic Trouble Code (DTC) Index

DTC Description Action B1352 Ignition Key­In Circuit Failure GO to Pinpoint Test W. B1575 Lamp Park Input Circuit Failure GO to Pinpoint Test V. B1577 Lamp Park Input Circuit Short to Battery GO to Pinpoint Test V. C1125 Brake Fluid Level Sensor Input Circuit Failure GO to Pinpoint Test J. C1189 Brake Fluid Level Sensor Input Circuit Short to Ground GO to Pinpoint Test J. C1223 Lamp Brake Warning Output Circuit Failure GO to Pinpoint Test J. C1225 Lamp Brake Warning Output Circuit Short to Battery GO to Pinpoint Test J. C1230 Speed Wheel Sensor Rear Center Input Circuit Failure GO to Pinpoint Test F. C1446 Brake Switch Circuit Failure GO to Pinpoint Test J.

Symptom Charts

Symptom Chart — Instrument Cluster (IC)

Condition Possible Sources Action

Fuse No communication with the Circuitry REFER to Module generic electronic module Generic electronic Communications Network. module (GEM)

Fuse Circuitry Instrument cluster (IC) The instrument cluster (IC) is Instrument cluster GO to Pinpoint Test A. inoperative (IC) connectors

Senders Powertrain control http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI0… 6/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING module (PCM)

Fuel sender Circuitry Incorrect fuel gauge indication GO to Pinpoint Test B. Instrument cluster (IC)

Instrument cluster Incorrect voltage gauge (IC) GO to Pinpoint Test C. indication Fuse Circuitry

Instrument cluster Incorrect oil pressure gauge (IC) GO to Pinpoint Test D. indication Circuitry PCM

Circuitry Coolant temperature Incorrect temperature gauge sender GO to Pinpoint Test E. indication Instrument cluster (IC)

PCM

Instrument cluster The speedometer is (IC) GO to Pinpoint Test F. inoperative Circuitry GEM

VERIFY the trip odometer reset The trip odometer is lever is not binding. If OK, Instrument cluster inoperative — speedometer REPAIR the instrument cluster (IC) OK (IC). REFER to Instrument Cluster (IC) in this section.

Circuitry Instrument cluster Incorrect tachometer indication GO to Pinpoint Test G. (IC) PCM

Instrument cluster http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI0… 7/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Incorrect speedometer (IC) GO to Pinpoint Test H. indication — odometer GEM functions correctly Tires

ABS warning indicator bulb The brake warning indicator is Circuitry never on — yellow ABS GO to Pinpoint Test I. warning indicator Instrument cluster (IC) ABS module

The brake warning indicator is Circuitry always on — yellow ABS GO to Pinpoint Test Z. warning indicator ABS module

Parking brake warning indicator bulb Circuitry The parking brake warning Parking brake switch GO to Pinpoint Test J. indicator is never/always on Rod stroke sensor

GEM Instrument cluster (IC)

Circuitry ABS module Brake fluid level The brake warning indicator is switch REFER to Brake System — always on — red BRAKE General Information — warning indicator Parking brake switch Hydraulic. Brake warning indicator relay GEM

SERVICE ENGINE SOON indicator bulb The SERVICE ENGINE SOON Circuitry GO to Pinpoint Test K. indicator is inoperative Instrument cluster

(IC)

The SERVICE ENGINE SOON Diagnostic trouble REFER to the Powertrain indicator is always on code (DTC) related Control/Emissions Diagnosis concern(s) (PC/ED) manual. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI0… 8/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

Circuitry The charge system warning REFER to Battery, Mounting indicator is always on Generator (charging and Cables. system)

High beam indicator bulb Circuitry The high beam indicator is GO to Pinpoint Test L. inoperative Instrument cluster (IC)

Multi­function switch (MFS)

LH turn indicator bulb Circuitry The LH turn indicator is GO to Pinpoint Test M. inoperative Instrument cluster (IC)

Multi­function switch (MFS)

RH turn indicator bulb Circuitry The RH turn indicator is GO to Pinpoint Test N. inoperative Instrument cluster (IC)

Multi­function switch (MFS)

The WAIT TO START indicator Circuitry GO to Pinpoint Test O. is inoperative — diesel only PCM

Circuitry The WATER IN FUEL indicator Water in fuel switch GO to Pinpoint Test P. is inoperative — diesel only WATER IN FUEL indicator bulb

The brake warning indicator is Circuitry REFER to Brake System — always on — brake motor Hydro­Max® module General Information — warning indicator (hydraulic Hydraulic. only) GEM

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI0… 9/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Instrument cluster (IC) The brake warning indicator is Indicator bulb never on — brake electric GO to Pinpoint Test Q. warning indicator (Hydro­ Circuitry Max® only) Hydro­Max® module GEM

Circuitry Instrument cluster The transmission warning (IC) indicator is never on — yellow GO to Pinpoint Test R. check trans Transmission warning indicator bulb

Circuitry The engine warning indicator Instrument cluster is never on — yellow engine (IC) GO to Pinpoint Test S. protect Engine warning

indicator bulb

Circuitry Instrument cluster The engine warning indicator (IC) GO to Pinpoint Test T. is never on — red stop engine Engine warning

indicator bulb

Circuitry Instrument cluster The brake warning indicator is (IC) GO to Pinpoint Test U. never on — red indicator Brake warning indicator bulb

GEM

Symptom Chart — Warning Chimes

Condition Possible Sources Action

Fuse(s) No communication with the REFER to Module Circuit(s) generic electronic module (GEM) Communications Network. GEM

Circuit(s) http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 10/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING The headlamp ON reminder chime Headlamp GO to Pinpoint Test V. does not operate correctly switch

GEM

Wiring, terminals or connectors The chime sounds when the door Key­in­ is ajar (no key in ignition and ignition GO to Pinpoint Test W. headlamps off) switch

Headlamp

switch GEM

Wiring, terminals or connectors The key­in­ignition chime is Key­in­ GO to Pinpoint Test X. inoperative ignition

switch GEM

The Hydro­Max® brake control Circuitry warning chime does not operate Hydro­Max® REFER to Brake System — correctly — Hydro­Max® brake flow switch General Information — Hydraulic. control systems only GEM

Circuitry Primary low pressure The low air pressure warning switch REFER to Brake System — chime does not operate correctly General Information — Air. — air brake system only Secondary low pressure

switch GEM

INSTALL a new GEM module. All the chimes are inoperative GEM REFER to Multifunction Electronic Modules.

The door ajar chime does not Circuitry GO to Pinpoint Test Y. operate correctly GEM

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Pinpoint Test A: The Instrument Cluster (IC) Is Inoperative Normal Operation Under normal operation, voltage is supplied the instrument cluster (IC) through circuit 640 (RD/YE). The instrument cluster (IC) is grounded through circuit 676 (PK/OG).

Possible causes An open in circuit 640 (RD/YE) or 676 (PK/OG) Fuse Instrument cluster (IC)

PINPOINT TEST A: THE INSTRUMENT CLUSTER (IC) IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

A1 CHECK CIRCUIT 640 (RD/YE) FOR AN OPEN

Disconnect: Instrument Cluster (IC) C220 . Ignition ON. Measure the voltage between instrument cluster C220b­11, circuit 640 (RD/YE) and ground.

Measure the voltage between instrument cluster (IC) C220c­ 12, circuit 640 (RD/YE) and ground.

Yes GO to A2. No VERIFY the central junction box (CJB) fuse 29 (10A) is OK. If OK, REPAIR circuit 640 (RD/YE) for an open. TEST the system for normal operation.

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Are the voltages greater than 10 volts?

A2 CHECK GROUND CIRCUIT 676 (PK/OG) FOR AN OPEN

Measure the resistance between instrument cluster (IC) C220b­5, circuit 676 (PK/OG) and ground.

Yes VERIFY the instrument cluster (IC) printed circuit connector is fully locked. If so, REPAIR the instrument cluster (IC). TEST the system for normal operation. No REPAIR circuit 676 (PK/OG) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Pinpoint Test B: Incorrect Fuel Gauge Indication Normal Operation The instrument cluster (IC) is hardwired to the RH fuel level sensor through circuit 29 (YE/WH), which is grounded through circuit 396 (BK/OG). The fuel level sensor is a variable resistor that ranges from 15 ohms ± 2 ohms at empty (E) and 160 ohms ± 4 ohms at full (F), controlled by the action of a float. The instrument cluster (IC) provides a signal voltage to the RH fuel sensor. As the fuel level changes, a float actuates the variable resistor and raises or lowers the fuel level signal voltage depending on the resistance of the fuel level sender. The instrument cluster (IC) monitors the changes in voltage and commands the fuel gauge with a corresponding movement of the pointer. Fuel is transferred to the RH fuel tank from the LH fuel tank by the fuel transfer pump. The fuel transfer pump monitors the fuel level in both fuel tanks. When the fuel level is lower in the RH fuel tank than the LH fuel tank, the fuel transfer pump turns on and transfers fuel from the LH to the RH fuel tank. NOTE: Fuel level is monitored in the RH tank only. The fuel level may not register with complete accuracy in regards to the amount of fuel in the entire fuel system. The fuel transfer pump does not transfer fuel from the RH tank to the LH tank. With fuel being used from the RH tank and transferred from the LH tank, the fuel level in both tanks remains relatively close and the http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 13/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING gauge registers the correct amount of remaining fuel in both tanks. If fuel is added to the RH fuel tank and not added to the LH fuel tank, the fuel gauge displays only the fuel level of the RH tank.

Possible causes An open in circuit 29 (YE/WH) or 396 (BK/OG) Instrument cluster (IC) Fuel sender

PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: This pinpoint test assumes that the fuel transfer pump is functioning correctly and fuel is transferring. Make sure to verify that the fuel transfer pump is operating and that fuel is transferring from the LH fuel tank to the RH fuel tank.

Test Step Result / Action to Take

B1 CHECK THE FUEL GAUGE OPERATION

Ignition OFF. Disconnect: RH Fuel Level SensorC3263 . Connect one lead of the instrument gauge tester to the RH fuel level sensor C3263­A, circuit 29 (YE/WH), harness side and the other lead to the RH fuel level sensor C3263­B, circuit 396 (BK/OG), harness side.

Yes DISCONNECT the instrument gauge tester. GO to B2. No Set the tester to 160 ohms. DISCONNECT the instrument gauge Ignition ON. tester. GO to B3. Wait 1 minute. Ignition OFF. Set the tester to 15 ohms. Ignition ON. Wait 1 minute. Observe the fuel gauge. The fuel gauge should read E (empty) or below. Ignition OFF. Set the tester to 160 ohms. Ignition ON. Wait 1 minute. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 14/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Observe the fuel gauge. The fuel gauge should read F (full) or above. Does the fuel gauge operate correctly?

B2 INSPECT THE FUEL TANK

Yes INSTALL a new fuel level sensor. REFER to Fuel Tank and Lines. TEST Visually inspect the fuel tank for any damage or deformation. the system for normal operation. Is the fuel tank OK? No VERIFY that the fuel level sensor is OK. INSTALL a new fuel tank. REFER to Fuel Tank and Lines. TEST the system for normal operation.

B3 CHECK CIRCUITS 29 (YE/WH) AND 396 (BK/OG) FOR AN OPEN

Ignition OFF. Disconnect: Instrument Cluster (IC) C220b . Connect a fused (5A) jumper wire between the RH fuel level sensor C3263­A, circuit 29 (YE/WH), harness side and the LH fuel level sensor C3263­B, circuit 396 (BK/OG), harness side.

Measure the resistance between the instrument cluster (IC) C220b­10, circuit 29 (YE/WH), harness side and the instrument cluster (IC) C220b­5, circuit 676 (PK/OG), Yes harness side. REMOVE the jumper wire. GO to B6. No REMOVE the jumper wire. GO to B4.

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Is the resistance less than 5 ohms?

B4 CHECK CIRCUIT 396 (BK/OG) FOR AN OPEN

Measure the resistance between the RH fuel level sensor C3263­B, circuit 396 (OG/BK), harness side and ground.

Yes GO to B5. No REPAIR the circuit. TEST the system for normal operation.

Is the resistance less than 5 ohms?

B5 CHECK CIRCUIT 29 (YE/WH) FOR AN OPEN

Measure the resistance between the RH fuel level sensor C3263­A, circuit 29 (YE/WH), harness side and the instrument cluster (IC) C220b­10, circuit 29 (YE/WH), harness side.

Yes http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 16/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING GO to B6. No REPAIR the circuit. TEST the system for normal operation.

Is the resistance less than 5 ohms?

B6 CHECK FOR CORRECT INSTRUMENT CLUSTER (IC) OPERATION

Disconnect all the instrument cluster (IC) connectors. Check for: Yes corrosion INSTALL a new instrument cluster (IC). damaged pins REFER to Instrument Cluster (IC) in pushed­out pins this section. TEST the system for normal operation. Connect all the instrument cluster (IC) connectors and make sure they seat correctly. No Operate the system and determine if the concern is still The system is operating correctly at this present. time. The concern may have been caused by a loose or corroded connector. Is the concern still present?

Pinpoint Test C: Incorrect Voltage Gauge Indication Normal Operation Under normal operation, voltage is provided to the instrument cluster (IC) through circuit 797 (LG/VT). The instrument cluster (IC) is grounded through circuit 676 (PK/OG).

Possible causes An open in circuit 676 (PK/OG) or 797 (LG/VT) Fuse Instrument cluster (IC)

PINPOINT TEST C: INCORRECT VOLTAGE GAUGE INDICATION NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

C1 CHECK BATTERY AND CHARGING SYSTEM

Check the battery and charging system. Refer to Battery, Yes http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 17/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Mounting and Cables. GO to C2. Is the battery and charging system OK? No REFER to Battery, Mounting and Cables.

C2 CHECK GROUND TO VOLTMETER CIRCUIT 676 (PK/OG) FOR AN OPEN

Disconnect: Instrument Cluster (IC) C220b . Measure the resistance between instrument cluster (IC) C220b­5, circuit 676 (PK/OG) and ground.

Yes GO to C3. No REPAIR circuit 676 (PK/OG) for an open.

Is the resistance less than 5 ohms?

C3 CHECK HOT AT ALL TIMES POWER SUPPLY — CIRCUIT 797 (LG/VT)

Disconnect: Instrument Cluster (IC) C220b . Measure the voltage between instrument cluster (IC) C220b­ 3, circuit 797 (LG/VT) and ground.

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No INSPECT central junction box (CJB) fuse 13 (20A) for an open. If OK, REPAIR circuit 797 (LG/VT) for an open. TEST the system for normal operation.

Is the voltage greater than 10 volts?

Pinpoint Test D: Incorrect Oil Pressure Gauge Indication http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 18/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

Normal Operation Under normal operation, when the oil pressure is normal, the oil pressure switch provides ground to the instrument cluster (IC) through circuit 31 (WH/RD).

Possible causes An open in circuit 31 (WH/RD) Instrument cluster (IC)

PINPOINT TEST D: INCORRECT OIL PRESSURE GAUGE INDICATION NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

D1 CHECK THE OIL PRESSURE SWITCH

NOTE: For correct operation of the oil pressure gauge, make sure the engine oil is at the correct level and the connector is securely attached to the oil pressure switch. During hard braking, a momentary drop in oil pressure is normal. Make sure the engine to chassis and engine to bulkhead ground straps are securely fastened. Ignition OFF. Disconnect: Oil Pressure Switch C103 . Connect a fused jumper wire between oil pressure sensor C103, Yes circuit 31 (WH/RD) and ground. For CAT and Cummins — REFER to the original engine manufacturer's service manual. For 6.0L — REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. No DISCONNECT the jumper wire. GO to D2.

Does the oil pressure gauge read normal?

D2 CHECK CIRCUIT 31 (WH/RD) FOR AN OPEN

Disconnect: Instrument Cluster (IC) C220b . Disconnect: Oil Pressure Switch C103 . Measure the resistance between oil pressure switch C103, circuit 31 (WH/RD) and instrument cluster (IC) C220b­6, circuit 31 (WH/RD).

Yes http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 19/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 31 (WH/RD) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Pinpoint Test E: Incorrect Temperature Gauge Indication Normal Operation Under normal operation, reference voltage is supplied from the instrument cluster (IC) to the coolant temperature sender through circuit 39 (RD/WH). The coolant temperature sender is grounded through circuit 676 (PK/OG).

Possible causes An open in circuit 39 (RD/WH) or 676 (PK/OG) A short to ground in circuit 39 (RD/WH) Coolant temperature sender Instrument cluster (IC)

PINPOINT TEST E: INCORRECT TEMPERATURE GAUGE INDICATION NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

E1 CHECK TEMPERATURE GAUGE OPERATION — COLD

NOTE: For correct operation of the temperature gauge, make sure the engine coolant is at the correct level and that the connector is securely mated to the coolant temperature sender. Yes Ignition OFF. GO to E3. Disconnect: Engine Coolant Temperature (ECT) Sender No C1276 . GO to E2. Ignition ON. Does the temperature gauge read in the cold band?

E2 CHECK CIRCUIT 39 (RD/WH) FOR SHORT TO GROUND

Disconnect: Engine Coolant Temperature (ECT) Sender C1276 . Measure the resistance between ECT C1276­2, circuit 39 http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 20/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING (RD/WH) and ground.

Yes GO to E4. No REPAIR circuit 39 (RD/WH) for a short to ground. TEST the system for normal operation.

Is the resistance greater than 10,000 ohms?

E3 CHECK THE TEMPERATURE GAUGE OPERATION — HOT

Connect a fused jumper wire between the 2 pins of ECT C1276.

Yes REMOVE the jumper wire. RECONNECT the coolant temperature sender. START vehicle and ALLOW engine to reach operating temperature. If the gauge is not in normal range, INSTALL a new coolant temperature sender. TEST the system for normal operation. No GO to E4.

Does the temperature gauge read in the hot band?

E4 CHECK CIRCUIT 676 (PK/OG) FOR AN OPEN

Disconnect: Engine Coolant Temperature Sender C1276 . Measure the resistance between ECT C1276­1, circuit 676 (PK/OG), and ground.

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 21/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Yes GO to E5. No REPAIR circuit 676 (PK/OG) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

E5 CHECK CIRCUIT 39 (RD/WH) FOR AN OPEN

Ignition OFF. Disconnect: Instrument Cluster (IC) C220b . Disconnect: Coolant Temperature Sensor C1276 . Measure the resistance between instrument cluster (IC) C220b­9, circuit 39 (RD/WH) and ECT C1276­2, circuit 39 (RD/WH).

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 39 (RD/WH) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Pinpoint Test F: The Speedometer Is Inoperative Normal Operation Under normal operation, vehicle speed is sent from the transmission control unit to the generic electronic module (GEM) through circuit 353 (LB). The GEM is grounded through circuit 676 (PK/OG). Vehicle speed is sent from the GEM to the instrument cluster (IC) through circuit 679 (GY/BK).

Possible causes An open in circuit 353 (LB), 676 (PK/OG) or 679 (GY/BK) A short to voltage in circuit 353 (LB), 676 (PK/OG) or 679 (GY/BK) http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 22/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING A short to ground in circuit 353 (LB), 676 (PK/OG) or 679 (GY/BK) Central junction box (CJB) Instrument cluster (IC)

PINPOINT TEST F: THE SPEEDOMETER IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

F1 CHECK THE GEM PID VSS GEM

Connect the scan tool. Monitor the GEM PID VSS GEM while driving the vehicle 0 to Yes 89 km/h (0 to 55 mph). GO to F5. Does the PID VSS GEM value agree with the vehicle No speed? GO to F2.

F2 CHECK CIRCUITS 676 (PK/OG) AND 353 (LB) FOR SHORT TO GROUND

Ignition OFF. Disconnect: Generic Electronic Module (GEM) C201a . On vehicles equipped with a manual or non­electronic automatic transmission, measure the resistance between GEM C201a­26, circuit 676 (PK/OG) and ground.

On vehicles equipped with a manual or non­electronic automatic transmission, measure the resistance between GEM C201a­22, circuit 353 (LB) and ground.

Yes GO to F3. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 23/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

No REPAIR circuit 353 (LB) or 676 (PK/OG) for a short to ground. TEST the system for normal operation.

On vehicles equipped with an electronic automatic transmission, measure the resistance between GEM C201a­ 22, circuit 353 (LB) and ground.

Is the resistance greater than 10,000 ohms?

F3 CHECK CIRCUITS 676 (PK/OG) AND 353 (LB) FOR AN OPEN

Disconnect: GEM C201a . Disconnect: Vehicle Speed Sensor (VSS) C1088 . Disconnect: Allison Electronic Control Unit C3112c . On vehicles equipped with a manual or non­electronic automatic transmission, measure the resistance between transmission speed sensor C1088­B, circuit 676 (PK/OG) and GEM C201a­26, circuit 676 (PK/OG).

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 24/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

On vehicles equipped with a manual or non­electronic automatic transmission, measure the resistance between Yes vehicle speed sensor C1088­A, circuit 353 (LB) and GEM GO to F4. C201a­22, circuit 353 (LB). No REPAIR circuit 353 (LB) or 676 (PK/OG) for an open. TEST the system for normal operation.

On vehicles equipped with an electronic automatic transmission, measure the resistance between GEM C201a­ 22, circuit 353 (LB) and Allison ECU C3112c­30, circuit 157 (PK/LB).

Is the resistance less than 5 ohms?

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 25/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

F4 CHECK CIRCUITS 676 (PK/OG) AND 353 (LB) FOR SHORT TO VOLTAGE

Measure the voltage between GEM C201a­10 circuit 676 (PK/OG) and ground.

Yes REPAIR circuit 353 (LB) or 676 (PK/OG) for a short to voltage. TEST the system for normal operation. No Measure the voltage between GEM C201a­22, circuit 353 For vehicles equipped with a manual or (LB) and ground. non­electronic automatic transmission, INSTALL a new speed sensor. For vehicles equipped with an electronic automatic transmission, REFER to WTEC III Troubleshooting in the appropriate Allison repair manual. TEST the system for normal operation.

Are the voltages greater than 10 volts?

F5 CHECK THE CENTRAL JUNCTION BOX (CJB) FOR AN OPEN CIRCUIT

Ignition OFF. Disconnect: GEM C201b . Disconnect: CJB C270b . Measure the resistance between CJB C270b­18 and fuse junction panel circuit 679 (GY/BK).

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 26/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Yes GO to F6. No INSTALL a new CJB. TEST the system for normal operation.

Is the resistance less than 5 ohms?

F6 CHECK THE CENTRAL JUNCTION BOX (CJB) FOR SHORT TO GROUND

Disconnect: GEM C201a . Disconnect: CJB C270b . Measure the resistance between CJB C270b­18 and ground.

Yes GO to F7. If DTC C1752 is present, GO to F8. No INSTALL a new CJB. TEST the system for normal operation.

Is the resistance greater than 10,000 ohms?

F7 CHECK THE CENTRAL JUNCTION BOX (CJB) FOR SHORT TO POWER

Measure the voltage between CJB C270b­18 and ground.

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 27/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Yes INSTALL a new CJB. TEST the system for normal operation. No GO to F8. If DTC C1751 is present, GO to F10.

Is the voltage greater than 10 volts?

F8 CHECK CIRCUIT 679 (GY/BK) FOR SHORT TO GROUND

Disconnect: Instrument Cluster (IC) C220b . Disconnect: CJB C270b . Measure the resistance between CJB C270b­14, circuit 679 (GY/BK) and ground.

Yes GO to F9. No REPAIR circuit 679 (GY/BK) for a short to ground. TEST the system for normal operation.

Is the resistance greater than 10,000 ohms?

F9 CHECK CIRCUIT 679 (GY/BK) FOR AN OPEN

Ignition OFF. Disconnect: Instrument Cluster (IC) C220b . Disconnect: CJB C270b . Measure the resistance between instrument cluster (IC) C220b­7, circuit 679 (GY/BK) and CJB C220b­14, circuit 679 (GY/BK).

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 28/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Yes GO to F10. No REPAIR circuit 679 (GY/BK) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

F10 CHECK CIRCUIT 679 (GY/BK) FOR SHORT TO VOLTAGE

Disconnect: Instrument Cluster (IC) C220b . Disconnect: CJB C270b . Measure the voltage between CJB C220b­14, circuit 679 (GY/BK) and ground.

Yes REPAIR circuit 679 (GY/BK) for a short to voltage. TEST the system for normal operation. No INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation.

Is the voltage greater than 10 volts?

Pinpoint Test G: Incorrect Tachometer Indication Normal Operation Under normal operation, engine RPM is sent from the engine control to the instrument cluster (IC) through circuit 648 (WH/PK).

Possible causes An open in circuit 648 (WH/PK) Instrument cluster (IC) Powertrain control module (PCM)

PINPOINT TEST G: INCORRECT TACHOMETER INDICATION NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 29/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING damage the connector.

Test Step Result / Action to Take

G1 CHECK CIRCUIT 648 (WH/PK) FOR AN OPEN

Ignition OFF. Disconnect: Instrument Cluster (IC) C220b . Disconnect: ECU . For vehicles with a Cummins ISB engine, measure the resistance between instrument cluster (IC) C220b­12, circuit 648 (WH/PK) and engine Cummins engine control module C1233a­41, circuit 648 (WH/PK).

For vehicles with a CAT 3126 engine, measure the resistance between instrument cluster (IC) C220b­12, circuit 648 (WH/PK) and engine CAT ECM C1232­38, circuit 648 (WH/PK).

Yes GO to G2. No REPAIR circuit 648 (WH/PK) for an open. TEST the system for normal operation.

For vehicles with a 6.0L engine, measure the resistance between instrument cluster (IC) C220b­12, circuit 648 (WH/PK) and powertrain control module (PCM) C175a­11, circuit 648 (WH/PK).

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Is the resistance less than 5 ohms?

G2 CHECK FOR CLEAN TACH OUT (CTO) CIRCUIT OPEN OR SHORT

Yes INSTALL a new instrument cluster (IC). Check for CTO circuit open or short. Refer to Powertrain REFER to Instrument Cluster (IC) in Control/Emissions Diagnosis (PC/ED) manual. this section. TEST the system for normal operation. Is the CTO circuit OK? No INSTALL a new powertrain control module (PCM). TEST the system for normal operation.

Pinpoint Test H: Incorrect Speedometer Indication — Odometer Functions Correctly Normal Operation Under normal operation, the instrument cluster (IC) displays vehicle speed received from the generic electronic module (GEM).

Possible causes Instrument cluster (IC)

PINPOINT TEST H: INCORRECT SPEEDOMETER INDICATION — ODOMETER FUNCTIONS CORRECTLY

Test Step Result / Action to Take

H1 CHECK THE SPEEDOMETER AT LOW SPEED

NOTE: Vehicle must be traveling at a steady speed while carrying out this test.NOTE: Only carry out test step H1 if speed limits do not allow test step H2 to be carried out. Yes Connect the scan tool. GO to H2. Monitor the GEM PID VSS GEM while driving the vehicle at 50 km/h (30 mph). No Hold vehicle speed steady when the PID VSS GEM is INSTALL a new instrument cluster (IC). REFER indicating 50 km/h (30 mph). to Instrument Cluster (IC) in this section. TEST the system for normal operation. Does the speedometer read 47­58 km/h (28­35 mph)? http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 31/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

H2 CHECK THE SPEEDOMETER AT HIGH SPEED

NOTE: Vehicle must be traveling at a steady speed while carrying out this test. Monitor the GEM PID VSS GEM while driving the Yes vehicle at 100 km/h (60 mph). The system is OK. Hold vehicle speed steady (set speed control, if No equipped) when the PID VSS GEM is indicating 100 km/h (60 mph). INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST Does the speedometer read 94­108 km/h (58­65 the system for normal operation. mph)?

Pinpoint Test I: The Brake Warning Indicator Is Never On — Yellow ABS Warning Indicator Normal Operation Under normal operation, ground is provided to the instrument cluster (IC) to illuminate the indicator through circuit 603 (DG).

Possible causes An open in circuit 603 (DG) Instrument cluster (IC)

PINPOINT TEST I: THE BRAKE WARNING INDICATOR IS NEVER ON — YELLOW ABS WARNING INDICATOR NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

I1 CHECK THE ABS WARNING INDICATOR CONTROL CIRCUIT

Ignition OFF. Disconnect: ABS ECU . Disconnect: Instrument Cluster (IC) C220a . On vehicles equipped with hydraulic brakes, measure the resistance between ABS control module C3150a­4, circuit 603 (DG) and ground.

Yes REPAIR circuit 603 (DG) for an open. TEST the system for normal operation. No INSTALL a new instrument cluster (IC). On vehicles equipped with air brakes, measure the http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 32/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING resistance between ABS control module C135a­E3, circuit REFER to Instrument Cluster (IC) in this 603 (DG) and ground. section. TEST the system for normal operation.

Is the resistance greater than 5 ohms?

Pinpoint Test J: The Parking Brake Warning Indicator Is Always/Never On Normal Operation On vehicles not equipped with power parking brakes, ground is provided to the generic electronic module (GEM) from the parking brake switch through circuit 338 (TN/RD). On vehicles equipped with power parking brakes, ground is provided to the GEM from the rod stroke sensor (also called the spring apply/air release travel sensor) through circuit 1896 (GY/RD). When the GEM receives a ground input from the parking brake switch or the spring apply/air release travel sensor, the GEM provides a ground signal to the instrument cluster (IC) to illuminate the indicator through circuit 162 (LG/RD).

Possible causes Circuit 57 (BK) open Circuit 162 (LG/RD) open, short to ground or voltage Circuit 338 (TN/RD) open, short to ground or voltage Circuit 1896 (GY/RD) open, short to ground or voltage Parking brake switch Rod stroke sensor (also called the spring apply/air release travel sensor) GEM Instrument cluster (IC)

PINPOINT TEST J: THE PARKING BRAKE WARNING INDICATOR IS ALWAYS/NEVER ON NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

J1 CHECK THE PARKING BRAKE SWITCH OPERATION

Ignition OFF. Connect the scan tool. Ignition ON. Yes Enter the following diagnostic mode on the scan tool: GEM GO to J10. PID . No http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 33/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Monitor the GEM PID PARK SW while engaging and If the PID always indicates OFF, GO to disengaging the parking brake. J2. Does the PID PARK SW indicate OFF when disengaged If the PID always indicates ON, GO to J7. and ON when engaged?

J2 CHECK THE PARKING BRAKE INPUT

Ignition OFF. Disconnect: Parking Brake Switch C2015 (Base Hydraulic Brakes) . Disconnect: Parking Brake Switch C306 (Air Brakes) . Disconnect: Rod Stroke Sensor C4295 (Power Parking Brakes) . Ignition ON. If equipped with base hydraulic brakes, monitor the GEM PID PARK SW while connecting a fused jumper wire between the parking brake switch C2015­A, circuit 338 (TN/RD), harness side and ground.

If equipped with air brakes, monitor the GEM PID PARK SW while connecting a fused jumper wire between the parking brake switch C306­C, circuit 338 (TN/RD), harness side and ground. Yes If equipped with power parking brakes, GO to J3. If not equipped with power parking brakes, GO to J5. No GO to J6.

If equipped with power parking brakes, monitor the GEM PID http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 34/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING PARK SW while connecting a fused jumper wire between the rod stroke sensor (also called the spring apply/air release travel sensor) C4295­D, circuit 1896 (GY/RD), harness side and ground.

Does the PID PARK SW indicate ON with the jumper wire connected?

J3 VERIFY THE POWER PARKING BRAKE SYSTEM OPERATION

Yes Engage and disengage the power parking brakes. GO to J4. Do the power parking brakes apply when engaged and No release when disengaged? REFER to Brake System — General Information — Hydraulic to continue diagnosis.

J4 CHECK PARKING BRAKE SWITCH INPUT TO THE STROKE ROD SENSOR

Ignition OFF. Engage the power parking brake. Measure the resistance between the stroke rod sensor C4295­E, circuit 338 (TN/RD), harness side and ground.

Yes INSTALL a new parking brake switch or rod stroke sensor. TEST the system for normal operation. No GO to J5.

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 35/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Is the resistance less than 5 ohms?

J5 CHECK CIRCUIT 57 (BK) FOR AN OPEN

Ignition OFF. If equipped with base hydraulic brakes, measure the resistance between the parking brake switch C2015­B, circuit 57 (BK), harness side and ground.

Yes INSTALL a new parking brake switch or rod stroke sensor. TEST the system for If equipped with air brakes or power parking brakes, normal operation. measure the resistance between the parking brake switch No C306­D, circuit 57 (BK), harness side and ground. REPAIR the circuit. TEST the system for normal operation.

Is the resistance less than 5 ohms?

J6 CHECK CIRCUIT 338 (TN/RD) FOR AN OPEN

Ignition OFF. Disconnect: GEM C201b . If equipped with base hydraulic brakes, measure the resistance between parking brake switch C2015­A, circuit 338 (TN/RD), harness side and the GEM C201b­17, circuit 338 (TN/RD), harness side. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 36/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

If equipped with air brakes, measure the resistance between the parking brake switch C306­C, circuit 338 (TN/RD), harness side and the GEM C201b­17, circuit 338 (TN/RD), harness side.

Yes INSTALL a new GEM. REFER to Multifunction Electronic Modules. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation.

If equipped with power parking brakes, measure the resistance between rod stroke sensor C4295­D, circuit 1896 (GY/RD), harness side and the GEM C201b­17, circuit 1896 (GY/RD), harness side.

Is the resistance less than 5 ohms?

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 37/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING J7 CHECK THE PARKING BRAKE SWITCH

Ignition OFF. Disconnect: Parking Brake Switch C2015 (Base Hydraulic Yes Brakes) . INSTALL a new parking brake switch. Disconnect: Parking Brake Switch C306 (Air Brakes) . TEST the system for normal operation. Ignition ON. No Monitor the GEM PID PARK SW with the parking brake If equipped with power parking brakes, switch disconnected. GO to J8. Does the PID PARK SW indicate OFF with the switch If not equipped with power parking brakes, disconnected? GO to J9.

J8 CHECK THE STROKE ROD SENSOR FOR A SHORT TO GROUND

Ignition OFF. Yes Disconnect: Stroke Rod Sensor C4295 . INSTALL a new stroke rod sensor. Monitor the GEM PID PARK SW with the parking brake REFER to Brake System — General switch disconnected. Information — Hydraulic. TEST the system for normal operation. Does the PID PARK SW indicate OFF with the switch disconnected? No GO to J9.

J9 CHECK CIRCUIT 338 (TN/RD) FOR A SHORT TO GROUND

Ignition OFF. Disconnect: GEM C201b . Measure the resistance between the GEM C201b­17, circuit 338 (TN/RD) (with base hydraulic or air brake systems) or circuit 1896 (GY/RD) (with power parking brakes), harness side and ground.

Yes INSTALL a new GEM. REFER to Multifunction Electronic Modules. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation.

Is the resistance greater than 10,000 ohms?

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J10 CHECK THE PARKING BRAKE WARNING INDICATOR OPERATION

Ignition OFF. Disconnect: GEM C201b . Ignition ON. Connect a fused jumper wire between the GEM C201b­8, circuit 162 (LG/RD), harness side and ground.

Yes INSTALL a new GEM. REFER to Multifunction Electronic Modules. TEST the system for normal operation. No If the light does not illuminate, GO to J11. If the light illuminates continuously, GO to J12.

Does the parking brake warning indicator illuminate when ground is applied to circuit 162 (LG/RD) and shut off when the ground is removed?

J11 CHECK CIRCUIT 162 (LG/RD) FOR AN OPEN

Ignition OFF. Disconnect: Instrument Cluster (IC) C220c . Measure the resistance between the instrument cluster (IC) C220c­10, circuit 162 (LG/RD), harness side and the GEM C201b­8, circuit 162 (LG/RD), harness side.

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 39/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

Is the resistance less than 5 ohms?

J12 CHECK CIRCUIT 162 (LG/RD) FOR A SHORT TO GROUND

Ignition OFF. Disconnect: Instrument Cluster (IC) C220c . Measure the resistance between the GEM C201b­8, circuit 162 (LG/RD), harness side and ground.

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation.

Is the resistance greater than 10,000 ohms?

Pinpoint Test K: The SERVICE ENGINE SOON Indicator Is Inoperative Normal Operation Under normal operation, ground is provided to the instrument cluster (IC) from the Cummins or CAT engine control or powertrain control module (PCM) to illuminate the indicator through circuit 658 (PK/LG).

Possible causes An open in circuit 658 (PK/LG) Cummins engine control CAT engine control PCM Instrument cluster (IC) http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 40/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING PINPOINT TEST K: THE SERVICE ENGINE SOON INDICATOR IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

K1 CHECK THE SERVICE ENGINE SOON WARNING INDICATOR CIRCUIT

Ignition OFF. Disconnect: Cummins or CAT Engine Control or PCM . Ignition ON. For vehicles with a Cummins ISB engine, connect a fused jumper wire between Cummins engine control C1233a­44, circuit 658 (PK/LG) and ground.

For vehicles with a CAT 3126 engine, connect a fused jumper wire between engine ECM C1232­28, circuit 658 (PK/LG) and ground.

Yes REPAIR the Cummins or CAT engine control or PCM. REFER to the engine manufacturer's repair manual. No GO to K2.

For vehicles with a 6.0L engine, connect a fused jumper wire between PCM C175b­17, circuit 658 (PK/LG) and ground.

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Does the SERVICE ENGINE SOON warning indicator illuminate?

K2 CHECK CIRCUIT 658 (VT/LG) FOR AN OPEN

Ignition OFF. Disconnect: Instrument Cluster (IC) C220a . For vehicles with a Cummins ISB engine, measure the resistance between instrument cluster (IC) C220a­7, circuit 658 (PK/LG) and Cummins engine control C1233­44, circuit 658 (PK/LG).

For vehicles with a CAT 3126 engine, measure the resistance between instrument cluster (IC) C220a­7, circuit 658 (PK/LG) and engine ECM C1232­28, circuit 658 (PK/LG).

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Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 658 (PK/LG) for an open. TEST the system for normal operation.

Click to Enlarge

For vehicles with a 6.0L engine, measure the resistance between instrument cluster (IC) C220a­7, circuit 658 (PK/LG) and PCM C175b­17, circuit 658 (PK/LG).

Is the resistance less than 5 ohms?

Pinpoint Test L: The High Beam Indicator Is Inoperative Normal Operation Under normal operation, voltage is supplied the instrument cluster (IC) from the high beam lamps to illuminate the indicator http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 43/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING through circuit 12 (LG/BK).

Possible causes An open in circuit 12 (LG/BK) Instrument cluster (IC)

PINPOINT TEST L: THE HIGH BEAM INDICATOR IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

L1 CHECK CIRCUIT 12 (LG/BK) FOR VOLTAGE

Ignition OFF. Disconnect: Instrument Cluster (IC) C220a . Ignition ON. NOTE: Headlamps must be on for this test. Place the multi­function switch in the HIGH BEAM position. Measure the voltage between instrument cluster (IC) C220a­ 10, circuit 12 (LG/BK) and ground.

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No GO to L2.

Is the voltage greater than 10 volts?

L2 VERIFY HIGH BEAM OPERATION

Yes Verify the high beam headlamps operation. REPAIR circuit 12 (LG/BK) for an open. Do the high beam headlamps operate correctly? TEST the system for normal operation. No

REFER to Exterior Lighting.

Pinpoint Test M: The LH Turn Indicator Is Inoperative Normal Operation Under normal operation, voltage is supplied the instrument cluster (IC) from the LH turn lamps to illuminate the indicator through circuit 3 (LG/WH).

Possible causes http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 44/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING An open in circuit 3 (LG/WH) Instrument cluster (IC)

PINPOINT TEST M: THE LH TURN INDICATOR IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

M1 CHECK CIRCUIT 3 (LG/WH) FOR VOLTAGE

Ignition OFF. Disconnect: Instrument Cluster (IC) C220b . Ignition ON. Place the multi­function switch in the LH turn signal position. Measure the voltage between instrument cluster (IC) C220b­ 16, circuit 3 (LG/WH) and ground.

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 3 (LG/WH) for an open. TEST the system for normal operation.

Does the voltage fluctuate between 0­10 volts?

Pinpoint Test N: The RH Turn Indicator Is Inoperative Normal Operation Under normal operation, voltage is supplied the instrument cluster (IC) from the LH turn lamps to illuminate the indicator through circuit 2 (WH/LB).

Possible causes An open in circuit 2 (WH/LB) Instrument cluster (IC)

PINPOINT TEST N: THE RH TURN INDICATOR IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

N1 CHECK CIRCUIT 2 (WH/LB) FOR VOLTAGE

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 45/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Ignition OFF. Disconnect: Instrument Cluster (IC) C220b . Ignition ON. Place the multi­function switch in the RH turn signal position. Measure the voltage between instrument cluster (IC) C220b­ 14, circuit 2 (WH/LB) and ground.

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 2 (WH/LB) for an open. TEST the system for normal operation.

Does the voltage fluctuate between 0­10 volts?

Pinpoint Test O: The WAIT TO START Indicator Is Inoperative — Diesel Only Normal Operation Under normal operation, ground is provided to the instrument cluster (IC) from the Cummins or CAT engine control or powertrain control module (PCM) to illuminate the indicator through circuit 464 (BK/PK).

Possible causes An open in circuit 464 (BK/PK) Instrument cluster (IC)

PINPOINT TEST O: THE WAIT TO START INDICATOR IS INOPERATIVE — DIESEL ONLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

O1 CHECK WAIT TO START INDICATOR ILLUMINATION

Ignition OFF. Disconnect: Cummins Engine Control Module C1233a, CAT ECM C1232 or Inline C1281 . Ignition ON. For vehicles equipped with a Cummins ISB engine, connect a fused jumper wire between Cummins engine control module C1233a­50, circuit 464 (BK/PK) and ground.

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For vehicles equipped with a CAT 3126 engine, connect a fused jumper wire between ECM C1232­31, circuit 464 (BK/PK) and ground. Yes REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. No GO to O2.

For vehicles equipped with a 6.0L engine, connect a fused jumper wire between inline C1281­1, circuit 464 (BK/PK) and ground.

Does the WAIT TO START indicator illuminate?

O2 CHECK CIRCUIT 464 (BK/PK) FOR AN OPEN http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 47/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Ignition OFF. Disconnect: Instrument Cluster (IC) C220a . Disconnect: Cummins Engine Control Module C1233a, ECM C6013 or Inline C1281 . For vehicles equipped with a Cummins ISB engine, measure the resistance between instrument cluster (IC) C220a­2, circuit 464 (BK/PK) and Cummins engine control module C1233a­50, circuit 464 (BK/PK).

For vehicles equipped with a CAT 3126 engine, measure the resistance between instrument cluster (IC) C220a­2, circuit 464 (BK/PK) and ECM C1232­31, circuit 464 (BK/PK).

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 464 (BK/PK) for an open. TEST the system for normal operation.

For vehicles equipped with a 6.0L engine, measure the resistance between instrument cluster (IC) C220a­2, circuit 464 (BK/PK) and inline C1281­1, circuit 464 (BK/PK).

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Is the resistance less than 5 ohms?

Pinpoint Test P: The WATER IN FUEL Indicator Is Inoperative — Diesel Only Normal Operation Under normal operation, ground is provided to the instrument cluster (IC) from the Cummins or CAT engine control or powertrain control module (PCM) to illuminate the indicator through circuit 643 (RD).

Possible causes An open in circuit 643 (RD) Instrument cluster (IC)

PINPOINT TEST P: THE WATER IN FUEL INDICATOR IS INOPERATIVE — DIESEL ONLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

P1 CHECK THE WATER IN FUEL INDICATOR ILLUMINATION

Ignition OFF. Disconnect: WIF Warning Relay C1455 . Ignition ON. Connect a fused jumper wire between WIF warning relay C159a­1, circuit 643 (RD) and ground.

Yes REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. No GO to P2.

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Does the WATER IN FUEL indicator illuminate?

P2 CHECK CIRCUIT 643 (RD) FOR AN OPEN

Ignition OFF. Disconnect: Instrument Cluster (IC) C220a . Measure the resistance between instrument cluster (IC) C220a­3, circuit 643 (RD) and WIF warning relay C1455­1, circuit 643 (RD).

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 643 (RD) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Pinpoint Test Q: The Brake Warning Indicator Is Never On — Brake Electric Warning Indicator (Hydro­Max® Only) Normal Operation Under normal operation, ground is provided to the instrument cluster (IC) from the anti­lock brake system (ABS) module to illuminate the indicator through circuit 886 (WH/LB).

Possible causes An open in circuit 886 (WH/LB) Instrument cluster (IC)

PINPOINT TEST Q: THE BRAKE WARNING INDICATOR IS NEVER ON — BRAKE ELECTRIC WARNING INDICATOR (HYDRO­MAX® ONLY) NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

Q1 CHECK THE BRAKE ELECTRIC WARNING INDICATOR CONTROL CIRCUIT

Ignition OFF. Disconnect: GEM C201a . Connect a fused jumper wire between GEM C201a­13, circuit 20 (WH/LB) and ground. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 50/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

Yes REFER to Brake System — General Information — Hydraulic. No REMOVE the jumper wire. GO to Q2.

Does the amber brake electric warning indicator illuminate?

Q2 CHECK CIRCUIT 886 (WH/LB) FOR AN OPEN

Disconnect: Instrument Cluster (IC) C220c . Disconnect: GEM C201a . Measure the resistance between instrument cluster (IC) C220c­5, circuit 20 (WH/LB) and GEM C201a­13, circuit 20 (WH/LB).

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 886 (WH/LB) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Pinpoint Test R: The Transmission Warning Indicator Is Never On — Yellow Check Trans Normal Operation Under normal operation, ground is provided to the instrument cluster (IC) from the transmission control module to illuminate the indicator through circuit 115 (LG/BK).

Possible causes An open in circuit 115 (LG/BK) Instrument cluster (IC)

PINPOINT TEST R: THE TRANSMISSION WARNING INDICATOR IS NEVER ON — YELLOW CHECK TRANS http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 51/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

R1 CHECK TRANSMISSION ECU CIRCUIT 115 (LG/BK)

Disconnect: Allison ECU C3112c . Connect a fused jumper wire between Allison ECU C3112c­ 31, circuit 115 (LG/BK) and ground.

Yes RETRIEVE the error codes from the Allison ECU. REFER to the appropriate Allison repair manual. No GO to R2.

Does the CHECK TRANS warning indicator illuminate?

R2 CHECK CIRCUIT 115 (LG/BK) FOR AN OPEN

Disconnect: Instrument Cluster (IC) C220a . Disconnect: Allison ECU C3112c . Measure the resistance between instrument cluster (IC) C220a­6, circuit 115 (LG/BK) and Allison ECU C3112c­31 (black connector), circuit 115 (LG/BK).

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 115 (LG/BK) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 52/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Pinpoint Test S: The Engine Warning Indicator Is Never On — Yellow Engine Protect Normal Operation Under normal operation, ground is provided to the instrument cluster (IC) from the Cummins or CAT engine control or powertrain control module (PCM) to illuminate the indicator through circuit 658 (VT/LG).

Possible causes An open in circuit 658 (VT/LG) Instrument cluster (IC)

PINPOINT TEST S: THE ENGINE WARNING INDICATOR IS NEVER ON — YELLOW ENGINE PROTECT NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

S1 CHECK ENGINE ECU CIRCUIT 658 (VT/LG)

Disconnect: Inline C1281 . Connect a fused jumper wire between engine Inline C1281­ 7, circuit 658 (VT/LG) and ground.

Yes REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. No GO to S2.

Does the ENGINE PROTECT warning indicator illuminate?

S2 CHECK CIRCUIT 658 (VT/LG) FOR AN OPEN

Disconnect: Instrument Cluster (IC) C220a . Disconnect: Inline C1281 . Measure the resistance between instrument cluster (IC) C220a­7, circuit 658 (VT/LG) and inline C2181­7, circuit 658 (VT/LG).

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 53/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING this section. TEST the system for normal operation. No REPAIR circuit 658 (VT/LG) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Pinpoint Test T: The Engine Warning Indicator Is Never On — Red Stop Engine Normal Operation Under normal operation, ground is provided to the instrument cluster (IC) from the Cummins or CAT engine control or powertrain control module (PCM) to illuminate the indicator through circuit 617 (PK/OG).

Possible causes An open in circuit 617 (PK/OG) Instrument cluster (IC)

PINPOINT TEST T: THE ENGINE WARNING INDICATOR IS NEVER ON — RED STOP ENGINE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

T1 CHECK ENGINE ECU CIRCUIT 617 (PK/OG)

Disconnect: Cummins ECU C1233a . For vehicles with a Cummins ISB engine, connect a fused jumper wire between Cummins ECU C1233a­43, circuit 617 (PK/OG) and ground.

Yes RETRIEVE the error code from the engine ECU. REFER to the Powertrain http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 54/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING For vehicles with a CAT 3126 engine, connect a fused Control/Emissions Diagnosis (PC/ED) jumper wire between engine ECM C1232­29, circuit 617 manual. (PK/OG) and ground. No GO to T2.

Does the STOP ENGINE warning indicator illuminate?

T2 CHECK CIRCUIT 617 (PK/OG) FOR AN OPEN

Disconnect: Engine ECU . Disconnect: Instrument Cluster (IC) C220a . For vehicles with a Cummins ISB engine, measure the resistance between instrument cluster (IC) C220c­1, circuit 617 (PK/OG) and Cummins ECU C1233a­43, circuit 617 (PK/OG).

Yes For vehicles with a CAT 3126 engine, measure the INSTALL a new instrument cluster (IC). resistance between instrument cluster (IC) C220c­1, circuit REFER to Instrument Cluster (IC) in 617 (PK/OG) and ECM C1232­29, circuit 617 (PK/OG). this section. TEST the system for normal operation. No REPAIR circuit 617 (PK/OG) for an open. TEST the system for normal operation.

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Is the resistance less than 5 ohms?

Pinpoint Test U: The Brake Warning Indicator Is Never On — Red Indicator Normal Operation Under normal operation, ground is provided to the instrument cluster (IC) from the generic electronic module (GEM) to illuminate the indicator through circuit 977 (VT/WH).

Possible causes An open in circuit 977 (VT/WH) Instrument cluster (IC)

PINPOINT TEST U: THE BRAKE WARNING INDICATOR IS NEVER ON — RED INDICATOR NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

U1 CHECK THE BRAKE WARNING INDICATOR CONTROL CIRCUIT

Disconnect: GEM C201a . Connect a fused jumper wire between GEM C201a­12, circuit 977 (VT/WH) and ground.

Yes REFER to Module Communications Network. No GO to U2.

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U2 CHECK CIRCUIT 977 (VT/WH) FOR AN OPEN

Disconnect: GEM C201a . Disconnect: Instrument Cluster (IC) C220c . Measure the resistance between instrument cluster (IC) C220c­9, circuit 977 (VT/WH) and GEM C201a­12, circuit 977 (VT/WH).

Yes INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. No REPAIR circuit 977 (VT/WH) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Pinpoint Test V: The Headlamp ON Reminder Chime Does Not Operate Correctly Refer to Wiring Diagrams Cell 59 , Multifunction Control Modules for schematic and connector information. Refer to Wiring Diagrams Cell 60 , Instrument Cluster for schematic and connector information. Normal Operation Under normal operation, when the main light switch is in the parklamps or headlamps position, voltage is sent to the generic electronic module (GEM) through circuit 257 (WH/RD). When the driver door is ajar, the driver ajar switch provides ground to the GEM through circuit 344 (BK/YE). When the key is removed from the ignition, ground is removed from circuit 158 (K/PK) to the GEM.

DTC B1575 (Lamp Park Input Circuit Failure) — is an on­demand DTC that sets in the GEM if the GEM detects a short to voltage on the park lamp input, circuit 257 (WH/RD).

Possible causes An open in circuit 257 (WH/RD) A short to voltage in circuit 257 (WH/RD) Main light switch GEM

PINPOINT TEST V: THE HEADLAMP ON REMINDER CHIME DOES NOT OPERATE CORRECTLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 57/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING V1 RETRIEVE RECORDED GEM DIAGNOSTIC TROUBLE CODES (DTCs)

Ignition OFF. Yes Use the recorded results from the GEM self­test. If DTC B1577, GO to V6. Enter the following diagnostic mode on the scan tool: Clear If DTC B1342, INSTALL a new GEM. Continuous DTCs . REFER to Multifunction Electronic Enter the following diagnostic mode on the scan tool: GEM Modules. CLEAR the DTC. TEST the On­Demand Self­Test . system for normal operation. Are any DTCs recorded? No GO to V2.

V2 CHECK IGNITION KEY IN/OUT STATUS — MONITOR THE GEM PID IGN KEY

Monitor the GEM PID IGN KEY while inserting and removing Yes the key from the ignition switch. GO to V3. Do the GEM PID IGN KEY values agree with the switch positions? No GO to Pinpoint Test W.

V3 CHECK THE PARKING LAMP OPERATION

Turn the headlamp switch to the PARK position and OFF Yes again. GO to V4. Do the parking lamps operate correctly? No

REFER to Exterior Lighting.

V4 CHECK THE DOOR OPEN WARNING INDICATOR SWITCH — MONITOR THE GEM PID D DR SW

Monitor the GEM PID D DR SW while opening and closing Yes the driver front door. GO to V5. Do the GEM PID D DR SW values agree with the door positions? No REFER to Interior Lighting.

V5 CHECK CIRCUIT 257 (WH/RD) FOR AN OPEN

Ignition OFF. Disconnect: GEM C201a . Measure the resistance between main light switch C205a­ 11, circuit 257 (WH/RD) and GEM C201a­17, circuit 257 (WH/RD).

Yes INSTALL a new GEM. REFER to http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 58/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Multifunction Electronic Modules. TEST the system for normal operation. No REPAIR circuit 257 (WH/RD) for an open. TEST the system for normal operation.

Is the resistance less than 5 ohms?

V6 CHECK CIRCUIT 257 (WH/RD) FOR A SHORT TO VOLTAGE

Ignition OFF. Disconnect: Main Light Switch C205b . Disconnect: GEM C201a . Measure the voltage between main light switch C205a­11, circuit 257 (WH/RD) and ground.

Yes REPAIR circuit 257 (WH/RD) for a short to voltage. TEST the system for normal operation. No GO to V7.

Is the voltage greater than 10 volts?

V7 CHECK THE MAIN LIGHT SWITCH FOR A SHORT TO VOLTAGE

Ignition OFF. Yes Connect: GEM C201a . INSTALL a new main light switch. Ignition ON. REFER to Exterior Lighting. TEST the system for normal operation. Monitor the GEM PID PARK SW while disconnecting main light switch C205b. No Does the GEM PID PARK SW indicate OFF when the main INSTALL a new GEM. REFER to light switch is disconnected? Multifunction Electronic Modules. TEST the system for normal operation. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 59/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

Pinpoint Test W: The Chime Sounds When The Door Is Ajar (No Key In Ignition And Headlamps Off) Refer to Wiring Diagrams Cell 59 , Multifunction Control Modules for schematic and connector information. Normal Operation The generic electronic module (GEM) receives the key­in­ignition warning status from the key­in­ignition warning switch through circuit 158 (BK/PK). When the key is inserted into the ignition lock cylinder, the key­in­ignition warning switch closes to ground. The GEM monitors the driver door ajar input from the LH front door and the key­in­ignition switch status. When the key is inserted into the ignition lock cylinder and the LH front door is open or ajar, the GEM sounds the key­in­ignition warning chime. The GEM receives the headlamp switch status from the headlamp switch through circuit 257 (WH/RD) and the LH front door ajar status from the LH front door ajar switch through circuit 344 (BK/YE). The GEM sounds the headlamps on warning chime when the LH front door is opened with the ignition switch in the OFF position, the key is removed from the ignition lock cylinder, and the headlamp switch is in the PARK or HEADLAMP ON position.

DTC B1352 (Ignition Key­In Circuit Failure) — is a continuous and on­demand DTC that sets if the GEM detects an open on the key­in­ ignition switch input, circuit 158 (BK/PK) with the ignition in the RUN/START position and the key­in­ignition switch open (key out indication).

This pinpoint test is intended to diagnose the following: Wiring, terminals or connectors Key­in­ignition warning switch (part of the ignition switch) GEM

PINPOINT TEST W: THE CHIME SOUNDS WHEN THE DOOR IS AJAR (NO KEY IN IGNITION AND HEADLAMPS OFF) NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

W1 CHECK THE GEM IGNITION KEY IN/OUT STATUS

Ignition ON. Enter the following diagnostic mode on the scan tool: GEM DataLogger . Yes Select the GEM key­in ignition PID (IGN KEY). Monitor the GO to W4. PID with the key removed from the ignition lock cylinder. No Remove the key from the ignition lock cylinder. GO to W2. Does the PID indicate the key is out of the ignition lock cylinder?

W2 CHECK THE GEM KEY­IN­IGNITION INPUT FOR A SHORT TO GROUND

Ignition OFF. Disconnect: GEM C201a . Measure the resistance between the GEM C201a­15, circuit 158 (BK/PK), harness side and ground.

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Yes GO to W6. No GO to W3.

Is the resistance greater than 10,000 ohms?

W3 CHECK CIRCUIT 158 (BK/PK) FOR A SHORT TO GROUND

Disconnect: Key­In­Ignition Warning Switch . Measure the resistance between the GEM C201a­15, circuit 158 (BK/PK), harness side and ground.

Yes INSTALL a new key­in­ignition warning switch. REFER to Key­In­Ignition Warning Switch in this section. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation.

Is the resistance greater than 10,000 ohms?

W4 CHECK THE HEADLAMP INPUT FOR A SHORT TO VOLTAGE

Ignition OFF. Make sure the headlamp switch is in the OFF position. Disconnect: GEM C201a . Measure the voltage between the GEM C201a­17, circuit 257 (WH/RD), harness side and ground.

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Yes GO to W5. No GO to W6.

Is any voltage present?

W5 CHECK THE HEADLAMP SWITCH

Yes Disconnect: Headlamp Switch C205a . REPAIR the circuit 257 (WH/RD) for a Carry out the headlamp switch component test. short to voltage. CLEAR the DTCs. REPEAT the self­test. Refer to Wiring Diagrams Cell 149 for component testing. No Is the headlamp switch OK? INSTALL a new headlamp switch. REFER to Exterior Lighting. REPAIR the circuit. CLEAR the DTCs. REPEAT the self­test.

W6 CHECK FOR CORRECT GEM OPERATION

Disconnect all the GEM connectors. Check for: corrosion Yes damaged pins INSTALL a new GEM. REFER to Multifunction Electronic Modules. pushed­out pins TEST the system for normal operation. Connect all the GEM connectors and make sure they seat No correctly. The system is operating correctly at this Operate the system and determine if the concern is still time. The concern may have been caused present. by a loose or corroded connector. Is the concern still present?

Pinpoint Test X: The Key­In­Ignition Chime Is Inoperative Refer to Wiring Diagrams Cell 59 , Multifunction Control Modules for schematic and connector information. Normal Operation The generic electronic module (GEM) receives the key­in­ignition warning status from the key­in­ignition warning switch through circuit 158 (BK/PK). When the key is inserted into the ignition lock cylinder, the key­in­ignition warning switch closes to ground. The GEM monitors the driver door ajar input from the LH front door and the key­in­ignition switch status. When the key is inserted into the ignition lock cylinder and the LH front door is open or ajar, the GEM sounds the key­in­ignition warning chime. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 62/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING DTC B1352 (Ignition Key­In Circuit Failure) — is a continuous and on­demand DTC that sets if the GEM detects an open on the key­in­ ignition switch input, circuit 158 (BK/PK) with the ignition in the RUN/START position and the key not in the ignition.

This pinpoint test is intended to diagnose the following: Wiring, terminals or connectors Key­in­ignition warning switch (part of the ignition switch) GEM

PINPOINT TEST X: THE KEY­IN­IGNITION CHIME IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

X1 RETRIEVE THE RECORDED DTCs FROM THE CONTINUOUS AND ON­DEMAND GEM SELF­TESTS

Yes Use the recorded results from the GEM self­test. GO to X2. Is DTC B1352 recorded? No GO to X5.

X2 CHECK THE GEM IGNITION KEY IN/OUT STATUS

Ignition ON.

Enter the following diagnostic mode on the scan tool: GEM Yes DataLogger . GO to X6. Select and monitor the GEM key­in­ignition PID (IGN KEY). No Does the PID indicate the key is in the ignition lock cylinder? GO to X3.

X3 CHECK THE KEY­IN­IGNITION SWITCH — MONITOR THE GEM PID IGN KEY

Ignition OFF. Disconnect: Clockspring C2274 . Connect a fused (5A) jumper wire between the clockspring C2274­10, circuit 158 (BK/PK), harness side and ground.

Yes REMOVE the jumper wire. INSTALL a http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 63/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING new key­in­ignition warning switch. REFER to Key­In­Ignition Warning Switch in this section. TEST the system for normal operation. No REMOVE the jumper wire. GO to X4.

Ignition ON. Monitor the GEM key­in­ignition PID (IGN KEY). Does the PID indicate the key is in the ignition lock cylinder with the jumper wire connected?

X4 CHECK CIRCUIT 158 (BK/PK) FOR AN OPEN

Ignition OFF. Disconnect: GEM C201a . Measure the resistance between the GEM C201a­15, circuit 158 (BK/PK), harness side and the clockspring C2274­10, circuit 158 (BK/PK), harness side.

Yes GO to X6. No REPAIR the circuit. TEST the system for normal operation.

Is the resistance less than 5 ohms?

X5 CHECK THE INTERIOR LAMPS OPERATION FROM THE LH FRONT DOOR

Monitor the interior lamps while opening the LH front door. Yes Do the interior lamps operate correctly from the LH front GO to X6. door? No REFER to Interior Lighting. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 64/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

X6 CHECK FOR CORRECT GEM OPERATION

Disconnect all the GEM connectors. Check for: Yes corrosion INSTALL a new GEM. REFER to damaged pins Multifunction Electronic Modules. pushed­out pins TEST the system for normal operation. Connect all the GEM connectors and make sure they seat No correctly. The system is operating correctly at this Operate the system and determine if the concern is still time. The concern may have been caused present. by a loose or corroded connector. Is the concern still present?

Pinpoint Test Y: The Door Ajar Chime Does Not Operate Correctly Normal Operation Under normal operation, when the driver door is ajar, the driver door ajar switch provides ground to the generic electronic module (GEM) through circuit 344 (BK/YE). When the key is removed from the ignition, ground is removed from circuit 158 (K/PK) to the GEM.

Possible causes An open in circuit 158 (K/PK) GEM

PINPOINT TEST Y: THE DOOR AJAR CHIME DOES NOT OPERATE CORRECTLY

Test Step Result / Action to Take

Y1 CHECK THE INTERIOR LIGHTS FOR CORRECT OPERATION WITH EACH DOOR

Open and close each door one at a time. Yes Do the interior lights illuminate and turn off with GO to Y2. the opening and closing of each door? No

REFER to Interior Lighting.

Y2 CHECK FOR GEM MODULE RECOGNITION OF IGNITION KEY IN THE RUN POSITION — MONITOR THE GEM PID IGN PID

Ignition OFF. Yes Connect the scan tool. INSTALL a new GEM module. REFER to Multifunction Electronic Modules. TEST the Monitor the GEM PID IGN PID. system for normal operation. Place the key in the START position. No Does the GEM PID IGN PID indicate RUN? REPAIR circuit 158 (BK/PK) for an open. TEST the system for normal operation.

Pinpoint Test Z: The ABS Warning Indicator Is Always On http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 65/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Refer to Wiring Diagrams Cell 42 , Vehicle Dynamic Systems for schematic and connector information. Refer to Wiring Diagrams Cell 60 , Instrument Cluster for schematic and connector information. Normal Operation The instrument cluster (IC) provides voltage internally to the ABS warning indicator and receives the ground from the ABS module through circuit 603 (DG). The ABS module is grounded internally when the ABS system is functioning correctly. If the ABS connector is disconnected, the ABS output circuit opens and the instrument cluster (IC) turns on the ABS warning indicator. If an ABS fault condition exists, the ABS module opens the output control circuit and the instrument cluster (IC) turns on the ABS warning indicator. For the hydraulic ABS brake system, the ABS module uses a warning indicator relay to turn on or off the ABS warning indicator in the instrument cluster (IC). The warning indicator relay receives voltage on the coil side through circuit 640 (RD/YE). The ABS module provides the controlling ground to the coil side of the relay through circuit 28 (LG/RD). The ABS warning indicator control circuit is hardwired from the ABS module through the ABS warning indicator relay to the instrument cluster (IC) through circuit 603 (DG). If an ABS fault condition exists, the ABS module closes the ground on circuit 28 (LG/RD) and the ABS warning relay opens the output circuit 603 (DG) turning on the ABS warning indicator.

This pinpoint test is intended to diagnose the following: Wiring, terminals or connectors ABS warning indicator relay ABS module Instrument cluster (IC)

PINPOINT TEST Z: THE ABS WARNING INDICATOR IS ALWAYS ON NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Test Step Result / Action to Take

Z1 CHECK FOR ABS MODULE DTCs

Yes

Check the ABS module for DTCs. REFER to Vehicle Dynamic Systems — Hydraulic or Vehicle Dynamic Are any DTCs recorded? Systems — Air. No GO to Z2.

Z2 CHECK THE ABS WARNING INDICATOR CONTROL CIRCUIT

Ignition OFF. Disconnect: ABS Module C135a or C155a (Air Brakes). Disconnect: ABS Module C3150a (Hydraulic Brakes). If equipped with hydraulic brakes, connect a fused (5A) jumper wire between the ABS module C3150a­4, circuit 603 (DG), harness side and ground

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Yes REMOVE the jumper wire. GO to Z8. No REMOVE the jumper wire. If equipped with air brakes, GO to Z3. If equipped with hydraulic brakes, GO to Z4. If equipped with air brakes, connect a fused (5A) jumper wire between the ABS module C135a­E3 or C155a­12, circuit 603 (DG), harness side and ground.

Ignition ON. Monitor the ABS warning indicator with the jumper wire connected. Does the ABS warning indicator turn off?

Z3 CHECK CIRCUIT 603 (DG) FOR AN OPEN

Ignition OFF. Disconnect: Instrument Cluster (IC) C220a. Measure the resistance between the instrument cluster (IC) C220a­11, circuit 603 (DG), harness side and the ABS module C135a­E3 or C155a­12, circuit 603 (DG), harness side.

http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 67/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Yes GO to Z9. No REPAIR the circuit. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Z4 CHECK THE ABS WARNING INDICATOR FROM THE ABS WARNING INDICATOR RELAY

Ignition OFF. Disconnect: ABS Warning Indicator Relay C2987. Connect a fused (5A) jumper wire between the ABS warning indicator relay C2987­3, circuit 603 (DG), harness side and ground.

Yes REMOVE the jumper wire. GO to Z6. No REMOVE the jumper wire. GO to Z5.

Ignition ON. Monitor the ABS warning indicator with the jumper wire connected. Does the ABS warning indicator turn off?

Z5 CHECK CIRCUIT 603 (DG) BETWEEN THE INSTRUMENT CLUSTER (IC) AND THE ABS WARNING INDICATOR RELAY FOR AN OPEN http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 68/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING Ignition OFF. Disconnect: Instrument Cluster (IC) C220a . Measure the resistance between the instrument cluster (IC) C220a­11, circuit 603 (DG), harness side and the ABS warning indicator relay C2987­3, circuit 603 (DG), harness side.

Yes GO to Z9. No REPAIR the circuit. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Z6 CHECK THE ABS WARNING INDICATOR RELAY

Ignition OFF. Yes Carry out the warning indicator relay component test. GO to Z7. Refer to Wiring Diagrams Cell 149 for component testing. No Is the warning indicator relay OK? INSTALL a new warning indicator relay. TEST the system for normal operation.

Z7 CHECK CIRCUIT 603 (DG) FOR AN OPEN BETWEEN THE ABS MODULE AND THE ABS WARNING INDICATOR RELAY

Measure the resistance between the ABS module C3150a­4, circuit 603 (DG), harness side and the ABS warning indicator relay C2987­4, circuit 603 (DG), harness side.

Yes REPAIR circuit 2229 (LG/RD) for short to ground. TEST the system for normal operation. http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 69/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING No REPAIR the circuit. TEST the system for normal operation.

Is the resistance less than 5 ohms?

Z8 CHECK FOR CORRECT ABS MODULE OPERATION

Disconnect all the ABS module connectors. Check for: Yes corrosion INSTALL a new ABS module. REFER to damaged pins Vehicle Dynamic Systems — Hydraulic or Vehicle Dynamic pushed­out pins Systems — Air. TEST the system for Connect all the ABS module connectors and make sure they normal operation. seat correctly. No Operate the system and verify that the concern is still The system is operating correctly at this present. time. The concern may have been caused Is the concern still present? by a loose or corroded connector.

Z9 CHECK FOR CORRECT INSTRUMENT CLUSTER (IC) OPERATION

Disconnect all the instrument cluster (IC) connectors. Check for: Yes corrosion INSTALL a new instrument cluster (IC). damaged pins REFER to Instrument Cluster (IC) in pushed­out pins this section. TEST the system for normal operation. Connect all the instrument cluster (IC) connectors and make sure they seat correctly. No Operate the system and determine if the concern is still The system is operating correctly at this present. time. The concern may have been caused by a loose or corroded connector. Is the concern still present?

Component Test

Gauge Test — Fuel Preliminary Setup http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 70/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING

1. Disconnect the fuel level sensor and pump C441. Connect one lead of Instrument Gauge System Tester to fuel level sensor and pump C441, circuit 29 (YE/WH) and the other lead to ground.

Check E (Empty) Indication

2. Set Instrument Gauge System Tester to 22.4 ohms. Key ON. Wait one minute. The fuel gauge should indicate E (empty). Key OFF.

Check F (Full) Indication

3. Set Instrument Gauge System Tester to 145 ohms. Key ON. Wait one minute. The fuel gauge should indicate F (full). Key OFF. Return to http://content.chiltonsonline.com/(S(li3lz1j1iaauis45tacnyk45)F(vBAdo63Q7FYPSQU­eJlLaoWp3F1VWg4YGBw7qpq_Tw0Ku_Vetb1hp4FEvvc8b_NdEvHcrI… 71/72 8/13/2015 2007 Ford F650 ­ Chassis Electrical > Instrumentation & Warning Systems > Instrumentation and Warning Chimes > DIAGNOSIS AND TESTING the pinpoint test.

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