Forward Lighting Systems 54.

27
General Information

See Fig. 1 for the locations of the forward exterior 4

lights on a typical Business Class® M2 vehicle. 1 2 3
H
BHM OFF
2 J1939
1 1 P
HI/LO/PASS

10 J1939 J1708

ON

9 CHM ACC
OFF

5
3 8 6

04/25/2006
7 f040553a
1. Multifunction Turn Signal Switch
2. Instrumentation Control Unit
3. Bulkhead Module
4 4. Headlight Switch
7 6 5 5. Ignition Switch
6. Chassis Module
12/20/2001
7 f543920a
7. Right Headlight, Low Beam
8. Right Headlight, High Beam
1. Clearance Light 9. Left Headlight, High Beam
2. Identification Light 10. Left Headlight, Low Beam
3. Side Marker/Turn Signal Light
4. Park/Turn Signal Light Fig. 2, Headlight System Function
5. Headlight, Low Beam
6. Headlight, High Beam other two are for the headlights. Either of the two
7. Fog Light (optional) headlight circuits running from the switch to the BHM
can activate the headlights. The double circuits act
Fig. 1, Forward Exterior Lights, All Models Except M2 as a fail-safe and allow the headlights to work even if
106V
one of the two wires is damaged or disconnected.
See Fig. 2.
Headlight System
The BHM monitors the headlight switch wiring and is
The Bulkhead Module (BHM) takes inputs from the capable of detecting error conditions in the headlight
multifunction turn signal switch via a J1939 message switch circuits. Faults discovered by the BHM may
from the instrumentation control unit (ICU) as well as be reported on the J1939 and/or J1708 datalinks and
the combination headlight/parking light switch, and may be viewed through ServiceLink®.
uses the information to control the headlights. See
Fig. 2. Headlight Assemblies
There are two headlight assemblies available for a
Headlight Switch Function Business Class M2 vehicle:
The headlight switch on the dash panel has three • composite headlights
positions: off, park (parking lights), and on (head-
lights). The Bulkhead Module (BHM) continuously • sealed-beam headlights
monitors the position of the headlight switch and Composite headlights are installed on all models ex-
broadcasts this information on the J1939 datalink. cept M2 106V. Sealed-beam headlights are only in-
There are three circuits that run from the headlight stalled on the M2 106V.
switch to the BHM. One is for the parking lights, the

Business Class M2 Workshop Manual, Supplement 10, September 2006 050/1

54.27 Forward Lighting Systems
General Information

See Fig. 1 for the locations of the forward exterior

lights on a vehicle with composite headlights.
High Beams Function
The Bulkhead Module (BHM) continually monitors the
See Fig. 3 for the locations of the forward exterior
position of the headlight switch and the position of
lights on a vehicle with sealed-beam headlights.
the multifunction turn signal switch to determine if the
headlights should be on low beams or high beams.
1 2 1 The instrumentation control unit (ICU) transmits the
multifunction turn signal switch position information to
the BHM via a J1939 message. When the headlight
switch is on and high beam or PASS is selected at
the multifunction turn signal switch, the BHM acti-
vates the left high beam and sends a J1939 mes-
sage to the Chassis Module (CHM) instructing it to
3 activate the right high beam. High beams operate
only with the ignition on.
The BHM is capable of detecting shorted circuits in
the left high beam wiring and the right high beam
wiring on the CHM. Faults discovered by the BHM
may be reported on the J1939 and/or J1708
datalinks and may be viewed through ServiceLink.
4 See Fig. 2.

5 Low Beams Function

The Bulkhead Module (BHM) continually monitors the
04/17/2006 f544776 position of the headlight switch and the position of
1. Clearance Light the multifunction turn signal switch to determine if the
2. Identification Light headlights should be on low beams or high beams.
3. Side Marker/Turn Signal Light The instrumentation control unit (ICU) transmits the
4. Headlight multifunction turn signal switch position information to
5. Park/Turn Signal Light the BHM via a J1939 message. When the headlight
switch is on and low beam is selected at the multi-
Fig. 3, Forward Exterior Lights, M2 106V Only function turn signal switch, the BHM activates the left
A composite headlight assembly provides separate low beam and sends a J1939 message to the Chas-
access to the low-beam bulb and high-beam bulb. sis Module (CHM) instructing it to activate the right
The separate bulb connections of a composite head- low beam.
light permit individual bulb replacement. NOTE: If the CHM does not see J1939 mes-
A sealed-beam headlight is an enclosed light assem- sages from the BHM, the right low beam is acti-
bly that is replaced as a single unit. The individual vated. If the BHM fails, the left low beam is
bulbs within the sealed-beam headlight are not activated.
replaceable. The BHM is capable of detecting shorted circuits in
The forward chassis harness supplies the headlights the left low beam wiring and the right low beam wir-
via an 8-pin connector. Depending on the type of ing on the CHM. Faults discovered by the BHM may
headlight assembly, short wiring connections are be reported on the J1939 and/or J1708 datalinks and
made from the 8-pin connector to the headlight. A may be viewed through ServiceLink. See Fig. 2.
composite headlight has two separate electrical con-
nections, one at each bulb of the headlight. A sealed-
beam headlight has a single electrical connection at
Daytime Running Lights
the rear of the headlight unit. All Business Class M2 vehicles can be equipped with
daytime running lights (DRL). Daytime running lights

050/2 Business Class M2 Workshop Manual, Supplement 10, September 2006

Forward Lighting Systems 54.27
General Information

are required on vehicles domiciled in Canada. The Low-beam DRL is activated with the headlight switch
customer can also request DRL. off, the ignition on, and the park brake released.
When these conditions are met, the BHM activates
IMPORTANT: When adding daytime running the left low beam and sends a J1939 message to the
lights to a vehicle that was built without DRL, CHM instructing it to activate the right low beam.
you must follow the "Adding a Feature" proce-
dure in Section 54.00, Subject 110. Adding or When operating as daytime running lights, the low-
beam headlights are pulse-width modulated at ap-
changing a reference parameter without follow-
proximately 85 percent. This is recognized as a volt-
ing this procedure may have legal conse- age supply to the low beams at a reading lower than
quences for the vehicle owner, which may in- battery voltage. If the headlight switch is turned on,
clude fines and having vehicles placed out of full battery voltage is supplied to the low beams.
service. The regulations in the Federal Motor
Vehicle Safety Standards (FMVSS) and Cana- DRL Using Turn Signal Lights
dian Motor Vehicle Safety Standards (CMVSS)
control the illumination intensity of daytime run- On a Business Class M2 vehicle with daytime run-
ning lights and the required marking of lights ning lights using turn signal lights, the front turn sig-
nals are powered by separate output pins on the
used as DRL. Some jurisdictions enforce these
CHM. A jumper harness must be installed to connect
regulations during vehicle inspections. the DRL outputs directly to the front turn signal cir-
The daytime running lights use either the low-beam cuits. The DRL outputs of the CHM continuously illu-
headlights or the front turn signal lights, depending minate the front turn signals when the ignition is on,
on the type of vehicle. On an M2 106V vehicle, the the headlight switch is off, and the turn signals are
low-beam headlights are used as the daytime run- not active. If the turn signal switch is activated when
ning lights. On all other M2 vehicles, the front turn the DRL is on, the CHM turns on and off the DRL
signal lights are used as the daytime running lights. output to the appropriate turn signal.
DRL functionality is programmed to the BHM whether
the low-beam headlights or the front turn signal lights Turn Signal Lights Function
are used.
See Subject 500 for DRL reference parameters and The Bulkhead Module (BHM) uses J1939 message
descriptions. inputs from the instrumentation control unit (ICU) to
instruct the Chassis Module (CHM) to activate the
NOTE: A vehicle that uses the low-beam head- turn signals. The ICU monitors the position of the
lights as the DRL cannot be converted to the multifunction turn signal switch. When the ICU sees
front turn signal lights as the DRL. The front turn that the driver has activated this switch, it sends a
signal lights do not meet the legal requirements J1939 message to the BHM. The BHM then checks
for lamp identification for use as DRL. whether the hazard switch has been activated. If the
hazard switch has not been activated, the BHM
A vehicle that uses the front turn signal lights as sends a J1939 message to the CHM instructing it to
the DRL cannot be converted to the low-beam illuminate the turn signal lights. See Fig. 4.
headlights as the DRL. The headlights will not
provide the legally-required illumination intensity. Exterior bulbs that provide turn signal identification
often contain dual filaments in order to provide other
vehicle lighting such as park lights or marker lights.
DRL Using Low-beam Headlights Exterior turn signals on a typical M2 are:
On an M2 106V vehicle with daytime running lights, • park/turn signal lights at the front of the vehicle
the pulse-width-modulated (PWM) DRL is only sup-
ported by BHM part number 06-49824-002 (software • side marker/turn signal lights on the front fend-
version 6.40 or higher). Since the CHM controls the ers
right low beam, the CHM must be part number 06- • taillights at the rear of the vehicle
34530-004 to possess PWM capabilities. PMW low-
beam DRL is used on an M2 106V vehicle. • raised fender lights (optional) viewable from
the front and side of the vehicle

Business Class M2 Workshop Manual, Supplement 10, September 2006 050/3

54.27 Forward Lighting Systems
General Information

2 3 4
NOTE: The CHM will activate the hazard lights
1 J1939 in the event the BHM loses communication with
BHM the CHM on the J1939 datalink.
LEFT/OFF/RIGHT J1708 The BHM is capable of detecting short circuits in the
J1939 right-turn and left-turn signal light wiring. Faults dis-
covered by the BHM may be reported on the J1939
and/or J1708 datalinks and may be viewed through
ServiceLink. See Fig. 4.
8 7 CHM 5

Marker Lights Function

6
01/15/2002 f040552 A marker light is any light that indicates the presence
of the vehicle to other drivers. This includes parking
1. Multifunction Turn Signal Switch
2. Instrumentation Control Unit lights, taillights, marker lights, identification lights,
3. Bulkhead Module and clearance lights. See Fig. 1 for forward maker
4. Hazard Switch light locations.
5. Rear Turn Signal Lights The Bulkhead Module (BHM) continually monitors the
6. Chassis Module
position of the headlight switch. When it sees that
7. Side Turn Signal Lights
8. Front Turn Signal Lights the operator has selected either headlights or parking
lights, the BHM does several things. It sends power
Fig. 4, Turn Signal Lights Function directly to the identification lights and clearance lights
that are mounted on the cab roof. It also sends
The CHM switches power on and off to all forward power through the Chassis Module (CHM) to the tail-
turn signals. The BHM operates the rear turn signals lights. Finally, the BHM sends a J1939 message to
by sending pulsed power through the CHM to the the CHM instructing it to turn on the side marker
taillights. The BHM is capable of detecting short cir- lights and park lights.
cuits in the turn signal wiring. Faults discovered by The BHM is capable of detecting shorted wires in the
the BHM may be reported on the J1939 and/or marker light circuits. Faults discovered by the BHM
J1708 datalinks and may be viewed through Service- may be reported on the J1939 and/or J1708
Link. datalinks and may be viewed through ServiceLink.
See Fig. 5.
Hazard Lights Function
Variations on Marker Light
Hazard lights are used to warn other drivers of emer-
gency situations. The same bulbs that are used for
Function
the turn signals are also used for the hazard lights. Marker lights may be programmed or adapted for
The BHM activates these lights based on the position functionality that differs from the headlight switch.
of the hazard and multifunction turn signal switches. Some common variations of marker light functionality
The BHM monitors the hazard switch directly. The are:
instrumentation control unit (ICU) transmits the multi-
function turn signal switch position information to the • battery-operated clearance lights
BHM via a J1939 message. When the hazard switch • clearance lights, identification lights, and tail-
is on and neither the right-turn nor the left-turn signal lights that are on at all times
is selected at the multifunction turn signal switch, the
• clearance lights and identification lights con-
BHM sends a J1939 message to the CHM instructing
trolled by a marker interrupt switch
it to activate all the forward lighting turn signals. The
BHM activates the right-turn and left-turn signal lights • marker lights turn off when the ignition is
at the rear of the vehicle by sending power through turned off
the CHM and to the lights.

050/4 Business Class M2 Workshop Manual, Supplement 10, September 2006

Forward Lighting Systems 54.27
General Information

3 3 turned off by placing the battery disconnect switch to

the off position.
2
2 The marker interrupt switch turns on the identification
1 lights, front park lights, side marker lights, and tail-
lights when the headlight switch is in the off position.
5 This switch turns off these lights when the headlight
J1939 4
H
switch is in either the park or on positions. The inter-
BHM OFF
rupt switch can also be programmed for use with
P marker lights that are on with the ignition off.
J1708

9
8
J1939 6 Fog Lights Function
Fog lights are available as an optional feature on a
Business Class M2 vehicle. Fog lights may only be
CHM activated if the ignition switch is on and the headlight
high beams are off.
The BHM continually monitors the position of the ig-
9 nition switch, multifunction turn signal switch, and the
8 7 6
04/05/2006 f040557a dash-mounted fog light switch. The fog light switch is
1. Instrumentation Control Unit a two-position latching smart switch that delivers sig-
2. Clearance Light (top of cab) nals directly to the BHM. If the fog light switch is on
3. Identification Lights (top of cab) and the BHM has determined that the other require-
4. Headlight Switch ments are met, the BHM sends a J1939 message to
5. Bulkhead Module the CHM instructing it to turn on the fog lights. The
6. Taillights CHM fog light outputs are at pins C and D of CHM
7. Chassis Module connector C3.
8. Side Marker Lights (side of hood)
9. Park Lights (front of hood) The BHM is capable of detecting shorted wires in the
fog lights circuits. Faults discovered by the BHM may
Fig. 5, Marker Lights Function be reported on the J1939 and/or J1708 datalinks and
may be viewed through ServiceLink. See Fig. 6.
See Subject 500 for the reference parameters re-
quired to program alternate marker light functionality.
Some parameter programming requires no installa- Snowplow Lights Provision
tion of additional features, while other parameters
may require additional wiring. A provision for installation of snowplow lights is an
optional feature on a Business Class M2 vehicle.
When a customer requests battery-operated clear- Freightliner does not install snowplow lights or
ance lights, a different harness is used for the clear- mounting hardware for the lights, only the provision
ance and identification lights. The clearance lights for customer-installed snowplow lights.
are connected directly to the battery splice pack in
the vehicle dash, while the identification lights are A snowplow installed on a vehicle may block the
connected to the BHM. standard vehicle headlights. When this situation oc-
curs, the snowplow light provision allows the cus-
Vehicles equipped with battery-operated clearance tomer to install an auxiliary set of headlights and ad-
lights are equipped with a battery disconnect switch. ditional park/turn signal lights above the snowplow.
The disconnect switch must be turned to the off posi-
tion to turn off the clearance lights. IMPORTANT: The customer installing the snow-
plow lights is responsible for complying with the
Vehicles equipped with marker lights that are pro- regulations regarding snowplow lights and day-
grammed to be on at all times are equipped with a
time running lights (DRL) functionality in the
battery disconnect switch. These marker lights are
Federal Motor Vehicle Safety Standards

Business Class M2 Workshop Manual, Supplement 10, September 2006 050/5

54.27 Forward Lighting Systems
General Information

2 Snowplow Lights Function

1 The Bulkhead Module (BHM) monitors the position of
the snowplow light switch. The snowplow light switch
3 is a two-position, latching smart switch that delivers
ON BHM signals directly to the BHM.
ACC FOG
LAMP
OFF
When the snowplow light switch is on and the BHM
has determined that the other requirements are met,
J1939 4 the BHM sends a message on the J1939 datalink to
the Chassis Module (CHM) instructing it to signal the
upper and lower control modules to switch the head-
light output from the standard headlights to the auxil-
CHM iary headlight connector. The CHM snowplow lights
5 control output is at pin C of the CHM C3 connector.
See Fig. 7.
04/05/2006 4 f544772 The low beams and high beams work with both the
1. Ignition Switch 4. Fog Lights standard and auxiliary headlights. The same system
2. Bulkhead Module 5. Chassis Module of daytime running lights that is used on the standard
3. Fog Light Switch headlights, whether using the turn signals or the low-
beam headlights (M2 106V), is used on the snow-
Fig. 6, Fog Lights Function plow lights. The DRL system used on the M2 106V
vehicle is also known as pulse-width-modulated DRL.
(FMVSS) and the Canadian Motor Vehicle
Safety Standards (CMVSS). The snowplow light harness overlays the main chas-
sis harness between the headlights and the CHM.
When an M2 vehicle is equipped with the snowplow The standard lighting circuits are intercepted at the
lights provision, the following electrical components connectors behind the headlights and rerouted
are already installed on the vehicle: through the upper and lower control modules, then
• dash-mounted PLOW LAMP switch (snowplow back to the headlights.
light switch) A vehicle with a composite, standard headlight
• snowplow light harness uses a different version of the snowplow light
harness than a vehicle model M2 106V with a
• upper control module and lower control module
mounted in the left, front wheel well sealed-beam, standard headlight.
The snowplow lights can only be turned on when the The two snowplow light connectors are located be-
ignition switch is on and the standard headlights are hind the headlights, one on each side. In addition to
on. the switch headlight output, the snowplow light con-
nectors provide the appropriate turn signal and
marker lights, which are always active.
WARNING
NOTE: The upper control module, which con-
When a vehicle is equipped with snowplow light trols the right snowplow lights, and the lower
provision but snowplow lights are not installed, control module, which controls the left snowplow
turning the PLOW LAMP switch on turns off both lights, are identical. Both control modules have
the standard headlights and the daytime running two 6-pin connectors—one black and one yel-
lights using low-beam headlights (M2 106V). Do
low. Make sure that the connectors are paired
not turn the PLOW LAMP switch on when snow-
plow lights are not installed. Doing so could correctly since the snowplow light harness is not
cause an accident resulting in serious personal color coded. The snowplow light harness has
injury or property damage. labels that indicate which connector each
branch is intended to connect to. One branch is

050/6 Business Class M2 Workshop Manual, Supplement 10, September 2006

Forward Lighting Systems 54.27
General Information

2 3

4
BHM 5
Left Headlight/DRL

Snowplow Lights
Upper Control
Module 6
Right Turn Signal/DRL
Marker
Control
CHM Right Headlight/DRL
Right Turn Signal/DRL 7
Marker
Snowplow Lights
Lower Control
Module
8
1

05/04/2006 9 f544838
1. Chassis Module 6. Right Snowplow Light Connector
2. Bulkhead Module 7. Left Snowplow Light Connector
3. Snowplow Lights Switch 8. Left Low- and High-beam Headlights
4. Upper Control Module for Right Snowplow Lights 9. Lower Control Module for Left Snowplow Lights
5. Right Low- and High-beam Headlights

Fig. 7, Snowplow Lights Function

longer that the other branch. The longer branch Control, All Models
is connected to the upper control module.
The control signal for the snowplow lights comes
Headlights, All Models from the Chassis Module, normally from pin C of the
C3 connector. This output is usually associated with
The headlight connectors on the main chassis har- fog lights; therefore, a vehicle cannot be equipped
ness are connected to the snowplow lights harness with both fog lights and a snowplow lights provision.
instead of the headlights. The low beam, high beam, The return for the upper and lower control module
and headlights common circuits are rerouted through relays is spliced from the headlight common form the
the snowplow light harness to the upper and lower associated module.
control modules. The control modules switch the sig-
nal between the standard headlights and the snow- Turn Signal Lights, All Models
plow light connector, and all of these circuits route Except M2 106V
back to the appropriate connectors behind the head-
lights. When the vehicle is equipped with daytime running
lights, the DRL overlay connector connects to the
The headlight connectors on the snowplow light har-
turn signal connector on the snowplow light harness.
ness connect to the headlights while the snowplow
When the vehicle is not equipped with DRL, the turn
lights circuits terminate at the snowplow light connec-
signal connector of the main harness connects to the
tor. Note that the snowplow headlight common cir-
turn signal connector on the snowplow light harness.
cuits are switched by the upper and lower control
The turn signal circuits are spliced to return to the
modules, while the ground circuits at the snowplow
DRL connectors on the main chassis harness and to
connector are not.

Business Class M2 Workshop Manual, Supplement 10, September 2006 050/7

54.27 Forward Lighting Systems
General Information

the upper and lower control modules for rerouting to

the snowplow light connectors.

Park Lights, All Models Except M2

106V
The park lights circuit is picked up from the trailer
output connection (C2) of the Chassis Module. Since
this circuit is also required for trailer wiring when the
vehicle has a towing provision, the circuit is spliced
from a short jumper section in to which the trailer
wiring can be connected. This circuit is provided to
both the upper and lower control modules and from
there to the snowplow light connectors.

Turn Signal and Park Lights, M2

106V Only
The turn signal/park light connectors on the main
chassis harness are connected to the snowplow light
harness instead of the turn signal/park lights. These
circuits are spliced with one path continuing to the
normal turn signal/park light connections, and the
other path routed through the upper and lower con-
trol modules to the snowplow light connectors.

050/8 Business Class M2 Workshop Manual, Supplement 10, September 2006

Forward Lighting Systems 54.27
Headlight Aim Checking and Adjusting

Before checking or adjusting the headlight aim, do

the following:
Adjusting Composite
• Remove any large amounts of mud or ice from
Headlights
the underside of the fenders.
1. Lift the flap over the rear end of the headlight
• Check the springs for sagging or broken bucket to expose the two plastic adjusting knobs
leaves. on each headlight. See Fig. 4.
• Check the suspension for proper function of NOTE: Horizontal aim should not be adjusted in
the leveling mechanism. On cabs with air sus- the field.
pensions, make sure that the height is properly
adjusted. 2. With the vehicle parked 25 ft (7.6 m) from the
screen or wall, put the headlights on low beams
• Check for damage to the hood and hinge as- and turn both adjusting knobs the same amount
sembly. Repair as necessary. as needed to adjust the lights until the beam pat-
• Clean the headlight lenses. tern meets the acceptable standard in Fig. 3.
• With the vehicle unloaded, check that the tires NOTE: Blocking off each light is not necessary,
are inflated to the recommended air pressure. but it can help to present a clearer beam pat-
tern.
Headlight Aim Checking 3. Remove the chocks from the front tires.

1. Park the vehicle on a level surface 25 ft (7.6 m)

from a screen or wall that can be used for aiming
Adjusting Sealed-beam
the headlights. Shut down the engine, apply the Headlights
parking brakes, and chock the front tires. See
Fig. 1. 1. Park the vehicle on a level surface 25 ft (7.6 m)
NOTE: The low-beam headlight is the top bulb from a screen or wall that can be used for aiming
the headlights. Shut down the engine, apply the
in the dual-beam assembly. parking brakes, turn on the headlight low beams,
2. On each headlight, find the bulb center. See and chock the front tires
Fig. 2.
2. Locate the headlight adjusting screws that are
3. Measure the distance from the ground to the accessible through the front of the headlight
center of each low-beam bulb and note those bezel. See Fig. 5.
distances.
3. Use a screwdriver to adjust the headlight beam
4. On the screen or wall 25 ft (7.6 m) away, make position as necessary to achieve the acceptable
the appropriate markings directly across from standard shown in Fig. 3.
each headlight and at the same height as mea-
4. Remove the chocks from the front tires.
sured for the headlight.
5. Turn on the headlights to the low-beam setting.
See Fig. 3 for the ideal and acceptable patterns
for both headlights.
• If either or both headlights do not aim into
the inner edges of the centerline, follow the
adjusting procedure below.
• If both headlights come close to the inside
of each headlight centerline as shown, no
further work is needed. Turn off the head-
lights and remove the chocks from the
front tires.

Business Class M2 Workshop Manual, Supplement 10, September 2006 100/1

54.27 Forward Lighting Systems
Headlight Aim Checking and Adjusting

1 2
6 ft (1.8 m)
3

6
)
t (7.6 m
5 25 f

01/20/2003 f544233
1. Vertical Centerline of Right Headlight 4. Projected Vehicle Centerline
2. Distance Between Headlights 5. Screen or Wall
3. Vertical Centerline of Left Headlight 6. Height of Lamp Centers

Fig. 1, Headlight Aiming Screen or Wall

11/06/2002 f544236

NOTE: Measure beam height from the ground to the

small dot roughly in the center of the headlight lens.
Fig. 2, Headlight Beam Height Adjusting Dot

100/2 Business Class M2 Workshop Manual, Supplement 10, September 2006

Forward Lighting Systems 54.27
Headlight Aim Checking and Adjusting

A 2 3
1
4

04/12/2006 f544778
1. Headlight Bezel
1 2. Horizontal Adjusting Screw
11/11/2002 f544153 3. Vertical Adjusting Screw
NOTE: The top view shows the ideal beam pattern; the 4. Headlight
bottom view shows an acceptable standard.
A. Vertical Centerline B. Horizontal Centerline Fig. 5, Sealed-beam Headlight Adjusting
1. Bright Area

Fig. 3, Headlight Beam Pattern

1
2

11/05/2002 f544235

NOTE: The right side headlight bucket is shown. The

left side is opposite.
1. Inboard Adjusting Knob
2. Outboard Adjusting Knob

Fig. 4, Headlight Adjusting Knobs

Business Class M2 Workshop Manual, Supplement 10, September 2006 100/3

Forward Lighting Systems 54.27
Exterior Lights Replacement

Before working on the vehicle, park it on a level sur-

face and shut down the engine. Set the parking
brake and chock the front and rear tires. 4

NOTE: Use gloves or a clean cloth or paper 3

towel when handling halogen bulbs; do not
handle them with bare hands. Oil from the skin
5
causes overheating and rapid blowout. If bulbs
are handled accidentally, use a cotton swab 2
dipped in rubbing alcohol to remove oil.
NOTE: There are two types of headlights used
on Business Class® M2 vehicles. Most M2 ve- 1
1
hicles have composite headlights. The M2 106V 04/03/2006 f544336a
vocational chassis has sealed-beam headlights. 1. Lower Mounting Adjustment Nut
When replacing headlights and bulbs, use the 2. High Beam Socket
correct replacement procedure for the type of 3. Low Beam Socket
headlight on the vehicle. 4. Park/Turn Socket and Connector Assembly
5. Headlight Connector

Composite Headlights Fig. 1, Headlight Bucket (rear view)

11. Return the headlight splash guard to its original

Headlight and Park/Turn Signal operating position.
Light Assembly Replacement
1. Open the hood. Headlight Bulb Replacement
2. Secure the headlight splash guard out of the 1. Open the hood.
way. 2. Remove the inner headlight cover by pressing
3. Disconnect the headlight and park/turn signal the tab at the top and pulling out.
light electrical connectors and cut any tie-straps 3. Disconnect the headlight connector. See Fig. 1.
that may be holding them to the headlight bucket
assembly. 4. Twist the high beam or low beam socket assem-
bly 1/8 of a turn counterclockwise to remove it
4. Remove the nuts from the two lower mounting from the headlight bucket assembly and access
adjustment studs. See Fig. 1. the bulb.
5. Remove the Torx® capscrew from the upper 5. Protecting the bulb with gloves or a cloth, unplug
mounting bracket. it from the socket. The bottom bulb in the assem-
6. Remove the headlight assembly. bly is the high beam lamp; the top bulb in the
assembly is the low beam lamp.
7. Place a new assembly on the mounting studs
and install the two nuts and washers. 6. Line up the bulb tabs and insert a new bulb into
the socket then twist it 1/8 of a turn clockwise to
NOTE: Before installing the new assembly, secure it.
verify that the lower mounting adjustments on
7. Connect the headlight connector.
the new assembly are set the same as the old
assembly. 8. Replace the inner headlight cover and snap it
into place.
8. Install the upper mounting capscrew.
9. Close the hood.
9. Connect the two electrical connectors.
10. Verify proper operation of the lights.
10. Verify the proper operation of the lights.

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54.27 Forward Lighting Systems
Exterior Lights Replacement

11. Check and adjust the headlight aim as described 2. Remove the headlight bezel and disconnect the
in Subject 100. park/turn signal light electrical connector at the
rear of the bezel.
Front Park/Turn Bulb NOTE: Do not turn the headlight adjustment
Replacement screws. These screws are used for beam ad-
justment only; they do not secure the headlight
1. Open the hood. retaining ring.
2. Twist the park/turn connector and socket assem-
3. Remove the screws that secure the headlight
bly 1/8 turn counterclockwise and remove it from
retaining ring, then remove the retaining ring.
the headlight bucket. See Fig. 1.
4. Ease the headlight from the housing to expose
3. Protecting the bulb with gloves or a cloth, pull
the electrical connector at the back of the light.
the bulb straight out from the socket.
5. Disconnect the wiring connector from the head-
4. To provide corrosion protection, coat the base of
light.
the new bulb with dielectric grease. For approved
lubricants, see Specifications 400. 6. Check the wiring connector for corrosion and in-
tegrity. Clean and/or repair as needed.
5. Push the new bulb straight into the socket.
7. Coat the prongs (connector terminals) of the new
6. Place the connector and socket assembly in the
headlight with dielectric grease to help prevent
headlight bucket and twist it 1/8 turn clockwise to
corrosion. For approved lubricants, see Specifi-
lock it in place.
cations 400.
7. Verify proper operation of the lights.
8. Firmly seat the wiring connector onto the prongs
of the new headlight.
Sealed-Beam Headlights 9. Place the headlight in the headlight housing and
position the light properly.
Headlight Replacement 10. Place the retaining ring over the headlight and
1. Remove the four screws that attach the headlight install the screws that secure the headlight.
bezel to the fender. See Fig. 2. 11. Verify proper operation of the headlights.
2 3 4 12. Connect the park/turn signal light electrical con-
1 1 nector.
13. Place the headlight bezel in the proper position
and install the four screws.
14. Check and adjust the headlight aim as described
in Subject 100.

Front Park/Turn Signal Light

Replacement
1. Remove the four screws that attach the headlight
bezel to the fender. See Fig. 2.
04/12/2006 f544777 2. Disconnect the park/turn signal light electrical
connector at the rear of the bezel.
1. Bezel Retaining Screw
2. Park/Turn Signal Light 3. Remove the four screws that attach the park/turn
3. Headlight Bezel signal light retainer to the back of the headlight
4. Headlight bezel. See Fig. 3.
Fig. 2, Sealed-Beam Headlight Assembly 4. Remove the park/turn signal light.

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Forward Lighting Systems 54.27
Exterior Lights Replacement

1.2 Remove the center console/dome light

3 4 assembly or headliner to access the cen-
ter three lights.
2
2. Disconnect the connector.
1
3. Remove the two mounting nuts and remove the
light assembly.
4. Install a new clearance light. Tighten the two
nuts to 60 lbf·in (677 N·cm).
5. Seal the hole with silicon sealant.
6. Connect the connector.
7. Replace the headliner or center console/dome
lamp and/or map pockets.
04/12/2006 f544779
1. Headlight Bezel Cab Clearance and
2. Park/Turn Signal Light
3. Park/Turn Signal Light Retainer Identification Light Bulb
4. Retainer Screw Replacement
Fig. 3, Sealed-Beam Park/Turn Signal Light 1. From outside the cab, remove the capscrew that
5. To provide corrosion protection, coat the electri- attaches the clearance light lens to the base.
cal connection of the new light with dielectric 2. Lift the lens cover at the rear with a screwdriver,
grease. For approved lubricants, see Specifica- and slide the cover forward off the locking tab.
tions 400.
3. Pull the bulb straight out to remove it.
6. Position the new park/turn signal light in the
headlight bezel. 4. To provide corrosion protection, coat the base of
the new bulb with dielectric grease.
7. Place the retainer over the park/turn signal light
and install the screws that secure the light to the For approved electrical terminal lubricants, see
bezel. Specifications 400.
8. Connect the park/turn signal light electrical con- 5. Plug in the new bulb and test for proper opera-
nector. tion.
9. Verify proper operation of the lights. 6. Install the lens on the base, making sure that it is
fully seated.
10. Place the headlight bezel in the proper position
and install the four screws. 7. Secure the clearance light in place with the cap-
screw.
Cab Clearance and IMPORTANT: Do not overtighten the capscrew
or damage to the lens may occur.
Identification Light Assembly
Replacement Front Side Marker/Turn Signal
1. Access the mounting nuts and electrical connec- Light Assembly Replacement
tions from inside the cab.
1. Open the hood.
1.1 Remove the left and right overhead map
pockets to access the outer two lights. 2. If the harness is being replaced, cut the two tie-
straps securing it at the molded splash guard.

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54.27 Forward Lighting Systems
Exterior Lights Replacement

3. Twist the marker/turn signal light connector 1/8

turn counterclockwise to disconnect the connec-
tor and harness.
4. Remove the two capscrews that attach the lens
to the fender.
5. Remove the marker/turn signal light lens.
6. Using two capscrews, install a new marker/turn
signal light lens on the fender.
IMPORTANT: Do not overtighten the capscrews
or damage to the lens may occur.
7. Install a new harness, if required, and connect
the electrical connector and bulb socket. Twist it
clockwise 1/8 turn to secure.
8. If a new harness was installed, secure it to the
molded plastic inner wheel well shroud using two
tie-straps at the openings. Secure the tie-straps
to the connector.

Front Side Marker/Turn Signal

Light Bulb Replacement
1. Open the hood.
2. Twist the connector 1/8 turn counterclockwise to
unplug the connector and bulb socket.
3. Pull the bulb straight out of the socket to remove
it. Push a new bulb straight into the socket to
replace it.
4. Insert the connector and bulbs into the lens as-
sembly and turn 1/8 turn clockwise to secure.

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Forward Lighting Systems 54.27
Programming and Messaging

Parameter Programming turn light functionality. The only DRL available for
version 6.10 is turn signal DRL. Turn-signal DRL is
available on all M2 chassis except the M2 106V vo-
When adding or changing a feature on a Business
cational chassis.
Class® M2 vehicle, you must use ServiceLink® to up-
date the programming on the vehicle.
Version 6.40 Daytime Running
IMPORTANT: When adding daytime running
lights (DRL) to an M2 vehicle that was built Lights
without DRL, you must follow the "Adding a DRL for software versions 6.40 or higher may be
Feature" procedure in Section 54.00. Adding or turn-signal DRL or headlight low-beam DRL. Low-
changing reference parameters without following beam DRL is a pulse-width modulated (PWM) signal
this procedure may result in serious legal con- at 85 percent duty cycle. Low-beam DRL is used on
sequences for the vehicle owner, which may the M2 106V vocational chassis. The reference pa-
include fines and having the vehicle placed out rameters program only the DRL functionality.
of service. The regulations in the Federal Motor
Vehicle Safety Standards (FMVSS) and Cana- Reference Parameters for
dian Motor Vehicle Safety Standards (CMVSS) Marker Lights
control the intensity of illumination of DRL lamps
and the required marking of lamps used as A marker light is any light that indicates the presence
of the vehicle to other drivers. This includes parking
DRL. Some jurisdictions enforce these regula- lights, taillights, marker lights, identification lights,
tions during vehicle inspections. and clearance lights.
Version 6.10 Daytime Running See Table 1 for the reference parameters for marker
light functionality.
Lights
For M2 vehicles with software version 6.10, the refer-
ence parameter programs both DRL and the stop/

Reference Parameters for Marker Lights

Parameter Description Functionality
No marker interrupt switch, the marker lights turn on with the
26-01019-000 Without marker interrupt switch
headlight switch.
The marker lights turn on with the headlight switch, a momentary
26-01019-001 With marker interrupt switch interrupt switch turns the marker lights off as long as the switch is
held.
Without marker interrupt switch, with No marker interrupt switch, the marker lights are on at all times.
26-01019-003
constant on marker lights The battery disconnect switch is used to turn off the lights.
The marker lights are on when the ignition is off or when the
With marker interrupt switch, marker
26-01019-004 headlight switch is turned on. A momentary interrupt switch turns off
lights on with ignition off
the marker lights when headlight switch is on.
Without marker interrupt switch, with No marker interrupt switch, the marker lights are on at all times.
26-01019-005
constant on marker lights The battery disconnect switch is used to turn off the lights.
No marker interrupt switch, the marker lights are turned off when
Without marker interrupt switch,
26-01019-006 the ignition is turned off. The headlight switch controls the marker
marker lights off with ignition off
lights for all other conditions.
Table 1, Reference Parameters for Marker Lights

Business Class M2 Workshop Manual, Supplement 10, September 2006 120/1

Forward Lighting Systems 54.27
Troubleshooting

IMPORTANT: Use ServiceLink® to troubleshoot Fault Conditions

the M2 electrical system. For specific circuit and
pin information for how the vehicle is wired, go See Table 2 for the headlight switch circuit condi-
to the Configuration screen in ServiceLink and tions that will create a fault. In these conditions, the
select the specific function in which you are in- BHM assumes the headlight switch status is on. The
reference parameters that program the BHM deter-
terested. mine whether or not a fault code is broadcast. There-
To troubleshoot specific inputs and outputs of fore, even if the BHM detects a fault, a fault code
this system, go to the Templates screen in Ser- may not be transmitted.
viceLink and select the template for the function If the BHM is programmed to transmit fault codes,
in which you are interested. they can be viewed through ServiceLink. Fault mes-
sages may be transmitted on the J1939 and/or the
J1708 data links until the ignition switch is turned off.
Headlight Switch Function
Input and Output Conditions
See Table 1 for the Bulkhead Module (BHM) re-
sponses to the headlight switch input/output condi-
tions.

Headlight Switch Input/Output Conditions

Headlight Switch Inputs to BHM Outputs from BHM
Park Lights Headlight On 1 Headlight On 2 Headlight Switch J1939 Headlight J1939 Headlight
Signal Signal Signal Status On/Off Message Park Message
Open Open Open Off Off Off
Closed Open Open Park Off On
Open Closed Open On On On
Open Open Closed On On On
Open Closed Closed On On On
Closed Open Closed On* On On
Closed Closed Open On* On On
Closed Closed Closed On* On On
* These are error conditions. For more information see "Fault Conditions."

Table 1, Headlight Switch Input/Output Conditions

Headlight Switch Fault Conditions

Description of Fault
Park Lights Headlight On 1 Headlight On 2 Action Taken by BHM
Signal Signal Signal
Closed Closed Open BHM may transmit a J1939 and/or a J1708 fault message.
Closed Open Closed BHM may transmit a J1939 and/or a J1708 fault message.
Closed Closed Closed BHM may transmit a J1939 and/or a J1708 fault message.
Table 2, Headlight Switch Fault Conditions

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54.27 Forward Lighting Systems
Troubleshooting

Headlight High Beams ence parameters that program the BHM determine
whether or not a fault code is broadcast. Therefore,
Function even if the BHM detects a fault, a fault code may not
be transmitted.
Input and Output Conditions If the BHM is programmed to transmit fault codes,
See Table 3 for the Bulkhead Module (BHM) re- they can be viewed through ServiceLink. Fault mes-
sponses to the headlight high beams input/output sages may be transmitted on the J1939 and/or the
conditions. J1708 data links until the ignition switch is turned off.
NOTE: The Flash-To-Pass function of the high
Fault Conditions beams only operates when the ignition is on
and the high beam switch is in the low beam
See Table 4 for the headlight high beams fault condi-
tions and the resulting actions of the BHM. The refer- position.

Headlight High Beams Input/Output Conditions

Inputs to BHM Outputs from BHM
Ignition Switch Headlight Switch
High Beam Switch Position* Left High Beam Right High Beam†
Position Position
On On High Beam/PASS On On
On On Low Beam Off Off
On Off High Beam/PASS Off Off
Off On High Beam/PASS Off Off
* Part of the multifunction turn signal switch
† Via J1939 message to the CHM

Table 3, Headlight High Beams Input/Output Conditions

Headlight High Beams Fault Conditions

Description of Fault Action Taken by BHM
BHM will assume the headlight switch is on, and may
Headlight switch is in error. transmit a fault message on the J1939 and/or J1708 data
links.
Position of multifunction turn signal switch is unavailable or BHM will assume the multifunction turn signal switch
in error. position is low.
BHM fails to receive five consecutive J1939 multifunction
BHM may transmit a J1939 and/or a J1708 fault message.
turn signal switch position messages from the ICU.
BHM receives a J1939 multifunction turn signal switch error
BHM may transmit a J1939 and/or a J1708 fault message.
message from the ICU.
Left high beam wiring shorted. BHM may transmit a J1939 and/or a J1708 fault message.
Right high beam wiring shorted. BHM may transmit a J1939 and/or a J1708 fault message.
Table 4, Headlight High Beams Fault Conditions

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Forward Lighting Systems 54.27
Troubleshooting

Headlight Low Beams ence parameters that program the BHM determine
whether or not a fault code is broadcast. Therefore,
Function even if the BHM detects a fault, a fault code may not
be transmitted.
Input and Output Conditions If the BHM is programmed to transmit fault codes,
See Table 5 for the Bulkhead Module (BHM) re- they can be viewed through ServiceLink. Fault mes-
sponses to the headlight low beams input/output con- sages may be transmitted on the J1939 and/or the
ditions. J1708 data links until the ignition switch is turned off.
NOTE: If the CHM does not see J1939 mes-
Fault Conditions sages from the BHM, the right low beam is acti-
vated. If the BHM fails, the left low beam is
See Table 6 for the headlight low beams fault condi-
tions and the resulting actions of the BHM. The refer- activated.

Headlight Low Beams Input/Output Conditions

Inputs to BHM Outputs from BHM
Headlight Switch High Beam Switch
Left Low Beam Right Low Beam†
Position Position*
On Low Beam On On
On High Beam/PASS On On
Off High Beam/PASS Off Off
* Part of the multifunction turn signal switch
† Via J1939 message to the CHM

Table 5, Headlight Low Beams Input/Output Conditions

Headlight Low Beams Fault Conditions

Description of Fault Action Taken by BHM
BHM will assume the headlight switch is on, and may
Headlight switch is in error. transmit a fault message on the J1939 and/or J1708 data
links.
Position of multifunction turn signal switch is unavailable or BHM will assume the multifunction turn signal switch
in error. position is low.
BHM fails to receive five consecutive J1939 multifunction
BHM may transmit a J1939 and/or a J1708 fault message.
turn signal switch position messages from the ICU.
BHM receives a J1939 multifunction turn signal switch error BHM may transmit a J1939 and/or a J1708 fault message.
message from the ICU.
Left low beam wiring shorted. BHM may transmit a J1939 and/or a J1708 fault message.
Right low beam wiring shorted. BHM may transmit a J1939 and/or a J1708 fault message.
Table 6, Headlight Low Beams Fault Conditions

Turn Signal Lights Function See Table 8 for the Bulkhead Module (BHM) re-
sponses to the turn signal lights system input/output
conditions.
Input and Output Conditions
See Table 7 for the Instrumentation Control Unit
(ICU) turn signal lights input/output conditions.

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54.27 Forward Lighting Systems
Troubleshooting

Fault Conditions If the BHM is programmed to transmit fault codes,

they can be viewed through ServiceLink. Fault mes-
See Table 9 for the turn signal lights fault conditions sages may be transmitted on the J1939 and/or the
and the resulting actions of the BHM. The reference J1708 data links until the ignition switch is turned off.
parameters that program the BHM determine
whether or not a fault code is broadcast. Therefore,
even if the BHM detects a fault, a fault code may not
be transmitted.

ICU Turn Signal Lights Input/Output Conditions

Input to ICU Outputs from ICU
Multifunction Turn Signal J1939 Right Turn
J1939 Left Turn Message
Switch Position Message
Left Turn Off On
Right Turn On Off
Off Off Off
Table 7, ICU Turn Signal Lights Input/Output Conditions

Turn Signal Lights System Input/Output Conditions

Inputs to BHM Outputs from BHM
J1939 Left J1939 Right Hazard Switch Left Turn and Right Turn and
Turn Message Turn Message Position Stop Lights Stop Lights
Off On Off Activated Deactivated
On Off Off Deactivated Activated
Off Off On Activated Activated
Table 8, Turn Signal Lights System Input/Output Conditions

Turn Signal Lights Fault Conditions

Description of Fault Action Taken by BHM
Left turn switch position is unavailable or in error. BHM will assume the J1939 left turn switch position is off.
Right turn switch position is unavailable or in error. BHM will assume the J1939 right turn switch position is off.
Hazard switch position is unavailable or in error. BHM will assume the hazard switch is on.
ICU sends an error indicator in the J1939 left turn switch
BHM may transmit a J1939 and/or a J1708 fault message.
position message.
ICU sends an error indicator in the J1939 right turn switch
BHM may transmit a J1939 and/or a J1708 fault message.
position message.
BHM fails to receive five consecutive left turn switch
BHM may transmit a J1939 and/or a J1708 fault message.
messages from the ICU.
BHM fails to receive five consecutive right turn switch
BHM may transmit a J1939 and/or a J1708 fault message.
messages from the ICU.
Left turn signal lights wiring shorted. BHM may transmit a J1939 and/or a J1708 fault message.

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Forward Lighting Systems 54.27
Troubleshooting

Turn Signal Lights Fault Conditions

Description of Fault Action Taken by BHM
Right turn signal lights wiring shorted. BHM may transmit a J1939 and/or a J1708 fault message.
Table 9, Turn Signal Lights Fault Conditions

Hazard Lights Function parameters that program the BHM determine

whether or not a fault code is broadcast. Therefore,
even if the BHM detects a fault, a fault code may not
Input and Output Conditions be transmitted.
See Table 10 for the instrumentation control unit turn If the BHM is programmed to transmit fault codes,
signal lights input/output conditions. they can be viewed through ServiceLink. Fault mes-
See Table 11 for the BHM responses to the hazard sages may be transmitted on the J1939 and/or the
lights system input/output conditions. J1708 data links until the ignition switch is turned off.

Fault Conditions
See Table 12 for the hazard lights fault conditions
and the resulting actions of the BHM. The reference

ICU Turn Signal Lights Input/Output Conditions

Input to ICU Outputs from ICU
Multifunction Turn Signal J1939 Right-Turn
J1939 Left-Turn Message
Switch Position Message
Left Turn Off On
Right Turn On Off
Off Off Off
Table 10, ICU Turn Signal Lights Input/Output Conditions

Hazard Lights System Input/Output Conditions

Inputs to BHM Outputs from BHM
Hazard Switch J1939 Left Turn J1939 Right Turn Left-Turn and Stop Right-Turn and Stop
Position Message Message Lights* Lights*
Off Off On Deactivated Activated
Off On Off Activated Deactivated
On Off Off Activated Activated
* For combination stop/turn lamps. For separate stop and turn lamps, only the turn lamps will be activated.

Table 11, Hazard Lights System Input/Output Conditions

Hazard Lights Fault Conditions

Description of Fault Action Taken by BHM
BHM will assume the left turn switch position is off, and may
Left turn switch position is unavailable or in error. transmit a fault message on the J1939 and/or J1708 data
links.

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54.27 Forward Lighting Systems
Troubleshooting

Hazard Lights Fault Conditions

Description of Fault Action Taken by BHM
BHM will assume the right turn switch position is off, and
Right turn switch position is unavailable or in error. may transmit a fault message on the J1939 and/or J1708
data links.
ICU sends a left turn switch error message to the BHM. BHM may transmit a J1939 and/or a J1708 fault message.
ICU sends a right turn switch error message to the BHM. BHM may transmit a J1939 and/or a J1708 fault message.
BHM fails to receive five consecutive left turn switch BHM may transmit a J1939 and/or a J1708 fault message.
messages from the ICU.
BHM fails to receive five consecutive right turn switch BHM may transmit a J1939 and/or a J1708 fault message.
messages from the ICU.
Left turn/stop lamp wiring shorted. BHM may transmit a J1939 and/or a J1708 fault message.
Right turn/stop lamp wiring shorted. BHM may transmit a J1939 and/or a J1708 fault message.
Table 12, Hazard Lights Fault Conditions

Marker Lights Function BHM determine whether or not a fault code is broad-
cast. Therefore, even if the BHM detects a fault, a
fault code may not be transmitted.
Input and Output Conditions
If the BHM is programmed to transmit fault codes,
See Table 13 for the Bulkhead Module (BHM) re- they can be viewed through ServiceLink. Fault mes-
sponses to the marker lights input/output conditions. sages may be transmitted on the J1939 and/or the
The marker interrupt switch is optional. If the vehicle J1708 data links until the headlight switch is turned
does not have a marker interrupt switch, the BHM to off.
operates in the same way as if the vehicle has a
marker switch that is open (off) all the time.

Fault Conditions
See Table 14 for the marker lights fault conditions
and the resulting actions of the Bulkhead Module
(BHM). The reference parameters that program the

Marker Lights Input/Output Conditions

Inputs to BHM Outputs from BHM
Park, Marker, Taillights,
Marker Interrupt
Headlight Switch License Plate Identification
Switch
Lights Lights
Park Off Activated Activated
Park On Deactivated Deactivated
On Off Activated Activated
On On Deactivated Deactivated
Off Off Deactivated Deactivated
Off On Activated Activated
Table 13, Marker Lights Input/Output Conditions

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Forward Lighting Systems 54.27
Troubleshooting

Marker Lights Fault Conditions

Description of Fault Action Taken by BHM
Status or position of the headlight switch is BHM assumes the headlight switch is on, and may transmit a fault message
in error. on the J1939 and/or J1708 data links.
Status or position of the marker interrupt BHM assumes that the marker interrupt switch is off, and may transmit a fault
switch is unavailable or in error. message on the J1939 and/or J1708 data links.
Any marker light output wiring is shorted. BHM may transmit a J1939 and/or a J1708 fault message.
Table 14, Marker Lights Fault Conditions

Fog Lights Function

Input and Output Conditions
See Table 15 for the Bulkhead Module (BHM) re-
sponses to the fog lights input/output conditions.

Fog Lights Input/Output Conditions

Inputs to BHM Outputs
Ignition Switch J1939 High Beam J1939 message from
Fog Light Switch Fog Lights
Position Status from ICU BHM to CHM
Off Off On Deactivate Off
On On On Deactivate Off
On Off On Activate On
Table 15, Fog Lights Input/Output Conditions

Snowplow Lights Provision Effect of the Snowplow Lights

Provision on Forward Lighting
Input and Output Conditions
System Troubleshooting
See Table 16 for the Bulkhead (BHM) responses to
the snowplow light input/output conditions. Identification of faults in the forward lighting system
can proceed normally when the snowplow lights pro-
Fault Conditions vision is installed and operating correctly. However,
problems with the snowplow light control modules
See Table 17 for the snowplow lights fault conditions and incorrect connections to the snowplow light har-
and the resulting actions of the BHM. The reference ness cannot be identified through the J1939 or J1708
parameters that program the BHM determine datalinks.
whether or not a fault code is broadcast. Therefore, A bad snowplow light control module or improper
even if the BHM detects a fault, a fault code may not connections can result in one or more lamps not illu-
be transmitted. minating when directed by the BHM, or in having one
If the BHM is programmed to transmit fault codes, or more lamps driven by the incorrect signal. Other
they can be viewed through ServiceLink. Fault mes- indications specifically associated with incorrect con-
sages may be transmitted on the J1939 and/or the nections of the M2 106V snowplow light harness in-
J1708 datalinks until the ignition switch is turned off. clude relay chatter in one of the snowplow light con-
trol modules or a fault message indicating the park
light and/or low-beam output is shorted.

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54.27 Forward Lighting Systems
Troubleshooting

Troubleshooting headlight, turn signal light, and park stalled; however, it is possible to do all checks with a
light operation when the snowplow light provision is digital multimeter to check the snowplow light con-
present is facilitated by having snowplow lights in- nector pins instead.

Snowplow Lights Input/Output Conditions

Inputs to BHM Outputs from BHM
Snowplow Lights Signal Headlight Switch Position Snowplow Lights J1939 Message
Open On Off
Closed On On
Open Off Off
Closed Off Off
Table 16, Snowplow Lights Input/Output Conditions

Snowplow Lights Fault Conditions

Description of Fault Action Taken by BHM
BHM will assume the snowplow light switch is off, and may transmit a fault message
Snowplow light switch is in error.
on the J1939 and/or J1708 datalinks.
BHM will assume the headlight switch is on, and may transit a fault message on the
Headlight switch is in error.
J1939 and /or J1708 datalinks.
Table 17, Snowplow Lights Fault Conditions

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Forward Lighting Systems 54.27
Specifications

Approved Electrical Lubricants

Manufacturer Lubricant
Standard Oil Co. White Vaseline
Shell Oil Co. No. 71032; No. 71306
Texaco, Inc. No. 955
Quaker State No. NYK-77
Table 1, Approved Electrical Lubricants

Replacement Bulb Part Numbers

Description Part Number Amps
Composite Headlight, Low Beam 9006 4.30
Composite Headlight, High Beam 9005 5.08
Front Park/Turn Signal Light 3157 2.23
0.33
Clearance and Identification Lights 193
(14.0 design volts)
0.27
Front Side Marker/Turn Signal Light 194
(14.0 design volts)
Table 2, Replacement Bulb Part Numbers

Wiring Diagrams See Table 4 for a connector face view and pinout
chart of the headlight connectors on the forward
chassis harness for the M2 106V model only.
IMPORTANT: The following wiring diagrams pro-
vide circuit details for the forward lighting electri- See Table 5 for a connector face view and pinout
cal system of a typical Business Class® M2 ve- chart of the park/turn signal light connectors on the
hicle. These details may not correspond to forward chassis harness.
every vehicle. See Table 6 for a connector face view and pinout
chart of the side marker/turn signal light connectors
See Fig. 1 for wiring details of the control inputs for
on the forward chassis harness.
a typical M2 vehicle forward exterior lighting system.
See Table 7 for a connector face view and pinout
See Fig. 2 for wiring details of the control outputs for
chart of the snowplow light connectors on the snow-
a typical M2 vehicle forward exterior lighting system.
plow light harness.
See Fig. 3 for a wiring diagram of the optional fog
lights.
See Fig. 4 for a wiring diagram of the optional snow-
plow lights provision.

Circuit Identification
See Table 3 for a connector face view and pinout
chart of the headlight connectors on the forward
chassis harness for all models except the M2 106V.

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54.27 Forward Lighting Systems
Specifications

Multifunction Turn
Signal Switch
Instrumentation
Control Unit 473 T 473 T 1
Cruise Control
Normal State
Multifunction turn B5 T 473
signal switch common
Left Turn
B6 T 473A 473A T 4 Signal Switch
Turn signal switches

B7 T 473B Right Turn

High beam switch
C1 Signal Switch

High Beam/
D5 Y J1939+ 473B T 5 Flash to Pass
J1939+

D9 DKG J1939− 38B T 3

J1939−
C2

Data Lines Hazard Switch

BK−W GNDE BK−W 2
B Y J1939+
J1939+
Battery
J DKG J1939− Ground
BK−W

J1939−
B2

GNDE BK−W 2
B8 T 38B GNDE BK−W 5
Hazard switch

B10 LTG 20 20 LTG 6 HEAD

Headlights on 1
OFF
B9 BR 23F 23F BR 4
Park lights on
PARK

B11 LTG 21 21 LTG 3 HEAD

Headlights on 2
B6
OFF
23F BR 1
PARK

H BR 29A 29A BR 10
Panel lights
B5
Bulkhead Module BR 29A BK GND BK 8 ILLUM
Interior Lights
Left Interior
Frontwall Ground Headlight Switch
04/21/2006 f544773

Fig. 1, Forward Exterior Lighting Inputs

400/2 Business Class M2 Workshop Manual, Supplement 10, September 2006

Forward Lighting Systems 54.27
Specifications

46 BR A B BK GND
Bulkhead Module
C BR 46 46 BR A B BK GND
Cab marker lights
B5

L LTG 20H 46 BR A B BK GND BK GND Cab

Left high beam
Ground
Identification Splice Pack
Left low beam or R LTG 20L 46 BR A B BK GND and Clearance SP1
low beam DRL B1 Lights
B Y J1939+ 46 BR A B BK GND
J1939+

J DKG J1939−
J1939−
B2
Data High Beam
20H LTG G E BK GND
Lines HDLP
G Y J1939+
J1939+
20L LTG A
Low Beam
R DKG J1939− HDLP
J1939−

C BR 102A 102A BR B Park Light A BK GND BK GND

Left front park light
TRN
With turn Left Left
F LTG 379L 38L Y C
signal DRL Turn Signal Headlamp
Left front turn/DRL Headlight
C4 TRN
Y 38L Assembly Ground
Without turn Post
signal DRL Turn Signal
N Y 38L 38L Y C B BK GND
Left front turn signal
C3
Left Side
D BR 46E 46E BR A
Left marker light Marker Light Marker/Turn
Light

M BR 46F 46F BR C Marker Light B BK GND

Right marker light
C4
Right Side
R DKG 38R 38R DKG A Turn Signal
Right front turn signal Marker/Turn
Without turn Light
DKG 38R signal DRL
K LTG 379R 38RDKG C Turn Signal A BK GND BK GND
Right front turn/DRL
C3 With turn
TRN
signal DRL
L BR 102B 102B BR B
Right front park light Park Light
C4
TRN
Right low beam or L LTG 21L 21L LTG A Low Beam E BK GND
low beam DRL C3 HDLP
K LTG 21H 21H LTG G Right Headlight Assembly
Right high beam High Beam
C4 HDLP
Chassis Module
05/10/2006 f544774

Fig. 2, Forward Exterior Lighting Outputs

Business Class M2 Workshop Manual, Supplement 10, September 2006 400/3

54.27 Forward Lighting Systems
Specifications

Smart Switch
Left Fog Light

J1939 C LTG 27L A B BK GND Left Headlight

Ground Post
BHM CHM
D LTG 27R A B BK
FOG
C3
LAMP
Right Fog Light

05/05/2006 f544775

Fig. 3, Fog Lights Wiring Diagram

D 20E 20E LTG

Left low R LTG 20L 20L LTG A
beam
E 20C 20C LTG
GND BK B
F 20F 20F LTG
Left high L LTG 20H 20H LTG C
A
beam A
B
D LTG 462L 462L LTG D
J1939
E LTG 462C 462C LTG E

F LTG 462H 462H LTG F

Bulkhead Module D B BK GND GND BK B

N Y 38L
Left turn
C3 Turn signal without DRL 38L Y A A Y 38L 38L BK C
F LTG 379L Turn signal with DRL
Left DRL
C4 102C/102A BR C C BR 102C/102A 102C/102A BR A
F BR 102C B C
Snowplow Lights Trailer marker
Switch C2 Non−106V
C BR 102A 106V Lower Control Module for Left Snowplow Lights
Left front park
C4

D LTG 21E 21E LTG

L LTG 21L 21L LTG A
Right low beam
C3
E LTG 21C 21C LTG
GND BK B

F LTG 21F 21F LTG

K LTG 21H 21H LTG C
Right high beam A
C4 A
Snowplow lights C LTG 462A B
D LTG 463L 463L LTG D
C3
E LTG 463C 463C LTG E
Left Headlight D
Grounding Post F LTG 463H 463H LTG F

B BK GND GND BK B
R DKG 38R
Right turn
C3 Turn signal without DRL 38R DKG A A DKG 38R 38R DKG C
K LTG 379R Turn signal with DRL
Right DRL
C3 102C/102B BR C C BR 102C/102B 102C/102B BR A
F BR 102C B C
Trailer marker
C2 Non−106V
L BR 102B 106V Upper Control Module for Right Snowplow Lights
Right front park
C4
Chassis Module

05/15/2006 f544844

Fig. 4, Snowplow Lights Provision Wiring Diagram

400/4 Business Class M2 Workshop Manual, Supplement 10, September 2006

Forward Lighting Systems 54.27
Specifications

Forward Chassis Harness Headlight Connectors (all models except M2 106V)

Left Headlight Right Headlight
Connector Pin Signal Name
Circuit Number Circuit Color Circuit Number Circuit Color

E H

D A f544821

A Low Beam 20L LTG 21L LTG

B — — — — —
C — — — — —
D — — — — —
E Ground GND BK GND BK
F — — — — —
G High Beam 20H LTG 21H LTG
H — — — — —
Table 3, Forward Chassis Harness Headlight Connectors (all models except M2 106V)

Forward Chassis Harness Headlight Connectors (M2 106V only)

Left Headlight Right Headlight
Connector Pin Signal Name
Circuit Number Circuit Color Circuit Number Circuit Color

C A f544845

A Low Beam 20L LTG 21L LTG

B Ground GND BK GND BK
C High Beam 20H LTG 21H LTG
Table 4, Forward Chassis Harness Headlight Connectors (M2 106V only)

Business Class M2 Workshop Manual, Supplement 10, September 2006 400/5

54.27 Forward Lighting Systems
Specifications

Forward Chassis Harness Park/Turn Signal Light Connectors

Left Park/Turn Signal Light Right Park/Turn Signal Light
Connector Pin Signal Name
Circuit Number Circuit Color Circuit Number Circuit Color

A B C f544822

A Ground GND BK GND BK

B Park Light 102A BR 102B BR
C Turn Signal 38L Y 38R DKG
Table 5, Forward Chassis Harness Park/Turn Signal Light Connectors

Forward Chassis Harness Side Marker/Turn Signal Light Connectors

Right Side Marker/Turn Signal
Left Side Marker/Turn Signal Light
Connector Pin Signal Name Light
Circuit Number Circuit Color Circuit Number Circuit Color

C 2A A
f544820

A Marker Light 46E BR 46F BR

B Ground GND BK GND BK
C Turn Signal 38L Y 38R DKG
Table 6, Forward Chassis Harness Side Marker/Turn Signal Light Connectors

400/6 Business Class M2 Workshop Manual, Supplement 10, September 2006

Forward Lighting Systems 54.27
Specifications

Snowplow Light Connectors

Left Side Connector Right Side Connector
Connector Pin Signal Name
Circuit Number Circuit Color Circuit Number Circuit Color

F D

A C f544846

A Park Light 102C/102A* BR 102C/102B* BR

B Ground GND BK GND BK
C Turn Signal 38L Y 38R DKG
D Auxiliary Low Beam 462L LTG 463L LTG
E Auxiliary Headlight Ground 462C LTG 463C LTG
F Auxiliary High Beam 462H LTG 463H LTG
* 102A and 102B are for model M2 106V only. 102C is for all other models.

Table 7, Snowplow Light Connectors

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