I am having the same problem on one of my trucks. I checked all the PDM and the VSM and all of the connections seem to be OK. Do you have any more info such as a wire diagram to conduct the test you have listed?
CAUSE D - IGN 2 VOLTAGE SHORTED TO BATTERY SOURCE
PROCEDURE OR ACTION:
1. Ensure truck power is OFF.
2. At the VSM, disconnect CPS 8 from VSM.
3. Select volts scale on DMM.
4. Measure voltage across the harness connector CPS 8, pin 6 (+) and the negative ( ) terminal of battery.
Is voltage approximately system voltage?
YES: The IGN voltage is shorted to an unswitched battery source within the harness. Refer to Electrical
Schematic in Diagrams and Schematics 8000 SRM 1152 to identify unswitched voltage sources. Locate and
repair/replace shorted wire/connection. See Wire Harness Repair 2200 SRM 1128.
NO: Go to Step 5.
5. Turn truck power ON.
6. Repeat Step 4.
Is voltage approximately system voltage?
YES: The IGN voltage is shorted to a switched battery source within the harness. Refer to Electrical Schematic
in Diagrams and Schematics 8000 SRM 1152 to identify switched voltage sources. Locate and repair/replace
shorted wire/connection. See Wire Harness Repair 2200 SRM 1128.
NO: Go to Cause E.
CAUSE E - FUNCTIONAL FAILURE IN CONTROLLER
PROCEDURE OR ACTION:
1. Ensure all previous procedures have been completed.
2. Ensure truck power is OFF.
3. Ensure that all connections to the controller are completely inserted.
4. Ensure truck power is OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Go to Step 5.
NO: Problem corrected. Resume operation.
5. At the DSC, press ENTER to access Main Menu.
6. Scroll to VIEW VERSIONS, press ENTER.
7. Scroll to TRUCK SERIAL NUMBER, press ENTER.
8. View the TRUCK SERIAL NUMBER on the display.
CAUSE A - IGN VOLTAGE SHORTED TO UNSWITCHED BATTERY SOURCE IN PDM OR PDM/VSM HARNESS
PROCEDURE OR ACTION:
1. Ensure truck power is OFF.
2. At the VSM, disconnect CPS 1.
3. Change DMM to volts scale.
4. At the VSM harness connector, measure the voltage across the DTC indicated switched IGN input wire (+) and
the negative terminal ( ) of the battery.
Is voltage approximately system voltage?
YES: The IGN input is shorted to an unswitched battery source. Go to Step 5.
NO: Go to Cause C.
5. Disconnect the corresponding connector from the PDM. Repeat the measurement in Step 4.
Is voltage approximately system voltage?
YES: The IGN input is shorted to an unswitched battery source within the PDM/VSM harness. Refer to Electrical
Schematic in Diagrams and Schematics 8000 SRM 1152 to identify unswitched voltage sources. Locate and
repair/replace shorted wire/connection. See Wire Harness Repair 2200 SRM 1128.
NO: Go to Step 6.
CAUSE B - IGN VOLTAGE SHORTED TO UNSWITCHED BATTERY SOURCE IN PDM OUTPUT HARNESS
PROCEDURE OR ACTION:
1. Refer to Electrical Schematic in Diagrams and Schematics 8000 SRM 1152 for the following steps.
2. With the DMM connected to the IGN voltage output pin at CPS 1, observe DMM while disconnecting each device
that connects to the indicated IGN source. When voltage goes to zero, identify the relevant harness for that
device.
3. Use DMM to verify localized STB on relevant harness. Locate and repair/replace shorted wire/connection. See
Wire Harness Repair 2200 SRM 1128.
CAUSE C - IGN VOLTAGE SHORTED TO SWITCHED BATTERY SOURCE IN PDM OR PDM/VSM HARNESS
PROCEDURE OR ACTION:
1. Remove the DTC indicated IGN Relay from the PDM.
NOTE: Turning on power with this relay removed will cause a DTC for the removed relay to be displayed on the DSC.
Ignore this new DTC.
2. Turn truck power ON.
3. Change DMM to volts scale.
4. At the relay socket, measure the voltage across socket terminal #87 (+) and the negative terminal ( ) of the
battery.
Is voltage approximately system voltage?
YES: The IGN voltage input is shorted to another switched battery source either in the PDM or another accessory
circuit. Go to Step 5.
NO: Relay contacts #87 and #30 are shorted. Replace relay. See Electrical System 2200 SRM 1142.
5. Ensure truck power is OFF.
6. Disconnect PDM connectors CPS 15 and CPS 16.
7. Turn truck power ON.
8. Repeat the measurement in Step 4.
Is voltage approximately system voltage?
YES: The IGN voltage is shorted to another switched battery source either in the PDM or another accessory
circuit connected to the VSM. Go to Step 9.
NO: The IGN circuit is shorted to another switched battery source in the circuitry connected to CPS 15 and/or
CPS 16. Review schematics for adjacent circuits, trace and isolate the source. See Wire Harness Repair 2200
SRM 1128.
9. Ensure truck power is OFF.
10. Remove indicated IGN output circuit pin from connector CPS 1.
DTC 522761-3
POSSIBLE CAUSE:
A. IGN VOLTAGE SHORTED TO UNSWITCHED BATTERY SOURCE IN PDM OR PDM/VSM HARNESS
B. IGN VOLTAGE SHORTED TO UNSWITCHED BATTERY SOURCE IN PDM OUTPUT HARNESS
C. IGN VOLTAGE SHORTED TO SWITCHED BATTERY SOURCE IN PDM OR PDM/VSM HARNESS
D. IGN 2 VOLTAGE SHORTED TO BATTERY SOURCE
E. FUNCTIONAL FAILURE IN CONTROLLER
VSM is vehicle system manager, located under the cowling, RH side of the steering column.
PDM is the fuse/relay box, located in front of the battery.
Check this area for dampness inside the box and/or corrosion on the terminals.
Especially if the machine has been recently washed.
OOH is out of range high, so i would suspect all are possible.
In short, you may have a short, battery voltage is getting where it shouldn't be. One of your switched lines has voltage when it shoud be off.
Also has it had any accessories added recently? strobes, extra lighting, if so how was it wired in?
Pdm is basically the fusebox. It may have gotten damp inside
Hi Ed
Are all the "possible Cause" related to the Fault code 522761-3?
What is the "PDM" & "VSM" sorry don't know these terms?
Thanks Nigel
DTC 521982-3 - Switched Battery Voltage 3 (IGN 3) OORH (TCU)
DTC 522760-3 - Switched Battery Voltage 1 (IGN 1) OORH
DTC 522761-3 - Switched Battery Voltage 2 (IGN 2) OORH
DTC 522762-3 - Switched Battery Voltage 3 (IGN 3) OORH
POSSIBLE CAUSE
A. IGN VOLTAGE SHORTED TO UNSWITCHED BATTERY SOURCE IN PDM OR PDM/VSM HARNESS
B. IGN VOLTAGE SHORTED TO UNSWITCHED BATTERY SOURCE IN PDM OUTPUT HARNESS
C. IGN VOLTAGE SHORTED TO SWITCHED BATTERY SOURCE IN PDM OR PDM/VSM HARNESS
D. IGN 2 VOLTAGE SHORTED TO BATTERY SOURCE
E. FUNCTIONAL FAILURE IN CONTROLLER