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You need to examine the wire down to the aux start relay. Pretty sure K1 couldn't cause this, but a short to ground down at the aux relay could. In a perfect world, enough current to melt insulation would pop a circuit breaker for the circuit, that is why they are there afterall. I would look...

Well if it was converted to 12V then everything 24V was probably disconnected. The CTIS controller is a microprocessor and probably needs its designed voltage to function. A given amount of work performed at 24V takes half the current of the same work performed at 12V so 24V uses a smaller...

Not familiar with the 916 but I would say you have a wiring issue. You could get 24V from 2 batts, but how would you charge the batteries? What you need is a 12-24V power converter capable of meeting the peak current demand of the CTIS...

Power for the start circuit comes thru the vim neutral start relay to the coil of K1(K1-86). You should have 24V at pin 86 with the sw on. If not the problem is in the VIM or wiring or neutral start authorization from the trans controller that controls the VIM relay. The other side of K1’s...

Current flows from X1 to pin 30 on K1. When energized(cranking), K1-30 connects to K1-87. K1-87 connects down to the aux start relay coil on the drivers frame rail just outboard of the starter. The other side of the aux start relay coil connects to ground...

Well the CTIS needs 24V(i am not aware of a 12v version) so you would have to provide it 24v somehow to keep this CTIS system... I don't understand the “no power running through the fuse slot for the CTIS system” statement. CB40 provides 24V to a pin on the CTIS connector...

IF that is the switch "Td" off of the uppermost two way check valve, it is probably the switch that controls the park and emergency lights in the dash annunciator panel(turns off the park/emer lights when park brake air is applied)...

Fan circuit is 24V powered from CB 22...

The trans will accept either 12 or 24V so you probably didn't kill anything. I would look to the circuit that powers the trans CB79 and there are fuses inside the Vehicle Interface Module(VIM). The start relay gets its power thru the VIM(neutral start safety) so the trans controller needs to...

Two batteries isn't your problem as lomg as they are connected correctly and the truck probably would not operate properly if they were not. I think quite a few of us run two batts... your problem is probably as mentioned, wrong voltage relay. That should be a 12V relay in that position, or it...

Ok, now I am tracking. Still check the rod end for crap... mine was full of sand and grease:)

Yea, you may need to have it relearn the shift points. You have come a long way with this truck. There is no cab lock. Are you referring to the folded bar assembly on the right frame rail? It doesn't lock the cab it keeps it from over-extending. In normal operation the cab should not tilt...

The ground lead isn't connected(nearest/outermost - terminals) but the rest looks OK...

Cool! Alt output is low, what did the voltmeter read before you cranked it? The first check for that is if the alt is receiving excitation from Relay K11. This should happen as soon as the oil pressure light extinguishes in the annunciator panel after start...

What tires do you have Michelin XML’s or Goodyear MVT’s? Here is a link to the goodyear military tire brochure. It has inflation and speeds listed. You will need to see if you have loadrange G or L, probably G, mine are G’s The chart is a little hard to follow so I attached a screenshot of...

You need to apply park air(release park brake) to enable air out of the rear emergency/trailer port(s). The park air circuit provides a control input to the trailer control valve and even when trailer is turned on, it wont apply air to the rear gladhand till the park air input is satisfied...

Found them... search “Hydraulic Fuse” or “Velocity Fuse” They make them in various sizes, flow trip points and reset methods...

The ABS controller I believe is made by Haldex. You should be able to get a part number off of it and search up exactly what is required to communicate with it... This is also probably something a large truck shop could read for you...

What you describe is called pilot activated and I don't think ours work quite like that. if they did they would require you to pump the tire or cab all the way down and could not lower with gravity as they do now. I believe the valves in the OEM cylinders work as a flow limiter. The flow...

Yep, no ABS in the A0/Manuals. Ideally you need a way to talk to the ABS processor to read the codes... The most vulnerable point on most ABS systems are the wheel sensors. A good hand over hand inspection of all the ABS sensor cables down to the wheels may show you some visual problem. You...