Freightliner Body Builder Reference Guide For Electrical Sys

EPA 2010 Models - M2106, M2112, 108SD, 114SD Electrical Body Builder Reference Guide Electrical System Overview 2010 Smart Plex Electrical Body Builder Reference Page 1 Rev A EPA 2010 Models

Electrical System Overview EPA 2010 Models Index Page 1 Index Page 2 Electrical Component Overview Page 3 Electrical Harness Overview Page 4 Electrical Power flow Overview Page 5 Page 6 Page 7 Page 8 Page 9 Bulk Head Module (BHM) Page 10 Bulk Head Module (BHM) Pin Detail Page 11 Chassis Module (CHM) Page 12 PNDB Power Net Distribution Box Positive Disconnect Switch Main Power Distribution Module (PDM) PDM / VBAT Fuse Coverage Chassis Module (CHM) Pin Detail Page 13 Multiplexing System Backbone Page 14 System Tap Points Page 15 J1708 Gateway Page 16 Low Current Smart Switches Page 17 High Current Switches (Battery Hot) Page 18 High Current Switch (BH) Schematics Page 19 High Current Switches (Ignition Interlocked) Page 20 High Current Switch (Ignition Interlocked) Schematics Page 21 High Current Switch Label Options Page 22 Body Builder Lighting Interface Page 23 Body Builder PDM Page 27 Trailer Electrical Schematics (Combination) PTO Installation Page 36 PTO PTO Controls Page 37 PTO Air Schematics Page 38 PTO Electrical Schematics Page 39 Hybrid PTO Options Page 40 Remote Start Stop Schematics Page 41 VDR Prep Information (NFPA) Page 42 SmartPlex VDR Connections Page 24 Body Lighting Interface Schematics Page 25 Trailer PDM Page 26 Trailer Electrical Schematics (Seperate) Page 28 Wired Rite Prep Page 29 Wired Rite Schematic Page 30 Wired Rite Trailer and Floor connections Page 31 Tail Lights Page 32 Tail Light Schematics Page 33 Transmission Interface Page 34 Engine Interface Page 35 2010 Smart Plex Electrical Body Builder Reference Page #2 Rev A

Accessory Air Valve Assembly (AAVA) (Multiple Modules ) Body lighting Interfaces (Module 353, 296) Dash Switches (Module 329) Tail Light Configurations (Module 294) Trailer Interfaces (Module 296, 297) (Module ) Engine Interface (Black Plug) (Plugs may also be frame located) 148, 163, 87L Transmission (Grey Plug) (Plugs may also frame located Interfaces. be (Module , 34C) Electrical Component Overview EPA 2010 Models 2010 Smart Plex Electrical Body Builder Reference Page #3 Rev A PNDB Power Net Distribution Box (Module 33P/281/293) Chassis Module (CHM Under Cab) (Module 335, 32K) Power Distribution (Module 285 PDM) Bulk Head Module (BHM) (Module 32A)

Electrical Harness Overview FORWARD CHASSIS HARNESS Module 1) Connections to Bulkhead module and Underhood PDM 2) Connections to headlamps 3) Connections to side marker/turn lamps 4) Connections to Chassis Module 288 AFT CHASSIS HARNESS Module 1) Connections to Chassis Module 2) Connections to tail lamps 28A MAIN CAB HARNESS Module 1) Connections to bulkhead connector 2) Connections to diagnostic connector (behind ignition switch) 3) Connections to CPC 4) Pass-thru connector to engine compartment 5) Gauge Cluster 6) HVAC unit and controler 7) Steering wheel horn and windshield wiper 320 OVERHEAD CAB HARNESS Module 287 1) Inline connection to Main cab Harness (at bottom of A pillar) 2) Connections to Marker Lamps 3) Connections to Dome Lamp FRONTWALL HARNESS Module 321 1) Connections to Bulkhead Module and Underhood PDM 2) Connection to Starter Mag Switch 3) Connection to Wiper Motor 4) Connection to the low coolant level sensor and horn (under surge tank) 5) Connection under cab to Washer pump and level switch 6) Pass-thru connector to Main Cab Harness and Powertrain Harness POWERTRAIN HARNESS Module 286, 283 1) Connections to the Bulkhead Module and Underhood PDM ABS/AMU HARNESS Module 332 1) Connections to Forward chassis harness and frame ground studs near Chassis module 2) Connections to AMU (Mod 877 without ABS) 3) Connections to Wabco ABS ECU 4) Connections to rear combo valves EPA 2010 Models 2010 Smart Plex Electrical Body Builder Reference Page #4 Rev A

Electrical Power Flow Overview EPA 2010 Models Battery Main PNDB TCM Trailer PDM Tail Lights BB PNDB Body Lighting Conn Transmission Connector BB PDM Trailer Connector Engine Connector Main PDM BHM Powertrain PDM ECM ICU CHM C2-F Trailer Marker Relay C2-H Trailer Turn Left Relay C2-E Trailer Turn Right Relay C2-A Trailer Power Relay C2-D Trailer Stop Lamp Relay Chassis Module Outputs Bulkhead Module Outputs B5.E - SPARE (Utility Light/Spotlight) B4.M - SPARE (Utility Light/Spotlight) B3.E - Horn B5.F - Cigar Lighter Output B5.H - Panel Lamps B7.A1 - Panel Lamps (Smart Switch) B5.G - SPARE (Ignition) B6.A9 - Accessory (HVAC) B6.A10 - Accessory (Radio) B4.F - SPARE (Left Heated Mirror) B4.E - SPARE (Right Heated Mirror) B6.A8 - Ignition (VCU) B2.K - Ignition (Engine) B1.P - Ignition (ABS) B5.A - Battery (Dome Lamps) B7.A12 - Battery (Smart Switch) B5.D - Instrument Cluster B5.B - Dome Lamps Switched B1.L - Left High Beam B2.L - Ignition (Trans) B1.F - Fuel Water Sensor Power B3.F - Wiper High B5.C - Clearance Lamps B1.K - Tail/License Plate B1.R - Left Low Beam B3.H - Wiper Low B3.G - Washer Pump B2.M - AC Clutch B4.B - Starter Relay (Crank) /Trailer Relay C3-A Optional Fuel Water Separator Heater C4-C Left Park Lamp C4-L Right Park Lamp C4-D Left Marker Lamp C4-M Right Marker Lamp C3-N Turn Left Front/Side C1-G Turn Left Rear C3-R Turn Right Front/Side C1-P Turn Right Rear C1-A Left Backup Lamp C1-J Right Backup Lamp C1-H Backup Alarm C3-L Right Low Beam C4-K Right High Beam C1-N Left Stop Lamp C1-L Right Stop Lamp C3-K Right DRL C4-F Left DRL C3-C Optional Fog/Road Lamps C3-D Optional Fog/Road Lamps C5-H AMU Solenoid #0 C5-J AMU Solenoid #1 C5-L AMU Solenoid #2 C5-M AMU Solenoid #3 ECM TCM BHM CHM ICU BB PNDB Main PNDB Main PDM Powertrain PDM BB PDM Trailer PDM Battery (296) Trailer Connector (353) Body Lighting Conn Engine Connector Transmission Connector (294) Tail Lights J1939 Multiplexed Network 2010 Smart Plex Electrical Body Builder Reference Page #5 Rev A

PNDB Power Net Distribution Box EPA 2010 Models INSTALLATION WITHOUT DISCONNECT SWITCH INSTALLATION WITH DISCONNECT SWITCH Primary Solenoid for Cut off Switch Battery Input Primary Solenoid Cut Off Switch Connection ATC Fuse Output ATC Fuses MIDI Fuse Output Fuse Cover and label Power Net Distribution Box (PNDB) The PNDB is a new power delivery for the SmartPlex to deliver more consistent and better protected power from the battery to the other components on the truck. The PNDB also has protected keep alive circuits that maintain power even with the cutoff switch is in the off position. The primary reason for this change is to provide power to the 2010 DEF purge system which drains urea from the delivery system and prevents the system from freezing during cold conditions. The PNDB located at the front wall is equipped with three MIDI fuses which supply power to the Main Power Distribution Module. These fuse connections have been relocated from the battery in 2010 to prevent corrosion and improve the trucks reliability in severe conditions. A secondary PNDB is available as an option for the body builder and will be located with the trailer and bodybuilder PDM located in the cab behind the drivers seat on day cabs or under the rear bench seat for crew cab units. designed system ATC -A ATC -B ATC -C ATC -D ATC Fuse output keeps power on after disconnect Mating connector 23-13153-410 1 A 2 2 3 1 A B C D B 3 C A D B E C F 4 D Battery Input 300 AMPS Max AFTER TREATMENT ECU EMERGENCY POWER RADIO AND CLOCK ALTERNATOR REMOTE SENSE GROUND X2 KEEP ALIVE CIRCUIT X1 SOLENOID CONTROL SIGNAL OFF LED INDICATOR SIGNAL ON SIGNAL RETURN GROUND 1 2 3 4 A B C D E F CONNECTOR PIN DESCRIPTION Fuse Description Function Rating Max. Fuse Allowed ATC-A Keep Alive Power After Treatment ECU 30 AMPS 30 AMPS ATC-B Keep Alive Power Emergency Power 20 AMPS 30 AMPS ATC-C Keep Alive Power Radio and Clock 5 AMPS 30 AMPS ATC-D Keep Alive Power Alternator Remote Sense 5 AMPS 30 AMPS MIDI-1 (Fuse 1) High AMP Fuse Powertrain PDM 175 AMPS 200 AMPS MIDI-2 (Fuse 2) High AMP Fuse PDM #2 125 AMPS 200 AMPS MIDI-3 (Fuse 3) High AMP Fuse PDM #1 125 AMPS 200 AMPS Solenoid Control 2010 Smart Plex Electrical Body Builder Reference Page #6 Rev A

Positive Cutoff Switch EPA 2010 Models Battery Box Disconnect Switch Mounting with box mounted air tanks (brackets will vary depending on application) 293-061 In Cab Mounted Disconnect Switch Mounting 293-058 Battery Box Mounting without box mounted air tanks 293-001, 293-061 Disconnect Switch Positive Disconnect Switch The disconnect switch system for 2010 has been reconfigured to provide better application coverage and offer two levels of power disconnect based on the options ordered with the truck. In cab disconnect switches will be offered in a locking or non locking configuration. Exterior battery mounted switches will be offered in the locking configuration only. Cutoff switches are equipped with red LED lights, which are when power is on. Trucks equipped with the body builder auxiliary power system will have an additional LED light on the switch. Note: Both PNDB units will be deactivated when the switch is in the off position. illuminated Axillary Body Builder Cutoff Switch Standard Cutoff Switch Standard Power LED Lockout Tab Auxiliary Power and Main Power LED Main Cab PNDB Connector Plug #23-13153-307 Body Builder PNDB Connector Plug #23-13662-401 1 3 2 1 4 2 3 293-057 293-061 293-060 293-058 NEGATIVE LOAD DISCONNECT W/CAB MTD DISCONNECT SWITCH NEGATIVE LOAD DISCONNECT W/BATTERY BOX DISCONNECT SWITCH POSITIVE LOAD DISCONNECT W/BATTERY BOX CTRL SWITCH W/LOCKING PROVISION POSITIVE LOAD DISCONNECT W/CAB MTD CTRL SW W/LOCKING PROV MTD OB DR DEAT POSITIVE LOAD DISCONNECT W/CAB MTD CONTROL SWITCH MTD OB DR SEAT 293-063 X2, Aux PNDB X1, Main PNDB 2010 Smart Plex Electrical Body Builder Reference Page #7 Rev A

The main Power Distribution Module (PDM) distributes battery power to the various control modules on the vehicle. The PDM contains mini fuses that the power feed circuits to these modules. For most trucks there will be spare fuse slots available customers to add additional wiring to the truck after purchased. There are four plugs attaching to the module that supply output connections. Common spare fuse sockets are listed below but may vary based on the options that have been requested. Common Spare Fuse locations F6, F10, F11, F14, F21, F23, F25, F26 protect for it is A B B A A C B G H E G D C B A D B F C D H H G G D C H E E F Single Wire Output found on Plug in Pin G Green PDM Plugs contain output wires PDM #1 (MIDI-3) PDM # 2 (MIDI-2) Engine Harness Plug (Green) Forward Chassis Harness Plug (Blue) Forward Chassis Harness Plug (Grey) Front Wall Harness Plug (Black) Main Power Distribution Module (PDM) Power Distribution Module Fuse Specications* Output MEGA Fuse Connection Fuse Location Primary Function Fuse Rating Secondary Function Fuse Rating Green A 1 F1 Spare { Green B Green H 1 F2 Blower Motor 30A { { { { { 2 F3 Spare Spare Spare 30A Green G 2 F4 30A 30A Black D 1 2 F5 Ignition Switch 5A { { Black C 1 1 F6 Hydromax Relay Gray F 1 1 F7 Bulkhead Module 30A { { Green C 2 2 2 2 2 2 2 2 F8 ICU3-M2 10A { { { Green D 2 1 1 1 1 1 1 F9 † 30A Blue G Green F 2 F10 Spare Spare { { { { { { { { Blue H F11 Spare { { { Black H F12 Radio/Diagnostic 20A { { Grey E F13 Chassis Module 30A { { Black B F14 Spare { { { Black A F15 Bulkhead Module 30A { { Blue A F16 ABS ECU (pneumatic) 15A ABS ECU (hydraulic) 25A 25A Blue C F17 Chassis Module 30A { { Blue B F18 Bulkhead Module 30A { { Grey G F19 Chassis Module 30A { { Black E F20 Bulkhead Module 30A { { Black F Grey H Grey B F21 Spare { { { Black G Blue E Blue D F22 Bulkhead Module 30A { { F23 Spare { { { { Grey D F24 Hydraulic Pump and Spare Grey C F25 Spare { { { Multiple Wire output Pin A & B on Grey Plug and Pin D on Blue Plug Grey A F26 Spare { { { Motor (hydraulic ABS) VBAT 1 BHM VBAT 2 BHM VBAT 3 BHM VBAT 4 BHM VBAT 5 BHM VBAT 1 CHM VBAT 2 CHM VBAT 3 CHM F VBAT Fuse Pin part number for harness connection 23-13213-120 TERM-FEMALE,(20-16) PAC12077411 23- -121 TERM- ,(14-12) PAC12129493 13213 FEMALE 23-13213-122 TERM-FEMALE,(10) PAC12077413 EPA 2010 Models 2010 Smart Plex Electrical Body Builder Reference Page #8 Rev A

Power Supply Fuses and Associated Outputs for the Bulkhead Module BHM Power Input BHM Power Input Pin Fuse Supplying BHM Power Input BHM Outputs Supplied BHM Power In Power Out Battery (dome lamps) B5.A Battery (smart switches) B7.A12 Ignition (VCU) B6.A8 Ignition (engine) B2.K Ignition (ABS) B1.P Ignition (trans) B2.L Fuel Water Sensor Power B1.F Dome Lamps Switched B5.B Left Low Beam B1.R A/C Clutch B2.M Smart Switch 1 Indicator B7.B4 Smart Switch 2 Indicator B7.B8 Smart Switch 3 Indicator B7.A5 Smart Switch 4 Indicator B7.A9 Smart Switch 5 Indicator B7.B10 VBAT1 B3.D Fuse 22 (30A) Battery (smart switch) B7.A12 Accessory (HVAC) B6.A9 Accessory (radio) B6.A10 Wake Up (instrument cluster) B5.D Left High Beam B1.L Wiper High B3.F VBAT2 B4.G Fuse 20 (30A) Horn B3.E Wiper Low B3.H Spare 8.0A HSD (ignition) B5.G Panel Lamps B5.H VBAT3 B1.N Fuse 18 (30A) Panel Lamps (smart switch) B7.A1 Clearance Lamps B5.C Tail Lamps/License Plate Relay B1.K* Washer Pump B3.G VBAT4 B4.K Fuse 15 (30A) 12V Output (cigar lighter) B5.F Spare 8.5A (utility light/spotlight) B5.E / B4.M Left Heated Mirror B4.F VBAT5 B1.J Fuse 7 (30A) Right Heated Mirror B4.E Power Supply Fuses and Associated Outputs for the Chassis Module CHM Power Input CHM Power Input Pin Fuse Supplying CHM Power Input CHM Outputs Supplied CHM Power In Power Out Right Low Beam C3.L Turn Right Front/Side C3.R Turn Right Rear C1.P Right Stop Lamp C1.L Left Stop Lamp C1.N Right DRL C3.K Fog/Road Lamps C3.C/C3.D VBAT1 C4.P Fuse 19 (30A) Trailer Turn Right C2.E Left Park Lamp C4.C Right Park Lamp C4.L Left Marker Lamp C4.D Right Marker Lamp C4.M Trailer Marker Relay C2.F Right High Beam C4.K Left Backup Lamp C1.A Right Backup Lamp C1.J Backup Alarm C1.H Turn Left Front/Side C3.N Turn Left Rear C1.G Left DRL C4.F VBAT2 C3.J Fuse 17 (30A) Trailer Turn Left C2.H Fuel Water Separator Heater C3.A AMU Solenoid 0 C5.H AMU Solenoid 1 C5.J AMU Solenoid 2 C5.L VBAT3 C4.J Fuse 13 (30A) AMU Solenoid 3 C5.M Output Pin Lamp/TrailerTail Output Pin VBAT Fuse System BHM and CHM output pins are powered by multiple VBAT fuses through the main PDM unit. If one of these fuses is tripped or blown then all pins in the circuit will be affected. For this reason seemingly unrelated issues can occur at the same time if a fuse is overloaded and trips. The lists below show which pins are controlled with the VBAT fuses. SmartPlex PDM VBAT Fuse Coverage EPA 2010 Models Bulkhead Module BHM Chassis Module CHM 2010 Smart Plex Electrical Body Builder Reference Page #9 Rev A

Bulk Head Module (BHM) The Bulkhead Module (BHM) The BHM is the primary command module for the electrical system. The module controls the operation of the other component the either directly or indirectly using messages sent over The Bulkhead Module is mounted on the driver side of the front wall and connects to the interior wiring through an opening in the front wall. The BHM has four harness connections on the engine side of the front wall and three harness connections to the cab interior. The BHM Unit contains all system parameters and the unit controls power flow and circuit protection to the various components of the electrical system. The BHM unit can also support up to 5 smart switches. The BHM is programable and can be changed and updated by flashing the unit through service link. Power supply for the BHM is supplied using VBAT fuses, which reside in the main PDM (see page 3) The BHM is programmable and the feature screen in service link can be used to or add parameters to the BHM SmartPlex modules in system the J1939 network. SmartPlex directly change B4 Front Wall Harness B3 Front Wall Harness B1 Forward Chassis Harness B2 Engine Harness B6 Dash Harness B5 Dash Harness B7 Dash Harness B5.E - SPARE (Utility Light/Spotlight) B4.M - SPARE (Utility Light/Spotlight) B3.E - Horn B5.F - Cigar Lighter Output B5.H - Panel Lamps B7.A1 - Panel Lamps (Smart Switch) B5.G - SPARE (Ignition) B6.A9 - Accessory (HVAC) B6.A10 - Accessory (Radio) B4.F - SPARE (Left Heated Mirror) B4.E - SPARE (Right Heated Mirror) B6.A8 - Ignition (VCU) B2.K - Ignition (Engine) B1.P - Ignition (ABS) B5.A - Battery (Dome Lamps) B7.A12 - Battery (Smart Switch) B5.D - Wake Up (Instrument Cluster) B5.B - Dome Lamps Switched B1.L - Left High Beam B2.L - Ignition (Trans) B1.F - Fuel Water Sensor Power B3.F - Wiper High B5.C - Clearance Lamps B1.K - Tail/License Plate/Trailer Relay B1.R - Left Low Beam B3.H - Wiper Low B3.G - Washer Pump B2.M - AC Clutch B4.B - Starter Relay (Crank) 6.7A 6.7A 6.7A 6.7A 6.7A 6.7A Combined 6.7A 6.7A 6.7A 6.7A 6.7A Combined 6.7A Combined 6.7A Combined 12A Combined 12A 12A Combined 12A 20A Combined - Bulkhead Module outputs have defined amperage limits. - If higher loads are required, bulkhead module outputs should be used as signal power in conjunction with a relay. Key Bulkhead Module Outputs Pin part numbers for harness connection FEMALE 23-13212-122 TERM-FEMALE,(10) PAC15326004 Inside Cab Connections: PAC12129494 TERM-FEMALE,(12-14) PAC12034046 TERM-FEMALE,(16-18) Outside Cab Connections: 23-13212-120 TERM-FEMALE,(18-16) PAC153047191 23-13212-121 TERM- ,(14-12) PAC15304720 EPA 2010 Models 2010 Smart Plex Electrical Body Builder Reference Page #10 Rev A