Navistar CV 2019 Series, Integration Manual

Page 1: ...ystems CV Integration Guide Jay E Bissontz Digital Watermark Page 1 of 84 Revision Date 9 12 2019 Navistar Electrical Systems CV Vocational Series Integration Guide Copyright Navistar Corporation 2019...

Page 2: ...ture TEM 22 3 8 Diesel Particulate Filter DPF Cleaning during Stationary PTO Operation 23 3 9 Mobile PTO Operating Modes and Programming 24 3 9 1 Mobile PTO in cab operation only Enable Conditions req...

Page 3: ...GE DESCRIPTION REASON FOR CHANGE REVISED BY 01 9 12 2019 ALL INITIAL DRAFT INITIATION OF DOCUMENT J BISSONTZ 2 Forward Warning In the pages of this document are a diverse set of truck chassis system a...

Page 4: ...l tools for safe and correct service Failure to use these special tools when required can cause injury to service personnel or damage to vehicle components DISCLAIMER INTERNATIONAL DOES NOT TAKE ANY R...

Page 5: ...t to jump start a vehicle having a frozen battery because the battery may explode If a frozen battery is suspected examine all fill vents on the battery If ice can be seen do not attempt to start with...

Page 6: ...tches the Body Controller and the Instrument Cluster Other data links in the vehicle allow other electrical controllers the BC and the Instrument Cluster to communicate with each other 3 2 Power Take...

Page 7: ...and comes with a cap which is the mating half to the truck harness connector This is the connector the Truck Equipment Manufacture TEM will use to wire in external electrical components such as a cont...

Page 8: ...Navistar Electrical Systems CV Integration Guide Page 8 of 84 Revision Date 9 12 2019 Figure 4 1 3 PTOM Mounting Location...

Page 9: ...KI4 2 Speaker Left Instrument Panel UQ3 10 Accessory Power Receptacle Instrument Panel 2 3 Instrument Cluster 11 Accessory Power Receptacle Instrument Panel 1 4 Ambient Light Sunload Sensor 12 USB Rec...

Page 10: ...er Take Off Jumper Harness Connector Part Information truck side Harness Type Engine OEM Connector 15326863 Service Connector 6040235C1 Description 16 Way F 150 GT Series Sealed BK Connector Part Info...

Page 11: ...ation Pin Color Circuit Terminal Type ID Function A BN WH 6085 I Power Take Off Remote Engine Start Switch Signal B BN 6381 I Power Take Off Relay Engage Signal Relay Coil High Side pin 86 C Not Occup...

Page 12: ...he relay driver turned on so they would not engage the PTO until reprogrammed at a dealer That has been corrected The three factory speeds are 1 900 RPM occurs with press and release of the PTO switch...

Page 13: ...PTO connector X191 has a cap installed at the assembly plant with a jumper between pins A and J The cap is a useable mating connector and it could be rewired as shown above To avoid setting internal...

Page 14: ...ed with a switch OR a potentiometer not both 2 For MY2015 17 continuity between pins A J is monitored must be maintained It can be interrupted only during the actuation of the kill switch Continuous l...

Page 15: ...d for dual stationary mobile mode pairing All PTO modes provide for engine rpm control and PTO load relay control engage disengage All PTO modes provide for safety interlocks for PTO load disengagemen...

Page 16: ...ed 6 Cruise Control must be OFF 7 Press and release the PTO In cab switch located below the center console The PTO telltale will blink rapidly until the PTO load relay becomes engaged Ref Note 3 below...

Page 17: ...4 The engine must be stopped and the Ignition key removed Vehicle can be locked if desired 5 From the Remote Switch Panel close and open the PTO Remote Arm Switch 6 Within 5 seconds open and close the...

Page 18: ...property damage may result from vehicle movement Always remove key from the ignition before operating Remote PTO 3 6 3 Preset PTO Remote Operation with In Cab Engage Enable Conditions requires progra...

Page 19: ...Filter DPF Cleaning during Stationary PTO Operation If the DPF becomes sufficiently loaded with soot during a PTO session the system will issue a DIC warning message and horn chirps as notification t...

Page 20: ...ility to change the default value for tap step via the Radio Customization menu The default values for both tap step and for ramp rate can be changed with a Navistar CV vehicle service tool 2 The acce...

Page 21: ...will lock upon reaching stable PTO Standby Speed default 900 rpm so maximum power is available 3 The first elevated engine speed PTO Standby Speed is not intended as a working speed but as a verificat...

Page 22: ...remote switch panel provided by Truck Equipment Manufacture TEM Starting Remote Operation from cab 1 With the engine running shift the transmission to P Park and release the brake pedal 2 Assure the c...

Page 23: ...or any horn chips if operating PTO remotely If the DIC message or horn chirp is presented during PTO operation see OWNER MANUAL Diesel Particulate Filter for information on how to clean or regenerate...

Page 24: ...The engine speed will remain at the current throttle setting or advance to PTO Standby Speed which ever value is greater If the engine rpm is above 1500 rpm the PTO relay will not engage until the eng...

Page 25: ...e hood is closed 3 Set the parking brake 4 Press and release the In Cab PTO Switch the PTO indicator LED will begin flashing 5 Within 10 seconds press and release the cruise Set switch The PTO indicat...

Page 26: ...he PTO Standby Speed setting The desired engine speed can now be adjusted with the cruise control buttons or the accelerator pedal The cruise set and resume buttons will operate similar to normal high...

Page 27: ...is still stored in memory Activating the Cruise Res switch will restore engine rpm to the last PTO Set speed Press and release the PTO in cab switch The PTO Load Relay will be disengaged and engine r...

Page 28: ...ent However when ordering any Navistar Emergency Vehicle vocational sales applications Automatic Engine Shutdown is disabled Emergency Vehicle provisions for PTO are limited to the disabling the follo...

Page 29: ...urn engine rpm to the PTO Standby Speed setting Press and release the Cruise Cancel switch The engine returns to base idle but the PTO load relay remains engaged The PTO Telltale will blink slowly ind...

Page 30: ...or any horn chips if operating PTO remotely If the DIC message or horn chirp is presented during PTO operation see OWNER MANUAL Diesel Particulate Filter for information on how to clean or regenerate...

Page 31: ...remove key from the ignition before operating Remote PTO 3 13 PTO Operational Speed Control 3 13 1 Variable PTO operational speed control provides the following functions Cruise Set Switch In cab or...

Page 32: ...s reached or until the maximum allowable PTO set speed is reached Alternatively the engine speed acceleration can be adjusted via the Radio Customization menu Table 4 4 2 Factory Preset Parameters The...

Page 33: ...RPM for Model Year 15 thru 16 13 PTO Set 2 Speed 1900 RPM 1700 RPM 2900 RPM for Model Year 17 thru 19 3100 RPM for Model Year 15 thru 16 14 Interlock or Redundant Emergency Stop Feedback NO NO YES 15...

Page 34: ...eed 2100 RPM 1100 RPM 2900 RPM for Model Year 17 thru 19 3100 RPM for Model Year 15 thru 16 29 PTO Standby Speed 900 RPM 700 RPM 2100 RPM 30 Engine Run Timer while PTO is Active 420 min 10 min 3480 mi...

Page 35: ...Control Maximum Input Signal Potentiometer Maximum 95 50 100 41 Engine Shutdown Enable Enabled Disabled Enabled 42 Driver Door Status Usage Enabled Disabled Enabled 43 Remote PTO InCab Control Enable...

Page 36: ...Additional in vehicle PTO module information can be accessed by the service technician to aid in troubleshooting Also see service manual for more information The Navistar service technician can acces...

Page 37: ...or life support operations or an emergency back up power source Safety and function of all equipment added by the Truck Equipment Manufacture TEM to the vehicle is the responsibility of the TEM TEM is...

Page 38: ...r switch independently or outside of the prescribed time window is insufficient to initiate a start When stopping the Remote Engine Shutdown Star t Switch operates independently supporting a fast shut...

Page 39: ...vehicle s engine This device is required to support an emergency shutdown initiated from outside the vehicle and in the vicinity of the remote location prominently visible and easily accessible should...

Page 40: ...the alternative chosen sets controls engine speed but the PTO System limits the maximum rate of change of engine speed during the transition to the newly selected speed This device must be selected ca...

Page 41: ...Return D Vehicle Ground Signal Reference Reference for all signals monitored for faults that would lead to a safety issue Measurement s made at various points within the system are taken with respect...

Page 42: ...TTLE HAND CONTROL Engine Speed Control L PTO Figure 5 1 1 NOTE Fast Idle RPO UF3 can be added by the dealer at extra cost Figure 5 1 2 Steering Wheel Controls Fast Idle is controlled using the Cruise...

Page 43: ...le UF3 Adding the Fast Idle 12WGJ feature is accomplished by reprogramming the Vehicle s Body Control Module BCM Navistar Dealers can acquire a new Vehicle Configuration Index VCI by contacting Techli...

Page 44: ...or Ignition Run Crank 12v outputs The configuration is accomplished by the RELOCATION of two fuses in the both the LH and RH Fuse blocks The configuration for battery or ignition is done in pairs Fuse...

Page 45: ...ide Page 45 of 84 Revision Date 9 12 2019 Figure 6 1 2 Truck Equipment Manufacture TEM Auxiliary Switches The outputs from the switches are located inside the cab into the LH IP Junction Block Figure...

Page 46: ...uipment Manufacture TEM added configured circuits Table 6 1 1 TEM Connector Part Numbers Connector Part Information Harness Type Truck Equipment Manufacture TEM OEM Connector 15547108 This connector i...

Page 47: ...ype ID Terminated Lead Diagnostic Test Probe Terminal Removal Tool Service Terminal Tray Core Crimp Insulation Crimp I 6042083C91 J 35616 35 VT J 38125 11A 7116 4112 02 9 C D II 6042084C91 J 35616 2A...

Page 48: ...output I 8XJP 5 6 Not Occupied 7 2340 Battery Positive Voltage 15 amp I 8 43 Accessory Voltage 10 amp II 9 5060 Low Speed GMLAN Serial Data II 10 1050 Ground I 11 1939 Run Crank Ignition 1 Voltage 15...

Page 49: ...ate only when the ignition is in the Run Crank mode simply relocate the 5 amp fuse from location 18 to that of location 5 NOTE do NOT populate both fuse 5 and fuse 18 locations at the same time NOTE T...

Page 50: ...Guide Page 50 of 84 Revision Date 9 12 2019 Figure 6 1 8 Wire Harness Pass thru location Figure 6 1 8 shows the location of the Truck Equipment Manufacture TEM wire harness pass through Truck Equipme...

Page 51: ...ission controller operation rough shifting and clutch slip problems as well as intermittent no crank issues have been reported In many cases the issue is resolved by restoring the OEM battery and cabl...

Page 52: ...be the same gauge c Welded studs added to the frame are recommended for the two required connection points The frame bolt clamping connection method presents multiple failure modes and is not recommen...

Page 53: ...electrical center should be made at the starter motor solenoid most recommended c If the stacking of multiple cables on the starter solenoid stud is a problem a single main cable to a junction block...

Page 54: ...Navistar Electrical Systems CV Integration Guide Page 54 of 84 Revision Date 9 12 2019 Figure 7 1 Remote Battery Connections Schmatic...

Page 55: ...rance Regular Production Option RPO UVC provides the following content for facilitating the installation of a rear view camera Rear camera calibration installed at assembly plant One camera unit compl...

Page 56: ...s CV Integration Guide Page 56 of 84 Revision Date 9 12 2019 Figure 8 1 1 Camera Extension Harness Mounting Bracket Extension harness Mounting Bracket Includes 2 not shown screws for securing camera t...

Page 57: ...on currently cannot be retrofitted as chassis wiring provisions are not provided without the option being present at the time of the vehicle build 8 Infor Radio Telephone Mobile radio Transcever Insta...

Page 58: ...or on transmission hump where they will not interfere with vehicle controls or passenger movement Great care should be taken not to mount any transceivers microphones speakers or any other item in the...

Page 59: ...e of glass If RF related interactions occur when using a hitch or bumper mount HF antenna on a vehicle that has body on frame construction i e pickup SUV connect a ground strap from the vehicle frame...

Page 60: ...aced in the transceiver negative lead to prevent possible transceiver damage in the event the battery to engine block ground lead is inadvertently disconnected For ONE PIECE TRANSCEIVERS where ignitio...

Page 61: ...he trunk through the rear bulkhead All attempts should be made to maintain as great a distance as possible between radio power leads and vehicle electronic modules and wiring If the battery is located...

Page 62: ...n Example of Remote Mounted Transceiver Table 9 1 1 Component Locations Remote Mounted Transceiver Component Descriptions by Location 1 Fuses 2 Battery 3 Grommet Installed in the Buldkead and Separate...

Page 63: ...ece Transceiver Component Descriptions by Location 1 Fuses 2 Battery 3 Grommet Installed in the Bulkhead and Separate from other vehicle Wires 4 Coax Cable 5 Roof antenna Location 6 Rear Deck Antenna...

Page 64: ...Installation Table 9 1 3 Part Numbers and Descriptions Part Number and Descriptions 1 Vehicle Battery Cable 2 Vehicle Battery 3 Contact Spacer 4 Adapter Terminal part of kit 1846855 5 Long Battery Ter...

Page 65: ...tep 6 4 Check for ground points and correct cable routing and antenna location Does the installation conform to Navistar guidelines Go to Step 6 Go to Step 5 5 Correct the installation Is the concern...

Page 66: ...ant connection illustrated Table 9 1 5 Terminal Adapter Parts Side Terminal Adapter Package Description AC Delco Catalog 7A10 Car Dealer Parts Book Kit 1846855 1846855 Bolt 7803 12004188 Spacer 7804 1...

Page 67: ...omponents within the doors consideration to moving parts and environment When considering a new location for component s be aware of the travel path of the moving window and its components Also being...

Page 68: ...r all its models Body builders and installers should refer to these manuals before connecting body lights and accessories to the vehicle electrical system to assure that circuits chosen are both appro...

Page 69: ...LE LINK 80 A 6 GUAGE 10 GAUGE FUSIBLE LINK 108 A 4 GUAGE 2 12 GAUGE FUSIBLE LINK 160 A CAUTION WIRE GAUGE IS DESIGNED TO MATCH FUSE CIRCUIT BREAKER RATING DO NOT INCREASE THE SIZE OF A CIRCUIT BREAKER...

Page 70: ...C1 SEAL WIRE LT GN 110 080 O D CABLE 16 20 GAUGE 1661375C2 BODY CONNECTOR 5 WAY MALE 1661377C1 TERMINAL FEMALE 14 16 GAUGE 1661376C1 LOCK 5 WAY MALE CONNECTOR 1677851C1 BODY CONNECTOR 5 WAY FEMALE 167...

Page 71: ...erminals and electrically check for continuity Standard Terminal 1 MATING END 2 CORE WINGS 3 INSULATION WINGS 4 CABLE 5 LOCK TANG 6 INSULATION 7 WIRE STRANDS 8 SOLDER Splice Inspection Splice Inspecti...

Page 72: ...1 Cut off the old clip or bad section of wire 2 Remove the insulation being careful not to cut any of the wire strands 3 Install the proper clip on the wire strands 4 Hand crimp the clip until securel...

Page 73: ...ad section of the wire 2 Remove insulation being careful not to cut any of the wire strands 3 Install the proper sleeve on the wire strands making sure the ends of the wire hit the stop 4 Hand crimp t...

Page 74: ...lded and covered with heat shrink Wire Repair This instruction addresses termination and splicing of J1939 wire Preparation of J1939 Wire for Connection 1 Strip back view C outer shield 3 1 8 in 76 mm...

Page 75: ...84 Revision Date 9 12 2019 Wire Splicing 1 Strip wire ends 1 4 inch 2 Re twist any loose wires Re Twist Any Loose Wires 3 Slide 2 inch pieces of heat shrink tube over wire for later use Put Heat Shrin...

Page 76: ...uide Page 76 of 84 Revision Date 9 12 2019 5 Insert ends of wires into splice joint and crimp 6 Solder the wires and crimp joint together Solder Wires Together 7 Center heat shrink tube over splice an...

Page 77: ...y and performance of the vehicle systems For repair procedure see Electrical Troubleshooting Guide S08250 or Data Link Repair in this manual This information based on SAE J1939 15 and TMC RP 142 These...

Page 78: ...property damage personal injury or death refer to the manufacturer s service information before working on any high voltage equipment By definition high voltage circuits and components contain voltage...

Page 79: ...n AC circuit Contacting an unknown AC or DC voltage may cause equipment damage electrical shock and or electrocution Only a trained technician may perform service inside high voltage components If wor...

Page 80: ...to be familiar with the equipment and circuit diagrams as well as to look for high voltage warning labels and orange conduit Inspect the vehicle for any equipment or circuits added after the truck wa...

Page 81: ...lone near high voltage equipment Always stand on an insulated dry surface when working on any electrical circuit Do not handle any kind of electrical device while standing in water while barefoot or w...

Page 82: ...al at levels greater than 60 volts High voltage can jump a larger air gap than low voltage If contact is made with high voltage it may not be possible to simply let go Towing a HEV with its drive whee...

Page 83: ...cable wiring or electrical harness must not rub on a sharp edge However due to the high abrasion resistance of synflex tubing it is permissible for synflex tubing to make contact with the lower edge...

Page 84: ...ED FROM DAMAGE YES DRIP POINT FOR HARNESS YES DISTANCE OF HARNESS TO FLAMMABLE FLUIDS 1 2 HARNESS LOCATION TO FLAMMABLE FLUIDS NOT DIRECTLY UNDER BATTERY CABLES TO FLAMMABLE FLUIDS 1 MINIMUM BATTERY C...