BODY BUILDER INSTRUCTIONS - Mack Trucks

1 body BUILDERINSTRUCTIONSMackTrucksElectricalW iringand ConnectionsCHU,CXU,GU, TD, MRU,LRSection3 IntroductionThis informationprovidesdesignand function,specificationand proceduredetailsforElectricalWiringand Connectionsfor :For informationonmDrivePTO installationand wiringsee Section9 PTOI nstallation, :For informationon PTO parameterprogrammingsee Section9 PTO ,followinga recommendationlistedin this manualdoesnotautomaticallyguaranteecompl iancewith applicablegovernmentregulationsis your responsibilityas the advisedthat the MACKT rucks,Inc. vehiclewarrantydoesnot applyto anyMACK vehiclethat has beenmodifiedin any way, whichin mack 'sjudgmentmightaffectthe vehiclesstabilityor Abbreviations ,page3 GeneralWiringDefinitions ,page4 Routingand ClippingGuidelines ,page5 BodyBuilderConnectors,SchematicExamples ,page17 RemoteStartn Stop ,page23 RemoteEngineStop ,page24 AddingAuxiliaryAcceleratorPedal ,page25 BodyLinkIII , page26 AuxiliarySwitchLocations(Cab) ,page30 PowerConnections ,page31 ControlLink II , page37 LR Workbrake ,page50 MackBodyBuilderInstructionsCHU,CXU,GU, TD, MRU, (94)

2 All RightsReserved WiringJ1939 ,page52 9-pinDiagnosticConnector ,page54 16-pinDiagnosticConnector ,page55 TerminationResistor ,page60 ParameterList ,page61 MultiplexingBodyBuilderJ1939 CAN , page77 SupportInboundand OutboundJ-1939 MessageInformation , page85 CHU,CXU,GU, TD, MRU, (94)Abbreviations ACCA daptiveCruiseControl BOCB ackof Cab CANC ontrollerAreaNetwork CDSC ustomDefinedStatement(replacedby DCL) DCL DataMaxControlLanguage ECME ngineControlModule EHT ElectronicHandThrottle EMSE ngineManagementSystem ESC EngineSpeedControl FMI FailureModeIdentification GMTG reenwichMeanTime MID MessageIdentifier(J1587source) PGNP arameterGroupNumber(J1939messageID) PID ParameterIdentification(J1587) PID ProductIdentification(ordercode) PTO PowerTake Off PTT2 PremiumTech Tool 2 SA SourceAddress(J1939unit identifier) SID SubsystemIdentification(J1587) SPN SuspectParameterNumber(J1939parameter) SSC SingleSpeedControl TCMT ransmissionControlModule VDA VehicleDataAdministration(OEMdatabase) VECUV ehicleElectronicControlUnit V-MACV ehicleManagementAnd Control(Mackbrandelectronicsname)MackBod yBuilderInstructionsCHU,CXU,GU, TD, MRU, ConnectionsPage3 (94)

3 All RightsReservedGeneralWiringDefinitionsTh e generalwiringdefinitionsprovidesa standardizedlist of terminologyusedin runningwires,hoses,and cablesthrough-out the causingdamageto the routedcommodityin a rubbingconditionduringvehicleoperationAW GA mericanWire GaugeBundledWithA numberof itemstied, wrapped,or otherwiseheld togetherCableTieA nylonplasticself-sizingstrap,UV resistant,capableof bundlingspecifiedload(s)duringvehicleope rationChafingTo wearawayby routedcommoditythat is bent or pressedinto ridgesDamagedAn item that differs from its originalconditionDroopingRouteditemshang ingdownwardwhichare detrimentalto safe vehicleoperationDual Fall(Pertainingto the CompressorDischargeLine)A high pointin the routingof the CompressorDis-chargeLine (locatedon the engine)wherebyany collectedmoistureis allowedto fall in two different di-rectionswhereit is eitherdissipatedby heat or is purgedHigh CurrentElectricalCablesWire sizes13 mm sq.

4 ( inchessq.) (6 AWG) and largerHigh NutExtendedclamplengthKinkedA tight bend,curl, or twist in the routedcommoditycausingflow to be restrictedLow CurrentElec-trical CablesWire sizes8 mm sq. ( inchessq) (8 AWG) and smallerLow NutStandardclamplengthMaterialGrade30 Minimumyield strengthof 30,000psiMaterialGrade50 Minimumyield strengthof 50,000psiMayVerb typicallyusedin a statementof practicethat is a permissiveconditionand carriesno requirementor can be includedto alter statementsof mandateor recommendationNot SecuredItemsnot fastened,bundledor tiedPlasticConduitCorrugatedor smoothwall tubingusedto protecthoses,harnesses,cables,tubing,pip es, or woundRoutedWithItemstakingthe samepath but not attachedto eachother( , parallelbut separate)

5 RubbingItemsthat contacteachotherand haveindependentmovementShallVerb typicallyusedin a statementof required,mandatoryor specificallyprohibitivepracticeregarding routingand clippingSharpEdgeA surfacecapableof cuttingor piercingthe routedcommodityduringvehicleoperationSho uldVerb typicallyusedin a statementof recommended,but not mandatory, practicein typicalsituationswith deviationsallowedif Engineeringjudgementor Engineeringstudyindicatesthe deviationisappropriateMackBodyBuilderIns tructionsCHU,CXU,GU, TD, MRU, ConnectionsPage4 (94)All RightsReservedTwistedDistortedfrom the routedcommodities originalshapeaboutit s cross-sectionalcenterlineTouchItemsthat contacteachotherbut do not haverelativemovementRoutingand ClippingGuidelines1 Bracketsusedin routingand clippingshouldbe MaterialGrade50 or betterto ensuresufficientclampload whensharingjoint connectionswith crossmembersor appliesonly to joint connectionsusinga low MaterialGrade30 are acceptableprovidedthe sharedjoint is usinga high nut.

6 The area of the clip bracketunderthe bolt headmustbe a leastas largeas the bolt Clipsthat scratchexteriormountingsurfacesshall not be used( , barbed/springtype)unlessthe materialis non-corrod-ing ( , plastic).Clipsmusthaverust Clip sizesshouldadequatelysecurethe bundlewithoutrestrictingflow, causingcollapse,or Bundlesshall be supportedat 24 inches(600 mm) maximumintervals,a cabletie shouldbe usedbetweenclip pointsonbundleswith the exceptionof electricalwiringharnesswhichshall havea maximumsupportdistanceof 18 inches(450mm) and a cabletie on bundlesbetweenclip and electricallines are bundledtogether, the commoditywith the greatercrosssectionalarea may determinethe minimumof two cableties shall be usedbe-tweenclip pointsto bundleelectricallines whenthe largerintervalis Supportelectricalcablesevery18 inches(450 mm)MackBodyBuilderInstructionsCHU,CXU,GU , TD, MRU, ConnectionsPage5 (94)

7 All RightsReservedSupportDistances,Continued W31041441 Supportcablesnear connectorsevery4 inches(100 mm)1 Electricalcablesand wiringharnessesare to be secured4 inches(100 mm) from the wire insertionend of the connectoror clippedto the Routingand clippingon purchasedcomponents( , engine/transmission)shouldnot includeremovingor replacingabolt(s),nut(s)or screw(s)installedby the manufacturer. In suchcaseswherethis is unavoidable,the bolt (s),nut(s)orscrew(s)shall be re-installedto the manufacturer s Bundlesshouldnot contactsharpedgesof occurif it is againsta smoothsurface,a smoothradiusededgeor a coinededgeand the bundleis securedto Hoses,tubing,pipesand electricalconduitsshall not rub eachotherbut may The fabricbraidedportionof the compressordischargehoseis compatibleto be bundledwith all routedair The compressordischargepipe shall be routedindependentof all Electriccables/harnessesmustnot be bundledwith fuel or electricalcables/harnessesmay be routedparallelwith fuel or hydrauliclines,howevermustremainseparate dby possible.

8 Electricalcables/harnesseswill be routedabovefuel or fuel or hydrauliclines mustrouteabovecircuitprotectedelectrical cables/harnesses,the fuel or hydrauliclines will haveno fittingsor potentialleak pointsaboveelectricalcables/harnessesand shall be minimizedto the shortestdistancepossibleover low currentelectricalca- All associatedmarkingson air and electricalharnessesshouldhavea Criticalclippinglocationsshall be designatedon the componentto insureproperplacementin the vehicle( , tape).10 Maximumsupportdistancefor compressordischargerigid pipe,30 inches(762 mm).Pipe to be isolatedfrom supportbrackets( rubberisolator).11 Maximumsupportdistancefor compressordischargeflex hose,24 inches(600 mm).12 Compressordischargeline shouldhavea constantfall from compressorto air dryer.

9 A dual fall is allowableprovidedit oc-curs on the engineand within24 inches(600 mm) of the in compressordischargepipe/hoseis one half the outerdiameterof the shouldhaveno dips in any of the is to avoidline blockagedue to watercollectingand freezingin the ,CXU,GU, TD, MRU, ConnectionsPage6 (94)All RightsReservedHeatingSpecificationsIn orderto maintainthe integrityof the cablesand hoses,observethe followingspecificationsfor routingnear a heat ,hose, or harnesstypeSpecificationElectricalcables and wiringharnesses5 inches(130 mm) in all directionsfrom turbocharger, exhaustcomponents,and otherhighheat componentsUnprotectedhoses,tubing,harnes ses,and cables6 inches(150 mm) above,5 inches(130 mm) besideand 4 inches(100 mm) belowHoses,tubing,harnesses,and cablesprotectedby re-flectiveheat sheathing3 inches(76 mm) above,2 inches(63,5mm) besideand 2 inches(51 mm) belowSiliconetransmissioncoolanthoses2 inches(51 mm) from exhaustmanifoldand turbo(withreflectiveheat sleeving),1 inch (25mm) from exhaustpipeHoses,tubing,harnesses,and cablesprotectedby aheat shield(no reflectivesheathing)3/8 inch (10 mm) betweenthe componentand the heat shield.

10 (Not valid for fuel lines)Refrigerantsuctionhoses8 inches(200 mm)W31098971 HeatRadiusfrom the Turbocharger, Front:5 inches(130 mm)MackBodyBuilderInstructionsCHU,CXU,GU , TD, MRU, ConnectionsPage7 (94)All RightsReservedW2106268 The SCR,DPF, and ,CXU,GU, TD, MRU, ConnectionsPage8 (94)All RightsReservedClippingGuidelinesClipping bracketsshouldbe designedand mountedto adequatelysupportthe mountedin a hangingpositionor supportedalongthree-quartersof the do not conformto the illustra-tionsshall be Whenhoses,wires,and cablescrossone another, securethemwith a preventsthe sawingmotionthat Whenroutingflex hosesthat are bent in two planes,clip themto hoseat the clamphas the effect of dividingthe hoseinto two the sectionof the hoseis bentin the sameplaneas the movement,the bendwill absorbthe movementand the hosewill not ,CXU,GU, TD, MRU, ConnectionsPage9 (94)All RightsReservedWhenroutingconnectorswith cableties, ensurethe cableties do not contactthe connectorlockingtab.