Electrical System Overview EPA 2010 Electrical …

1 EPA 2010 Models - M2106, M2112, 108SD, 114 SDElectricalBody Builder Reference GuideElectrical System Overview2010 Smart Plex Electrical Body Builder Reference Page 1 Rev AEPA 2010 ModelsElectrical System OverviewEPA 2010 ModelsIndexPage 1 IndexPage 2 Electrical Component OverviewPage 3 Electrical Harness OverviewPage 4 Electrical Power flow OverviewPage 5 Page 6 Page 7 Page 8 Page 9 Bulk Head Module (BHM)Page 10 Bulk Head Module (BHM) Pin DetailPage 11 Chassis Module (CHM)Page 12 PNDB Power Net Distribution Box Positive Disconnect SwitchMain Power Distribution Module (PDM)PDM / VBAT Fuse CoverageChassis Module (CHM) Pin DetailPage 13 Multiplexing System BackbonePage 14 System Tap PointsPage 15 J1708 GatewayPage 16 Low Current Smart SwitchesPage 17 High Current Switches (Battery Hot)Page 18 High Current Switch (BH) SchematicsPage 19 High Current Switches (Ignition Interlocked)Page 20 High Current Switch (Ignition Interlocked) SchematicsPage 21 High Current Switch Label OptionsPage 22 Body Builder Lighting InterfacePage 23 Body Builder PDMPage 27 Trailer Electrical Schematics (Combination)PTO InstallationPage 36 PTO PTO ControlsPage 37 PTO Air SchematicsPage 38 PTO Electrical SchematicsPage 39 Hybrid PTO OptionsPage 40 Remote Start Stop SchematicsPage 41 VDR Prep Information (NFPA)

2 Page 42 SmartPlex VDR ConnectionsPage 24 Body Lighting Interface SchematicsPage 25 Trailer PDMPage 26 Trailer Electrical Schematics (Seperate)Page 28 Wired Rite PrepPage 29 Wired Rite SchematicPage 30 Wired Rite Trailer and Floor connectionsPage 31 Tail LightsPage 32 Tail light SchematicsPage 33 Transmission InterfacePage 34 Engine InterfacePage 35 2010 Smart Plex Electrical Body Builder Reference Page #2 Rev AAccessory 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 (Module , 34C) Electrical Component OverviewEPA 2010 Models2010 Smart Plex Electrical Body Builder Reference Page #3 Rev APNDB Power Net DistributionBox (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 OverviewFORWARD 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 28 AMAIN CAB HARNESS Module 1) Connections to bulkhead connector 2) Connections to diagnostic connector (behind ignition switch) 3)

3 Connections to CPC4) Pass-thru connector to engine compartment5) Gauge Cluster6) HVAC unit and controler7) 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 HarnessPOWERTRAIN 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)

4 Connections to rear combo valves EPA 2010 Models2010 Smart Plex Electrical Body Builder Reference Page #4 Rev AElectrical Power Flow OverviewEPA 2010 ModelsBatteryMain PNDBTCMT railer PDMTail LightsBB PNDBBody Lighting ConnTransmission ConnectorBB PDMT railer ConnectorEngine ConnectorMain PDMBHMP owertrain PDMECMICUCHMC2-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 OutputsBulkhead Module - SPARE (Utility light /Spotlight) - SPARE (Utility light /Spotlight) - Horn - Cigar Lighter Output - Panel Lamps - Panel Lamps (Smart Switch) - SPARE (Ignition) - Accessory (HVAC) - Accessory (Radio) - SPARE (Left Heated Mirror) - SPARE (Right Heated Mirror) - Ignition (VCU) - Ignition (Engine) - Ignition (ABS) - Battery (Dome Lamps) - Battery (Smart Switch) - Instrument - Dome Lamps Switched - Left High Beam - Ignition (Trans) - Fuel Water Sensor Power - Wiper High - Clearance Lamps - Tail/License Plate - Left Low Beam - Wiper Low - Washer Pump - AC Clutch - Starter Relay (Crank)

5 /Trailer RelayC3-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 ECMTCMBHMCHMICUBBPNDBMainPNDBMainPDMP owertrainPDMBBPDMT railerPDMB attery(296) Trailer Connector(353) Body Lighting ConnEngineConnectorTransmission Connector(294) Tail LightsJ1939 Multiplexed Network2010 Smart Plex Electrical Body Builder Reference Page #5 Rev APNDB Power Net Distribution BoxEPA 2010 ModelsINSTALLATION WITHOUTDISCONNECT SWITCHINSTALLATION WITHDISCONNECT SWITCHP rimary Solenoidfor Cut off SwitchBattery InputPrimary SolenoidCut Off Switch ConnectionATC Fuse OutputATC FusesMIDI Fuse OutputFuse Coverand labelPower 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 PNDB also has protected keep alive circuits that maintain power even with the cutoff switch is in the off position.

6 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 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 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 forcrew cab units. designed System ATC -AATC -BATC -CATC -DATC Fuse outputkeeps power on afterdisconnectMating connector23-13153-4101A2231 ABCDB3 CADBECF4 DBattery Input300 AMPS MaxAFTER TREATMENT ECUEMERGENCY POWERRADIO AND CLOCKALTERNATOR REMOTE SENSEGROUNDX2 KEEP ALIVE CIRCUITX1 SOLENOID CONTROLSIGNAL OFFLED INDICATORSIGNAL ONSIGNAL RETURNGROUND1234 ABCDEFCONNECTORPINDESCRIPTIONFuseDescrip tionFunctionRatingMax.

7 Fuse AllowedATC-AKeep Alive PowerAfter Treatment ECU30 AMPS30 AMPSATC-BKeep Alive PowerEmergency Power20 AMPS30 AMPSATC-CKeep Alive PowerRadio and Clock5 AMPS30 AMPSATC-DKeep Alive PowerAlternator Remote Sense5 AMPS30 AMPSMIDI-1 (Fuse 1)High AMP FusePowertrain PDM175 AMPS200 AMPSMIDI-2 (Fuse 2)High AMP FusePDM #2 125 AMPS200 AMPSMIDI-3 (Fuse 3)High AMP FusePDM #1125 AMPS200 AMPSS olenoid Control2010 Smart Plex Electrical Body Builder Reference Page #6 Rev APositive Cutoff SwitchEPA 2010 ModelsBattery Box Disconnect Switch Mounting with box mounted air tanks (brackets will vary depending on application) 293-061In Cab Mounted Disconnect Switch Mounting 293-058 Battery Box Mounting without box mounted air tanks293-001, 293-061 Disconnect Switch Positive Disconnect SwitchThe disconnect switch System for 2010 has been reconfiguredto provide better application coverage and offer two levelsof power disconnect based on the options ordered with the cab disconnect switches will be offered in a locking or non locking battery mounted switches will be offered in the locking configuration switches are equipped with red LED lights, which are when power is equipped with the body builder auxiliary power System will have an additional LED light on the switch.

8 Note: Both PNDB units will be deactivated when the switch is in the off position. illuminated Axillary Body Builder Cutoff Switch StandardCutoff Switch Standard Power LEDL ockout TabAuxiliary Powerand Main Power LEDMain Cab PNDBC onnector Plug #23-13153-307 Body Builder PNDBC onnector Plug #23-13662-4011321423293-057293-061293-06 0293-058 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 293-063X2, Aux PNDBX1, Main PNDB2010 Smart Plex Electrical Body Builder Reference Page #7 Rev AThe main Power Distribution Module (PDM)

9 Distributesbattery power to the various control modules on 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 are four plugs attaching to the module that supply output spare fuse sockets are listed below but mayvary based on the options that have been Spare Fuse locations F6, F10, F11, F14, F21, F23, F25, F26protect for it is ABBAACBGHEGDCBADBFCDHHGGDCHEEFS ingle Wire Outputfound on Plug in Pin GGreenPDM Plugs contain outputwiresPDM #1(MIDI-3)PDM # 2 (MIDI-2)Engine HarnessPlug (Green)Forward ChassisHarness Plug (Blue)Forward ChassisHarness Plug (Grey)Front WallHarness Plug (Black)Main Power Distribution Module (PDM)

10 Power Distribution Module FuseSpecications*OutputMEGAFuseConnectio nFuseLocationPrimaryFunctionFuseRatingSe condaryFunctionFuseRatingGreen A1F1 Spare{Green BGreen H1F2 BlowerMotor30A{{{{{2F3 SpareSpareSpare30 AGreen G2F430A30 ABlack D12F5 IgnitionSwitch5A{{Black C11F6 Hydromax RelayGray F11F7 BulkheadModule30A{{Green C22222222F8 ICU3-M210A{{{Green D2111111F9 30 ABlue GGreen F2F10 SpareSpare{{{{{{{{Blue HF11 Spare{{{Black HF12 Radio/Diagnostic20A{{Grey EF13 ChassisModule30A{{Black BF14 Spare{{{Black AF15 BulkheadModule30A{{Blue AF16 ABSECU(pneumatic)15 AABSECU(hydraulic)25A25 ABlue CF17 ChassisModule30A{{Blue BF18 BulkheadModule30A{{Grey GF19 ChassisModule30A{{Black EF20 BulkheadModule30A{{Black FGrey HGrey BF21 Spare{{{Black GBlue EBlue DF22 BulkheadModule30A{{F23 Spare{{{{Grey DF24 HydraulicPumpandSpareGrey CF25 Spare{{{Multiple Wire output Pin A & B on Grey Plug and Pin Don Blue PlugGrey AF26 Spare{{{Motor(hydraulicABS)VBAT 1 BHMVBAT 2 BHMVBAT 3 BHMVBAT 4 BHMVBAT 5 BHMVBAT 1 CHMVBAT 2 CHMVBAT 3 CHMFVBATFusePin part number for harness connection23-13213-120 TERM-FEMALE,(20-16) PAC1207741123--121 TERM-,(14-12) PAC1212949313213 FEMALE23-13213-122 TERM.}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}} }}}}}}}}}}}}}}}}}}}}}