International 3200, DuraStar, WorkStar, 8000 truck Service Manual

TABLE OF CONTENTS

Description SectionPage #

FORWARD.................................................................................................................................................................01-1

INTRODUCTION........................................................................................................................................................02-1

ELECTRICAL SYSTEM OVERVIEW.........................................................................................................................03-1

GENERAL ELECTRICAL ..........................................................................................................................................04-1

GENERAL..................................................................................................................................................................05-1

BODY CONTOLLER..................................................................................................................................................06-1

BATTERY, IGNITION, AND ACCESSORY TAPS ....................................................................................................07-1

CB AND 2-WAY RADIO ACCOMMODATION PACKAGES.....................................................................................08-1

POWER WINDOWS, LOCKS, REMOTE KEYLESS ENTRY....................................................................................09-1

FUSED BATTERY CONNECTIONS INSIDE CAB....................................................................................................10-1

PRODUCTIVITY FEATURES ....................................................................................................................................11-1

FOG, PLOW, GUIDE POST AND WIG WAG ACCOMMODATIONS .......................................................................12-1

BODY BUILDER WIRING FOR STOP/TAIL/TURN LIGHTS ....................................................................................13-1

WORK LIGHT AND OUTSIDE CAB POWER FEATURES.......................................................................................14-1

AIR CONDITIONING..................................................................................................................................................15-1

TRANSMISSION SPARE INPUT/OUTPUTS AND TRANSMISSION CODES .........................................................16-1

GAUGES....................................................................................................................................................................17-1

REMOTE POWER MODULES...................................................................................................................................18-1

SWITCHES AND SWITCH LABLE PART NUMBERS AND INFORMATION ..........................................................19-1

POWER FEATURES USING REMOTE POWER MODULES ...................................................................................20-1

INDICATOR LIGHTS AND ALARMS ........................................................................................................................21-1

BODY BUILDER INTEGRATION HARNESS............................................................................................................22-1

PTO POWER TAKE OFF ..........................................................................................................................................23-1

REMOTE ENGINE SPEED CONTROL FEATURES.................................................................................................24-1

REMOTE AIR SOLENOID MODULE.........................................................................................................................25-1

REMOTE START/STOP ............................................................................................................................................26-1

LIFT GATE ACCOMMODATION PACKAGE............................................................................................................27-1

POWERPACK 3 PRIMARY AND TEMPORARY MOUNT FEATURE ......................................................................28-1

THEFT DETERRENT.................................................................................................................................................29-1

HYBRID ELECTRIC VEHICLE ..................................................................................................................................30-1

ELECTRICAL FUNCTIONALITY WITHOUT ASSOCIATED FEATURE CODES.....................................................31-1

CROSS REFERENCE ...............................................................................................................................................32-1

INDEX

Electrical Data Body Builder Book

October 2012

TABLE OF CONTENTS - PAGE 1

TABLE OF CONTENTS

TABLE OF CONTENTS - PAGE 2

October 2012


FORWARD

FORWARD

■

CONTENTS

In this manual, Navistar

®

Inc. provides information about its different products to assist those who wish to modify these products for individual applications. Navistar does not recommend or approve any firm nor make any judgments on the quality of the work performed by a particular firm. Individuals who use the services of a Body

Builder must satisfy themselves as to the quality of the work.

The party installing a body, a fifth wheel, any other equipment, or making any modifications to complete the vehicle for delivery and make it road-ready is responsible to see that the completed vehicle complies with all applicable certification procedures and safety standards, as may be set forth in Federal, State, and local statutes, rules and regulations.

Specifications, descriptions and illustrative material in this literature are as accurate as known at time of publication but are subject to change without notice. Illustrations are not always to scale and may include optional equipment and accessories but may not include all standard equipment.

In addition to this Body Builder Electrical Data Book, publication CT-471, Body Builder Data, may be required. The

CT-471 - Body Builder Data is a set of booklets which includes a General Information Body Builder Data booklet for information about the Navistar, Inc. product line; model series Body Builder Data booklets which contain information related to the features and specifications for each of their respective models; Component Body Builder Data booklet containing information for components which have common application in two or more truck series, Body Builder

Engine Programming information and any supplemental Body Builder Data booklets containing information for components which have common application in two or more truck series.

■

SAFETY INFORMATION

IMPORTANT - Read the following before starting the service procedure.

You must follow your company safety procedures when you service or repair equipment. Be sure to understand all of the procedures and instructions before you begin work on the unit.

Navistar uses the following types of notations to give warning of possible safety problems and to give information that will prevent damage to the equipment being serviced or repaired.

WARNING - A warning indicates procedures that must be followed exactly. Personal injury or possible death, along with damage to the vehicle, can occur if the procedure is not followed.

CAUTION - A caution indicates procedures that must be followed exactly. If the procedure is not followed, damage to equipment or components can occur.

NOTE - A note indicates an operation, procedure or instruction that is important for correct service.

Some procedures require the use of special 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.


October 2012

SECTION 01 - PAGE 1

FORWARD


October 2012


INTRODUCTION

INTRODUCTION

DISCLAIMER: NAVISTAR DOES NOT TAKE ANY RESPONSIBILITY FOR CUSTOMER OR BODY BUILDER

WIRING.

NOTE: After-market installed wiring for engine speed control must comply with the following guidelines:

1.

Sealed switches and connectors must be used for switches and connections that are exposed to the weather or to salt spray emanating from the vehicle's tires.

2.

Route and clip wiring to minimize chafing and exposure to weather. Use conduit, loom, and/or tape to achieve this.

3.

Fuse all power leads as close to the power source as possible. Remember fuses protect the wiring - size fuses accordingly.

4.

All ground connections that will be made to the frame or body must be connected to clean bare metal. Remove all dirt, paint, grease and rust that would insulate the terminal from ground. After connecting the ground, seal the connection with a good quality grease or surface sealant to protect the connection from corrosion.

5.

Spliced wires should be twisted together and soldered. Use a heat shrink tube with a meltable inner wall to seal the connection. Do not expose splices to the weather.

WARNING: To avoid serious personal injury, possible death, or damage to the vehicle, make sure the transmission is in neutral, parking brake is set, and the wheels are blocked before undertaking service procedures. In addition, turn off the engine when you leave the vehicle. Never leave the vehicle unattended with the engine running.

WARNING: To avoid personal injury, possible death, or damage to the vehicle when adding electrical features, disconnect batteries. Reconnect batteries when installation is complete.

•

Whenever disconnecting battery terminals always disconnect the ground terminal first. When reconnecting, always connect the ground terminal last.

•

To prevent injury to the eyes, face, limbs and body, it is imperative that lighted materials, flames or sparks be kept away from the vent openings of the battery. The gas mixture in the battery cells, which escapes through the vents, could ignite and/or cause an explosion. This is particularly true when jumper cables are being used.

•

In addition, inhaling of gas produced by the normal operation of the battery could result in partial or permanent damage to the respiratory system.

•

Always wear eye protection when working around batteries. Do not attempt 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 jumper cables as long as the battery remains frozen. Thaw out the battery and recharge.

•

Do not check battery condition by shorting (flashing) across terminals.

•

Failure to observe these instructions could result in personal injury and/or damage to the vehicle.

Battery cable terminals must be clean and tight. Use hot water and common baking soda for removing terminal corrosion and for cleaning the top of the battery. Brighten the contact surface with steel wool, apply a light coat of lubricant sealing grease such as Fleetrite

®

472141-C1 or equivalent and reassemble. Be sure the terminals are clamped tightly and that the battery is clamped securely in place.

When working around the terminals and battery, use extra care to avoid shorting. A good practice is to insulate pliers and screwdrivers.


October 2012


INTRODUCTION


October 2012


ELECTRICAL SYSTEM OVERVIEW


■

INTERNATIONAL

®

DIAMOND LOGIC

®


■ ■

Multiplexing Architecture

Unlike the electrical systems on previous models, which utilized point-to-point wiring for all input signals and output loads, this system uses multiplex technology to provide control and communication between major functional areas of the vehicle. Multiplexing simply means: communicating multiple pieces of information via a single twisted pair of wires (called the data link) without requiring a wire for each piece of information. This information could be gauge information such as engine oil pressure, or switch information that controls vehicle functions such as headlamps.

The electrical system relies on a collection of electronic circuit modules and software to perform vehicle functions instead of implementing similar features using complex wire harness designs with electromechanical relays and switches. These electronic module components are connected together by data links. The data links can be thought of as computer networks that allow the electronic components on the vehicle to communicate with one another.

The concept of multiplexing is not new since data links for communicating between engine controllers, the instrument cluster and the diagnostic connector have been used for several years.

The goal of multiplexing is to reduce cab harness wiring and to simplify circuits. This is accomplished by using a low current data link for communicating between cab switches, 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.

■ ■

Data Links

Navistar’s multiplexing uses two types of data-links, J1708 and J1939. The J1708 data link is often referred to as ATA and J1939 is often referred to as CAN. These two types are utilized in four separate data links on the vehicle.

•

Power Train data-link – J1939

This data-link provides a path for communication between the engine controller, transmission controller, antilock brake system (ABS) controller, pyrometer ammeter module (PAM), Body Controller (BC), auxiliary gauge switch pack (AGSP) and the electronic gauge cluster (EGC). It also provides the capability for programming and diagnostic functions via the 9-pin diagnostic connector through the use of the appropriate service tool and diagnostic cable interface.

•

Body Builder data-link – J1939

This data-link provides a path for communication between the remote power module(s), remote engine speed control module and the BC.

•

Switch data-link – J1708

This J1708 data-link provides a path for communication between the center panel switch packs, door pods and

BC.

•

ATA data-link – J1708

This is the same J1708 data-link (sometimes referred to as ATA) that has been used in the past. The J1708 data-link is available, but is no longer the primary data link for communicating with the engine diagnostic and programming tool. The J1708 data-link has historically been used to provide programming capability and diagnostic information for various control modules including the ABS and the engine.


October 2012



■

BODY CONTROLLER (BC)

The heart of the multiplex system is the BC.

Body Controller (BC)

f_001

The BC communicates with the switch packs on the switch datalink, controllers from other features on the power train datalink, and RPMs (remote power modules) and the RESCM (remote engine speed control module) on the Body

Builder datalink. It also receives input from various sensors and hard wire inputs throughout the truck. The BC converts these inputs, in accordance with the programmed “rules,” into data to be transmitted on the datalinks.

It is also the power source for circuits that feed some of the components, controlled by the multiplexed switches, inside and outside of the cab. The primary vehicle software programming resides in the BC.


October 2012



■

REMOTE POWER MODULE (RPM)

RPMs provide a method of distributing and controlling power to various device loads on the vehicle, outside the cab, without running high current wires from in-cab switches to the loads or splicing into existing wiring.

Remote Power Module (RPM)

f_002

The RPM is connected to the BC via the Body Builder J1939 datalink (the BC is capable of controlling up to seven

RPMs on the vehicle). The only factory-installed wires connected to the RPM are battery power for driving the loads and the datalink cable. Connectors for Body Builder-installed inputs and outputs are also provided. Power is fed to the RPM through a fusible link to the battery source. Each RPM has six independently controllable, 20 Ampere

(AMP) outputs (80A maximum per RPM) with virtual (software programmable) fusing similar to the BC. If higher current capacity is needed, two outputs can be paralleled or the RPM can control a high current relay while still maintaining logic and diagnostic capability without having to wire to the inside of the cab.

Because the RPM is connected to the BC via the datalink, it also serves as an “integration gateway” to the BC and the vehicle electrical system. Six digital inputs on each RPM allow information from body accessories to be communicated to the BC and processed for interlocks, operator information/warning, etc. These inputs also allow the

Body Builder to add body-mounted switches to turn on or off the same electrical devices controlled by in-cab switches.

Additional information concerning the use and installation of RPMs is contained in the applicable Feature sections that follow (see 60AAA/60AAB in particular for detailed data on RPM connectors/pin functions, wiring, and mounting).

The following is an example of how a vehicle electrical system might be configured.


October 2012



International

®

Diamond Logic

®

Electrical System

f_003

The International

®

Diamond Logic

®

electrical system, in conjunction with the Diamond Logic

®

Builder software, provides the Body Builder with unprecedented flexibility in adding and customizing the electrical features on a vehicle.


October 2012


GENERAL ELECTRICAL


Navistar vehicle electrical systems are becoming increasingly complex with the addition of a BC, electronic engine and transmission controls, electronically driven instrument gauges, and Antilock Brake Systems (ABS) to name a few. While most systems still operate on battery voltage (12 volts), some systems operate at as high as 107 volts

(electronic fuel injection) and as low as five (5) volts (electronic engine controls).

Navistar publishes Electrical Circuit Diagram Manuals for 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 appropriate and not overloaded. Modifications not defined in the circuit diagram book are not to be made to the vehicle electrical/electronic control systems without first contacting Navistar for assistance at its Tech

Central Department, telephone 1-800-336-4500.

■

J1939 HIGH SPEED DATA LINK CABLE (SAE J1939/15)

The information in this section applies to all 3200, DuraStar, WorkStar, and 8000 models.

Performing the proper repairs or modifications of the cable is critical to the integrity 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.

■

COLOR CODE SYSTEM FOR INTERNATIONAL

®

TRUCK

Table 1

Color

Red

Pink

Light Blue

Yellow

Dark Blue

Brown

Orange

Gray

Tan

Green

Light Green

Violet

White

Black

Description

Alternator/Battery Feeds

Ignition Feeds

Accessory Feeds

Headlight System (Daytime Running Lights, Fog, Hi-Beam,etc.); Data Link J1939(+)

Interior Lights (Dome, Panel, etc.); Data Link J1708(+)

Exterior Lights (Tail, Market, Clearance, etc.)

Exterior Lights (Turn, back-up, etc.)

Engine/Chassis Systems (Fuel Solenoid, Horn, etc.); Data Link J1708(-)

Engine/Chassis Monitoring Systems (Gauges)

Data Link J1939(-)

Driver Aid Systems (Windshield Washer, Heater, etc.)

Engine Controls - Electronic

GND

Battery GND Cables or Computer Data Link Systems

NOTE: The wiring in multiple conductor jacketed cable does not follow the above color code system. See the electrical circuit diagram manual for specific colors and circuit numbers used with each system. Use only

“GXL", “SXL" or “TXL" insulated wire. Crimp and solder all connections.

■

RECOMMENDED CIRCUIT PROTECTION

Table 2

Wire Gauge

18 Ga

16 Ga

14 Ga

12 Ga

10 Ga

8 Ga

6 Ga

4 Ga

Protective Device Size

10 AMP Fuse/Circuit Breaker





12 Gauge Fusible Link

10 Gauge Fusible Link

2-12 Gauge Fusible Link

Maximum Current (Amps)

8 A

12 A

16 A

20 A

24 A

80 A

108 A

160 A


October 2012 SECTION 04 - PAGE 1


CAUTION: Wire gauge is designed to match fuse/circuit breaker rating. Do not increase the size of a circuit breaker or fuse. To do so could cause wiring to overheat and burn.

■

CIRCUIT PROTECTION DEVICES

Table 3

Size

7.5 A

10 A

15 A

20 A

25 A

30 A

Size

5 A

7.5 A

10 A

15 A

20 A

25 A

30 A

Circuit Breakers

Type III - Manual Reset






Fuses

Mini - SAE J2077

Mini - SAE J2077

Mini - SAE J2077

Mini - SAE J2077

Mini - SAE J2077

Mini - SAE J2077

Mini - SAE J2077

Part Number

3536177C1

3536178C1

3536179C1

3536180C1

3536181C1

3536182C1

Part Number

3534208C1

3546109C1

3534209C1

3534210C1

3534211C1

3534212C1

3534213C1

Brown

Red

Blue

Yellow

White

Green

Color

Color

Tan

Brown

Red

Blue

Yellow

Natural

Green

Circuit breakers and fuses can be installed in the chassis wiring using the following in-line connectors:

•

1676841C91 - Inline socket and cable for circuit breaker/fuse (20 A Maximum)

•

1682115C91 - Inline socket and cable for circuit breaker/fuse (30 A Maximum)

Table 4

Size

20 A

20 A

30 A

30 A

Devices

Autofuse

Circuit Breaker - Type III

Autofuse

Circuit Breaker - Type III

Part Number

131224C1

3529688C1

571691C1

3529690C1

Color

Yellow

Green

■

ELECTRICAL COMPONENTS COMMONLY USED BY EQUIPMENT INSTALLERS

Table 5

3200, DuraStar,

WorkStar

Type

3534164C1

3573312C1

3573311C1

589390C1

589391C1

1652325C1

1661375C2

1661377C1

1661376C1

1677851C1

1671609C1

1677914C1

587579C1

At Fuse Block

Terminal Fuse Block (18/20 Gauge)



At Tail Lights

Seal, Wire - (Blue) .165-.138 O.D. Cable (12-14 Gauge)

Seal, Wire - (Gray) .137-.111 O.D. Cable (14-16 Gauge)

Seal, Wire - (LtGn) .110-.080 O.D. Cable (16-20 Gauge)

Body Connector, 5-Way Male

Terminal, Female - 14/16 Gauge

Lock, 5-Way Male Connector

Body Connector, 5-Way Female

Terminal, Male - 14-16 Gauge

Lock, 5-Way Female Connector

Sealing Plug (for Empty Connector Cavities)

NOTE: Any unused circuit cavities must be plugged with sealing plugs provided with chassis harness.


October 2012



■

CONNECTORS 4450 AND 4460

Connectors 4450 and 4460 have their mating connectors attached filled with cavity plugs. To use connectors, remove cavity plugs and use the following:

Table 6

Terminals

2033912C1

2033911C1

Cavity Seals

Wire Gauge

12, 14

16, 18, 20

Wire Gauge

0589390C1

0589391C1

1652325C1

12

14

16, 18, 20

Mating Connector Part Numbers

4450 Connector

4450 Lock

4460 Connector

4460 Lock

2039312C91

2039342C1

3553961C1

3554019C1

■

STANDARD TERMINALS AND SPLICES

1.

Cut the cable just before the insulation wings on the terminal.

2.

Remove the insulation being careful not to cut any of the wire strands (¼ inch exposed copper stranding is typical).

3.

Position cable in the new terminal.

4.

Hand crimp the core wings first, then the insulation wings.

5.

Check to ensure copper stranding is not cut as this can cause “hot spots”.

6.

Ensure no copper is exposed beyond the insulation crimp as this will allow a pivot point and the copper stranding will break.

7.

Solder all hand crimped terminals and electrically check for continuity.

NOTE: Always use the recommended crimp tool for each terminal. A detailed crimp chart is included in the repair kit.




f_004

Standard Terminal

1. Mating End

2. Core Wings

3. Insulation Wings

4. Cable

5. Lock Tang

6. Insulation

7. Wire Strands

8. Solder

■

SPLICE CLIP INSTALLATION

NOTE: A new clip must be located a minimum of 1.5 inches (40 mm) from a connector, sleeve or another clip

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 securely fastened.

5.

Solder the clip and electrically check for continuity.

6.

Cover the entire splice with splice tape. Extend the tape onto the insulation on both sides of the splice(s).


October 2012



f_005

Splice Clip Installation

1. Insulation

2. Wire Strands

3. Clip (Positioned Correctly)

4. Crimped Correctly

5. Solder

6. Tape

■

SPLICE INSPECTION

Splice Inspection

1. Terminal Application

2. Insulation Crimp

3. Wire Strands Visible in this Area

4. Core Crimp

5. Solder Application

6. Good Solder Application

7. Crimp and Seal Heat Application

8. Evidence of Glue


October 2012 f_006



■

CRIMP AND SEAL SPLICE SLEEVE INSTALLATION

Part Number

3517501C1

3517502C1

3517503C1

2644000R1

Description

12-10 AWG Splice

16-14 AWG Splice

22-18 AWG Splice

Dual Wall Heat Shrink, 50mm

Quantity

2

7

2

50

NOTE: A new sleeve must be located a minimum of 1.5 inches (40 mm) from a connector, clip or another sleeve.

1. Cut off the old sleeve or bad 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 to the sleeve. Gently tug on the wire to make sure that they are secure.

NOTE: Always use the recommended crimp tool for each sleeve. A detailed crimp chart is included in the

Repair Kit.

CAUTION: Use appropriate heat gun. Do not use a match or open flame to heat the sleeve seal.

5. Electrically check the sleeve and wire cable for continuity.

f_007

Crimp and Seal Splice Sleeve Installation

1. Wire Strands

2. Wire Stop

3. Crimp Connector

4. Evidence of Glue

■

DATA LINK REPAIR

■ ■

J1708

Repairs to damaged J1708 circuits should be accomplished using similar types of wiring. Splices should be crimped and soldered. Insure the twist in the wire pair (one twist per inch) is maintained and individual wires are covered with heat shrink.

■ ■

J1939/11 Shielded Only

Repairs to damaged J1939 circuits should be accomplished using identical types of wiring. Splices should be crimped, soldered and covered with heat shrink. Insure the twist in the wire pair (one twist per inch) is maintained and that any wire bundles in the engine compartment are shielded and covered with heat shrink.


October 2012



■ ■

Wire Repair

This instruction addresses termination and splicing of J1939 wire.

f_008

Preparation of J1939 Wire for Connection

1. Strip back (view C) outer shield 3 1/8 in. (76 mm).

2. Strip (view A) green wire and yellow wire 1/4 in. (6.35 mm) being careful not to cut individual strands.

3. Re-twist all three wires (one twist per inch) if they have separated.

4. Sleeve drain wire (view B) may be soldered to aid in sleeving.

5. Install terminals on green and yellow wire ends, and crimp.

6. The 1/4" heat shrink tube (view D) will be shrunk later after the wires have been inserted into the crimp connector.

■

WIRE SPLICING

1. Strip wire ends 1/4 inch.

2. Re-twist any loose wires (one twist per inch).

Re-Twist Any Loose Wires

f_009




3. Slide 2-inch pieces of insulated heat shrink tube over wire for later use.

Put Heat Shrink Tube Over Each Wire

4. Put heat shrink tube over each wire.

5. Insert ends of wires into splice joint and crimp.

6. Solder the wires and crimp joint together.

f_010

Solder Wires Together

7. Center heat shrink tube over splice and shrink.

f_011


October 2012



.

Center Heat Shrink Tube Over Splice

8. Wrap wires with foil tape. Maintain at least 1/2 wrap overlap. f_012

Center Heat Shrink Tube Over Cable

9. Center heat shrink tube over the splice and shrink.

f_013

Center Heat Shrink Tube Over Cable


October 2012 f_014



■

J1939 HIGH SPEED DATA LINK CABLE (SAE J1939/15)

Performing the proper repairs or modifications of the cable is critical to the integrity and performance of the vehicle systems. (For repair procedure see Electrical Troubleshooting Guide - S08250 or Data Link Repair in this manual.) This information is based on SAE J1939/15 and TMC RP 142.

These instructions are intended for modifications that meet the SAE spec; i.e., no internal resistor. When extending the backbone the proper materials must be used. The data link cable consists of a twisted pair of insulated wires and is covered by an insulating jacket. The data link cable must meet the SAE - specified characteristic impedance of 120 ohms. Never splice regular automotive type wire such as GXL, SXL or TXL into the data link cable. Use data link cable furnished by Raychem, part number 2021D0309.

The backbone is the main part of the cable. This is terminated at each end with a 120 ohm resistor. When adding a device the backbone must be extended. This is done by removing the resistor, inserting the backbone extension, then plugging the resistor and the device into the extension.

The International

®

high performance vehicle will always have a power train J1939 system. This is for key operations that come from the factory direct. A second J1939 system is put in place for body builders and will be referred to as body builder J1939. Circuit diagrams are shown in Chapter 9 of the Circuit Diagram Book

(S08322) under Remote Power Units, Solenoid Packs, Remote Engine Speed Controller.

■ ■

J1939

J1939 is a high speed serial communications data link. The system requires two resistor caps. The first resistor cap for Body Builder J1939 currently starts in the engine compartment. The second resistor cap ends where the last module is placed. The wire between these two resistors is called the backbone. The backbone cannot be longer than 131.2 feet (40m). A module can tap into the backbone. This point is called the Node. The distance between two nodes cannot be less than 3.9 inches (0.1m). The cable length from the node to the module cannot be longer than 9.8 feet (3m).

With the research of the robustness of the J1939-15 lite (unshielded) International

®

removed the shield from their high performance vehicle in January 2002. Mixing of the shielded (J1939-11) and unshielded (J1939-15) is not recommended.

■ ■

Adding Body Builder J1939, Power and Grounds

Without any Body Builder J1939: Ask Service Parts for “the components needed to add the Body Builder J1939 datalink to the vehicle. Service part kits are available to add the datalink, RPMs and switch packs."

Most of the software information is processed in the BC. Therefore, the J1939 wires must be connected to the

BC. Refer to Circuit Diagram Manual S08322, Chapter 10, Remote Power Units, Solenoid Packs, Remote

Engine Speed Controller for proper circuit installation.

■

HIGH VOLTAGE CIRCUITS (GREATER THAN 50 VOLTS) ON INTERNATIONAL

®

AND BUSES

TRUCKS

Only a trained technician may perform service inside high voltage components. When working around or maintaining high voltage circuits, please seek high voltage training.

WARNING: To avoid 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 levels that may cause equipment damage, electrical shock, and/or electrocution if handled incorrectly.

NOTE: The intent of this section IS to provide some basic guidelines when working on or around International

® vehicles that are equipped with high voltage electrical equipment and circuits. For specific instructions, maintenance, or service information on specific equipment or options, refer to the service manuals for the specified truck models and component(s). It IS NOT the intent of this section to provide detailed service instructions for high voltage equipment and circuits.


October 2012



High voltage systems require the maintainer to be familiar with two types of electrical systems.

•

DC (Direct Current)

Most DC systems on today's trucks use 12 volt negative GND. Some systems can store DC electricity in batteries with operating voltages as high as 600 DC volts.

•

AC (Alternating Current)

The main difference between AC and DC systems is that the voltage levels in DC systems remain constant while the voltage levels in AC systems are constantly changing. When measuring an AC system, it is important to know that the average voltage is zero, and that is why A VOLTMETER SET TO DC WILL NOT INDICATE

THE PRESENCE OF AN AC VOLTAGE WHEN CONNECTED TO AN AC CIRCUIT!

High voltage can be lethal. Always refer to the manufacturer of the high voltage component when maintenance or repairs are needed. In most cases, diagnostics and repair are performed after the high voltage circuits are disabled. If working around or maintaining high voltage circuits, please seek high voltage training.

WARNING: To avoid property damage, personal injury, or death, circuits must be checked using a voltmeter for the presence of both DC and AC voltages. A voltmeter set to DC will not indicate the presence of an AC voltage when connected to an 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 working around or maintaining high voltage circuits, please seek high voltage training.

■

UNDERSTANDING HIGH VOLTAGE EQUIPMENT AND CIRCUITS ON INTERNATIONAL

®

PRODUCTS

Some examples of high voltage equipment that can be encountered on products are as follows:

■ ■

Auxiliary Power Units (APUs)

APUs are basically small diesel powered generator units that are integrated into the vehicle electrical system.

APUs are utilized in combination with inverters and battery chargers. APUs are often set up to automatically start when the electrical management system deems it necessary to maintain battery charge or electrical demand requires it.

NOTE: APU high voltage wiring may NOT be marked for easy identification as high voltage.

■ ■

Shore Power

Shore power is a connection from a vehicle to an external 120 volt AC power source. The vehicle is equipped with an exterior receptacle that allows connection to an external “shore” power source.

NOTE: High voltage shore power wiring may NOT be marked for easy identification as high voltage.

■ ■

Inverters

Inverters are electronic devices used to change DC (Direct Current) into AC (Alternating Current). Some inverters contain converters that also convert AC to DC for battery charging or running 12V equipment.

NOTE: High voltage wiring for inverters may NOT be marked for easy identification as high voltage.

■ ■

Hybrid Electric Vehicles (HEVs)

HEVs combine internal combustion engines with high voltage batteries, electric motors, and inverters to offer higher fuel efficiency and lower emissions without compromising power, range, and convenient fueling of conventional vehicles. Regardless of the HEV design, high electrical voltages and currents are present.

NOTE: The industry standard for high voltage cables is for the cables to be covered in ORANGE CONDUIT.

If orange conduit is observed on a vehicle, please review the safety precautions for that system.




■

HOW TO IDENTIFY HIGH VOLTAGE CIRCUITS

High voltage circuits are not always connected with large wires. The best way to identify high voltage equipment or circuits is 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 was built (owner/operators may add high voltage components such as inverters or APUs).

All electrical circuits associated with APUs, shore power, inverters, and HEVs should be considered high voltage. The standard for high voltage cabling on HEVs is orange. APUs, inverters, shore power, and cabin

110/120V outlet wiring may not indicate high voltage by visual inspection (they may not be marked and are

NOT orange in color).

■

SERVICING NAVISTAR PRODUCTS

The following steps outline the appropriate method to follow to identify and address any maintenance or service on Navistar products with factory-installed high voltage equipment.

2. Review the line-set ticket provided with the vehicle or from ISIS, and identify all high voltage components.

Inspect the vehicle for any equipment or circuits added after the truck was built (owner/operators may add high voltage components such as inverters or APUs that could be live and powering circuits in the vehicle

EVEN WITH THE IGN OFF AND THE BATTERIES DISCONNECTED).

3. Refer to manufacturer’s service publications for identified high voltage components.

4. Physically locate high voltage components on the vehicle and disable them according to manufacturer’s instructions (some components may require a waiting period or special procedures to discharge the voltage completely).

5. Use Best Work Practices (see below) when performing work on electrical systems.

■ ■

Best Work Practices

WARNING: To avoid personal injury or death, permit only trained responsible and capable persons to operate or maintain the equipment. Carelessly operating or neglecting maintenance despite the safe design of any vehicle and its high voltage equipment may result in personal injury or death.

The danger of injury through electrical shock is possible whenever electrical power is present. Most fatal injuries result from high-voltage exposure; however, people can sustain severe injuries from low voltage power if it has a high current flow.

•

Be aware of ALL high voltage equipment on the vehicle; review line-set/build ticket and the owner and service manuals of high voltage equipment BEFORE starting any work.

•

When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued, and never work alone 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 while hands or feet are wet.

•

Always work in an adequately illuminated area.

•

Always use appropriate protective equipment: insulated gloves, rubber gloves, goggles/face shield, safety shoes, protective clothing, and insulated tools when working on electrical components/circuits of the vehicle.

•

Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock or burns and may get caught in moving components causing injury.

•

When working on vehicles that have high voltage devices or equipment, use appropriate alerting techniques in plain view to warn people that may be in the general area and to prevent inadvertent activation of any disabled high voltage circuit(s) during service: safety signs, safety symbols, tags, barricades, cones, etc.

•

Keep a fire extinguisher close by at all times. Extinguishers rated “ABC” by the National Fire Protection

Association are appropriate for use on the electrical system. Make sure the extinguisher is properly charged


October 2012



and be familiar with its use. Consult the local fire department with any question pertaining to fire extinguishers.

•

Ensure that the high voltage power, high voltage power generating equipment and high voltage storage devices are disconnected, locked out, or otherwise disabled BEFORE working on or around the vehicle, its electrical circuits, or components. Unless disabled, Auxiliary Power Units (APUs) may start at any time without warning; when this occurs, the circuits associated with the APU become energized with potentially lethal high voltage. Some components may require a waiting period or special procedures to discharge the voltage completely.

•

Use an appropriate electrical tester and procedures to confirm that the power is disconnected BEFORE performing any work on or near any high voltage components/circuits.

•

Exercise caution around output circuits even when the input power is off. Parallel power sources and energy storage devices can still be dangerous. Be familiar with the high voltage equipment installed on the vehicle.

Some systems contain high voltage condensers that may require time to discharge after power is removed.

•

After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.

•

After completion of any electrical work, BEFORE restoring the power, verify that parts and/or tools are removed from the work area and that the fasteners are firmly tightened to the specified torque and the connectors are correctly connected.

•

Voltage can be fatal 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 wheels on the ground may cause the motor to generate electricity. Consult the operator’s/owner’s manual for proper towing procedures.

•

If a high voltage fuse or circuit protection device trips, do not re-energize the circuit until it has been determined that the circuit is safe. See manufacturer’s troubleshooting procedures before servicing a high voltage system.

•

Reference OSHA Regulations as necessary and applicable.

■

SUPPRESSION

International

®

strongly recommends these electromagnetic devices be electrically suppressed, when adding electromagnetic devices such as relays, magnetic switches, and solenoids.

Unsuppressed electromagnetic devices can generate large voltage spikes which are conducted into the vehicle electrical system. These voltage spikes may adversely affect customer added electronic devices and in some instances may affect International

®

installed electronic components.

When installing electromagnetic devices, specify suppressed units. If suppressed units are not available, diode suppression may be added as shown below:

The following suppressed relays and magnetic switches are available from International

®

.

Table 8

Part Number

1691520C91

1693479C91

3519350C1

Suppressed Relays and Magnetic Switches

Description

Magnetic Switch - Continuous Duty (Suppressed) 100 AMP

Magnetic Switch - Intermittent Duty (Suppressed) 100 AMP

Micro Relay – SPDT (Suppressed), NO – 20 AMP, NC – 10 AMP

■

WELDING INFORMATION

Whenever electric welding is done on any part of the vehicle, it is not necessary to disconnect the

International

®

electronic modules in the cab such as the BC, ESC or RPM, and the instrument cluster. The welder's GND must be connected as close to the weld as possible. If the vehicle is equipped with an

International

®

engine, disconnect both the positive (+) and the negative (-) battery cables including the electronic power feeds prior to electric welding. If it is necessary to weld close to an electronic component, it is




recommended that the component be temporarily removed.

Consult manufacturer’s instructions for all other electronic modules such as Allison Transmission, Eaton Auto

Shift Transmission, Bendix ABS, Wabco ABS, Cummins Engine, Caterpillar Engine, and Detroit Diesel Engine.

■

ROUTING GUIDELINES

Any hosing, tubing, battery 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 of the frame rail flange when the tubing is making the transition from the outside to down and under the rail. This does not mean that proper clearance or the need for protective wrap is not needed when synflex line contacts sharp edges or threaded fasteners.

Any hosing, tubing, battery cable, wiring or electrical harness must not rub or make contact with a hot surface.

There should be 5" minimum clearance from the exhaust depending on the situation. The further back from the turbo, the less clearance required.

Nothing should rub or make contact with the copper compressor discharge tubing other than the clamp(s) that support it.

All hosing, tubing, battery cables or electrical harnesses should be supported at least every 18" to 20".

Straplocks used to directly clamp or support battery cables or main engine wiring harnesses must be no less than 7/16" in width.

Straplocks are not to be used on any bulk hose materials (heater hoses, make-up lines, etc.).

■ ■

Route and Clip Recommendations

Table 9

Heat Source

Exhaust Manifold to Muffler Inlet

Aftertreatment

Muffler Inlet to Tail Pipe Out

Other (EGR Discharge Pipe/Hose)

Distance From

6”

8”

3”

1/2”


October 2012



■ ■

Electrical Harness

Table 10

Problem

Sharp or Abrading Surface

Tension Along Harness/Wires/Hoses

Distance From Moving Parts

Connector Clipped to Avoid Damage

Connectors Are Sealed

Max Eyelets Per Stud

Harness Protected From Damage

Drip Point For Harness

Distance of Harness to Flammable Fluids

Harness Location to Flammable Fluids

Battery Cables to Flammable Fluids

Battery Cable to Conductive Surface

Battery Cable Tie Strap

Harness Contact with Metal Surface

P-Clamps — Electrical

P-Clamps Fastening Support

High Pressure Pipe/Hose (>200 PSI)

Harness Through Metal Holes

Full Articulated Position

Clipping Fixed MAX Distance — Harness

Splices

Requirement

No Contact

None

1”

Yes

Yes

3

Yes

Yes

1/2”

Not Directly Under

1” Minimum

1/2” Minimum

1/2” (250 Pound) Wide

No Relative Motion

Cushioned Only

No Cantilever

Don’t Clip Anything to Them

Use Grommet

Operates Without Damage

14”

Use Shrink Wrap

■

ELECTRICAL DO’S AND DON'TS

The information in this section applies to all DuraStar 3200, 4200, 4300, 4400, and WorkStar models.

Table 11

Item

Accessory (power taps with key in “Accessory” mode)

Battery - Clean (unfused) power and maxi-fused power feeds and GND connection points

Do

Connect to accessory relay output in the inside cab fuse block; circuit A12B.

Don’t

Connect to key switch accessory output.

Use inline Maxi-holder from Mega-fuse unfused side.

Exceed additional 45 AMPS

Exceed 3 ring terminals total on Maxi-fuse stud.

GND

GND — with ammeter

IGN (power taps with key in “IGN”)

Start (power taps with key in “Start”)

BC (access to pinouts of discrete circuits)

Electric City Horn

Air Horn (or Air Horn Accommodation)

CB Radio (or CB Accommodation)

Radio installation for customer aftermarket radio accommodation

GND additional electrical loads (customer supplied devices) to chassis or GND studs located on the dash panel.

GND to frame or dash GND stud to allow for ammeter to register current.

Connect to the IGN relay output in the inside cab fuse block; circuit A13FC

Connect to the starter relay input circuit A17 at the outside fuse block.

Connect to BC outputs only.

GND to vehicle batteries for additional loads.

GND directly to batteries for meter signal.

Connect circuits directly to key switch IGN circuits.

Connect circuits directly to the key switch start circuits.

a) Exceed BC outputs amperage refer to BC section b) Connect to signal inputs of the BC a) Connect to circuit A85E (Dash), M85E,

M85N, or M85L (Forward chassis) and M85H

(Horn jumper) or b) Only use suppressed type horn assembly.

Connect air line to output side of the solenoid pack controlled through BC.

Use power connector 2303 and CB antenna connector 2306 at CB opening in overhead console with optional code 08RCB a) Connect to pigtail (A13B) owner/operator

IGN feed b) Use a relay if load exceeds 5 AMPS.

Connect to Electric City Horn circuit without a diode for protection.

Connect to input side of air switch electrical circuit.

Exceed 10 AMPS.

Exceed 5 AMPS.




Item

Cruise/Stationary Throttle via Remote Throttle module and via hardwire for remote hook-up

Engine Warning for remote panel display

Vehicle Speed output with Manual

Transmission for optional feature control; i.e., sand spreader

Vehicle Speed output with Automatic

Transmission for optional feature control; i.e., sand spreader

Tachometer Signal Output for remote panel display

Do Don’t

For I6 or V8 engines without optional code

12VZA - Add circuit to Pins 16, 49, 60, and 68 of Engine ECM connector 6020 depending on desired function, or add a Remote Engine

Speed Control Module (RESCM). Refer to

12VZA Component Information Diamond

Logic

®

Controller Engine Control Features and

Connect to the BC Cruise Control Input circuits.

Programmable Parameters for vehicles equipped with these optional codes or the

RESCM.


12VZA - Add circuit to Pin 22 of Engine ECM connector 6020 depending on desired function; or add a RESCM. Refer to 12VZA Component

Information Diamond Logic

®

Controller Engine

Connect directly to oil pressure sensor circuit.

Control Features and Programmable

Parameters for vehicles equipped with these optional codes. Install discrete oil pressure sensor or tap signal off the ATA or public J1939

Datalink.


12VZA - Add circuit to Pin 72 of Engine ECM connector 6020 depending on desired function; or add a RESCM. This provides 30,000 pulse/mile output for speed. Use an isolated

Dual wound sensor with manual transmission.

Refer to Component Information Diamond

Logic

®

Controller Engine Control Features and a) Connect into the speedometer sensor circuit on the engine.

b) Wire into Speed sensor circuit on transmission. Use sensors in parallel with existing output speed sensor. It will cause VSS

Diagnostic Trouble Code DTC to set.

Programmable Parameters for vehicles equipped with 12VZA optional code.


12VZA - Add circuit to Pin 72 of Engine ECM connector 6020 depending on desired function; or add a RESCM. This provides 30,000 pulse/mile output for speed. Use an isolated

Dual wound sensor with manual transmission.


Logic

®


Programmable Parameters for vehicles equipped with 12VZA optional code. This Connect into the speedometer sensor circuit on the engine.

provides 30,000 pulse/mile output for speed.


Logic

®


Programmable Parameters for vehicles equipped with 12VZA optional code. Allison

Transmission utilizes a variable frequency pulse generated by Transmission ECU. For vehicle speed information, refer to Allison service information, Connector 7205, cavity F

(provides this signal connection point)


12VZA - Add circuit to Pin 71 of Engine ECM connector 6020 depending on desired function; or add a RESCM. This provides a 12/pulse/eng

RPM. Refer to Component Information

Diamond Logic

®

Controller Engine Control

Features and Programmable Parameters for vehicles equipped with 12VZA optional code.

Connect into the tachometer sensor circuits on the engine.


October 2012



Item

Engine Coolant Temperature Gauge Output

Signal for remote panel display

Alternator warning light output circuit for remote panel display

Low Air warning signal for remote panel display

Park Brake Warning Output Signal for circuit interlock features installed

Trans Warning Output signal for remote panel display

Transmission Interface (Body Builder

Connections

Back Up Lights

Clearance/Marker Lights

Dome Light

Fog Light

Headlights (including Plow Lights without Plow

Light option

Panel Lights

Stop Lights

Tail Lights

Do

Install discrete Engine Coolant Temperature sensor. Refer to Component Information

Diamond Logic

®

Controller Engine Control

Features and Programmable Parameters.

Refer to ATA Datalink or public J1939 support information.

Connect wire to alternator warning light output terminal and connect the other side of the warning light circuit to IGN feed. NOTE:

Available on Remy alternator only.

a) Tap into air line with additional sensor or b) Refer to public J1939 Data Link information to extract Air PSI signal..

a) Tap into air line with additional switch for vehicles with air brakes or b) Connect into BC connector 1601 pin F1 with a 12 volt active signal Air or Hydraulic brake vehicle

Connect wire to ECU circuit 115 for WTC III and circuit 125 for LCT 2000/24000 transmission models. Circuit goes open to

GND to actuate a remote mounted light. An external relay is required if current is .05 AMPS or greater.

See the Transmission section in this manual

S08323 for Body Builder connection information.

Connect into Body Builder connectors 4450;

Cavity E circuit 71, or connect into tail light harness Connector 9303. Refer to Body Builder

Connections and circuit diagrams.

Connect into Body Builder connector 4450;

Cavity D circuit 58, or connect into tail light harness Connector 9303. Refer to Body Builder


a) Connect into BC connector 1604; Pin J for output circuit.

b) Theater Dimming must be turned off in the

BC.Connect into any door switch circuit.

a) Connect into BC connector 1603; Pin F for the left Fog Lamp and Pin K for the right Fog

Lamp output circuit.

b) Fog Light accommodation must be added to the BC.

c) Add Fog Light Switch.

Connect into Plow Light 7-way Harness connector provided with optional code 08THJ

Connect into panel lamp Bus connector 1002 located behind the Instrument Panel (IP) left of the interior fuse panel.

Connect into Body Builder connector (4450 cavity B and C; circuits 56 left/57 right combined) (4460 cavity A and B; circuits 56 left

/57 right separate), or connect into tail light harness connector 9303. Refer to Body Builder


Connect into Body Builder connector 4450;

Cavity A circuits 68 or connect into tail light harness Connector 9303. Refer to Body Builder


Don’t

Connect into Engine Coolant Temperature sensor circuits.

Connect warning light circuit to GND circuit.

Connect into electrical Low Air sensor circuits

Connect into existing air park brake switch electrical circuit b) Exceed 200 ma total.

a) Splice into the transmission harness for signal uses b) Utilize this signal for vehicle shutdown system.

Splice into the transmission harness for signal uses.

Exceed 6 AMPS total circuit

Exceed 20 AMPS total circuit.


Connect into fog light switch circuit.

Exceed 10 AMPS.

Connect into headlight switch circuit.


Connect into panel dimmer switch circuit or

Panel light adapter circuit A62N.

Exceed 5 AMPS.

Connect into the stop light switch circuit at the brake pedal.

Exceed 8 AMPS total.

Exceed 20 AMPS Total Circuit.




Turn Signals

Work Light

RPM Connection

Remote mounted Fuel Level (Low Fuel

Warning)

HVAC Interrupt (A/C compressor clutch and

Blower fan interrupts)

Clutch switch

Brake Switch

Item Do

Connect to Body Builder connector (4450 cavity B and C; circuits 56 left/57 right combined) (4460 cavity A and B; circuits 56 left/57 right separate) a) Connect into BC connector 1603 Pin G Work

Light Output circuit.

b) Work lamp accommodation (595ABR) must be programmed into the BC.

c) Add Work Light push button switch to instrument cluster.Exceed 10 AMPS.

Connect to Body Builder connectors at the

RPM (J3-output circuits and J4- remote inputs).

Refer to RPM Section.

Install additional fuel sender. Extract fuel gauge data from the Public J1939 data link.

Add a secondary A/C Evaporator to cool remote areas by tapping into the refrigerant lines with the authorized hoses. Use only the standard HVAC Control for controlling the A/C system.

Install additional switch.

Install additional switch.

Don’t

Connect to the input side of the turn signal switch or the BC circuit inputs.


Exceed 10 AMPS.

Exceed 20 AMPS per channel output with a maximum 80 AMPS total draw per module

Connect to fuel level gauge sender circuit or short existing fuel sending unit to chassis GND.

Connect into HVAC A/C clutch circuit between the BC and the A/C compressor clutch for purposes of controlling the A/C system.

Connect to the high side of the pressure transducer or either of the A/C system thermistors.

Connect into the clutch switch or circuit.

Connect into the brake switch or circuit.

■

HOW DO I - GENERAL INFORMATION

The International

®

parts system is set up to give part information that is specific to a particular vehicle that has been built. This includes all optional features that were ordered. If a feature is to be added after the vehicle was built, the dealer must be provided with the vehicle VIN number, the last 8 characters, and the feature code to be added. The dealer will contact “Parts Spec” to obtain a listing of parts required for that feature.

The circuits provided for the feature will be what are referred to as “overlay circuits” and are to be layered on and taped to existing harnesses. In some cases, a total harness may be provided. The harness may include standard wiring circuits.

The body builder will have to refer to the circuit diagram book for connector cavity information. If the decision is made to build the overlay locally, part numbers of the terminals can be found in the “Connector Body

Composites” section at the rear of the circuit diagram manual S08322.

All hardware associated with a specific feature code, switches, brackets, etc. will be provided. The body builder must decide which parts are to be ordered – it is not required that all parts for a code be ordered. Generally, except for a few features, there are no “kits” available, hence, detailed instructions are not provided, and this section will cover some basic direction.

If a feature is not available on a specific model, a parts list will not be provided.

Some features will require reprogramming of the Body Controller (BC). If reprogramming is required, the vehicle must be returned to the dealer.

If the body builder adds a feature, they must assume full responsibility for proper operation of that feature.

International

®

parts purchased from any International

®

Truck Dealer carry a one-year, unlimited mileage warranty. Other than the one year parts warranty, International

®

assumes no warranty for Body Builder installed components or the labor to repair the Body Builder added feature if it is determined that the failure is not OEM related.


October 2012


GENERAL

GENERAL

The following section provides basic information of how to integrate TEM's electrical systems with the vehicle electrical system. This section includes feature descriptions, programming information and sales codes where applicable. Also included is a description of how the feature works and in some cases, how the feature can be used.

If the vehicle was not ordered with the desired feature, this section covers basic information on how to add a feature to the vehicle.

An index of feature codes covered in this section is included in the table below.

Before proceeding, review the Introduction information.

Table 12

Feature Code

04SBL

08518

08585

08718

08HAA

08HAB

08HAE

08HAG

08HAH

08HAT

08HAU

08NAA

08RBK

08RCB

08REA

08RGA

08SAJ

08THG

08THH

08THJ

08THN

08THU

08THV

08TKK

08TME

08TMG

08TMH

Feature Code Index

Description

Optional Aux. Air Pressure Gauge - Hydraulic

Gauges

Chassis

Cigar Lighter

Auxiliary Toggle Switch for Fog or Driving Lights

Section Name

In Cab Battery Feed Power Source

Fog, Plow and Guide Post Accommodation

Power Source, Cigar Type Receptacle

Body Builder Wiring, End of Frame Without

Packages


Bodybuilder Wiring for Stop/Tail/Turn Lights

Connector — Separate Stop/Turn/Tail Only

Body Builder Wiring, Back of Cab With Connector


— Combined and Separate Stop/Turn/Tail

Body Builder Wiring, End of Frame With Connector


— Combined and Separate Stop/Turn/Tail

Electric Brake Accommodation Package for


Separate Stop/Turn, End of Frame

Electric Brake Accommodation Package for


Combined Stop/Turn, End of Frame

Body Builder Wiring for ease of connecting

Body Builder Wiring, Through Dash, Inside Cab accessory equipment

Body Builder Wiring for Tail/Amber,

Turn/Marker/Backup/Accessory, Power/Ground and

Stop/Turn

Body Builder Wiring for Stop/Tail/Turn Lights

Extending Frame and Tail Light Harnesses — 8 ft.


Dual CB Radio Antennas CB and 2-Way Radio Accommodation Packages

Header — Mounted CB Radio Accommodation

Package

CB and 2-Way Radio Accommodation Packages

2-Way Radio Accommodation Wiring Package —

10 ft.

2-Way Radio Accommodation Package — Routed to Header Console

CB and 2-Way Radio Accommodation Packages

B and 2-Way Radio Accommodation Packages

In Cab Switch Controls for Body Accessories, 2

RPM’s (BOC)/12 Momentary Switches

Auxiliary 7–Way Trailer Socket

Auxiliary 7–Way Trailer Socket

Auxiliary Harness for Front Plow Lights and Turn

Signals — 3 ft.

Hazard Lights Override Stop Lights

7-Way Trailer Socket with Battery Fed Circuit to

Remote power Modules




Packages

Productivity Features

Center Pin with 30 Amp Fuse and Relay Controlled by Switch


Front Harness for Guidepost Lights


Packages

Trailer Auxiliary Feed Circuit, 30 amp Accessory feed

7–Way Trailer Socket at End of Frame —

Independent of Stop Lights



7–Way Trailer Socket at End of Frame — Combined with Stop Lights

Switched Power to Cab Roof


Worklight and Outside Cab Power Features

Section & Page #

Section 17-Page 3

Section 10-Page 1

Section 12-Page 1

Section 10-Page 1

Section 13-Page 3

Section 13-Page 5

Section 13-Page 5

Section 13-Page 15

Section 13-Page 15

Section 22-Page 2

Section 13-Page 5

Section 13-Page 11

Section 08-Page 1

Section 08-Page 1

Section 08-Page 2

Section 08-Page 2

Section 18-Page 1

Section 13-Page 10

Section 13-Page 10

Section 12-Page 9

Section 11-Page 5

Section 13-Page 10

Section 12-Page 13

Section 13-Page 11

Section 13-Page 18

Section 13-Page 18

Section 14-Page 6


October 2012


GENERAL

Feature Code

08TMN

08TNP

08VZR

08VZS

08WAA

08WAD

08WCK

08WCM

08WCS

08WEB

08WEE

08WEX

08WGA

08WGB

08WGC

08WGD

08WGL

08WGP

08WGR

08WHX

08WHY

08WKM

08WJA

08WJB

08WJH

08WJT

08WJU

08WJV

08WJW

08WLL

08WLM

08WLN

08WMA

08WPL

08WPM

08WPZ

08WRB

08WSK

Description

Trailer Connection Socket

Feature Code Index

Auxiliary Harness for Front Snow Plow Application



Packages

Section Name


RPM (BOC)/6 Momentary Switches


RPM’s (BOC)/12 Momentary Switches

Remote Power Modules


Pedestal Mounted Work Light (Truck Lite 81 Series) Worklight and Outside Cab Power Features

Battery Disconnect Switch — Battery Box-Mounted Battery, Ignition & Accessory Taps

Power Source, 2–Post Terminal Type

Power Source for Power Lift Gate Feed


Liftgate Accommodation Package

Battery Disconnect Switch — Cab Floor-Mounted

Positive Disconnect

Extending Frame and Tail Light Harnesses — for

Drop Frame Beverage Body

Battery, Ignition & Accessory Taps

Bodybuilder Wiring for Stop/Turn/Tail Lights

Passenger- Controlled Air Horn — Instrument

Panel-Mounted Switch

Auxiliary Harness for Auxiliary Power Source

One Universal Air Solenoid, N/C

Two Universal Air Solenoids, N/C

Three Universal Air Solenoids, N/C

Four Universal Air Solenoids, N/C

Windshield Wiper Speed Control Forced to Slowest

Speed

Five Universal Air Solenoids, N/O

Six Universal Air Solenoids, N/O

Battery Disconnect Switch — Battery Box-Mounted

Positive Disconnect

Battery Disconnect Switch — Cab Floor-Mounted

Remote Air Solenoid Module

Bodybuilder Wiring for Stop/Turn/Tail Lights










Positive Disconnect

6 Universal Air Solenoids. N/C Remote Air Solenoid Module

Special 200 AMP Max. Lift Gate Power Source — 2

Gauge Power Cable


Power Source For Customer Lift Gate — 0 Gauge

Power Cable

Power Source, Dual Pole Terminal for Power Lift

Gate Feed



Battery Disconnect Switch (Power to PDC) {Joseph

Pollak} – Lever Operated, Mounted on Battery Box


Battery Disconnect Switch (Power to PDC) –

Locking, Key Operated, Mounted on Battery Box


Pollak} – Lever Operated, Cab Mounted




Pollak} – Key Operated, Cab Mounted


Pedestal-Mounted Work Light

Fog Lights (Peterson) – Amber, Rectangular –

WorkStar Series

Fog Lights (Peterson) – Clear, Rectangular –



Packages


Packages WorkStar Series

Work Light Accommodation Package –

Customer-Supplied Light or Aux. Application


Fog Lights – Amber, Oval – DuraStar Series

Fog Lights – Clear, Oval – DuraStar Series

Test Exterior Lamps Except Back-Ups

Headlights on with Wipers


RPM (EOF)/6 Momentary Switches


Packages


Packages




Section & Page #

Section 13-Page 10

Section 12-Page 9

Section 18-Page 1

Section 18-Page 1

Section 14-Page 1

Section 07-Page 5

Section 10-Page 1

Section 27-Page 1

Section 07-Page 5

Section 13-Page 13

Section 25-Page 5

Section 13-Page 13

Section 25-Page 1

Section 25-Page 1

Section 25-Page 1

Section 25-Page 1

Section 11-Page 4

Section 25-Page 1

Section 25-Page 1

Section 07-Page 5

Section 07-Page 5

Section 25-Page 1

Section 27-Page 1

Section 27-Page 1

Section 27-Page 1

Section 07-Page 5

Section 07-Page 5

Section 07-Page 6

Section 07-Page 6

Section 14-Page 1

Section 12-Page 1

Section 12-Page 1

Section 14-Page 1

Section 12-Page 1

Section 12-Page 1

Section 11-Page 1

Section 07-Page 4

Section 18-Page 1


October 2012


GENERAL

Feature Code

08WSM

08WTJ

08WXB

08WXN

08WZG

08WZP

08XBK

08WXD

12VXT

12VXU

12VXV

12VXY

12VYL

12VZA

12VZB

13GSB

13GSS

13WDH

13GUE

13GUG

13WDN

13WUA

13WUB

13WUC

13WUD

13WUE

13WUG

13WUH

13WUJ

13WUK

13WUL

13WUM

Feature Code Index

Description

In-Cab Switch Controls for Body Accessories, 1

RPM (BOC)/6 Momentary Switches

Section Name


In-Cab Switch Controls for Body Accessories, 1

RPM (EOF)/6 Latched Switches

Headlight Warning System

Worklights (2) (Grote) 60 series



Work Light and Outside Cab Power Features

In-Cab Junction Stud-100A Battery Feed for Body

Builders

Battery Warning Indicator Light

Auxiliary 40 Amp Circuit, Switch-Controlled

Park Brake Alarm

Remote Engine Speed Control: Stationary, Variable

Speed Control

Remote Engine Speed Control: Stationary, Pre-Set

Speed Control

Remote Engine Speed Control: Mobile, Variable

Body Builder Integration Harness


Work Light and Outside Cab Power Features


Remote Engine Speed Control Features



Speed Control

Remote-Mounted Engine Speed Control Remote Engine Speed Control Features

Accessory Wiring for Road Speed Wire Coiled

Under Instrument Panel

Remote-Mounted Engine Speed Control, Direct

Wire — for Post 2007 International

®

Engines



Engine Control, Remote Mounted for PTO with

MaxxForce 11 & 13 Engines

Eaton 6-Spd Hybrid without ePTO Capability

6-Spd Auto Manual with Electronic Shift Controls not with ePTO capability – Beverage Tractor only

Wiring for Transmission/PTO Controls for Allison

2000, 2100, 2200, 2400, 2500 Series

Transmission, Manual {Eaton Fuller Eaton Hybrid


Hybrid Electric Vehicle


PTO (Power Take OFF) and PTO Hourmeter

EH-8E406A-UP} 6-Speed Automated Manual,

Hybrid Drive Unit, With Electronic Shift Controls, ePTO Capability, Less APG Capability

Transmission, Manual {Eaton Fuller Eaton Hybrid

EH-8E406A-UPG} 6-Speed Automated Manual,

Hybrid Drive Unit, With Electronic Shift Controls, ePTO Capability, APG Capability

PTO Control, Dash Mounted

Allison Spare Input/Output for Rugged Duty Series

(RDS); General Purpose Trucks, Construction

Allison Spare Input/Output for Emergency Vehicle

Series (EVS); Rescue, Ambulance



Automatic Neutral Allison WT Transmission Shifts to Neutral When Park Brake is Engaged

Allison Spare Input/Output for Highway Series (HS);

General Purpose Trucks


Transmission Spare Input/Outputs and

Transmission Codes


Transmission Codes


Transmission Codes


Allison Spare Input/Output for Emergency Vehicle

Series (EVS); Fire/Pumper, Tank, Aerial/Ladder

Allison Spare Input/Output for Truck Recreational

Vehicle (TRV)

Transmission Codes


Transmission Codes



(RDS); Airport Refueler, Sewer Evac


(RDS); Front Loaders, Rear Loaders, Recycling/

Transmission Codes


Transmission Codes


Transmission Codes

Packer Trucks


(RDS); Side Loaders



Transmission Codes


Transmission Codes (RDS); Street Sweeper

Allison Spare Input/Output for Pupil Transportation

Series (PTS)


Transmission Codes


October 2012


Section 30-Page 1

Section 23-Page 54

Section 16-Page 6

Section 16-Page 6

Section 16-Page 6

Section 16-Page 6

Section 16-Page 6

Section 16-Page 6

Section 16-Page 6

Section 16-Page 6

Section 16-Page 6

Section 16-Page 6

Section 16-Page 6

Section & Page #

Section 18-Page 1

Section 18-Page 2

Section 11-Page 6

Section 14-Page 1

Section 22-Page 3

Section 07-Page 8

Section 14-Page 5

Section 11-Page 3

Section 24-Page 12

Section 24-Page 12

Section 24-Page 13

Section 24-Page 1

Section 24-Page 39

Section 24-Page 1

Section 24-Page 1

Section 30-Page 19

Section 30-Page 19

Section 23-Page 54

Section 30-Page 1

60AAE

60AAG

60AAH


GENERAL

October 2012

Section & Page #

Section 16-Page 6

Section 16-Page 7

Section 16-Page 7

Section 16-Page 7

Section 16-Page 7

Section 16-Page 7

Section 16-Page 7

Section 23-Page 54

Section 30-Page 1

Section 30-Page 1

Section 30-Page 1

Section 11-Page 6

Section 11-Page 6

Section 17-Page 3

Section 17-Page 4

Section 17-Page 5

Section 17-Page 6

Section 17-Page 8

Section 17-Page 9

Section 17-Page 11

Section 17-Page 11

Section 09-Page 1

Section 09-Page 1

Section 09-Page 1

Section 09-Page 1

Section 15-Page 1

Section 09-Page 1

Section 23-Page 83

Section 18-Page 2

Section 18-Page 2

Section 28-Page 1

Section 18-Page 2

Section 28-Page 1

Section 18-Page 2

Section 18-Page 2

Section 18-Page 2

Section 18-Page 2

Section 18-Page 2

Section 18-Page 1


GENERAL

Feature Code

60AAN

60ABA

60ABB

60ABC

60ABD

60ABE

60ABK

60ABL

60ABM

60ABN

60ACA

60ACB

60ACC

60ACD

60ACE

60ACG

60ACH

60ACJ

60ACK

60ACS

60ACT

60ACU

60ACV

60ACW

60ACX

60AJA

60AJC

60AJD

60AJE

60AJG

60AJH

60AJJ

Feature Code Index

Description

Remote Power Module (1) With No Switches

Cable Shift PTO Accommodation Package

Section Name



Muncie Lectra-Shift PTO Accommodation Package PTO (Power Take OFF) and PTO Hourmeter

Remote Start/Stop Remote Start/Stop Feature

Remote Start/Stop With Emergency Pump

Accommodation

Remote Start/Stop Feature

Electric Over Hydraulic PTO Accommodation

Package

Electric Over Air (Non-Clutched) PTO

Accommodation Package

PTO (Power Take OFF)


Electric Over Air (Clutched) PTO Accommodation

Package

I/O Expansion Harness

I/O Expansion Harness

Unadvertised Code for Remote Power Module with

One Latched Switch


Two Latched Switches


Three Latched Switches


Four Latched Switches

In Cab Switch Controls for High Current (40AMP)

Body Accessories

In Cab Switch Control (1) With Vehicle Speed

Interlock for Body Accessories








Power Features Using Remote Power Modules


In Cab Switch Controls (2) With Vehicle Speed

Interlock for Body Accessories


Five Latched Switches


Six Latched Switches

In Cab/External Switch for Body Accessories (3–

Way Momentary), Two Switches


Way Momentary), Two Switches


Way Momentary), Three Switches

Unadvertised Code for Remote Power Module with an Additional Six Latched Switches

Body Integration Input/Output Expansion Harness

(DLB Controlled




Power Features using Remote Power Modules





Theft Deterrent Feature

Throttle Control Accommodation for Single

Customer- Mounted External Engine Speed Control

Switch – Recovery Applications

Theft Deterrent


Special Gauge Cluster Indicators and Alarms (Gate

Open and Rear Alert) for Refuse Applications

Indicator Lights and Alarms

Special Gauge Cluster Indicators and Alarms

(Boom Not Stowed and Outriggers Not Stowed) for

Utility Applications



Customer- Mounted External Engine Speed Control

Switch – General Purpose



Customer- Mounted External Engine Speed Control Remote Engine Speed Control Features

Switch – Utility Applications

Remote Throttle Control for Dual Function Engine

Running/Emergency Power Engine Off

Remote Throttle Control for Customer- mounted

Momentary Switch – Refuse Applications



Section 24-Page 25

Section 24-Page 29

Section 24-Page 32

Section 24-Page 36

Section & Page #

Section 18-Page 2

Section 23-Page 1

Section 23-Page 6

Section 26-Page 1

Section 26-Page 3

Section 23-Page 17

Section 23-Page 26

Section 23-Page 35

Section 22-Page 1

Section 22-Page 1

Section 18-Page 13

Section 18-Page 13

Section 18-Page 13

Section 18-Page 13

Section 20-Page 1

Section 20-Page 2

Section 20-Page 7

Section 18-Page 13

Section 18-Page 13

Section 20-Page 14

Section 20-Page 16

Section 20-Page 19

Section 18-Page 13

Section 22-Page 1

Section 29-Page 1

Section 24-Page 21

Section 21-Page 1

Section 21-Page 5


October 2012


GENERAL

Feature Code

60AJK

60AJL

60AJM

60AJN

60AJR

60AJS

60AJT

60AJU

60AJV

60AJW

60AJX

60AJY

60AJZ

60AKA

60AKB

60AKC

60AKD

60AKE

60AKG

60AKK

60AKL

595AKY

595ANR

595ABC

Feature Code Index

Description

Body Integration, Indicator Lights (Body Up and

Gate Open) Plow/Dump Applications

Section Name


Remote Power Module (1) With 6 Latched

Switches

Remote Power Module (2) With 12 Latched

Switches

International

®

Diamond Logic

®

PowerPack 3,



Battery Box Mount

Dash Indicator Light – Red (1)



PowerPack 3 Primary and Temporary Mount

Features




Indicator Lights and Alarms Dash Indicator Light – Red (6)

Dash Indicator Light – Green (1)



Brake Applied Connection




Indicator Lights and Alarms Dash Indicator Light – Green (6)

Dash Indicator Light – Yellow (1)






Indicator Lights and Alarms Dash Indicator Light – Yellow (6)

Auxiliary Power Generator – Hybrid Mounted Inside

Rail, Back of Cab

Auxiliary Power Generator – Hybrid Mounted Left

Side Outside Rail, Back of Cab

PTO Control, Engine Compartment (LS)

Bdy INTG, Headlight Wig Wag, Park Brake Disables

Wig Wag

Bdy INTG, Headlight Wig Wag, Park Brake Disables

High Beam, Enables Low Beam


Features


Features

PTO (Power Take Off) and PTO Hourmeter


Packages


Packages

Electrical Functionality without associated feature

Dome Light Features codes

Electrical Functionality without associated feature

Park Brake Applied Connection codes

Electrical Functionality without associated feature codes

Section & Page #

Section 21-Page 9

Section 18-Page 2

Section 18-Page 3

Section 28-Page 16

Section 21-Page 12

Section 21-Page 12

Section 21-Page 12

Section 21-Page 12

Section 21-Page 12

Section 21-Page 12

Section 21-Page 12

Section 21-Page 13

Section 21-Page 12

Section 21-Page 12

Section 21-Page 12

Section 21-Page 12

Section 28-Page 15

Section 28-Page 15

Section 23-Page 44

Section 12-Page 14

Section 12-Page 14

Section 31-Page 1

Section 31-Page 2

Section 13-Page 3


October 2012


BODY CONTROLLER

BODY CONTROLLER

■

3200, DURASTAR, WORKSTAR MODELS

At the center of the Diamond Logic

®

Electrical System is the Body Controller (BC). The BC is an electronic module that provides multiple analog and switched input/output interfaces to monitor vehicle sensors and control vehicle functions through solid state switches, relay driver outputs, and serial data communications.

Serial datalinks connected to the BC include the following:

•

A drivetrain J1939 datalink to communicate information between the engine, transmission, Antilock Brake

System (ABS), the BC, and the Instrument Panel (IP)

•

A switch datalink for communicating switch status between the rocker switch assemblies (in the IP and the switches in the door pods) and the BC

•

A Body Builder datalink to interface optional input/output modules with the BC

The BC is located under the IP behind a kick plate to the left of the driver’s left foot. All connections are now located inside the cab with the exception of the power connection that passes through the dash panel to the engine compartment. The BC provides a standard interface signals for the park brake set signal. This interface signal is described at the end of this section. The BC receives battery power from the maxi-fuse block and

Ignition (IGN) power from the IP harness.

Body Controller (BC)

f_015

NOTE: Pins E3, E5, and E7 of the BC 32-way connector (1602) are the Zero Volt References (ZVR) for various sensors on the vehicle and should NEVER have battery voltage applied to them. Doing so will permanently damage the BC. Do not connect other Ground (GND) signals to the ZVR.

NOTE: All connectors are viewed as looking at the terminal side of the connector.


October 2012


BODY CONTROLLER

■

BC CONNECTOR J3 (1600)

BC Connector J3 (1600)

f_016

Table 13

Pin

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

#1600 In-Cab

32-Way Connector

A12

A13

A14

A15

A16

Air Chassis

Pin Description

Hydraulic Full Power Chassis

Pin Description

Type Automatic

Transmission

Automatic

Transmission

Input (Gnd Active) Accessory Switch Input Accessory Switch Input Accessory Switch Input Accessory Switch Input

Input (Gnd Active) AC Request AC Request AC Request AC Request

Input (Gnd Active) AC Diagnostics

Headlight Dimmer

Manual Transmission

AC Diagnostics







Input (Gnd Active)


Switch (Highbeam

Switch)

Electric Horn Switch

Input


Switch)


Input


Switch)


Input


Switch)


Input












Right Turn Signal

Switch Input


Switch Input


Switch Input


Switch Input

Left Turn Signal Switch Left Turn Signal Switch Left Turn Signal Switch Left Turn Signal Switch

Input

Washer Fluid Low

Switch

Wiper Switch 0



Air Park Brake Switch

Input


Switch




Air Park Brake Switch

Input


Switch




Manual Park Brake

Switch

Input


Switch




Manual Park Brake

Switch

Door Switch Input

Flash-to- Pass Switch

Input

Washer Pump

IGN Switch InputI



Input

Washer Pump




Input

Washer Pump




Input

Washer Pump


B1

B2

B3*

B4

Input (Gnd Active)


Open Open Open Open

Primary Air Pressure Primary Air Pressure Auxiliary Air Pressure Auxiliary Air Pressure

Input (Gnd Active) Secondary Air PressureSecondary Air Pressure

Input (Gnd Active) Open Clutch Switch

Open

Open

Open

Clutch Switch


October 2012


BODY CONTROLLER

Pin

B5

B6

B7

B8

B9

B10

B11

#1600 In-Cab


B12

B13

B14

B15

B16

Air Chassis

Pin Description


Pin Description

Type


Input (Gnd Active



Automatic

Transmission

AC Accumulator Inlet

Sensor



Sensor

Automatic

Transmission


Sensor



Sensor

MD: Open MD: Open

SS: Engine Oil Temp (Cat SS: Engine Oil Temp (Cat engine only) engine only)

Transmission Oil

Open Open

PTO State Input

Temperature Sensor

(Manual) OR PTO State

PTO State Input

Transmission Oil

Temperature Sensor

Input

(Manual) OR PTO State

Input

Fuel Level Sensor Input Fuel Level Sensor Input Fuel Level Sensor Input Fuel Level Sensor Input

— Right Side — Right Side — Right Side — Right Side


Fuel Level Sensor Input Fuel Level Sensor Input Fuel Level Sensor Input Fuel Level Sensor Input

— Left Side — Left Side — Left Side — Left Side

Input (Gnd Active) FR(Front) Axle Oil TempFR(Front) Axle Oil TempFR(Front) Axle Oil TempFR(Front) Axle Oil Temp

Input (Gnd Active) RR(Rear) Axle Oil Temp RR(Rear) Axle Oil Temp RR(Rear) Axle Oil Temp RR(Rear) Axle Oil Temp


AC Pressure

Transducer Signal

AC Pressure


AC Pressure


AC Pressure




Input (Gnd Active)


AC Accumulator Outlet AC Accumulator Outlet AC Accumulator Outlet AC Accumulator Outlet

Sensor

Brake Application

Sensor

Brake Application

Sensor

Open

Sensor

Open

Pressure

Open

Steering Wheel Cruise

Switches Input

Pressure

Open



Open



Open



The circuit attached to pin B3 should NOT have additional connections or splices added on an air chassis.

NOTE: All outputs will handle up to a 500 milliAmpere load unless stated otherwise.

NOTE: Circuits labeled “Gnd Active", “12v Active", or “5v Active” are open circuit until active.

No connections or splices are allowable on any signals that are highlighted in bold italic.


October 2012


BODY CONTROLLER

■



f_017

Table 14

Pin

E1

E2

E3

E4

E5

E6

E7

E8

E9

#1601 In-Cab


Type

Output (Low Side Driver)





Output (Low Side Driver)

Output (Low Side Driver)


Output (High Side Driver)

Air Chassis

Pin Description


Pin Description

Automatic

Transmission

Manual Transmission Automatic

Transmission


TEM Pump Inhibit Relay TEM Pump Inhibit Relay TEM Pump Inhibit Relay TEM Pump Inhibit Relay

OR TEM Aux Relay

Driver 2

TEM Engine Stop Relay

OR TEM Aux Relay

OR TEM Aux Relay

Driver 2


OR TEM Aux Relay

Driver 1

OR TEM Aux Relay

Driver 2


OR TEM Aux Relay

Driver 1

Auto Neutral Relay OR

LCT Column Shifter IGN

Relay OR Advanced

OR TEM Aux Relay

Driver 2


OR TEM Aux Relay

Driver 1 Driver 1

Auto Neutral Relay OR

LCT Column Shifter IGN

Relay OR Advanced

Open OR Advanced

Logic Relay Driver #3

Open OR Advanced



MD: Theft Deterrent OR

Advanced Logic Relay

Driver #4

SS: Theft Deterrent OR


MD: Theft Deterrent OR


Driver #4

SS: Theft Deterrent OR


Theft Deterrent OR


Driver #4

Theft Deterrent OR


Driver #4

Driver #4

40 Amp Aux Circuit OR


Driver #4

40 Amp Aux Circuit OR 40 Amp Aux Circuit OR 40 Amp Aux Circuit OR

Stop Relay (Brake Pedal) Stop Relay (Brake Pedal) Stop Relay (Brake Pedal) Stop Relay (Brake Pedal)

Windshield Wiper

High/Low Speed


Power (On/Off)

MD: LCT Shifter — PB position unlock solenoid

SS: LCT Shifter— PB position unlock solenoid

OR Odometer Shut-off

Relay

Air Solenoid #7/Relay

Driver #7





MD: Open

SS: Odometer Shut-off

Relay


Driver #7





MD: LCT Shifter — PB position unlock solenoid

SS: LCT Shifter— PB position unlock solenoid

OR Odometer Shut-off

Relay


Driver #7





Open


Driver #7


October 2012


BODY CONTROLLER

Pin

E10

E11

E12

E13

E14

E15

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

#1601 In-Cab


Air Chassis

Pin Description


Pin Description

Type Automatic

Transmission

Manual Transmission Automatic

Transmission






Trailer Tail Lights (Tractor or Body Builder Lighting)/


Driver #13

Trailer Auxiliary Circuit

OR TEM PTO

Engagement Relay

(Lectra-Shift)


Driver #3


Driver #5

Trailer Tail Lights (Tractor or Body Builder Lighting)/


Driver #13

Trailer Auxiliary Circuit

OR TEM PTO

Engagement Relay

(Lectra-Shift)


Driver #3


Driver #5

Body Builder Tail Lights/


Driver #13

TEM PTO Engagement

Relay (Lectra-Shift)


Driver #3


Driver #5

Body Builder Tail Lights/


Driver #13

TEM PTO Engagement

Relay (Lectra-Shift)


Driver #3


Driver #5

Output (High Side Driver) Right Plow Lights Relay Right Plow Lights Relay Right Plow Lights Relay Right Plow Lights Relay

Trailer Right Turn Signal Trailer Right Turn Signal


(Tractor or Body Builder

Lighting)/Air Solenoid

#14 (Truck)/Relay Driver

#14




#14

Body Builder Right Turn

Signal/Air Solenoid #14/

Relay Driver #14

Body Builder Right Turn


Relay Driver #14

Output (High Side Driver) Park Brake Relay


Park Brake Relay


Park Brake Relay


Park Brake Relay



Driver #11


Driver #11


Driver #11


Driver #11



Driver #12


Driver #12


Driver #12


Driver #12



Driver #6


Driver #6


Driver #6


Driver #6



Driver #8


Driver #8


Driver #8


Driver #8



Driver #9


Driver #9


Driver #9


Driver #9



Driver #10


Driver #10


Driver #10


Driver #10



Driver #4 Driver #4 Driver #4 Driver #4

Output (High Side Driver) Left Plow Lights Relay Left Plow Lights Relay Left Plow Lights Relay Left Plow Lights Relay



Driver #2


Driver #2


Driver #2


Driver #2

Output (High Side Driver) Fuel Pump Transfer Fuel Pump Transfer Fuel Pump Transfer Fuel Pump Transfer

Output (High Side Driver) Particulate Trap Indicator Particulate Trap Indicator Particulate Trap Indicator Particulate Trap Indicator


Trailer Left Turn Signal




Trailer Left Turn Signal




Body Builder Left Turn


Relay Driver #16

Body Builder Left Turn


Relay Driver #16




#16

Trailer Marker Lights



#16

Trailer Marker Lights




#15


#15

Trailer or Body Builder

Stop Lights

Exhaust System High

Temperature Indicator


Stop Lights

Exhaust System High


Body Builder Marker

Lights/Air Solenoid #15/

Relay Driver #15


Stop Lights

Exhaust System High


Body Builder Marker

Lights/Air Solenoid #15/

Relay Driver #15


Stop Lights

Exhaust System High


NOTE: All outputs will handle up to a 500 mAmp load unless stated otherwise.


NOTE: For Air Solenoid/Relay Driver wiring see the Air Solenoid section of this manual or consult the applicable circuit diagram manual.


October 2012


BODY CONTROLLER


*Ampere

■



f_018

Table 15

E13

E14

E15

E16*

F1

F2

F3

F4

F5

F6

E5

E6

E7

E8

E1

E2

E3

E4

E9

E10

E11

Pin

Pin

E12

#1602 In-Cab


Type

Type

Input/Output

Input/Output

Reference

Output

Reference

Output

Reference

Output

Input (Gnd Active)

Input (Gnd Active)


Input/Output

Input/Output



GND

Input (Gnd Active)

Input/Output

Input/Output

Input (Gnd Active)

Input/Output

Input/Output

Air Chassis

Pin Description


Pin Description

Automatic Transmission Manual Transmission

Automatic Transmission Manual Transmission

Switch Datalink –

Switch Datalink +

ZVR (1)

+5V Output (A)

ZVR (2)

+5V Output (B)

ZVR (3)

+5V Output (C)

Switch Datalink –

Switch Datalink +

ZVR (1)


ZVR (2)


ZVR (3)


Automatic

Transmission

Automatic

Transmission

Switch Datalink –

Switch Datalink +

ZVR (1)


ZVR (2)


ZVR (3)


N/A

Open

Headlight Enable

Air Horn Solenoid/Air

N/A

Open



N/A

Open



Solenoid #1/Relay Driver

#1

N/A

Brake Switch Input


AC Coupled GND

J1939 Shield Datalink

J1939– Datalink

J1939+ Datalink


J1939– Datalink

J1939+ Datalink

Solenoid #1/Relay Driver Solenoid #1/Relay Driver

#1

N/A





J1939– Datalink

J1939+ Datalink


J1939– Datalink

J1939+ Datalink

#1

N/A





J1939– Datalink

J1939+ Datalink


J1939– Datalink

J1939+ Datalink



Switch Datalink –

Switch Datalink +

ZVR (1)


ZVR (2)


ZVR (3)


N/A

Open



Solenoid #1/Relay Driver

#1

N/A





J1939– Datalink

J1939+ Datalink


J1939– Datalink

J1939+ Datalink


October 2012


BODY CONTROLLER

#1602 In-Cab


Pin

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

Air Chassis

Pin Description


Pin Description

Type Automatic Transmission Manual Transmission Automatic

Transmission

Input (Gnd Active)

N/A

Air Horn Switch Input

N/A


N/A


Input (Gnd Active) Seat Belt Alarm Input Seat Belt Alarm Input Seat Belt Alarm Input

Input (Gnd Active)

Backup Light State OR

Electric Trailer Brake





Controller Input

Input (Gnd Active)

Input (Gnd Active)

Controller Input

MD: Hood Switch Input for

HEV

TEM Aux Input 2

Controller Input

Two Speed Axle Switch

Input

TEM Aux Input 2

Open


Input (Gnd Active)

MD: N/A

SS: Variable Speed

Engine Fan

TEM Aux Input 1

MD: N/A


Engine Fan

TEM Aux Input 1

TEM Aux Input 2

MD: N/A


Engine Fan

Input (Gnd Active)

Input (Gnd Active)

TEM Remote Start/Stop

Switch Input


Switch Input

MD: SAAR Input

SS: Single Speed T-Case SS: Single Speed T-Case

Motion Sensor Motion Sensor

TEM Aux Input 1


Switch Input

MD: SAAR Input


N/A


Seat Belt Alarm Input



Controller Input

Two Speed Axle Switch

Input

TEM Aux Input 2

MD: N/A


Engine Fan

TEM Aux Input 1


Switch Input

MD: SAAR Input

The circuit attached to pin E16 should NOT have additional connections or splices added on a hydraulic chassis.

NOTE: All outputs will handle up to a 500 mAmp load unless stated otherwise.


NOTE: For Air Solenoid/Relay Driver wiring see the Air Solenoid section of this manual or consult the applicable circuit diagram manual.



October 2012


BODY CONTROLLER

■



f_019

Table 16

Pin

E

F

G

H

A

B

C

D

J

K

L

M

*Field Effect Transistor

Type

10 AMP FET*

10 AMP FET

10 AMP FET

10 AMP FET

12 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

#1603 In-Cab


Signal Description

Right Front Turn Signal

Left Front Turn Signal

AC Compressor

Left Rear Turn Signal

Electric Horn

Left Fog Lamp

Work Light

Left Heated Mirror

Lift Gate

Right Fog Lamp

Right Heated Mirror

Right Rear Turn Signal


October 2012


BODY CONTROLLER

■


Table 17

Pin

E

F

G

H

J

A

B

C

D

K

*Field Effect Transistor


f_020

Type

20 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

10 AMP FET

#1604 In-Cab


Signal Description

Windshield Wiper Power

Headlamp, Low Beam — Left

Headlamp, High Beam — Left

N/A

Cab GND

Park, Marker, Clearance, ID Lamp #2

Park, Marker, Clearance, ID Lamp #1

Headlamp, Low Beam — Right

Cab Dome Lamp Circuit

Headlamp, High Beam

— Right


October 2012


BODY CONTROLLER


October 2012


BATTERY, IGNITION & ACCESSORY TAPS


■

STANDARD BATTERY AND IGNITION TAPS

F

EATURE

C

ODE

D

ESCRIPTION

None

See radio and power source connections and fused battery connection sections for additional information.

Battery, Ignition (IGN) and accessory taps allow the customer to obtain battery IGN and accessory power from various locations on the vehicle to operate various Body Builder or after-market accessories such as lights, motors, heaters, cell phones, computers, etc.

NOTE: When adding any circuit, be sure to protect the circuit being added. See the General Electric section for circuit protection information.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

Battery Connections

Location 1: Exterior battery tap in battery box.

Attach to battery post using ring terminals. Circuits should not be connected to the battery if vehicle is equipped with sealed battery terminals.

NOTE: Do not use starter stud for battery power, as extra terminals may cause nut to loosen.

Location 1: Exterior Battery Tap In Battery Box

f_021


October 2012



Location 2: Exterior battery tap driver's side engine compartment mega-fuse assembly

Location 2: Exterior Battery tap Driver’s side Engine Compartment

f_022

Table 18 – Battery Feed Connection Points

Circuit Max. Current Terminal Size Nut Torque Special Description Location

Number

—

—

(Amperes)

20

—

5/16

3/8

12 Nm/9 lbf-ft

15 Nm/11 lbf-ft

Instructions

—

**

Mega-Fuse Stud,

Fused Side*

Positive Battery

Terminal*

Outside Dash Panel,

Driver’s Side

Battery Box

* Additional “in-line” fuse of appropriate size must be added for circuit being added. Fuse should be located close to power source.

Special Instructions

**Circuits should not be connected to the battery if vehicle is equipped with sealed battery terminals.

NOTE: Do not use starter stud for battery power, as extra terminals may cause nut to loosen.


October 2012



C

ONNECTING TO

IGN S

YSTEM

Location 1: Located by inside fuse panel.

Passenger Side PDC

f_023

Table 19

Circuit

Number

A14G

Color Max. Current

(Amps)

15

Special

Instructions

A

Description Location

A13B

Red

Pink 5 B

Pigtail at fuse block

Pigtail protected by 5 AMP fuse

Inside Cab,

Passenger Side

Inside Cab,

Passenger Side

Special Instructions a. Circuit A14G circuit protected by a 15 AMP fuse in fuse block. A relay is required if the battery load exceeds 15 AMPS.

b. Circuit A13B circuit protected by a 5 AMP fuse in fuse block. A relay is required if the battery load exceeds

5 AMPS.


October 2012



On most vehicles, there are unused IGN bussed fuse locations in the PDC. These can be used for low current

IGN loads provided that the total IGN load in the PDC does not exceed the 40A rating for the ISO cube IGN relay. For relay and fuse descriptions, see the product graphic located on the inside of the PDC cover.

Fuse terminal part numbers

18 gauge – 3515517C1

16 gauge – 3573312C1

14 gauge – 3573312C1

12 gauge – 3573311C1

T

ESTING

•

For Battery taps, test to see that battery voltage is present at all times.

•

For Accessory taps, test to see that battery voltage is present when the IGN key is in “Accessory” or “IGN” key states

•

For IGN taps, test to see that battery voltage is present when the IGN key is in “IGN” key state.

■

HEADLIGHTS ON W/WIPERS

08WRB

HEADLIGHTS ON W/WIPERS Headlights Will Automatically Turn on if Windshield Wipers are turned on. There are two functions, Lights On With Wipers (LOWW) and Day Time Running Lights (DTRL), available with this sales code.

Function (LOWW): The Lights On With Wipers (LOWW) function turns on the low beam headlights (tail, marker

& clearance lights are also turned on with low beam headlights) whenever the windshield wipers are ON steady or intermittent. The headlights will not be enabled in washer mode. When the wipers are turned OFF, headlights will remain ON until the key is turned OFF or the headlight switch is cycled from OFF to ON to OFF.

Function (DTRL): The Day Time Running Lights (DTRL) function will turn on low beam headlights at 75% of normal brightness whenever the key is in the RUN position and the Park Brake is OFF.

Both features may be enabled or disabled by using Diamond Logic

®

Builder programming software.

NOTE: DTRL is required by law for Canadian registered vehicles and the feature must not be disabled.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature codes: 595ALB

•

Software feature codes that must be removed: NONE

•

The Lights_on_with_Wipers parameters activates the Lights On With Wipers function when the On/Off box is checked. If it is not checked the function is deactivated.

•

The DTRL_Enabled parameter activates the daytime running lights function when the On/Off box is checked.

If it is not checked the function is deactivated.


October 2012



Table 20

Parameter

Lights_on_with

_Wipers

ID

317

DTRL_Enabled 188

Description

Activate/Deactivate headlights on with wipers. A value of 1 enables and a value of 0 disables this feature.

Activate/deactivate daytime running lights. A value of 1 enables and a value of 0 disables this feature.

Default

Off

On

Units

On/Off

On/Off

Min

N/A

N/A

Max

N/A

N/A

Step

N/A

N/A

NOTE: The DTRL_Enable parameter is accessible only to Dealers.

W

IRING

I

NFORMATION

None

T

ESTING

1.

If LOWW is wanted to be activated on the vehicle, check the parameter box for Lights_on_with_Wipers and program the Body Controller.

2.

Turn on the wipers (Steady or Intermittent) and verify that the low beam headlights, tail, marker and/or clearance lights are turned on.

3.

Turn off the wipers and verify that the above lights are OFF.

H

OW TO

A

DD

T

HIS

F

EATURE

•

For 08WRB, the software feature code 595ALB must be enabled on the vehicle using the Diamond Logic

®

Builder software (see local dealer).

•

Set the desired programmable parameters for each signal using the Diamond Logic

®

Builder software (see local dealer if software is not owned).

■

BATTERY DISCONNECT SWITCH

08WAD

BATTERY DISCONNECT SWITCH {Joseph Pollak} Lever Operated

08WCS

BATTERY DISCONNECT SWITCH {Joseph Pollak 51-315} Positive Type, Lever Operated, Mounted on Cab

Floor

08WHX

BATTERY DISCONNECT SWITCH {Joseph Pollak 51-316} Locking, Key Operated, Positive Type, Mounted on

Battery Box

08WHY

BATTERY DISCONNECT SWITCH {Joseph Pollak 51-316} Positive Type, Locking, Key Operated, Mounted on

Cab Floor

08WJT

BATTERY DISCONNECT SWITCH {Joseph Pollak} Lever Operated, Disconnect Power to PDC, Does Not

Disconnect Charging Circuits, Mounted on Battery Box

08WJU

BATTERY DISCONNECT SWITCH {Joseph Pollak} Locking, Key Operated, Disconnects Power to PDC, Does

Not Disconnect Charging Circuits, Mounted on Battery Box


October 2012



08WJV

BATTERY DISCONNECT SWITCH (Joseph Pollak) for Cab Power Disconnect Switch; Cab Mounted, Lever

Operated, Disconnects Power to PDC, Does Not Disconnect Charging Circuits

08WJW

BATTERY DISCONNECT SWITCH {Joseph Pollak} Key Operated, Disconnects Power to PDC, Does Not

Disconnect Charging Circuits, Cab Mounted

The disconnect switch is used to shut down the entire battery-fed electrical system. When a vehicle is not going to be used for several days or longer, this switch will shut off the system so that the electrical components on the vehicle, if left on, do not drain the batteries of their charge. Customers have the choice between a key or lever operated battery disconnect switch.

NOTE: The disconnect switch should never be used to shut off the engine as there is a possibility of the alternator generating a high positive voltage spike which may result in electrical damage.

Battery Disconnect Switch (08WAD)

f_024

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

No additional wiring is necessary if the vehicle is ordered from International

®

with the sales feature codes listed above.

T

ESTING

1. Close switch.

2. Verify that the vehicle is providing 12-14 Volts to the starter motor.

3. Verify vehicle will start.

4. Turn engine off.

5. Open disconnect switch.

6. Verify vehicle systems do not have any electrical power.

H

OW

T

O

A

DD

T

HIS

F

EATURE

The disconnect switch cannot be put into the battery Ground (GND) cable as was previously done. The electronic modules will provide a GND path around the master disconnect switch if this is tried. The engine and transmission modules must always be connected to the batteries, even when the master disconnect switch is open. Separate power and GND circuits are provided on each vehicle to the engine and transmission electronics. To install a master disconnect switch, splice into the positive battery cable, or use OEM cables, going from the batteries to the cranking motor and insert disconnect switch into that circuit (NOT 08WJT,

08WJU, 08WJV or 08WJW), as shown in Figure f_025. For 08WJT, 08WJU, 08WJV and 08WJW, the battery disconnect switch must be inserted in the positive cable after the starter motor and all battery power leads from


October 2012



the starter motor positive terminal must be re-routed to the load side of the master disconnect switch. Ensure that adequate electrical insulation is used between the positive battery cable, the switch mounting, and the surrounding area. Place boots or covers over the disconnect switch studs to protect the batteries and cables from accidental shorting. Do not disturb the direct connections from the battery to the engine or transmission electronics. To reduce corrosion, dielectric grease should cover eyelets and studs.

CAUTION: Make sure that batteries are disconnected prior to performing any electrical work.

If a non-OEM switch is to be used, make sure it is designed to handle at least 1,000 AMPS (intermittent duty)

Installation Circuit for Battery Disconnect Switch (not 08WJT, 08WJU, 08WJV or 08WJW)

f_025

NOTE: If there is more than one positive cable, eyelet terminals will have to be stacked on the switch stud.

Some installations may not have GND strap to rail – if none exists, there is no need to add one.


October 2012



■

BATTERY WARNING INDICATOR

08WZP

BATTERY WARNING Green Indicator Mounted on Left Side of Instrument Panel above left side switch panel.

May be used with factory code 08WAD, 08WCS, 08WHX, 08WHY, 08WJT, 08WJU, 08WJV or 08WJW (battery disconnect switch for cab power) or with a customer supplied disconnect.

The indicator will illuminate any time the battery disconnect switch is turned on regardless of key position.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

H

OW

T

O

A

DD

T

HIS

F

EATURE

Green “Battery On” indicator light and associated wiring to the battery disconnect switch.

Green “Battery On”

Indicator Light

f_026


October 2012


CB & 2-WAY RADIO ACCOMMODATION

CB & 2-WAY RADIO ACCOMMODATION PACKAGES

■

CB RADIOS

Refer to the Circuit Diagram Manual S08322, Chapter 4, Cab Accessories, CB Power Radio.

08RCB

CB RADIO Accommodation Package; Header Mounted; Feeds From Accessory Side of Ignition (IGN) Switch;

Includes Power Source and Two Antenna Bases with Wiring

•

When installing a CB radio, this feature provides the power circuits required for hook-up. This accommodation package includes a two-way connector with 10 Ampere (AMP) accessory power feed and cab Ground (GND), dual CB antenna cables routed from the mirrors to the cab overhead console panel opening, and two CB antenna mounts located at the top of each mirror. A strap is also provided in the header to mount the customer-supplied CB radio. The CB antennas are not provided with this code. If the two antennas are desired, an additional feature code 08RBK must be ordered.

08RBK

CB ANTENNA (2) {Pana-Pacific} Full Wave; 4.0’ Length Includes “International

®

” Name on Top

•

Provides two 4’ long CB antennas.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

Locations for connecting to the vehicle IGN and cab GND have been provided. The table below lists the connection point along with information about that point. For a complete diagram of the IGN system and for connector and terminal part numbers, see vehicle circuit diagram manual.

Table 20

Feature Codes

08RCB

Max. Current (Amps)

10

Power Feed

Accessory

Description

CB Radio Accommodation Package

(Includes 2 Antenna Bases and Cable)

The mating connector for the CB connector is 1661196C1 and terminal 1661209C1 (16 gauge).

T

ESTING

To test these circuits, refer to the above chart and verify that battery voltage is present in the correct key-state for each respective feature.

H

OW

D

O

I A

DD

T

HESE

F

EATURES

?

If the vehicle was ordered without one of the desired features, they can be installed in the field. Refer to the section “How Do I” General Information section of this electrical guide for information on obtaining required parts. The same parts that are used in the OEM installation are available (cables, components, etc.). Also, refer to the circuit diagram that applies to the vehicle to aid in the installation.


October 2012



■

2-WAY RADIOS

Refer to the Circuit Diagram Manual S08322, Chapter 4, Cab Accessories, 2-Way Radio.

08REA

2-WAY RADIO Wiring Effects; Wiring With 20 AMP Fuse Protection, Includes IGN Wire With 5 AMP Fuse, Wire

Ends Heat Shrink and 10’ Coil Taped to Base Harness

•

Feature code 08REA provides a fused 20 AMP battery feed power wire, GND wire and fused 5 AMP IGN feed for applications requiring two–way radio communications such as local municipal government units or state DOT highway maintenance vehicles. The three wires are taped to the main cab harness.

08RGA

2-WAY RADIO Wiring Effects; Wiring With 20 AMP Fuse Protection, Includes IGN Wire with 5 AMP Fuse, Wire

Ends Heat Shrink and Routed to Center of Header Console in Cab

•

Feature code 08RGA provides a fused 20 AMP battery feed power wire, GND wire and fused 5 AMP IGN feed for applications requiring two–way radio communications such as local municipal government units or state DOT highway maintenance vehicles. The three wires are located in the center of the header console in the cab.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

Locations for connecting to the vehicle IGN have been provided. The table below lists the connection point along with information about that point. For a complete diagram of the IGN system and for connector and terminal part numbers, see vehicle circuit diagram manual.

Table 21

Feature Code Max. Current (AMPS)

08REA

08RGA

20

5

20

5

Power Feed

Battery

IGN

Battery

IGN

Description

Power feed to two-way radio

IGN feed to two-way radio

Power feed to two-way radio

Ignition feed to two-way radio


October 2012



f_027

08REA and 08RGA provide radio power and GND directly from the battery to minimize electrical noise on the line.

The cable is coiled up under the Instrument Panel (IP) as shown above in 08REA, and is of sufficient length to route to the back of the Travelcrew cab.

The wiring is located in the center of the header console in the cab for 08RGA.

T

ESTING

To test these circuits, refer to the applicable circuit diagram for the feature and verify that battery voltage is present in the correct key-state for each respective feature.

H

OW

T

O

A

DD

T

HESE

F

EATURES

If the vehicle was ordered without one of the desired features, it can be installed in the field. Refer to the “How

Do I” General Information section of this electrical guide for information on obtaining required parts. The same parts that are used in the OEM installation are available (cables, components, etc.). Also, refer to the circuit diagram that applies to the vehicle to aid in the installation.


October 2012




October 2012


POWER WINDOWS, LOCKS, REMOTE

KEYLESS ENTRY

POWER WINDOWS, LOCKS, REMOTE KEYLESS ENTRY

■

KEYLESS ENTRY SYSTEM REMOTE/WINDOW, POWER

Refer to the Circuit Diagram Manual S08322, Chapter 4, (Page 4 & 5) Cab Accessories, Front Door Windows and Locks (Power), or For Crew for crew cab vehicles.

16WKZ

KEYLESS ENTRY SYSTEM REMOTE With Panic and Auxiliary Buttons, Includes One Key Fob (Transmitter)

16VCN

KEYLESS ENTRY SYSTEM REMOTE With Panic and Auxiliary Work Light Function, Includes One Key Fob

(Transmitter)

16VCP

KEYLESS ENTRY REMOTE W/ TRAILER FUNCTION

16WJU

WINDOW, POWER (2) and Power Locks, Left and Right Doors

16WJV

WINDOW, POWER (4) and Power Door Locks, Front and Rear Doors, Left and Right

16WSS

WINDOW, POWER and Power Lock, Left Side Only

Driver and passenger power windows and door locks are available. The driver switches are located on the driver door trim and can control all door windows and locks. The passenger switches are located on the passenger door trim and can control the passenger door window and all locks. Window express down is available for all window switches by momentarily depressing the window down switch. The driver can “lockout” all non-driver controllable window switches by momentarily depressing the lower left switch on the driver door control.

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

F

OR

S

ALES

C

ODE

:

16VCN: 595ABZ & 595ABT

16WJU: 595ABY

16WJV: 595AEJ

16WKZ, 16VCP: 595ABZ

16WSS: 595ALE


October 2012



KEYLESS ENTRY

Driver's Side Door Pod

f_028

Passenger's Side Door Pod

f_029

The International

®

Keyless Entry System uses electronic door pods in the driver and passenger side doors which also operate the power door locks and the power windows. If equipped with Remote Keyless Entry

(optional code), the memory in the receiver (front passenger door pod) learns the transmitter codes from the key fobs (transmitters) and only recognizes those which it has learned in the programming process. Each vehicle's passenger side door pod has the ability to learn up to six transmitter codes allowing the vehicle to be accessed by six different key fobs. Each key fob has a unique code which can be learned by any number of

RKE equipped vehicles.

The key fob controls the following functions:

•

Chirp of the horn and doors lock if the lock button is pressed on the key fob.

•

Autolock function, which automatically locks the doors at a vehicle speed of 15 MPH see details below.

•

Panic function, button with horn symbol, which chirps the horn on/off in unison with the headlights and park lights for three minutes when the panic button on the key fob is pressed and the ignition (IGN) switch is off. If the button is pressed prior to the time out period, the lights, etc. will go off


October 2012



KEYLESS ENTRY

•

Pressing the “AUX” button will toggle the work light circuit on. Pressing the button will turn the work light off.

Vehicle must be ordered with work light or work light accommodation package.

With the IGN on, if wheel-based vehicle speed is above the auto lock speed, the park brake was released below the auto lock speed and is still released, and the doors were closed below the auto lock speed and are still closed, all doors will lock.

The auto lock feature will only lock the doors once regardless of the number of times the truck stops and starts.

Cycling the key and/or opening the door, while below the auto lock speed, will allow the auto lock feature to lock the doors again when the speed conditions are met.

NOTE: Horn chirp, auto lock are programmable parameters.

Keyless Entry Controller

f_030

T

RANSMITTER

L

EARNING AND

E

RASING

Before the transmitter can be used for the first time, it has to be "learned" by the receiver. Up to 6 transmitters with different identification codes can be learned by a single RKE Pod.

These procedures are designed for manual learning/erasing operations on a complete vehicle. They can be used for learning replacement transmitters, for using up to six transmitters for accessing the same vehicle, or for accessing any number of vehicles using the same transmitter. If RKE is being added to the vehicle, additional programming of the Body Controller (BC) is required to operate the horn, panic, and dome light functions with RKE.

P

ROCEDURE FOR

E

RASING

A

LL

L

EARNED

T

RANSMITTERS

1. Cycle the IGN from Off to On.

NOTE: Step 2 must be initiated (all four buttons pressed) within 10 seconds of this IGN event.

2. On the driver door pod, do the following:

While holding down the driver window-up, driver window-down, and unlock switches, depress and hold the lock switch. All four switches must be held for at least 5 seconds. Six or seven seconds is recommended. After the

5 seconds, the door pod RKE unit will erase all learned transmitters and the RKE will be disabled. At this point, the erase procedure is finished and a new IGN cycle must be initiated to perform any transmitter learning.

P

ROCEDURE FOR

L

EARNING A

T

RANSMITTER

NOTE: This learning procedure cannot be performed during the same IGN cycle as the "erase all learned transmitters" procedure. If necessary, the erase procedure should be completed before this procedure is started.


October 2012



KEYLESS ENTRY

1. Cycle the IGN from Off to On (leaving the IGN on will not work, it must be cycled). Step 2 must be initiated

(all four buttons pressed) within 10 seconds of this IGN event.

2. On the passenger door pod, do the following:

While holding down the window-up, window-down, and unlock switches, depress and hold the lock switch.

All four switches must be held for at least 5 seconds. Six or seven seconds is recommended.

3. After the 5 seconds, the Door Pod RKE unit will enter "Learn Mode" and stay there for 10 seconds (or until a transmitter is learned). Once the RKE enters the "Learn Mode", the four buttons can be released. During the ten second "Learn Mode" any function on the new fob/transmitter must be keyed at least twice (See

NOTE 1).

NOTE: After the transmitter is learned, the next keying of the new transmitter will perform the indicated function. It is recommended that the transmitter be successively keyed until the selected key's function is actually performed; i.e., pressing the lock button on the transmitter two times should learn its code; on the third push, it should lock the door and momentarily beep the city horn. This is a good way to quickly confirm the success of the learning.

NOTE: Steps 1 through 5 of the learning process must be repeated for each transmitter to be learned.


October 2012



KEYLESS ENTRY

■

PARTS INFORMATION

Replacement key fobs/transmitters can be obtained from Service Parts by ordering part number 3544938C2.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature code for sales code 16VCN or 16WKZ: 595ABZ

Turning the Panic_Enable parameter ON enables the Panic Mode feature of the keyless remote. The panic function chirps the horn on/off in unison with the headlights and park lights for three minutes when the panic button on the key fob is pressed and the IGN switch is off. If the button is pressed prior to the time out period, the lights and horn will go off.

Turning the Chirp_Enable parameter ON enables the Chirp feature for the keyless remote. The chirp feature results in a “chirping” sound when the truck is locked and unlocked.

Table 22

Parameter

Panic_ Enable

Chirp_ Enable

ID

644

647

Description

Enable/disable the Panic Mode for the Keyless Remote. A value of 1 enables and a value of 0 disables the feature.

Enable/disable the remote lock

"chirp" for Keyless Remote. A value of 1 enables and a value of

0 disables the feature.

Default

On

On

Units

No_Units

No_Units

Min

N/A

N/A

Max

N/A

N/A

Step

N/A

N/A

The AutoLock_Speed parameter sets the vehicle speed at which the vehicle doors will lock automatically.

Table 23

Parameter

AutoLock_

Speed

ID

652

Description

uto lock speed. The speed at which the vehicle doors will lock automatically (requires power locks); Setting this parameter to zero will disable auto door locks.

Default Units

15 mph

Min

0

Max

155

Step

1

W

IRING

I

NFORMATION

When using the “Aux” feature, the work light circuit can be used for other features other than a work light - see

“Work Light Feature for additional information.

If truck was built with power locks but not the keyless entry, see “How Do I Add Work Light Feature.”

With the Diamond Logic

®

Builder software, one other system can be activated. For example, the Aux button could turn on headlights or hazard lamps, not both.

H

OW

T

O

A

DD

T

HIS

F

EATURE

The Remote Keyless Entry (RKE) feature can be added if power windows/power locks

(16WJU/16WJV/16WSS) are already installed on the vehicle by replacing the standard front passenger side door pod with an RKE compatible door pod.

•

Software feature code 595ABZ must be enabled on the vehicle using the Diamond Logic

®

Builder software

(see local dealer).


October 2012



KEYLESS ENTRY

•

Remove the existing passenger side door pod and replace it with the RKE compatible pod, part number

3544937C6 as described below. The desired quantity of remote key fobs, part number 3544938C2, must also be ordered.

•

Set the applicable programmable parameters, chirp enable, panic enable - see above, using the Diamond

Logic

®

Builder software (see local dealer if not owned). The auto lock with vehicle speed option should already be set since power locks are installed.

•

As noted above, additional wiring may be required if the Aux button on the key fob will be utilized for turning on a work light or other functions.

•

Program the RKE receiver to recognize the desired key fobs as described above.

R

EMOVAL

/R

EPLACEMENT OF

P

ASSENGER

S

IDE

D

OOR

P

OD

To remove the door pod use the DIN Radio Removal Tool part number 2504954C1.

f_031

Insert the extraction tools (2) into the two holes on either side of the pod housing until the locking tabs are fully depressed. The pod can then be removed from the door panel and the extraction tools removed.

f_032

To install the new replacement pod, connect the appropriate connectors and push the pod in until the locking tabs are fully engaged.


October 2012


FUSED BATTERY CONNECTIONS INSIDE

CAB

FUSED BATTERY CONNECTIONS INSIDE CAB

■

FUSED BATTERY CONNECTIONS INSIDE CAB

08518

CIGAR LIGHTER

•

Provides cigar lighter.

08718

POWER SOURCE Cigar Type Receptacle without Plug and Cord

•

This option provides a power source for customers who wish to use CB radios, hand held spotlights or trouble lights, or other accessories that plug into the power socket receptacle for 12-Volt power.

08WCK

POWER SOURCE, TERMINAL TYPE 2-Post

•

Customers often desire the ability to power 12-volt accessories with the truck’s electrical system. This option provides a power source for items equipped to receive power from post-type terminals.

Refer to the Circuit Diagram Manual S08322, Chapter 4, Cab Accessories, Cigar Lighter and Power Feeds.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

Locations for connecting to the vehicle Ignition (IGN) have been provided. The table below lists the connection point along with information about that point. For a complete diagram of the IGN system and for connector and terminal part numbers, see vehicle circuit diagram manual.

Table 24 – Vehicle Ignition Connections.

Feature Code Max. Current

08WCK

08718

08518

(Amperes)

20

20

15

Power Feed

Battery

Battery

Battery

Description

Power Source, Two Post-Type

Power Source (Cigar-Type Receptacle)

Cigar Lighter (provides customer with a 15

AMP battery supply)


October 2012


FUSED BATTERY CONNECTIONS INSIDE

CAB

Power Source Connections

f_033

T

ESTING

To test these circuits, refer to the applicable circuit diagram for the feature and verify that battery voltage is present in the correct key-state for each respective feature.

H

OW

T

O

A

DD

T

HESE

F

EATURES

If the vehicle was ordered without one of the desired features, it can be installed in the field. Refer to the “How

Do I” General Information section of this electrical guide for information on obtaining required parts. The same parts that are used in the OEM installation are available (cables, components, etc.). Also, refer to the circuit diagram that applies


October 2012


PRODUCTIVITY FEATURES


■

TEST EXTERIOR LAMPS EXCEPT BACK UPS

08WPZ

Test Exterior Lights Pre-Trip Inspection will cycle all exterior lamps except back-up lights.

Exterior light test feature allows easier verification of light illumination during walk-around checks. Exterior lights shall illuminate in a fashion that allows the operator to verify the illumination of exterior lights. Feature

595AZY comes with push button “LMPv” (Lamp Check) to activate the lamp test. If this sales code is not ordered, the feature 595AES may be added for functionality without the push button.

For feature 595AZY, to enable the external lamp check sequence:

•

Turn the key to IGN or ACCESSORY

•

All exterior lights are off

•

All of the external lights inputs, park light switch, service brake switch, cruise switch and key state have a good status

•

Set the park brake

•

Push the ELC button in the cluster

To disable the external lamp check sequence, the operator must:

•

Press the service brake OR

•

Manually turn on any of the external lights OR

•

Turn the key to the off or crank position OR

•

Release the park brake.

NOTE: A bad status on any of the external light inputs, park light switch, service brake switch or key state will also terminate the lamp check sequence.

For feature 595AES, to enable the external lamp check sequence:

•

Turn the key to IGN or ACCESSORY

•

All exterior lights are off

•

All of the external lights inputs, park light switch, service brake switch, cruise switch and key state have a good status

•

Set the park brake

•

Simultaneously press the cruise on and cruise resume switches

THEN

•

Press and release the brake pedal.

To disable the external lamp check sequence, the operator must:

•

Press the service brake OR

•

Manually turn on any of the external lights OR

•

Turn the key to the off or crank position OR

•

Release the park brake.

NOTE: (Note: A bad status on any of the external light inputs, park light switch, service brake switch or key state will also terminate the lamp check sequence)

The backup lamp cannot be included within this test since the ESC does not control this lamp's functionality.

The lamp test repeatedly flashes all the lights on in the following sequence. This allows the operator to get outside the vehicle and verify that all the lights are working properly.

The following sequence is repeated with no delay between the steps; the programmable time parameter (PP) shall have a default value of two seconds, a minimum of one second, and a maximum of 10 seconds, with increments of one second. This parameter is set at FLEET access.


October 2012



Table 25

Sequence Number

0

1

2

7

8

9

5

6

3

4

Lights Requested On

High Beam on Plow (if plow is installed)

High Beams and Park Lights on

Fog Lamps (if installed) and Park Lights on

If fog lamps not installed, skip sequence one

Low Beam on Plow (if plow installed)

Low Beam and Park Lights on

Right Front and Rear Turn Light and Park Lights on

Left Front and rear Turn Light and park Brake Lights on

All Lights Off

Brake Lights

All Lights Off

Time In This

Sequence

PP

PP

PP

PP

PP

PP

PP

PP

PP

PP

PP

Push Button Switch Located Below the Instrument Cluster (595AZY)

f_034

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature code: 595AZY or 595AES

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

Table 26

Parameter Parameter Parameter

Name

Ext_Lamp_

Test_ Seq_Time

ID#

2230

Description

The time between each step of the exterior lamp check

Default

Settings

2

Units

5

Minimum

Value

Maximum

Value

1 10

STEP

1


October 2012



W

IRING

I

NFORMATION

None required.

T

ESTING

Refer to the FEATURES/BODY FUNCTION section.

H

OW

T

O

A

DD

T

HIS

F

EATURE

1. Enable the software feature code using the Diamond Logic

®


2. Set the desired programmable features from the table above.

■

ALARM, PARKING BRAKE

08WXD

ALARM, PARKING BRAKE Electric Horn Sounds in Repetitive Manner when Vehicle Park Brake is “NOT” Set,

With Ignition (IGN) “OFF” and any Door Open.

The purpose of the parking brake alarm is to alert drivers if they fail to set the park brake before exiting the vehicle. For this feature to be activated, ALL of the following conditions MUST occur:

•

The IGN switch is in the off position.

•

The parking brake is not set.

•

A cab door is open.

Once activated, the electric horn will sound for 60 seconds, which is the factory default setting for this programmable parameter. To deactivate the parking brake alarm, press on the brake pedal to immediately quiet the horn, and then make sure the IGN switch is in the run or accessory position and set the park brake.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

•

Required software feature code: 595AZV

•

595AJD activates this feature; however, the parameters below can be found under 595AYC.

S

OFTWARE

F

EATURE

C

ODE

T

HAT

M

UST

B

E

R

EMOVED

None

Park_Brake_Alarm_Duration parameter determines the maximum amount of time the horn will sound when the alarm is triggered. The default time is set at 60 seconds, but the range is from 0 to 180 seconds.

Park_Brake_Alarm_Suspend parameter determines the amount of time the alarm will suspend after the brake pedal is depressed in order to allow the driver to complete the steps to deactivate the park brake alarm. The default time is set at 10 seconds, but the range is from 0 to 60 seconds.

Park_Brake_Alarm_KeyOff_Enable parameter allows for the selection of the park brake alarm to work in either key off or key on/off.

Table 27

Parameter

Park_Brake_

Alarm_ Duration

Park_Brake_

Alarm_

Suspend

Park_Brake_

Alarm_ KeyOff_

Enable

ID

1951

1952

2457

Description

The amount of time the horn will sound when alarm activated

Amount of time the alarm will suspend before brake is depressed

Park brake alarm depends on

Key=Off, or not

Default

60

10

1

Units

S

S

On/Off

Min

0

0

0

Max

180

60

1

Step

1

10

1

W

IRING

I

NFORMATION

No additional wiring is required for this feature.


October 2012



H

OW

T

O

A

DD

T

HESE

F

EATURES

This feature is software only and can be added by activating software feature code 595AZV with Diamond

Logic

®

Builder.

■

WINDSHIELD WIPER SPEED CONTROL

08WGL

Windshield Wiper Speed Control forces wipers to slowest Intermittent Speed when the park brake is set and left on for a predetermined time.

Feature 08WGL is a software feature that forces the windshield wipers to their slowest intermittent speed when the park brake is set and the wipers are left on for a programmable period of time

(Wipers_To_Low_Int_Timeout).

The user may override this feature by manually moving the wiper switch to another position. The wipers will remain at this speed for the same programmable period of time and then return to their slowest intermittent speed after that time has passed.

If the IGN switch is turned off, this feature will be overridden.

There are two programmable parameters associated with this feature: Wipers_To_Low_Int_Enabled and

Wipers_To_Low_Int_Timeout. These parameters can be modified by anyone with the appropriate interface tool and Fleet access or higher.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software Feature Codes that must be installed: 08WGL — 595AJD

595AJD activates this feature; however, the parameters below can be found under 595AYC.

The Wipers_To_Low_Int_Enabled parameter shall enable or disable this feature. The default setting shall be

ON when this feature is ordered.

The Wipers_To_Low_Int_Timeout parameter shall determine the amount of time the park brake has to be set before the wipers are forced to their slowest intermittent speed. The default value for this parameter is 60 seconds. The minimum time allowed is 10 seconds and the maximum time allowed is 300 seconds with 10 second intervals.

Table 28

Parameter

Wipers_To_Low_

Int_Enabled

Wipers_To_Low_

Int_Timeout

ID

2171

2228

Description

Enables or disables the wiper speed override, if it is present.

Defines the amount of time the parking brake has to be set before the wiper speed is overridden.

Default

1

60

Units

None

S

Min

0

10

Max

1

300

Step

1

10

W

IRING

I

NFORMATION

This feature is software driven.

T

ESTING

1. Start vehicle and make sure the parking brake is engaged.

2. Turn the windshield wipers on any setting except for the slowest intermittent speed.

3. Leave the wipers on this setting for 60 seconds without adjusting the wiper speed.

4. After 60 seconds, the wipers should slow to the lowest speed.

5. Adjust the wiper speed control.

6. The wiper setting should match the user set speed.


October 2012



H

OW

T

O

A

DD

T

HESE

F

EATURES

Use the Diamond Logic

®

Builder software to install the appropriate software and determine correct settings for programmable parameters.

■

HAZARD LIGHT OVERRIDE STOP LIGHTS

08THN

TURN SIGNAL SWITCH With Hazard Flasher Overrides Brake, to be done With Programming System

Controller.

This feature is for vehicles with combination stop and turn lamps. This feature allows hazard flashers to continue flashing when service brakes are applied. This feature is used on bulk fuel transport where some states require hazard lamps to remain flashing when stopped at R/R crossings. When the Stop Override

Hazard programmable parameter below is turned on, this feature allows hazard flashers on the rear of the vehicle to stop flashing and stay illuminated as long as the brake pedal is depressed.

This feature can be enabled or disabled by using the Diamond Logic

®

Builder software.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required Software Feature Codes: 0595AAL

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

Activating the Stop_Override_Hazard_Enabled parameter means that the brake lights will override the hazard lights if both are activated at the same time.

Table 29

Parameter ID Max Step

Stop_ Override_

Hazard_ Enabled

562

Description

Activate/deactivate stop light override of flashing hazards on rear of vehicle. A value of 1 enables and a value of 0 disables this feature.

Default Units Min

On On/Off N/A N/A N/A

W

IRING

I

NFORMATION

None required.

T

ESTING

Stop Override Hazard Disabled:

1. Turn on the Hazard lights and verify normal operation (flashing), front and rear.

2. Depress the brake pedal and verify that both front and rear hazard lights remain flashing.

Stop Override Hazard Enabled:

1. Turn on the Hazard lights and verify normal operation, front and rear.

2. Depress the brake pedal and verify that both rear stoplights are on (not flashing) and that the front hazard lights remain flashing.

3. Release the brake pedal and verify that normal operation of the flashing hazards resumes at the rear of the vehicle.

H

OW

T

O

A

DD

T

HIS

F

EATURE

If it is desired to have the HAZARD lights override the STOP lights, then the Stop_Override_Hazard_Enabled parameter must be turned OFF.


October 2012



■

HEADLIGHT WARNING BUZZER

08WXB

HEADLIGHT WARNING BUZZER Sounds When Head Light Switch is on and Ignition Switch is in “Off”

Position.

The purpose of the Headlight Warning Buzzer is to alert drivers if their headlights are still in when the vehicle is turned off.

This feature can be enabled or disabled by using the Diamond Logic

®

Builder software.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required Software Feature Codes: 0595BHH

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

Table 30

Parameter ID Max Step

Exterior_Lamp_

Warn

2179

Description

se this parameter to enable exterior lamp reminder. A value of 1 will result in an audible warning when the vehicle is off and the lights are on. A value of 0 is used to deactivate the audible warning

Default Units Min

On On/Off 0 1 N/A

W

IRING

I

NFORMATION

None required.

T

ESTING

Exterior_Lamp_Warn Disabled:

1. Turn the key off.

2. Turn headlights on. There should be no warning.

Exterior_Lamp_Warn Enabled:

1. Turn the key off.

2. Turn headlights on. The warning will beep five times (with the door closed).

3. Open door. The warning will buzz continuously.

H

OW

T

O

A

DD

T

HIS

F

EATURE


®

Builder software to install the appropriate software and determine correct settings for programmable parameters.

■

SEATBELT WARNING PREWIRE

16HCK

SEATBELT WARNING PREWIRE for 1 to 3 Belts.

16HCL

SEATBELT WARNING PREWIRE for 4 to 6 Belts.

These features include Seat Belt Switches and Seat Sensors for belted positions in the cab and a harness routed to the center of the dash for the aftermarket installation of a Data Recorder and Seat Belt Indicator

System.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None


October 2012



W

IRING

I

NFORMATION

Refer to the circuit diagram manual chapter 4, pages 39-41 for wiring information.

■

ELECTRICAL LOAD CONTROL 11.8 VOLTS

595BMY

ELECTRICAL LOAD CONTL 11.8 Volts

595BMY is the Electrical Load Control/Shedding (ELCS) intended to protect the vehicle’s batteries from excessive discharge. The goal is to save enough charge to deliver sufficient power to the starting system to start the engine. The feature is intended to provide a convenient means of automatically shutting down loads overnight in order to conserve energy. This feature is specifically designed to be used for a Celadon split battery system. The first shed point for this system shall be 11.8 Volts. The second shed point is at 10 V and the third is at 9 V.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature code: 595BMY and (595AYE or 595AYS or 595BJM or 595BJH)

Conflicts with Software feature: 595ACL, 595BRM

Features disabled by the Electrical Load Control/Shedding (ELCS) with an available parameter to specify the level include the following: Work Lights, Fog Lights, Heated Mirrors, Air Shield Lights, Sleeper Dome Light,

Floor Search Lights, Skirt Light, Fuel Heater and Aux Trailer Circuit.

595AMU – WORK LIGHT Rocker Switch

595ABR – WORK LIGHT Push Button B

595AAU – HEATED MIRRORS Rocker Switch, Aftermarket only

595AMP – HEATED MIRRORS in Push Button Location B, Aftermarket only

595AMR – HEATED MIRRORS in Push Button Location A

595ACE – FOG LIGHTS Rocker Switch

595AMS – FOG LIGHTS Push Button Location A

595AMT – FOG LIGHTS Push Button Location B

595BMJ – FOG LIGHTS REAR ECE R38 Compliant, Red LED

595ADK – AIR SHIELD LIGHTING

595AAS – INTERIOR DOME LIGHTS in Sleeper

595AAT – INTERIOR FLOOR LIGHTS in Sleeper

595ADU – INTERIOR FLOOR LIGHTS in Cab

595 AEG – SKIRT LIGHTS Customer Supplied

595ADG – FUEL HEATER Will be Activated by ESC

595ADB – TRAILER AUX CIRCUIT Accessory Powered

595ADC – TRAILER AUX CIRCUIT Battery Powered

The Load_Shed _Level_Work_Light parameter specifies at what level the work light may be shed or loaded.

The Load_Shed _Mirror_Heat_Level parameter specifies at what level the work heated mirrors may be shed or loaded.

The Load_Shed _Level_Fog_Light parameter specifies at what level the fog light may be shed or loaded.


October 2012



The Load_Shed _Level_Air_Shield_Lights parameter specifies at what level the air shield lights may be shed or loaded.

The Load_Shed _Sleeper_Dome_Light parameter specifies at what level the sleeper dome light may be shed or loaded.

The Load_Shed _Floor_Search_Lights parameter specifies at what level the floor search lights may be shed or loaded.

The Load_Shed _Level_Skirt_Light parameter specifies at what level the skirt light may be shed or loaded.

The Load_Shed _Level_Fuel_Heater parameter specifies at what level the fuel heater may be shed or loaded.

The Load_Shed _Level_Aux_Trailer_Circuit parameter specifies at what level the auxiliary trailer circuit may be shed or loaded.

For features 595AMU or 595ABR: Table 78

Parameter

Load_Shed_Level_

Work_Light

ID

2327

Description

Level at which load or shed occurs

(0 = Do not load shed,

1= Load shed at first level,

2 = Load shed at second level,

3 = Load shed at third level

For features 595AAU or 595AMP or 595AMR: Table 79

Parameter

Load_Shed_Mirror

_Heat_Level

ID

2360

Description






For features 595AAS:Table 82

Parameter ID

Load_Shed_

Sleeper_Dome-

Light

2363

Description






Default

1

Default

1

Default

1

Units

List

Units

List

Units

List

Min

N/A

Min

N/A

Min

N/A

Max

N/A

Max

N/A

Step

N/A

Step

N/A

For features 595ACE or 595AMS or 595AMT or 595BMJ: Table 80

Parameter

Load_Shed_Level_

Fog_Light

ID

2369

Description






Default

1

Units

List

Min

N/A

Max

N/A

Step

N/A

For features 595ADK: Table 81

Parameter ID

Load_Shed_Level_

Air_Shield_Lights

511

Description






Default

1

Units

List

Min

N/A

Max

N/A

Step

N/A

Max

N/A

Step

N/A


October 2012



For features 595AAT or 595ADU: Table 83

Parameter

Load_Shed_Floor_

Search_Lights

ID

2324

Description






For features 595AEG:Table 84

Parameter ID

Load_Shed_Level_

Skirt_Light

2370

Description






For features 595AMU or 595ABR:Table 85

Parameter

Load_Shed_Level_

Fuel_Heater

ID

2054

Description






For features 595ADB or 595ADC:Table 86

Parameter

Load_Shed_Level_

Aux_Trailer_Circuit

ID

601

Description






Default Units Min Max Step

1


1


1


1

List

List

List

List

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

W

IRING

I

NFORMATION

No additional wiring is needed.

T

ESTING

No physical testing is specified for this feature. If there is access to DLB, the signal for Battery Voltage could be set below 11.8 V to test those features that should be shed at level 1, but it is not recommended that the actual battery voltage be allowed to drain just to test the feature.

H

OW

T

O

A

DD

T

HIS

F

EATURE

Select software feature 595BMY using the Diamond Logic

®

Builder software (See Local Dealer). If any of the related features are installed on the vehicle, specify the desired load shed level for these features using the

Diamond Logic

®

Builder software.


October 2012




October 2012


FOG, PLOW, GUIDE POST & WIG WAG

ACCOMMODATION PACKAGES

FOG, PLOW, GUIDE POST & WIG WAG ACCOMMODATION PACKAGES

■

FOG/DRIVING LIGHTS

Codes 08585, 08WPL, 08WPM, 08WLM, and 08WLN

Refer to the Circuit Diagram Manual S08322, Chapter 9, Lights, Fog Light and Work Light.

■ ■

DuraStar

08585

TOGGLE SWITCH, AUXILIARY and Wiring; For Driving Lights or Fog Lights Mounted by Customer

08WPL

FOG LIGHTS (2) Amber, Oval, With H355W Halogen Bulb

08WPM

FOG LIGHTS (2) Clear, Oval, With H355W Halogen Bulb

■ ■

WorkStar

08585

TOGGLE SWITCH, AUXILIARY and Wiring; For Driving Lights or Fog Lights Mounted by Customer

08WLM

FOG LIGHTS {Peterson} Amber, Halogen, Rectangular

08WLN

FOG LIGHTS {Peterson} Clear, Halogen, Rectangular

Feature codes 08WPL, 08WPM, 08WLM, and 08WLN come with the fog light system (wiring and fog lamps) completely installed. Feature code 08585 is an accommodation package that comes with wiring and a fog light connector. Customer must supply the mating connector, terminals, and seals, and must install the fog lamps.

All above features operate as follows: to turn on the fog lamps; the headlamps must be on and in the low beam position. The lamps will go off if the headlamps are switched to high beam.


October 2012




f_035

1603 (BC J1)

1603 (BC J1)

f_036


October 2012




Fog Light Switch in Switch Pack

f_037

Depending on the other features ordered on the vehicle, the fog light button switch could also be located on the left of the steering column under the instrument cluster.

Fog Light Switch Located Under the Instrument Cluster

f_038

For the customers who prefer to mount their own lamps, installation integrity is improved with the factory toggle switch and wiring feature.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

- R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES

:

595ACE for Rocker Switch

595AMT for Push Button in Location B under the instrument cluster

595AMS for Push Button in Location A under the instrument cluster

595AHT for 08585

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None


October 2012




Table 31

Parameter

Left_Fog_Light

_Hi_Current

Left_Fog_Light

_Lo_Current

Left_Fog_Light

_OC_Current

Load_Shed_

Level_Fog_

Lights

Right_Fog_

Light_Hi_

Current

Right_Fog_

Light_Lo_

Current

Right_Fog_

Light_OC_

Current

ID

2309

2310

2311

2369

2312

2313

2314

Description

Left Fog Light High Current Detection Level

(AMPS)

Left Fog Light Low Current Detection Level

(AMPS)

Left Fog Light Open Circuit Detection Level

(AMPS)

Level for Load Shed for the Fog Lights

Right Fog Light High Current Detection Level

(AMPS)

Right Fog Light Low Current Detection Level

(AMPS)

Right Fog Light Open Circuit Detection Level

(AMPS)

Default

10

0.5

0.5

0

10

0.5

0.5

Units

A

A

A

List

A

A

A

Min

0

0

0

N/A

A

A

A

Max

10

10

10

N/A

0

0

0

Step

0.1

0.1

0.1

N/A

10

10

10

W

IRING

I

NFORMATION

With feature 08585 and if the vehicle is a 3200, 4200, 4300 or 4400, a “thin” fog lamp must be used if mounted in the bumper opening.

The fog lamp connections are located at the front of the frame on each side. See view below.

Care must be taken when adding fog lamps as lamps may have a GND wire and also have a grounded base.

Be sure that the feed circuit, cavity A, the connector at front of frame, is not connected to GND.

Mating connector part number 587568C91

Terminal (16 gauge) part number 587575C1

Seal part number 1652325C1


October 2012




f_039

Thin fog lamps must be used if mounted in the bumper opening of the 3200, 4200, 4300 and 4400 models.

View of Fog Lamp Breakout


October 2012 f_040




View of Bumper Mounting - WorkStar Models

f_041

T

ESTING

1. Activate fog light switch with the IGN key on and the headlamp switch on the low-beam mode.

2. Verify that pin F (labeled Left_Fog_Light) and pin K (labeled Right_Fog_Light) in DLB located in connector

(#1603 J1) are providing battery voltage.

3. Verify that the fog lights are functioning correctly.

4. Turn the fog light switch OFF.

5. Verify that the fog light output goes OFF.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature code 595ACE, 595AMY, or 595AMS (depending on switch location) must be enabled on the vehicle using the Diamond Logic

®

Builder software (see local dealer if not owned).

•

Install fog light switch part number 3563064C1 in the designated switch pack location or part number

3610765C1 for the pushbutton switch located below the instrument cluster. Use Diamond Logic

®

Builder

•

software to determine the fog light switch assignment after the software has been programmed into the BC.


®

Builder software (see local dealer if not owned).

•

Customer must wire the desired load into pin F (labeled Left_Fog_Light) and pin K (labeled Right_Fog_Light) on the BC hood connector (#1603 J1).


October 2012




■

FOG LIGHT INSTALLATION

M

ODELS

: 4200, 4300, 4400, 8500

There are two fog light kits available from your International

®

dealer, 2507255C91, Fog Lights Clear and

2507254C91 Fog Lights Amber. These kits provide the parts for the slim line fog lights for the DuraStar models only. The installation instructions are shown below for reference.

WARNING: Turn off IGN switch before starting procedure to avoid injury.

D

ESCRIPTION

This section addresses installation, switching, and programming of fog lights on International

®

4200, 4300,

4400, and 8500 trucks.

Table 32 – Parts Information

Part Number

2507254C91

2507255C91

Description

Amber Light Kit

Clear Light Kit

Quantity

1

1

Install fog lights using hardware included in the kit. The Figure below shows installation.

Front View with Attachment Points

f_042


October 2012




S

WITCH

I

NSTALLATION

Refer to the Figure below.

If there is an available switch opening in location one, install the fog light control switch in this location. If, in location one, the switch pack module is fully populated, install a six pack (part number 3549776C4) in location two. Additional switch blanks (part number 3533950C1) may be needed to cover unused switch locations.

Control Panel

f_043

Location 1: Six pack

Location 2: Six Pack

Location 3: Twelve Pack

W

IRING

F

OG

L

IGHTS

Refer to the Circuit Diagram Manual S08322, Chapter 9, Lights, Fog Light and Work Light for circuit installations.

P

ROGRAMMING

F

OG

L

IGHTS

Adding fog lights will require reprogramming the system controller. See local dealer.


October 2012




Table 33 – Fog Light Kit - Clear

Part Number

2507255C91

3555568C91

3535162C1

306132C1

3560279C91

3560225C91

3549438C91

3554890C1

3552493C1

3526712C1

3535292C1

30592R1

2507524R1

Table 34 – Fog Light Kit - Amber

Part Number

2507254C91

3555569C91

3535162C1

306132C1

3560279C91

3560225C91

3549438C91

3554890C1

3552493C1

3526712C1

3535292C1

30592R1

2507524R1

Description

Fog Light Kit Clear

Light, Fog w/Brkt (Clear) Slim

Nut, Hex Metr Prev Torq*M8X1.25

Strap, Cable Lock

Harness, *Fog Lights

Harness, Electrical, Chassis Wi

Switch, Light *Assy — Fog Light

Screen, Air Intake Radiator Gau

Bolt, Sems M6X1.0–25 SST Blk Ox

Nut, Special *M6

Bolt, Sems All 6mm X15 Torx

Nut, Speed Standard Part M6 X1

Manual, Inst Fog Light Instl

Description

Fog Light Kit Amber

Light, Fog w/Brkt (Amber) Slim

Nut, Hex Metr Prev Torq*M8X1.25

Strap, Cable Lock

Harness, *Fog Lights

Harness, Electrical, Chassis Wi

Switch, Light *Assy — Fog Light

Screen, Air Intake Radiator Gau

Bolt, Sems M6X1.0–25 SST Blk Ox

Nut, Special *M6

Bolt, Sems All 6mm X15 Torx

Nut, Speed Standard Part M6 X1

Manual, Inst Fog Light Instl

■

AUXILIARY FRONT LIGHTS

Refer to the Circuit Diagram Manual S08322, Chapter 9, Lights, Aux Headlights, Snow Plow Lights.

Feature Code Description

08THJ

AUXILIARY HARNESS 3.0’ for Auxiliary Front Headlights and Turn Signals for Front Plow Applications

08TNP

AUXILIARY HARNESS 5.0’ for Auxiliary Front Headlights and Turn Signals for Front Plow Applications

When front-mounted equipment blocks the vehicle headlamps and turn lamps, such as a snowplow, this feature code is available to connect additional lamps to be used in place of the normal headlamps. These features provide either a 3-foot or a 5-foot extension harness with a sealed 7-way connector cap for front-mounted auxiliary headlights, park or identification, right turn signal, left turn signal and ground. The connector is located behind the driver’s side headlight under the hood.

The harness and connector provide a 20 Amp high and low beam feed, a 10 Amp right and left turn signal feed and a 20 Amp park light feed. The connector comes with a mating connector and sealing plugs pre-installed.

The auxiliary park or identification, right and left turn signals are directly tied to the respective front lighting circuits. When the headlight switch is turned to the PARK or ON position, both the vehicle park and auxiliary park lights will come on. If the turn signal switch is activated, both the vehicle turn and auxiliary turn signal lights will come on.


October 2012




An auxiliary lighting switch labeled PLOW LIGHTS is mounted in the dash panel. The switch controls whether the auxiliary or vehicle headlights are on. The headlamp switch must be ON for the auxiliary headlamps to operate. Note that both sets of headlamps cannot be turned on at the same time. The plow light switch will only function with the key in the ON or ACCESSORY position.

This option is not available with the fog light or customer-mounted fog light options and is not available factory-installed on DuraStar models.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

- R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

:

•

595AMV – Push button located in position A below instrument cluster

•

595AMW – Push button located in position B below instrument cluster

•

595AYY – Rocker switch

Plow Lights Push Button Locations

f_044


October 2012




Plow Light Rocker Switch

f_045

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

595AMS, 595AMT, 595ACE

W

IRING

I

NFORMATION

The circuit ratings are as follows: the headlamp hi beam 20 AMP, the headlamp low beam 20 AMP, the left turn

10 AMP, the right turn 10 AMP and the park 15 AMP. Since the auxiliary park and turn current is shared with vehicle lighting current, make sure the added lighting does not exceed the stated current rating for each circuit.

All circuit protection is internal to the BC (Body Controller).

NOTE: If the plow lights are turned on without the lights being connected, the BC will log a headlamp fault code.

Table 35 – Aux. Connector Circuit Identification

Circuit Number

M64HI

M11-GE

M64LO

M56D

M58F

M57D

Plug

Cavity

E

F

G

A

B

C

D

Function

Hi Beam

GMD

Low Beam

T/S Left

Park

T/S Right

Plug


October 2012




f_046

To mate with the chassis harness use the following:

Table 36 – Part Information

Part

2039312C91

587579C1

2033912C1

589391C1

2039342C1

Quantity

6

6

1

1

1

The terminals and seals in the above table are for 14-gauge cable.

Description

Body, Connector 7 Way Metri-Pack 280 Series, Sealed - FEM

Plug, Filler, Sealing Weatherpack - GREEN

Terminal, Cable, Cable* Metri-Pack 280 Series Male Blade

Seal, Cable Terminal Weatherpack - Gray

Lock, Connector Body

NOTE: It is suggested that an extra connector (Part # 2039312C91), be completely filled with plugs, which can be saved and connected to the chassis harness connector when the plowing season is over – this procedure protects against corrosion.

T

ESTING

1.

Activate the plow light switch in the dash using the Diamond Logic

®

Builder software for switch locations.

2.

Turn on vehicle park lights.

3.

Verify that auxiliary connector Cavity E has battery voltage levels present.

4.

Turn ON vehicle headlights to the LOW BEAM position.

5.

Verify that auxiliary connector Cavity C has battery voltage levels present.

6.

Turn vehicle headlights to the HIGH BEAM position.

V

ERIFY THAT AUXILIARY CONNECTOR

C

AVITY

A

HAS BATTERY VOLTAGE LEVELS PRESENT

.

1.

Turn on vehicle left turn signal.

2.

Verify that auxiliary connector Cavity D has intermittent voltage levels present.

3.

Turn on vehicle right turn signal.

4.

Verify that auxiliary connector Cavity F has intermittent voltage levels present.

5.

Turn off the plow light switch.

6.

Verify all vehicle lights are operating correctly.

H

OW

T

O

A

DD

T

HIS

F

EATURE

There is a plow light kit available 2585355C91 to facilitate installation. The instructions that come with the kit are shown below.

NOTE: If the vehicle has hydraulic brakes, the instructions for installing relay circuits do not apply as the cavities have factory-installed circuits in the cavities indicated DO NOT REMOVE THESE CIRCUITS, use alternate open cavities. Be sure to mark the function of the added relays on the decal located on the bottom of the PDC cover.


October 2012




■ ■

Kit, Auxiliary (Snowplow) Light Instructions

2585355C91

Refer to the Circuit Diagram Manual S08322, Chapter 9, Lights, Aux Headlights, Snow Plow Lights for circuit information on installing this feature.

■

FRONT GUIDE POST LIGHTS

08THV

DISCONNECT, FRONT HARNESS for Guide Post Lights; Connectors Located at Headlight Connection, for

Customer Installation

This feature provides two additional connectors located in the front wiring harness for front parking or identification lights. This feature is commonly used for customer or Body Builder- added guidepost lights typically mounted at each end of the front bumper. These connectors come with mating connectors and sealing plugs pre-installed. The guide post light circuit is directly tied to the vehicle parking light system, so when the headlight switch is turned to the park or on position, these auxiliary lights will turn on with the standard vehicle lighting. This feature should be used in any application where operation in tight spaces requires constant identification of the vehicle’s width.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software Feature Codes that must be added: NONE

Software Feature Codes that must be removed: NONE

W

IRING

I

NFORMATION

Refer to the Circuit Diagram Manual S08322, Chapter 9, Lights, Light System – Marker, Park, Tail, Turn, and

Stop Lights.

Table 37 – Connector Cavity Information and Parts Required

Connector

P/N

1661778C1

Cavity

A

B

Circuit #

Left Side Right Side

M58H

M58-GA

M58J

M58-GB

Gauge

16

16

Plug part number: 2025431C1

Lock part number: 1661874C1

Term Seal

Part Number Part Number

1661875C1

1661875C1

1661872C1

1661872C1

T

ESTING

1. Turn the Headlight switch to PARK position and verify that both right and left guide post lights are on.

2. Turn the Headlight switch to ON position and verify that both right and left guide post lights are on.

H

OW

T

O

A

DD

T

HIS

F

EATURE

If the vehicle was not ordered with the feature, it may be added. Refer to the part numbers identified in the

Wiring section above for information on parts and components. See also “How Do I” - General Information section of this electrical guide.


October 2012




■

HEADLIGHTS WIG WAG

60AKK

HEADLIGHTS WIG WAG With Highbeam Flash

60AKK is the Wig Wag feature for emergency vehicles. This feature provides 13 different flash patterns for vehicle high beams. High beams will only flash when the park brake is released. If high beams are requested from the headlight switch, the high beams will come on steady. The headlight switch has ultimate control.

60AKL

HEADLIGHTS WIG WAG With Lowbeam or Highbeam Flash

60AKL is the Wig Wag feature for non-emergency vehicles. This feature provides 13 different flash patterns for vehicle headlights. High beams will only flash when park brake is released. Low beams will flash whenever requested to. Headlight switch has ultimate control. When vehicle is moving, if high beams are selected, low beams will flash; if low beams are selected, high beams will flash.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Wig_Wag_Cad

This parameter specifies the Wig Wag pattern for the headlights. The following table indicates the pattern and timing for the headlights.

Table 38

Setting

7

8

5

6

3

4

1

2

9

10

11

12

13

Wig Wag Pattern

Standard Left, Right Pattern – 75 flashes per minute

Standard Left, Right pattern – 150 flashes per minute

2 Left then 2 Right flashes (repeat) – 75 flashes per minute




Standard Left, Right pattern 3 flashes, then 3 flashes of both (repeat) – 75 flashes per minute




Standard Left, Right pattern 2 flashes, then 2 flashes of both, Left 2 flashes, Right 2 flashes (repeat 2x), then

2 flashes of both, Left 3 flashes, Right 3 flashes (repeat 2x), then 2 flashes of both, Left 4 flashes, Right 4 flashes, then 2 flashes of both, then repeat entire pattern –150 flashes per minute

Standard and non-standard Left and Right patterns with flashes of both at varying lengths of time

Standard Left, Right pattern with flashes of both at varying lengths of time

Daytime_Running_Lights_Disable

This parameter (Daytime_Running_Lights_Disable), when set ON provides the capability to disable the daytime running lights when the Wig Wag is ON.


October 2012




■ ■

Emergency Vehicle

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

F

OR

60AKK

595BLN

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

595BLP

Table 39

Parameter

Wig_Wag_Cad

ID

2629

Description

Determines method of flashing for the wig wag headlights

Default Units

1

■ ■

Non-Emergency Vehicle

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

F

OR

60AKL

595BLP

S

OFTWARE

F

EATURE

C

ODE

T

HAT

M

UST

B

E

R

EMOVED

595BLN

Number

Min

1

Max

13

Step

1

Table 40

Parameter

Daytime_Running_Lights

_Disable

Wig_Wag_Cad

ID

2630

2629

Description

Provides the ability to disable the daytime running light during wig wag

Determines method of flashing for the wig wag headlights

Default Units

Off

1

On/Off

Number

Min

N/A

1

Max

N/A

13

Step

N/A

1

W

IRING

I

NFORMATION

Wig Wag switch is located in one of the multiplex switch housings.

W

IG

W

AG

I

NHIBIT

I

NPUT

This input is located in the Body Controller on Connector 1600, pin B15. This input allows a customer to hook up an external input to access the wig wag feature and tie it into a customer-supplied master switch. The inhibit input wire is a blunt cur wire located inside the cab near the steering column under the dash.

Wig Wag Enable Switch


October 2012 f_047




T

ESTING

60AKK (Emergency Vehicles)

1. Turn Wig Wag switch on with Park Brake released.

2. Verify that High Beams are flashing in the pattern selected by the Wig_Wag_Cad parameter.

3. Set Park Brake and verify that Wig Wag pattern stops.


5. Verify the High Beams are flashing in the pattern selected by the Wig_Wag_Cad parameter.

6. Turn Wig Wag switch off and verify that Wig Wag stops.

60AKL (Non-Emergency Vehicles)


2. Verify that High Beams are flashing in the pattern selected by the Wig_Wag_Cad parameter.

3. If Daytime_Running_Light_Disable parameter was set, verify that Daytime Running Lights are not on during the Wig Wag.

4. Set Park Brake and verify that Wig Wag pattern stops.


6. Verify the High Beams are flashing in the pattern selected by the Wig_Wag_Cad parameter.

7. Turn Wig Wag switch off and verify that Wig Wag stops.

H

OW

T

O

A

DD

T

HIS

F

EATURE

Install Wig Wag Switch in the switch pack position shown in Diamond Logic

®

Builder after adding feature

595BLN or 595BLP.

60AKK (Wig Wag for Emergency Vehicles)

Set Wig_Wag_Cad parameter to desired pattern using the Diamond Logic

®

Builder software, or see a dealer.

60AKL (Wig Wag for Non-Emergency Vehicles)

Set Wig_Wag_Cad parameter to desired pattern using the Diamond Logic

®


Turn on Daytime_Running_Light_Disable, if desired using the Diamond Logic

®



October 2012


BODY BUILDER WIRING FOR

STOP/TAIL/TURN LIGHTS

BODY BUILDER WIRING FOR STOP/TAIL/TURN LIGHTS

■

STOP/TURN/TAIL

International

®

provides standard rear stop and turn signal lights on every vehicle. If the Body Builder or TEM needs to add different rear light configurations, such as separate stop and rear turn signals, various methods are offered to tap into the tail light circuits. The first and most common way is to use the standard sealed tail light 5-way Packard connector to provide lighting circuits for body-mounted lights that need combined stop and rear turn signals. It is recommended that a sealed mating connector and terminals be used to attach body wiring to the vehicle wiring. If the existing rear lighting is used and a marker or identification light feed is needed, International

®

recommends using the 5-way connector on the driver side rear tail light. Other optional methods for adding various light configurations are available (feature codes 08HAA, 08HAB, and 08NAA).

A feed terminal for body marker lights is provided in "terminal D" position on the left tail lamp. To wire body lights, Body Builders are to attach a terminal (International number 12129493) and seal (International

®

®

part number 2033816C1 or Packard Electric part

part number 589391C1 or Packard Electric part number 12015193) to the body feed cable. The cable can then be snapped into the empty cavity of the existing 5-way connector

(Note: if a splice is absolutely necessary, use heat shrink tubing with proper wire).

To connect to the tail light wiring harness, instead of using the OEM tail lights, use International

®

connector

1677851C1 or Packard Electric P12186400. Be sure to use a terminal plug in any unused cavities in the connector body. Alternately, order feature code 08NAA which includes separate wiring for standard left and right tail lights with 8' of extra cable for extending tail light wiring and separate wiring for left and right body-mounted tail lights.

The standard tail light connectors are located at the lights mounted to both the driver and passenger sides of the frame rail at the rear.

■

STANDARD TAIL, MARKER, AND CLEARANCE LAMP CONNECTION

This feature is standard with standard tail lamps.

International

®

provides a connection point at the left rear standard tail lamp. The connection point is made available so that power can be provided to additional tail, marker and clearance lamps.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

There is an unused cavity in the left rear tail lamp connector that can be used to provide tail, marker and clearance power. Remove the connector from the lamp and remove the cavity seal. Terminate added circuit with terminal and seal below, and insert into cavity D.

Table 41

Parts

Terminal (12 gauge)

Seal

Part Numbers

2033816C1

589390C1

NOTE: Circuit is protected internally by the Body Controller (BC) at 15 Amperes (AMPS). If current is close to or exceeds 15 AMPS, a relay must be added.


October 2012




If the rear lighting is to be entirely body-mounted, and a connection to the rear harness tail lamp connector is needed, use connector, terminal and seal specified below.

Table 42

Parts

Connector

Terminal

Lock

Seal

Part Numbers

1677851C1

1687848C1 — 10 Gauge

2033912C1 — 12-14 Gauge

1677914C1

0589390C1 — 10-12 Gauge

0589391C1 — 14-16 Gauge

Feed Terminal Location on Left Tail Lamp

f_048


Feed Terminal Location on Left Tail Lamp

October 2012 f_049




T

ESTING

When additional lights are added, test those lights for functionality and test the connection point for battery voltage.

■

BODY BUILDER WIRING AT END OF FRAME

Refer to the Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Body Builder and Trailer

Socket – Back of Cab (BOC) and EOF.

08HAA

BODY BUILDER WIRING To EOF, With Stop, Tail, Turn, and Marker Lights Circuits, Ignition (IGN)-Controlled

Auxiliary Feed and Ground (GND), Less Trailer Socket

This feature is for vehicles that have heavy-duty lighting requirements. This feature has a 30 AMP IGN Feed.

Right and left turn signals can support up to seven turn lamps per side. Code 08HAA is designed for separate stop and turn lamps only. The 7-wire breakout is located at the EOF, and there is no connector. The wires are blunt-cut with heat shrink covering.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software Feature Codes that must be added: 595ABC


These parameters should be left at their factory default values!

Table 43

Parameter

LT_FT_Turn_

Lo_Current

LT_FT_Turn_

Hi_Current

LT_FT_Turn_

OC_Current

RT_FT_Turn_

Lo_Current

RT_FT_Turn_

Hi_Current

RT_FT_Turn_

OC_Current

ID

1910

1911

1912

1913

1914

1915

Description

Park and ID Lights Low Current

Detection Level (AMPS)

Park and ID Lights High Current


Park and ID Lights Open Circuit








Default

0.5

10

0.5

0.5

10

0.5

Units

A

A

A

A

A

A

Min

0

0

0

0

0

0

Max

10

10

10

10

10

10

Step

0.1

0.1

0.1

0.1

0.1

0.1

W

IRING

I

NFORMATION

08HAA gives 7 wires located at EOF that are blunt-cut.

Table 44 – 08HAA

Cavity

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Circuit Number

R70

R68

R94

R58

R56

R57

R10

Maximum Current

30 A

20 A

30 A

20 A

15 A

15 A

N/A

Description

Stop Lights

Park Lights

IGN Feed

Identification Lights

Left Turn

Right Turn

GND

Fused by

F7-D F4-E4

F3-B D2-C2

F8-D F4-E4

F3-D D4-C4

F2-A F1-E1

F2-C F3-E3

Connector pinout is labeled as Trailer Socket (9734) connector in Circuit Diagram Manual S08322, Chapter 10,

Chassis Accessories, Body Builder and Trailer Socket – BOC and EOF. The connector itself is not supplied, and wires are blunt-cut.


October 2012




Location of 7-Wire Breakout at EOF

f_050

T

ESTING

WARNING: To avoid property damage, personal injury or death, park the vehicle on a level surface, set the parking brake, chock the wheels and turn the engine off.

1. Turn on vehicle headlights.

2. Verify that the taillight circuit (# R68) has battery voltage levels present.

3. Verify that the marker light circuit (# R58) has battery voltage levels present.

4. Turn off vehicle headlights.

5. Turn on left turn signal in vehicle.

6. Verify that left turn circuit (# R56) is cycling between battery voltage and GND.

7. Turn off vehicle left turn signal.

8. Turn on right turn signal in vehicle.

9. Verify that right turn circuit (# R57) is cycling between battery voltage and GND.


11. Put the vehicle in reverse.

12. Turn the key to the accessory or IGN position.

13. Verify that the IGN circuit (# R94) has battery voltage levels present.

14. Press the vehicle brake pedal.

15. Verify that the stop circuit (# R70) has battery voltage levels present.

16. Release brake pedal.

C

IRCUIT

D

IAGRAM

See Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Body Builder and Trailer Socket –

BOC and EOF.


October 2012




H

OW

T

O

A

DD

T

HIS

F

EATURE

Feature 08HAA is not available with code 08HAG and 08HAH Electric Trailer Brake or codes 08TME and

08TMG Trailer Connection Socket and 08THH Aux Trailer Socket with Center Pin Circuit. If the vehicle has any of these codes, 08HAA cannot be installed in the vehicle.

This feature is not easy to install, and every effort should be made to order the vehicle with the desired code.

Refer to the “How Do I” General Information section of this electrical guide for obtaining information on obtaining required circuits.

Refer to the 7-way socket at EOF for information covering circuit connections and use of the circuit diagram manual to aid in assembly.

■

BODY BUILDER WIRING

Refer to the Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Body Builder Connections.

08HAB

BODY BUILDER WIRING, BOC AT LEFT OF FRAME, includes 7-way sealed connector for tail/amber/backup/accessory power/GND and sealed connectors for combination stop/turn and a 3-way for separate stop/turn lights.

08HAE

BODY BUILDER WIRING, BOC REAR OF FRAME, includes 7-way sealed connector for tail/ amber/backup/accessory power/GND and sealed connectors for combination stop/turn and a 3-way for separate stop/turn lights.

08HAU

BODY BUILDER WIRING INSIDE CAB; Includes Sealed Connectors for Tail/Amber,

Turn/Marker/Backup/Accessory, Power/Ground, and Stop/Turn.

These features provide power to operate various body loads or after-market accessories such as stop/tail/backup/marker/rear turn signal lights, motors, heaters, etc. There are two connectors that come with these options. A 7-way and a 3-way both have sealed mating connectors and sealing plugs pre-installed. The

7-way connector provides the combined stop and turn signal circuits while the 3-way provides the separate stop and turn signal circuits. It is always recommended that sealed mating connector terminals be used to attach body wiring to the vehicle wiring. Also, if this option is used in place of the standard rear lighting connector, it is recommended that a mating connector with sealing plugs be placed into the standard rear tail light connector.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software Feature Codes that must be added: 595ABC




October 2012




Table 45

Parameter

LT_FT_Turn_

Lo_Current

LT_FT_Turn_

Hi_Current

LT_FT_Turn_

OC_Current

RT_FT_Turn_

Lo_Current

RT_FT_Turn_

Hi_Current

RT_FT_Turn_

OC_Current

ID

1910

1911

1912

1913

1914

1915

Description

Park and ID Lights Low

Current Detection Level

(AMPS)

Park and ID Lights High


(AMPS)

Park and ID Lights Open

Circuit Detection Level

(AMPS)

Park and ID Lights Low


(AMPS)

Park and ID Lights High


(AMPS)

Park and ID Lights Open

Circuit Detection Level

(AMPS)

Default

0.5

10

0.5

0.5

10

0.5

Units

A

A

A

A

A

A

Min

0

0

0

0

0

0

W

IRING

I

NFORMATION

08HAB: Connectors are located inside the driver’s side frame rail at the BOC.

08HAE: Connectors are located inside the driver’s side frame rail at the EOF.

08HAU: Connectors are located inside the cab.

Max

10

10

10

10

10

10

Table 46 – 7-Way Connector Information

Wire Number Cavity Gauge

N68BB

N56BB

N57BB

N54BB

N71BB

N12BB

N11-GD

E

F

G

A

B

C

D

14

16

16

14

16

14

12

Color Description

Brown

Yellow

Light Green

Brown

Light Blue

Light Blue

White

Tail Light

Left Turn Light

Right Turn Light

Marker Light

Back-up Light

Accessory Feed

GND

Fuse Rating

(Amps)

20

10

10

20

10

20

--

Available

Current (Amps)

20

8

8

20

6

20

--

Table 47 – More 7-Way Connector Information

Description

(4450) 7-Way Connector

Lock

12 Gauge Seals

14 Gauge Seals

16 Gauge Seals

12 Gauge Terminals

14 Gauge Terminals

16 Gauge Terminals

Chassis Harness

2039311C91

Body Builder Harness

2039342C1

589390C1

589391C1

1652325C1

2039312C91

2039344C1

3535486C1

2039343C1

1687848C1

2033912C1

2033911C1

Step

0.1

0.1

0.1

0.1

0.1

0.1


October 2012




Table 48 – 3-Way Connector Information

Wire Number Cavity Gauge Color Description

N56BC

N57BC

N70BB

A

B

C

16

16

14

Orange

Orange

Orange

Left Turn Light

Right Turn Light

Stop Light

Fuse Rating

(Amps)

10

10

15

Available

Current (Amps)

6

6

15

Table 49 – More 3-Way Connector Information

Description

(4460) 7-Way Connector

Lock

14 Gauge Seals

16 Gauge Seals

14 Gauge Terminals

16 Gauge Terminals

Chassis Harness

1686834C1

Body Builder Harness

1664408C1

589391C1

1652325C1

3553961C1

2033816C1

2033819C1

2033912C1

2033911C1

7-Way and 3–Way Connectors for 08HAB (BOC)


October 2012 f_051


1



7-Way and 3–Way Connectors for 08HAE (EOF)

f_052

7-Way and 3–Way Connectors for 08HAU (Inside Cab)


October 2012 f_053




T

ESTING


For Combined Stop and Turn:


2. Verify that the tail light circuit, Cavity A of 7-way socket with brown 14 gauge wire, has battery voltage levels present.

3. Verify that the marker light circuit, Cavity D of 7-way socket with brown 14 gauge wire, has battery voltage levels present.

4. Turn OFF vehicle headlights.


6. Verify that left turn/stop circuit, Cavity B of 7-way socket with orange 16 gauge wire, is cycling between battery voltage and GND.



9. Verify that right turn/stop circuit, Cavity C of 7-way socket with orange 16 gauge wire, is cycling between battery voltage and GND.



12. Verify that the body backup lights are working correctly.

13. Verify that the backup light circuit, Cavity E of 7-way socket with orange 16 gauge wire, has battery voltage levels present.

14. Take the vehicle out of reverse.

15. Turn key to accessory or IGN position.

16. Verify that the accessory circuit, Cavity F of 7-way socket with light blue 14 gauge wire, has battery voltage levels present.


18. Verify that the brake lights are functioning correctly.

19. Verify that the left turn/stop circuit, Cavity B of 7-way socket with orange 16 gauge wire, AND the right turn/stop circuit, Cavity C of 7-way socket with orange 16 gauge wire have battery voltage levels present.


For Separate Stop and Turn:

1. Turn ON vehicle headlights.

2. Verify that the tail light circuit, Cavity A of 7-way socket with brown 14 gauge wire, has battery voltage levels present.

3. Verify that the marker light circuit, Cavity D of 7-way socket with brown 14 gauge wire, has battery voltage levels present.



6. Verify that left turn circuit, Cavity A of 3-way socket with orange 16 gauge wire, is cycling between battery voltage and GND.




October 2012




9. Verify that right turn circuit, Cavity B of 3-way socket with orange 16 gauge wire, is cycling between battery voltage and GND.



12. Verify that the backup light circuit, Cavity E of 7-way socket with orange 16 gauge wire, has battery voltage levels present.

13. Take the vehicle out of reverse.

14. Turn key to accessory or IGN position.

15. Verify that the accessory circuit, Cavity F of 7-way socket with light blue 14 gauge wire, has battery voltage levels present.


17. Verify that the stop circuit, Cavity C of 3-way socket with orange 14 gauge wire, has battery voltage levels present.


H

OW

T

O

A

DD

T

HIS

F

EATURE

This feature is not easy to install and every effort should be made to order the vehicle with the desired code.

Refer to the “How Do I” General Information section of this electrical guide for obtaining information on obtaining required circuits.

Refer to the 7-Way Socket at EOF for information covering circuit connections and use of the circuit diagram manual to aid in assembly.

■

AUXILIARY 7-WAY TRAILER SOCKET

Refer to Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Body Builder and Trailer Socket –

BOC and EOF.

08THG

AUX. TRAILER SOCKET 7-Way; With Battery Fed Circuit to Center Pin, With 25 AMP Fuse and Relay

Controlled by Switch with Indicator Light on Instrument Panel (IP) Fed from Hot Battery Feed (Not Wired Thru

Key Switch)

08THH

AUX. TRAILER SOCKET 7-Way; With Battery Fed Circuit to Center Pin, With 25 AMP Fuse and Relay

Controlled by Switch with Indicator Light Controlled by Accessory Side of Key Switch, Switch Mounted on IP

08THU

TRAILER SOCKET 7-Way; With Battery Fed Circuit to Center Pin, With 30 Amp Fuse and Relay Controlled by

Switch With Indicator Light on Instrument Panel Fed from Hot Battery Feed, When Parking Brake Is Applied,

Not Wired Thru Key Switch

08TMN

TRAILER CONNECTION SOCKET {Phillips STA-DRY} 7-Way; Equipped With ABS Feed, Mounted at BOC and End of Frame Locations

These features allow a customer to connect two trailer lighting circuits to the vehicle. These options provide the same functionality as sales code 08HAB but provide a second 7-way socket next to the existing 7-way socket at the BOC.


October 2012




S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

A

DDED

None

Refer to feature code 08HAB for wiring and installation information. The circuits from the first 7-way trailer socket are directly spliced to the circuits of the second 7-way trailer socket. Part numbers for the connector and terminals remain the same.

■

TRAILER AUXILIARY FEED CIRCUIT, 30 AMP ACCESSORY FEED


BOC and EOF.

08TKK

TRAILER AUXILIARY FEED CIRCUIT for Electric Trailer Brake Accommodation/Air Trailer ABS; With 30 Amp

Fuse and Relay, Controlled by Ignition Switch

These features enables a truck to be wired to accommodate multiple trailer sockets that will drive the electrical loads of either an air brake type trailer or a trailer with electric brakes.

The 30 amp feed may be used for air brake Trailer ABS Power or as a charging circuit for electric trailer brake batteries.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

A

DDED

None

Refer to feature code 08HAB for wiring and installation information. The circuits from the first 7-way trailer socket are directly spliced to the circuits of the second 7-way trailer socket. Part numbers for the connector and terminals remain the same. The circuit is routed to the end of the frame rail with blunt cut wires.

■

EXTENDING TAIL LIGHT HARNESSES

08NAA

TAIL LIGHT WIRING MODIFIED Includes: Separate Wiring for Standard Left and Right Tail Lights, With 8.0’ of

Extra Cable; Separate Wiring for Left and Right Body-Mounted Tail Lights, With 8.0’ of Extra Cable

Feature code 08NAA provides eight additional feet of stop, turn, and tail light wiring to relocate the stop/turn lights provided with the vehicle.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

The extra harness length for code 08NAA is coiled at the EOF on both the right and left frame rail per view below. The loose harness connector is covered with a sealed connector. If standard tail lights are being removed, use sealing cap to protect open connector.

If a harness is to be connected to the OEM connector, see below for parts requirements. The part number for the 08NAA extension harness is 3547275C91.


October 2012




Table 50 – Left Side Connector

Connector Cavity Information and Parts Required to connect to OEM Connector

Connector P/N Cavity Circuit # Description Term P/N Seal P/N

1677851C1

A

B

C

D

E

S71H

S68F

S56E

Plug

S10-GF

Back up

Tail

Stop/Turn

--

GND

2033911C1

2033911C1

2033911C1

2033911C1

2033911C1

589391C1

589391C1

589391C1

589391C1

589391C1

Table 51 – Right Side Connector

Connector Cavity Information and Parts Required to connect to OEM Connector

Connector P/N Cavity Circuit # Description Term P/N Seal P/N

1677851C1

A

B

C

D

E

S71G

S68G

S57E

Plug

S10-GE

Back up

Tail

Stop/Turn

--

GND

2033911C1

2033911C1

2033911C1

2033911C1

2033911C1

589391C1

589391C1

589391C1

589391C1

589391C1

Plug P/N – 587579C1

Connector Lock P/N – 1677914C1

H

OW

T

O

A

DD

T

HIS

F

EATURE

See the part numbers identified in the “Wiring Information” section of this document.

f_054


October 2012




■

CENTER CHASSIS EXTENSION HARNESS

08WEB

SPECIAL WIRING HARNESS, BODY for Chassis, With 6' Additional Length to Accommodate Drop Frame

Beverage Body Application

Feature code 08WEB provides an additional 6 feet to the center chassis harness. This feature is to accommodate drop frame applications but may be specified when additional chassis harness length is desired.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

A 6’ extension of the center chassis harness, part number 3560971C91, is provided for Beverage Body

Applications. A 24-pin connector is provided at the end of the extension.

H

OW

T

O

A

DD

T

HIS

F

EATURE

See the part numbers identified in the “Wiring Information” section of this document.

f_055


October 2012




■

AUXILIARY HARNESS FOR AUXILIARY POWER SOURCE

08WEX

AUXILIARY HARNESS for Auxiliary Power Source; 30 Amp, Key Switched, 2-Pin Connector, Located on Floor

Between Seats

This feature consists of an ignition key switched wiring that is routed up the right “A” pillar to the back of cab to a coil that when stretched out can reach between the seats. The circuit is protected with a 30 AMP fuse. This feature is only available on the 7000 models.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

The wiring inside back of cab includes both GND and feed circuits, and the circuits are terminated to a two pin connector. The GND circuit is white, and the Ign12V feed is orange.

Connector Part Number: 0587568C91

Connector ref # 1872F

View of Coiled Wire Location , Viewed From Inside Vehicle

f_056

This switch is “hard wired” and there are no multiplex circuits associated with this feature. NOTE - This feature does depend on IGNITION key position, and can not be turned on with the key off.


October 2012




If wire is to be routed out of cab the desired hole location for the harness to exit the cab and location may vary from customer to customer, circuits are left on the floor for customer to drill hole.

Note that there are floor or back of cab reinforcements that should not be drilled into. Remove interior components to locate harness and determine best hole location. Install grommet into the hole and seal around cables and grommet to prevent leakage of moisture into cab.

When connecting to load, be sure to use sealed connectors or a splice protected with heat shrink sleeve with an adhesive inner lining.

T

ESTING

1. Turn on ignition switch.

2. Verify that the added feature operates.

3. Verify that the feed wire is receiving battery voltage.

H

OW

T

O

A

DD

T

HIS

F

EATURE

If the vehicle was not ordered with the feature, it may be added. For information on parts and components, see

“How Do I” General Information section of this electrical guide.

■

ELECTRIC TRAILER BRAKES

Refer to the Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Electric Trailer Brake.

08HAG

ELECTRIC TRAILER BRAKE/LIGHTS Accommodation Package to Rear of Frame (ROF); for Separate Trailer

Stop, Tail, Turn, Marker Light Circuits; Includes Electric Trailer Brake Accommodation Package With Cab

Connections for Mounting Customer- Installed Electric Brake Unit, Less Trailer Socket

08HAH

ELECTRIC TRAILER BRAKE/LIGHTS Accommodation Package to Rear of Frame; for Combined Trailer Stop,

Tail, Turn, Marker Light Circuits; Includes Electric Trailer Brake Accommodation Package With Cab

Connections for Mounting Customer-Installed Electric Brake Unit, Less Trailer Socket

These features provide a four-circuit breakout, blunt-cut with heat shrink covering located under the Instrument

Panel (IP) on the left side of the steering column. The circuits include a Ground (GND) circuit, an electric brake feed to electric trailer brakes, a 30 Ampere (AMP) power circuit plus the stop lamp feed. The circuits are designed to work with all popular electric trailer brake controllers.

The two different features are designed to handle trailers with separate stop and turn and combination stop and turn circuits.

The seven circuits that connect to the trailer are located at the rear of frame and are blunt cut with heat shrink covering. The appropriate socket assembly needs to be added by the customer.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature codes: 595AHU, 595ABC

Software Feature Codes That Must Be Removed: 0595ABS



October 2012




Table 52

Parameter

LT_FT_Turn_

Hi_Current

LT_FT_Turn_

Lo_Current

LT_FT_Turn_

OC_Current

RT_FT_Turn_

Hi_Current

RT_FT_Turn_

Lo_Current

RT_FT_Turn_

OC_Current

ID

1911

1910

1912

1914

1913

1915

Description

Left front turn signal high current detection level (AMPS)

Left front turn signal low current detection level (AMPS)

Left front turn signal open circuit detection level (AMPS)

Right front turn signal high current detection level (AMPS)

Right front turn signal low current detection level (AMPS)

Right front turn signal open circuit detection level (AMPS)

Default

10

0.5

0.5

10

0.5

0.5

Units

A

A

A

A

A

A

Min

0

0

0

0

0

0

Step

10

10

10

10

10

10

Max

0.1

0.1

0.1

0.1

0.1

0.1

W

IRING

I

NFORMATION

For circuit installation, see Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Electric Trailer

Brake.

The circuit colors/function to the electric brake controller are as follows:

Table 53

Circuit

Power feed to the controller

Stop lamp feed

Feed to electric trailer brakes

GND

Wire Color

Black

Red

Grey

White

Wire Gauge

12

16

10

16

08HAG and 08HAH provides seven blunt-cut wires located at end of frame and four blunt-cut wires located under cab IP.

The following are the wires for the circuits found in the blunt-cut wires located at the end of the frame.

Table 54

Circuit Number Maximum Description/Labeled Color

R70

R68

R94

R58

R10

Current

08HAG and 08HAH Label Number (Connector 9724)

30 A

20 A

30 A

20 A

N/A

Stop Lights

Park Lights

Trailer Brake

Identification Lights

GND

Red

Brown

Grey

Brown

White

R56

R57

08HAG Connector (Connector 9724)

15 A

15 A

Left Turn

Right Turn

08HAH Connector (Connector 9724)

Yellow

Light Green

R56

$57

15 A

15 A

Left/Stop Turn

Right/Stop Turn

Yellow

Light Green

08HAG and 08HAH Label ETB Controller (Connector 1923)

AJ11-GNA

A14NS

A70NS

A94T

--

30 A

15 A

20 A

GND Signal

Power Supply Signal

Stop Lights

Elec Brake Signal

White

Black

Red

Dark Blue


October 2012




Location of 4-Wire Breakout under Dash

f_057

Location of 7-Wire Breakout at End of Frame

F_050

NOTE: Many trailers combine trailer marker lamps with the tail lamp. If this has been done, leave the black circuit covered with the heat shrink tube.


October 2012




T

ESTING

1. Make proper trailer connections.

2. Turn on headlights.

3. Verify that the brown tail light wire and the black identification light wire have battery voltage levels present.

4. Turn off headlights.

6. Verify that the red brake wire has battery voltage levels present.

7. Release the footbrake.

8. Turn on the left turn signal.

9. Verify that the yellow left turn signal wire is cycling between battery voltage and GND.

10. Turn off left turn signal.

11. Turn on the right turn signal.

12. Verify that the light green right turn signal wire is cycling between battery voltage and GND.

13. Turn off right turn signal.

14. Activate trailer brakes with the trailer brake controller.

15. Verify that the dark blue electric trailer brake wire has variable voltage levels present commensurate with the position of the brake controller lever.

16. Verify that trailer brakes are functioning correctly by calibrating the electric trailer brake controller according to the manufacturer’s instructions.

■

TRAILER SOCKETS


BOC and EOF.

08TME

TRAILER CONNECTION SOCKET 7-Way; Mounted at EOF, Wired for Turn Signals Independent of Stop,

Compatible with Trailers That Have Amber or Side Lamps

08TMG

TRAILER CONNECTION SOCKET 7-Way; Mounted at EOF, Wired for Turn Signals Combines With Stop,

Compatible With Trailers That Use Combined Stop, Tail, Turn Lamps

These features are used to connect trailer lighting circuits to the vehicle. These options are for providing separate and combined stop and turn signals and are located at the EOF. These 7-way sockets provide

IGN-controlled fused 30 AMP center pins for trailer Antilock Brake Systems (ABS). Feature 08TMG is designed for trailers with combined stop and turn lamps. With all trailer connection features, the socket is a standard SAE recommended socket used in the trucking industry. The circuit arrangement in the socket is also the same as

SAE recommendation, except for 08TMG which has no separate stop circuit.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software Feature Codes that must be added: 595ABW, 595AAD, and 595ABC.

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None



October 2012




Table 55

Parameter ID

LT_FT_Turn_

Lo_Current

LT_FT_Turn_

Hi_Current

LT_FT_Turn_

OC_Current

RT_FT_Turn_

Lo_Current

RT_FT_Turn_

Hi_Current

RT_FT_Turn_

OC_Current

1910

1911

1912

1913

1914

1915

Description


Detection Level (Amps)











Default

0.5

10

0.5

0.5

10

0.5

Units

A

A

A

A

A

A

Min

0

W

IRING

I

NFORMATION

A 7-Way Trailer socket is provided at the end of the driver’s side frame rail.

0

0

0

0

0

Max

10

10

10

10

10

10

Step

0.1

0.1

0.1

0.1

0.1

0.1

f_058

Trailer Socket (Mating End View)


October 2012




Table 56 – Electrical Description of 08TME

Circuit Description

GND

Tail Lamp

Right Turn

Left Turn

Marker

Stop

Center Pin

Table 57 – Electrical Description of 08TMG

Fused

--

20

15

15

20

30

30


GND

Tail Lamp

Right Turn

Left Turn

Marker

Stop

Center Pin

Fused

--

20

15

15

20

--

30

Available Current

--

20

15

15

20

30

30

Available Current

--

20

15

15

20

Not Provided

30

Color

White

Brown

Green

Yellow

Black

Red

Blue

Color

White

Brown

Green

Yellow

Black

--

Blue

T

ESTING

08TME


2. Verify that the tail lights circuit (brown wire, top left cavity on trailer socket) has battery voltage levels present.

3. Verify that trailer marker circuit (black wire, top right cavity on trailer socket) has battery voltage levels present.


5. Turn on vehicle right turn lamp.

6. Verify that the trailer right turn lamp circuit (green wire, bottom left cavity on trailer socket) is cycling between battery voltage and GND.

7. Turn off vehicle right turn lamp.

8. Turn on vehicle left turn lamp.

9. Verify that the trailer left turn lamp circuit (yellow wire, bottom right cavity on trailer socket) is cycling between battery voltage and GND.

10. Turn off vehicle left turn lamp.


12. Verify that the trailer brake light circuit (red wire, bottom center cavity on trailer socket) has battery voltage levels present when the IGN key is in the accessory position.

13. Verify that trailer brake circuit (Blue wire, center cavity on trailer socket) has battery voltage levels present.


08TMG


2. Verify that the tail lights circuit (brown wire, top left cavity on trailer socket) has battery voltage levels present.

3. Verify that trailer marker circuit (black wire, top right cavity on trailer socket) has battery voltage levels present.


5. Turn on vehicle right turn lamp.


October 2012




6. Verify that the trailer right turn/stop lamp circuit (green wire, bottom left cavity on trailer socket) is cycling between battery voltage and GND.

7. Turn off vehicle right turn lamp.

8. Turn on vehicle left turn lamp.

9. Verify that the trailer left turn/stop lamp circuit (yellow wire, bottom right cavity on trailer socket) is cycling between battery voltage and GND.

10. Turn off vehicle left turn lamp.


12. Verify that the right turn/stop circuit (green wire, bottom left cavity on trailer socket) and the left turn/stop circuit (yellow wire, bottom right cavity on trailer socket) have battery voltage levels present.

13. Verify that the trailer brake light circuit (red wire, bottom center cavity on trailer socket) has battery voltage levels present when the IGN key is in the accessory position.


H

OW

T

O

A

DD

T

HIS

F

EATURE

Adding these features after the vehicle is built is not an easy task. It is encouraged that the vehicle be ordered with the desired feature.

Refer to the “How Do I” General Information section of this electrical guide to obtain information on circuits and components. It is necessary to have the circuit diagram manual that applies to the vehicle to complete the installation.

The installation requires additional fuses and relays be added to the Power Distribution Center (PDC) in the cab. Be sure to label the function of the added relays and fuses to the decal on the underside of the PDC cover.

The loose circuits will be numbered and correspond to the circuits outlined in the circuit diagram manual.


October 2012





October 2012


WORK LIGHT AND OUTSIDE CAB POWER

FEATURES

WORK LIGHT AND OUTSIDE CAB POWER FEATURES

■

WORK LIGHT/AUXILIARY REAR LIGHT

Refer to the Circuit Diagram Manual S08322, Chapter 9, Lights, Fog Light and Work Light.

■ ■

Tractor

08WLL

WORK LIGHT; Pedestal Mounted With Switch on Instrument Panel

08WAA

WORK LIGHT; Pedestal Mounted With Switch on Instrument Panel (Truck Lite 81 Series)

■ ■

Straight Truck

08WMA

WORK LIGHT TOGGLE SWITCH, on Instrument Panel and Wiring Effects for Customer Furnished Back of

Cab Light

08WXN

WORK LIGHT (2) (Grote) 60 Series, Mounted Under Hood One Each Side

With the International

®

-installed work light (08WLL, 08WAA), nighttime trailer hook-ups are made easier with a work light mounted at the Back of Cab (BOC) on tractors. This light illuminates the fifth wheel area of the vehicle. Both features include a switch in the Instrument Panel (IP), or 08WMA can also come with a push button switch located below the instrument cluster. Either switch will illuminate when the switch is on. These features provide an out-of-cab load on pin G of the Body Controller (BC) connector #1603. The feature without the light (08WMA) can be used to satisfy any number of electrical needs for vehicles with straight truck brakes

(4091) such as lights inside dry van boxes, small pumps, and illumination to aid in various job functions.

If the engine is off, there is a time out feature, which is factory set at 120 minutes. The time out period can be changed through the Diamond Logic

®

Builder software (see local dealer if not owned). If the vehicle is running, the work light will not time out after 120 minutes. If the work light is left on when the vehicle is moving, the green indicator light in the work light switch will flash.

1603 (BC J1)


October 2012 f_059



FEATURES

Work Light Located in Switch Pack

f_060

Push Button Switch Located Below the Instrument Cluster

f_061

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

-R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES

08WLL, 08WAA: 595ABR Switch located in the switch pack

08WMA:

•

595ABR or

•

595AMU Switch located below the instrument cluster in position B and

•

595AJE

08WXN:

•

595AMU Switch located below the instrument cluster on right side

The Work_Light_Timeout_Enable parameter is used to set the amount of time that the customer desires the work light to remain on after the IGN key is turned off. This parameter is for customers who desire to have their work light time out after a specified length of time so that the light does not drain the battery(s) in case the operator forgets to turn the work light off.


October 2012



FEATURES

If the current in the work light circuit falls below the level set by the Work_Light_Lo_Current parameter, the

Body Controller (BC) will register a fault code.

If the current in the work light circuit exceeds the level set by the Work_Light_Hi_Current parameter, the Body

Controller (BC) will shut off the circuit and register a fault code.

The Work_Light_OC_Current parameter should be left at its factory default of zero.

Table 58

Min Parameter

Work_Light_

Timeout_ Enable

Work_Light_

Lo_Current

Work_Light_

Hi_Current

Work_Light_

OC_Current

Load_Shed_

Level _Work_

Light

Work_Light_Off_

Speed

2327

2568

ID

640

1898

1899

1900

Description

This signal is a parameter that can be adjusted to vary the amount of time that the work light will remain on after the IGN key is turned off. If this value is set to 6, the work light will remain on for 60 minutes after the

IGN key is turned off.

Work Light Low Current Detection Level

(Amps)

Work Light High Current Detection Level

(Amps)

Work Light Open Circuit Detection Level

(Amps)

Level at which GEN2 work light is shed

Speed at which the Work Light will be turned off

Default Units

120

0

10

0

1

90

Min

A

A

A

List

Mph

10

0

0

0

0

1

Max

1440

10

10

10

3

90

Step

10

0.1

0.1

0.1

1

2

W

IRING

I

NFORMATION

The maximum current load for the work light/aux light is 10 AMPS. The circuit protection is internal to the Body

Controller (BC).

Table 59 – Parts Required to Connect to Work Light Cable

Connector Part #

1661778C1

Lock Part #

1661874C1

Term Part #

1661875C1

Seal Part #

1661872C1

Table 60 – Terminals Designed for 16-Gauge Wire

Connector Cavity

A

B

Circuit Number

N65

N65-G


Work Light Feed

Work Light GND


October 2012



FEATURES

Arrow Indicates Location of Work Light Connector (Straight Truck)

f_062


Arrow Indicates Location of Work Light (Tractor)

October 2012 f_063



FEATURES

T

ESTING

1. Activate work light switch.

2. Verify that pin G (labeled Work_Light) on the Body Controller (BC) connector (#1603) is providing battery voltage.

3. Verify that the work light (or alternate load) is functioning properly.

4. Turn work light switch OFF.

5. Verify that the work light output goes OFF.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

For 08WLL, the software feature code 595ABR must be enabled on the vehicle using the Diamond Logic

®


•

For 08WMA, the software feature codes 595ABR or 595AMU (dependent on switch location) and 595AJE must be enabled on the vehicle using the Diamond Logic

®


•

For 08WXN, the software feature code 595AMU must be enabled on the vehicle using Diamond Logic

®


•


®

Builder software (see local dealer if software is not owned).

•

The customer must then wire the desired load into the pin labeled Work_Light on the Body Controller (BC) output connector (#1603 – Work Light).

•

The customer must install a 3-position momentary rocker switch (part number 3549804C91) in the switch pack or appropriate part number for switch located below the gauge cluster. The switches are backlit with an amber light for better viewing during night operations. The switch has a green indicator light in the top half of the switch to indicate when the work light is on.

■

AUXILIARY 40 AMP CIRCUIT, SWITCH CONTROLLED

Refer to the Circuit Diagram Manual S08322, Chapter 10, Aux and Power Source.

08XBK

SWITCH, AUXILIARY Switch 40 AMP Circuit for Customer Use; Includes Wiring Connection in the engine compartment near the megafuse

Feature code 08XBK provides a 40 AMP battery feed for customer use. An in-cab rocker switch controls the circuit. A blank window switch is provided with this feature along with a graphic overlay kit that allows custom labeling of the switch function.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software Feature Codes that must be added: 595AJH Body Controller (BC) Prog, SWITCH AUXILIARY In

Center Panel, With 40 AMP Fuse Circuit, Accessory-Controlled

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

W

IRING

I

NFORMATION

A blunt-cut wire (light green) taped back to the dash harness near the megafuse is provided for customer interface to this circuit. The battery feed to this wire is through a relay that is enabled by a 12V signal from the

Body Controller (BC) connector 1601 pin E5 when the switch is activated.


October 2012



FEATURES

f_064

T

ESTING

To test this circuit, verify that battery voltage is present at the wire provided when the in-cab switch is activated with the IGN key in the on or accessory position. The green indicator in the rocker switch shall be illuminated when the output is on.

H

OW

T

O

A

DD

T

HIS

F

EATURE


“How Do I” - General Information section of this electrical guide.


®

Builder software to add the following software feature: 595AJH BC Prog, SWITCH

AUXILIARY In Center Panel, With 40 AMP Fuse Circuit, Accessory-Controlled.

Also refer to the “Center Panel” tab in the Diamond Logic

®

Builder software to determine the assigned location of the rocker switch for this feature.

■

OTHER EXTERNAL LIGHTING

08TMH

SWITCH, AUXILIARY Accessory Control; for Wiring in Roof, With Maximum of 20 AMP Load with Switches in the Instrument Panel

This feature consists of a switch mounted in the center panel with wiring that is routed up the right “A” pillar. The circuit is protected with a 20 AMP fuse. This feature is only available on the WorkStar models.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

The wiring in the roof includes both GND and feed circuits, and the circuits are blunt-cut covered with a heat shrink sleeve. The GND circuit is white, and the feed is brown.

Switch Part Number: 3557932C1

Switch Label: "Roof Aux"


October 2012



FEATURES

View of the Right Pillar and Roof Area, Viewed From Inside Vehicle

f_065

Switch Controlling the Aux Roof Circuit Will Be In One of Three

Switch Positions Viewed Above

f_066

This switch is “hard wired” and there are no multiplex circuits associated with this feature. The switch is lighted to give an “ON” indication.

NOTE: This feature does not depend on any IGN key position, and can be turned on with the key off. Care must be taken as leaving the switch on may discharge the batteries.


October 2012



FEATURES

Since the desired hole location for the harness to exit the cab and location may vary from customer to customer, circuits are left in roof for customer to drill a hole.

NOTE: There are roof reinforcements that should not be drilled into or through. Lower the headliner to locate the harness and determine the best location to drill a hole. Install a grommet into the drilled hole and seal around the cables and grommet to prevent leakage of moisture into cab.

When connecting to load, be sure to use sealed connectors or a splice protected with heat shrink sleeve with an adhesive inner lining.

T

ESTING

1. Turn on in-cab switch.

2. Verify that the added feature operates.

3. Verify that the feed wire is receiving battery voltage.

H

OW

T

O

A

DD

T

HIS

F

EATURE


“How Do I” General Information section of this electrical guide.


October 2012



FEATURES

■

IN-CAB LIGHTING

ELECTRICAL SYSTEM 12-Volt, Standard Equipment

This standard connection provides a fused connection point (5 AMPS maximum for all circuits connected to this point) to allow auxiliary lights to be dimmed as the panel lights are dimmed.

This circuit utilizes a Pulse Width Modulated (PWM) signal. Do not connect a relay coil to it.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software Feature Codes that must be added: NONE


W

IRING

I

NFORMATION

The connection is located under the instrument panel left of the interior fuse panel.

f_067

To connect to this circuit, remove the lock from the wire side of the bus bar connector and insert the added wire with terminal (terminal part number 1661208C1) on an unused connection point.

NOTE: The cover opposite the wires should also be removed to verify that the new connection is properly seated.

Re-install the cover and lock.

T

ESTING

Check that the added circuit properly dims when the panel dimmer switch is activated with the headlamp switch in the PARK or ON position.


October 2012



FEATURES

■

LIGHTS ON WITH WIPERS (LOWW)/DAY TIME RUNNING LIGHTS (DTRL)

Parameter 317

Lights On With Wipers (LOWW) - None

The Lights On With Wipers (LOWW) function turns on low beam headlights (tail, marker and clearance lights are also turned on with low beam headlights) whenever the windshield wipers are ON steady or intermittent.

The headlights will not be enabled in washer mode. When the wipers are turned OFF, headlights will remain

ON until the key is turned OFF or the headlight switch is cycled from OFF to ON to OFF.

Parameter 188

Day Time Running Lights (DTRL) – None

The Day Time Running Lights (DTRL) function will turn on low beam headlights at 75% of normal brightness whenever the key is in the RUN position and the Park Brake is OFF.

Both features may be enabled or disabled by using the Diamond Logic

®

Builder software. Note: the DTRL is required by law for Canadian registered vehicles and the feature must not be turned off.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature code: 595ALB

Software Feature Codes that must be removed: 595ALH

Table 61

Parameter ID

LOWW_

Enabled

DTRL_ Enabled

(See Note)

317

188

Description

Activate/Deactivate headlights on with wipers. A value of 1 enables and a value of 0 disables this feature.

Activate/Deactivate day time running lights. A value of 1 enables and a value of 0 disables this feature.

Default

Off

On

Units

On/Off

On/Off

NOTE: The DTRL_Enable parameter is accessible only to Dealers.

W

IRING

I

NFORMATION

None required.

T

ESTING

Min

N/A

N/A

Max

N/A

N/A

Step

N/A

N/A

LOWW

1. Turn on wipers (to the low speed) with IGN switch in run position.

2. Verify that the low beam headlights (and tail, marker and clearance lights) are on.

3. Turn on wipers (intermittent) with IGN in Run position.

4. Verify low beam headlights are on.

5. Turn off wipers and verify headlights remain on.

6. Cycle the Headlight switch and verify that headlights are off.

DTRL

1. Set the IGN switch to run with the park brake off.

2. Verify that low beam headlights are on.


October 2012



FEATURES

3. Set the park brake to on and verify that the low beam headlights turn off.

4. Set the IGN switch to accessory with the park brake off and verify that the low beam headlights are off.

H

OW

T

O

A

DD

T

HIS

F

EATURE

LOWW

1. Activate the LOWW_Enabled parameter using the Diamond Logic

®


DTRL

2. Go to your local dealer and have them enable the DTRL_Enabled parameter with their version of the

Diamond Logic

®

Builder software.


October 2012



FEATURES


October 2012


AIR CONDITIONING


■


Refer to the circuit diagram in S08322, Chapter 12, Air Conditioning.

16WKB

Air Conditioner (International

®

Blend Air) with integral heater, defroster and R134-A Refrigerant.

This is an electrical connection point for detecting when the air conditioner clutch is on. No direct electrical connection point is provided for tapping into the A/C clutch wire. However, if an A/C clutch connection is necessary, the Body Builder may use proper splice techniques to tap into wire AC77A. The added load required by the Body Builder should not exceed two Amperes (AMPS). This control wire shall be at battery volts when the A/C clutch is on and 0 volts when off. The software in the Body Controller (BC) determines when the A/C clutch should be on or off based upon the mode of the HVAC controls in the cab and condenser temperatures and high side pressures of the A/C system.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

WIRE GAUGE: 16 Gauge

WIRE NUMBER/COLOR: AC77A-LTGN

BC connector (1603): Pin C

TERMINAL: 3534163C1

CIRCUIT DIAGRAM: See Electrical Circuit Diagram Manual S08322 Chapter 12, Air Conditioning.

BC located in the cab behind the kick plate next to the driver’s left foot

f_001

T

ESTING

1. Start the vehicle. Turn on air conditioner.

2. Verify that the wire feeding the body load is at battery volts when the A/C Clutch is ON and 0 volts when

OFF.

3. Ensure that no faults codes are present when the truck is on.


September 2012



B

ODY

B

UILDER

I

MPORTANT

I

NFORMATION

In some applications it may be advantageous to add an additional A/C evaporator to cool remote areas of the vehicle. The following procedures and part numbers will accommodate this addition.

NOTE: Do not break into the A/C clutch circuit for the purpose of controlling the A/C system.

Do not connect to the high side of the pressure transducer.

Do not connect to either of the A/C system thermistors.

P

ARTS

I

NFORMATION

2007 MaxxForce DT and MaxxForce 9 Engines, Low Cab Mount

Hose, A/C assy accumulator to compressor – 3613035C92

Hose, A/C assy condenser to evaporator – 3613034C93

Hose, A/C assy compressor to condenser – 3613033C94

2007 MaxxForce DT, MaxxForce 9 and MaxxForce 10 Engines, Mid High Cab




2007 MaxxForce 7




P

ROCEDURE


WARNING: Wear a face shield, or other adequate eye protection, and nonporous gloves when working with refrigerant. The temperature of liquid refrigerant may cause injury or blindness if the refrigerant contacts the eyes. Should liquid refrigerant come in contact with skin, remove contaminated clothing, including shoes and treat the injury as though the skin had been frostbitten. See a doctor immediately.

WARNING: Refrigerant must be recovered from the air conditioning system before any components of the system are replaced. Removing components while pressure is in the system will cause personal injury or death.

1. Recover the refrigerant from the A/C system.

2. Remove the A/C hose from the condenser to the evaporator and install the new hose.

3. Remove the A/C hose from the accumulator to the compressor and install the new hose.

4. Install the A/C hose from the new evaporator to the aux. fitting on the newly installed hose from the condenser to the evaporator.

5. Install the A/C hose from the new evaporator to the aux. fitting on the newly installed hose from the accumulator to the compressor.

7. Recharge the system using R-134A refrigerant. The original truck system holds 30 oz. and the new evaporator should require an additional 16 oz. The additional requirement will vary from system to system depending on the length of hoses and the capacity of the new evaporator. The additional capacity will also require an additional 40 cc (1.2 fl. Oz.) of PAG oil in the system.


September 2012



CAUTION: Failure to add additional PAG oil to the increased capacity A/C system will result in improper lubrication and lead to premature component failure.

8. Operate the vehicle to make sure the A/C is performing properly and is not leaking.

■

A/C COMPRESSOR ACCOM. DUAL; FOR LOW SPEED ACCELERATION DISABLE, FOR

AFTERMARKET A/C SYSTEM

595AZR

This feature shall activate high side relay driver outputs A/C Compressor Clutch RD1 and A/C Compressor

Clutch RD2. Output will be defaulted to turn off when vehicle is not accelerating from a stop. This feature is used to reduce engine load added by the AC compressors.

N

ORMAL

O

PERATION

The feature shall set AC_Clutch_RD_1 and AC_Clutch_RD_2 if the following conditions are true:

•

(Ignition Signal is ON AND Current Gear is in Neutral AND Park Brake is Set)

OR

•

(Ignition Signal is ON AND Current Gear is not in Neutral AND Park Brake is not Set AND Wheel Based

Vehicle Speed is less than 1mph AND Accelerator Pedal Position is less than Accelerator 8%)

OR

•

(Ignition Signal is ON AND Current Gear is not in Neutral AND Park Brake is not Set AND Wheel Based

Vehicle Speed is greater than 4mph AND Engine Speed is greater than or equal to Engine Speed AC

Compressor On Speed)

The feature shall reset AC_Clutch_RD_1 and AC_Clutch_RD_2 if the following conditions are true:

•

Ignition Signal is Off

OR

•

(Current Gear is not in Neutral AND Park Brake is not set AND Wheel Based Vehicle Speed is less than or equal to 4mph AND Accelerator Pedal Position is greater than or equal to Accelerator 8%)

NOTE: Please use the Diamond Logic

®

Builder software to determine pin locations on the Body Controller.

If pin locations F13 and F14 are being used by other features, contact Vehicle Programming Support for assistance.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software feature codes can be added through the Diamond Logic

Parameters are also programmable through the Diamond Logic

®

®

Builder software. Programmable

Builder software.

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AZR

C

ONFLICTS

W

ITH

S

OFTWARE

F

EATURE

595ABC

There are no programmable parameters associated with this feature.


September 2012



W

IRING

I

NFORMATION

See the graphic below. Install the circuits, as illustrated, if they were not factory installed.

f_052

T

ESTING

1. With Park Brake released, Air Conditioning Demand on and compressor running, accelerate from a stop.

The Compressor (s) should be shut off, upon initial acceleration is completed.

2. The Compressor (s) should be shut off, upon initial acceleration is completed.


September 2012


TRANSMISSION SPARE INPUTS/OUTPUTS

AND TRANSMISSION CODES

TRANSMISSION SPARE INPUTS/OUTPUTS AND TRANSMISSION CODES

■

AUTOMATIC TRANSMISSION INTERFACES

13AHE

TRANSMISSION, AUTOMATIC {ALLISON 1000_HS} 4th Generation Controls; Close Ratio, 5-Speed, With

Overdrive; Less PTO Provision, Includes Park Pawl, Less Retarder, With 19,500-lb GVW & 26,000-lb GCW

Max

13AHK

TRANSMISSION, AUTOMATIC {ALLISON 1000_PTS} 4th Generation Controls; Close Ratio, 5-Speed, With

Overdrive; Less PTO Provision, Includes Park Pawl, Less Retarder, With 19,500-lb GVW & 26,000-lb GCW

Max

13AKX

TRANSMISSION, AUTOMATIC {ALLISON 1000_RDS} 4th Generation Controls; Close Ratio, 5-Speed, With

Overdrive; Includes Park Pawl, With PTO Provision, Less Retarder, With 19,500-lb GVW & 26,000-lb GCW

Max.

13AKY

TRANSMISSION, AUTOMATIC {ALLISON 1000_EVS} 4th Generation Controls; Close Ratio, 5-Speed, With

Overdrive; Includes Park Pawl, With PTO Provision, Less Retarder, With 19,500-lb GVW & 26,000-lb GCW

Max.

13AHG


Overdrive; Less PTO Provision, Less Retarder, With 26,000-lb GVW & GCW Max.

13AHJ

TRANSMISSION, AUTOMATIC {ALLISON 2500_HS} 4th Generation Controls; Wide Ratio, 5-Speed, With


13AHL



13AHN

TRANSMISSION, AUTOMATIC {ALLISON 2500_PTS} 4th Generation Controls; Wide Ratio, 5-Speed, With


13AHP

TRANSMISSION, AUTOMATIC {ALLISON 2100_RDS_P} 4th Generation Controls; Close Ratio, 5-Speed, With

Overdrive; With PTO Provision, Less Retarder, With 26,000-lb GVW & GCW Max.

13AHS

TRANSMISSION, AUTOMATIC {ALLISON 2500_RDS_P} 4th Generation Controls; Wide Ratio, 5-Speed, With

Overdrive; On/Off Hwy; 33,000 lb GVW & GCW Max., With PTO Provision, Less Retarder


October 2012




13AHT


Overdrive; Refuse; With PTO Provision, Less Retarder, With 24,200-lb GVW Max.

13AHU

TRANSMISSION, AUTOMATIC {ALLISON 2100_EVS_P} 4th Generation Controls; Close Ratio, 5-Speed, With


13AHW

TRANSMISSION, AUTOMATIC {ALLISON 2500_EVS_P} 4th Generation Controls; Wide Ratio, 5-Speed, With


13AHY

TRANSMISSION, AUTOMATIC {ALLISON 2500_MH} 4th Generation Controls; Wide Ratio, 5-Speed, With

Overdrive, Less PTO Provision, Less Retarder, With 33,000-lb GVW & GCW Max.

13ALN

TRANSMISSION, AUTOMATIC {ALLISON 2500_SP} 4th Generation Controls; Wide Ratio, 5-Speed, With


13AHH


Overdrive; Includes Park Pawl, Less PTO Provision, Less Retarder, With 26,000-lb GVW & GCW Max.

13AHM


Overdrive; Includes Park Pawl, Less PTO Provision, Less Retarder, With 26,000-lb GVW & GCW Max.

13AHR


Overdrive; Includes Park Pawl, With PTO Provision, Less Retarder, With 26,000-lb GVW & GCW Max.

13AHV

TRANSMISSION, AUTOMATIC {ALLISON 2200_EVS_P} 4th Generation Controls; Close Ratio, 5-Speed, With

Overdrive; Includes Park Pawl, With PTO Provision, Less Retarder, With 26,000-lb GVW & GCW Max.

13ALG

TRANSMISSION, AUTOMATIC {ALLISON 2200_SP} 4th Generation Controls; Close Ratio, 5-Speed, With

Overdrive; Includes Park Pawl, With PTO Provision, Less Retarder, With 26,000-lb GVW & GCW Max. Military use only.

13AHZ


Overdrive; Includes Oil Level Sensor, Less PTO Provision, Less Retarder, With 80,000-lb GVW & GCW Max.


October 2012




13AJA


Double Overdrive; Includes Oil Level Sensor, Less PTO Provision, Less Retarder, With 80,000-lb GVW & GCW

Max.

13AJB


Overdrive, Includes Oil Level Sensor, Less PTO Provision, Less Retarder, School Max. Bus GVW N/A

SCHOOL BUS

13AJC


Overdrive; Includes Oil Level Sensor, Less PTO Provision, Less Retarder, Shuttle Bus, With 33,000 lb GVW &

GCW Max.

13AJE


Overdrive; On/Off Hwy; Includes Oil Level Sensor, With PTO Provision, Less Retarder, With 80,000-lb GVW &

GCW Max.

13AJG


Overdrive; Refuse/Mixer; Includes Oil Level Sensor, With PTO Provision, Less Retarder, With 62,000-lb GVW

13AJH


Double Overdrive; On/Off Hwy; Includes Oil Level Sensor, With PTO Provision, Less Retarder, With 80,000-lb

GVW

13AJJ


Double Overdrive; Refuse/Mixer; Includes Oil Level Sensor With PTO Provision, Less Retarder, With 62,000-lb

GVW Max.

13AJK


Overdrive; On/Off Hwy; Includes Oil Level Sensor, With PTO Provision, Less Retarder, With 80,000-lb GVW &

GCW Max.

13AJL


Overdrive; Refuse/Mixer; Includes Oil Level Sensor, With PTO Provision, Less Retarder, With 60,000-lb GVW

13AJM


Overdrive; Specialty PTO; Includes Oil Level Sensor, With PTO Provision, Less Retarder, MAX. GVW N/A


October 2012




13AJN


Double Overdrive; On/Off Hwy; Includes Oil Level Sensor, With PTO Provision, Less Retarder, With 80,000-lb

GVW & GCW Max.

13AJP

TRANSMISSION, AUTOMATIC {ALLISON 3500_RDS_P} 4th Generation Control; Wide Ratio, 6-Speed, With

Double Overdrive; Refuse/Mixer; Includes Oil Level Sensor, With PTO Provision, Less Retarder, With 60,000-lb

GVW Max.

13AJR

TRANSMISSION, AUTOMATIC {ALLISON B-300} 4th Generation Controls; 5-Speed; With Overdrive, Includes

Oil Level Sensor, With Deep Sump, Less PTO Provision and Less Retarder, With 38,000-lb GVW Max.

13AJU

TRANSMISSION, AUTOMATIC {ALLISON 3000EVS_P} 4th Generation Controls; Close Ratio, 6-Speed; With

Double Overdrive, Includes Oil Level Sensor, With Provision for PTO, Less Retarder, Max. GVW N/A

13AJV


Overdrive, Includes Oil Level Sensor, With Provision for PTO, Less Retarder, Max. GVW N/A

13AJW

TRANSMISSION, AUTOMATIC {ALLISON 3500EVS_P} 4th Generation Controls; Wide Ratio, 6-Speed; With

Double Overdrive, Includes Oil Level Sensor, With Provision for PTO, Less Retarder, Max. GVW N/A

13AJX


Overdrive, Includes Oil Level Sensor, With Provision for PTO, Less Retarder, Max. GVW N/A

13AKA

TRANSMISSION, AUTOMATIC {ALLISON 3000TRV_P} 4th Generation Controls; Close Ratio, 6-Speed; With

Double Overdrive, Includes Oil Level Sensor, With Provision for PTO Gear, Less Retarder, Max. GVW N/A with

40,000-lb

13AKB

TRANSMISSION, AUTOMATIC {ALLISON 3000TRV_P} 4th Generation Controls; Close Ratio, 5-Speed; With

Overdrive, Includes Oil Level Sensor, With Provision for PTO Gear, Less Retarder, Max. GVW N/A with

40,000-lb GCW

13AKG


Overdrive, Includes Oil Level Sensor, Less PTO Provision, Less Retarder

13AKH


Double Overdrive, Includes Oil Level Sensor, Less PTO Provision, Less Retarder


October 2012




13AKJ


Overdrive; Includes Oil Level Sensor, Less PTO Provision, Less Retarder

13AKK


Double Overdrive; Includes Oil Level Sensor, Less PTO Provision, Less Retarder

13AKL


Overdrive; Includes Oil Level Sensor, With PTO Provision, Less Retarder

13AKM


Double Overdrive; Includes Oil Level Sensor, With PTO Provision, Less Retarder

13AKN


Overdrive; Includes Oil Level Sensor, With PTO Provision, Less Retarde

13AKP


Double Overdrive; Includes Oil Level Sensor, With PTO Provision, Less Retarder

13AKR

TRANSMISSION, AUTOMATIC {ALLISON 4000EVS_P} 4th Generation Controls, Close Ratio, 5-Speed; With

Overdrive, Includes Oil Level Sensor, With Provision for PTO, Less Retarder

13AKS


Double Overdrive; Includes Oil Level Sensor, With Provision for PTO, Less Retarder

13AKT


Overdrive; Includes Oil Level Sensor, With Provision for PTO, Less Retarder

13AKU


Double Overdrive; Includes Oil Level Sensor, With Provision for PTO, Less Retarder

13ALH

TRANSMISSION, AUTOMATIC {ALLISON 3000_SP_P} 4th Generation Controls; Close Ratio, 5-Speed,

Overdrive; Includes Oil Level Sensor, With PTO Provision, Less Retarder, Military Support/Tactical MILITARY

ONLY


October 2012




13ALJ

TRANSMISSION, AUTOMATIC {ALLISON 4500_SP_P} 4th Generation Controls; Wide Ratio, 5-Speed, With

Overdrive; Includes Oil Level Sensor, With PTO Provision, Less Retarder, Military Support/Tactical

13WDH

WIRING, TRANS BODY BUILDER Installed Wiring for Transmission/PTO Controls, for Allison 2000, 2100,

2200, 2400, 2500 Series Transmission Only

13WUA

ALLISON NEUTRAL Allison WT Transmission Shifts to Neutral When Parking Brake is Engaged and Remains on Neutral When Park Brake is Disengaged

13WUB

ALLISON SPARE INPUT/OUTPUT for Highway Series (HS); General Purpose Trucks

13WUC

ALLISON SPARE INPUT/OUTPUT for Rugged Duty Series (RDS); General Purpose Trucks, Construction

13WUD

ALLISON SPARE INPUT/OUTPUT for Emergency Vehicle Series (EVS); Rescue, Ambulance

13WUE

ALLISON SPARE INPUT/OUTPUT for Emergency Vehicle Series (EVS); Fire/Pumper, Tank, Aerial/Ladder

13WUG

ALLISON SPARE INPUT/OUTPUT for Truck Recreational Vehicle (TRV)

13WUH

ALLISON SPARE INPUT/OUTPUT for Rugged Duty Series (RDS); Airport Refueler, Sewer Evac

13WUJ

ALLISON SPARE INPUT/OUTPUT for Rugged Duty Series (RDS); Front Loaders, Rear Loaders,

Recycling/Packer Trucks

13WUK

ALLISON SPARE INPUT/OUTPUT for Rugged Duty Series (RDS); Side Loaders

13WUL

ALLISON SPARE INPUT/OUTPUT for Rugged Duty Series (RDS); Street Sweeper

13WUM

ALLISON SPARE INPUT/OUTPUT for Pupil Transportation Series (PTS)

13WUP

ALLISON SPARE INPUT/OUTPUT for Bus Series (B)


October 2012




13WUR

ALLISON SPARE INPUT/OUTPUT for Dump/Construction with Two-Speed Axle or Auxiliary Transmission

(RDS)

13WUS

ALLISON SPARE INPUT/OUTPUT for Rugged Duty Series (RDS); General Purpose Trucks Modified for Single

Input Auto Neutral

13WUT

ALLISON SPARE INPUT/OUTPUT for Emergency Vehicle Series (EVS); Without Split Shaft PTO

13WUU

ALLISON SPARE INPUT/OUTPUT for Specialty Transmission Series (SP)

13WUV

ALLISON SPARE INPUT/OUTPUT for Highway Series (HS); General Purpose Trucks Modified for Single Input

Auto Neutral

13WUZ

ALLISON SPARE INPUT/OUTPUT for Emergency Vehicle Series (EVS), 127/198 includes J1939 Based Auto

Neutral; Fire/Pumper, Tank, Aerial/Ladder

13WVB

ALLISON SPARE INPUT/OUTPUT for Emergency Vehicle Series (EVS), 108/174 Includes J1939 Based Auto

Neutral; Rescue, Ambulance

The features listed above describe both Allison transmission sales features as well as Allison vocational electrical interface sales features. Review each entry carefully, and choose the transmission and optional electrical interface feature that is right for the particular equipment application. Allison electrical interface connections are optional equipment on International

®

vehicles. Choose one of the features described below to receive a cable harness interface connection on a vehicle factory-installed.

Allison provides electrical inputs and outputs for a variety of vehicle controls. The controls may be specific for fire truck, emergency vehicle, loader, etc. See Allison Controls and General Information for details.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

See Allison Controls and General Information for technical details and circuit design.

With the Allison 3000/4000 Series, there are two connectors – 7205 and 7206. Connectors 7205 and 7206 have their mating connectors attached filled with cavity plugs. The interface connections are located in between the radiator pipe and the engine on the driver side of the engine.


October 2012




To use these connectors, remove cavity plugs and use the following:

Table 62

Connector

3525874C1

Terminals

1667742C1

Cable Seals

1661872C1

Connector

3525872C1

Terminals

1661875C1

Cable Seals

1661872C1

Mating Connector for 7205

Connector Lock

3525875C1

Wire Gauge

16, 18, 20

Wire Gauge

16, 18, 20

Mating Connector for 7206

Connector Lock

3525873C1

Wire Gauge

16, 18, 20

Wire Gauge

16, 18, 20

Cavity Plug

2025431C1

Cavity Plug

2025431C1 f_068


October 2012




The circuit numbers on the harness correspond to the circuit numbers used by Allison. The table below gives the Allison 3000/4000 circuit number which corresponds to the circuit numbers in the International

®

harness connectors. For a complete circuit diagram of the transmission wiring and for connector and terminal part numbers, see Circuit Diagram Manual S08322, Chapter 11, Transmission.

Table 63

Cavity

E

F

G

H

A

B

C

D

E

F

G

H

A

B

C

D

Circuit Number I/O

Connector Number 7205

K92B103

K92#161

K92#157

K92#124

K92#122

K92#105

K92#164

K92#162


--

Input

Input

Output

Input

Output

Output

Input

K92#101

K92#117

K92C103

K92#143

K92#142

K92#145

K92#130

K92#123

Input

Input

--

Input

Input

Output

Output

Input

Maximum Current

--

--

--

500 mAMP*

--

--

500 mAMP

--

--

--

--

--

--

500 mAMP

500 mAMP

--

*milliAmpere

NOTE: See Allison technical manual for suggested circuit design.

NOTE: See special features table below for package content.

NOTE: MUST COMPLY WITH FMVSS STANDARD #102.

The Allison 1000/2000 series has a single connector – 7205. Connector 7205 has its mating connector attached and filled with cavity plugs. The interface connections are located in between the radiator pipe and the engine on the driver side of the engine.


October 2012 f_069




To use connector, remove cavity plugs and use the following:

Table 64

Connector

3525874C1

Terminals

1667742C1

Cable Seals

1661872C1

Connector Lock

3525875C1

Wire Gauge

16, 18, 20

Wire Gauge

16, 18, 20

Cavity Plug

2025431C1

The circuit numbers on the harness correspond to the circuit numbers used by Allison. The table below gives the Allison 1000/2000 circuit number which corresponds to the circuit numbers in the International

®

harness connectors. For a complete circuit diagram of the transmission wiring and for connector and terminal part numbers, see Circuit Diagram Manual S08322, Chapter 11, Transmission.

Table 65

Cavity

E

F

G

H

A

B

C

D

Circuit Number I/O


L92C103

L92#143

L92#150

L47C125

L92#101

L92#123

L92#145

L92#105

--

Input

Output

Output

Input

Output

Output

Input

Maximum Current

--

--

500 mAMP*

--

--

--

500 mAMP

--

*milliAmpere

NOTE: See Allison technical manual for suggested circuit design.

NOTE: See special features table below for package content.

NOTE: MUST COMPLY WITH FMVSS STANDARD #102.


October 2012




I-L

I-Q

I-W

I-Y

I-Z

I-AA

I-AG

I-F

I-G

I-H

I-J

I-AJ

I-A

I-C

I-D

I-E

The following tables show the various vocational feature codes that are available. Note the Group and Package number correspond to Allison Group and Package number.

NOTES for the tables below:

M = Mode Button Located on Shift Tower

# = Not Available with Code 13AAZ or 13WUA

@ = Requires Code 13AAZ, Automatic Neutral

% = Requires Code 13WUA, Automatic Neutral

* = Not Activate

Table 65

Spare

Input/Output

Package Content

Code

Group

Package

Other

Requirements

13WU#B

98

200

13WUC#

99

113

Highway Series

(HS)

Rugged Duty

Series (RDS)

General Purpose

Trucks

General Purpose

Trucks,

Construction

13WUD#

108

174

Emergency

Vehicle Series

(EVS)

Rescue,

Ambulance

13WUE#

107

120

Emergency

Vehicle Series

(EVS)

Fire/Pumper, Tank,

Aerial/Ladder

13WUG#

110

113

13WUH#

102

150

Truck Recreational

Vehicle (TRV)

Rugged Duty Series

(RDS)

Airport, Refueler,

Sewer Evac

Function # Function Name

O-A

O-B

O-C

O-D

O-G

O-J

O-I

O-O

O-Q

O-S

Secondary Shift

Schedule

PTO Enable

Shift Selection Transition

Auxiliary Function Range

Inhibit (STD)


Inhibit (Special)

Auxiliary Hold

Engine Brake &

Preselect Request

Fire Truck Pump Mode

Auto Neutral for PTO

(STD)

Two-Speed Axle Enable

Direction Change Enable

ABS Input

Retarder Enable

Service Brake Status

Auto Neutral for Refuse

Packer & PTO Enable

4th Gear Lockup for

Pump Mode

Engine Brake Enable

Sump/Retarder


Range Indicator

Output Speed Indicator A

PTO Enable


Engine Overspeed

Indicator

Service Indicator

Retarder Indicator

Neutral Indicator for PTO

M

102/157

121

161

162

104

164

145

105

124

M

143

101*

142

102/157

122*

121

161

162

104

164

145

105

130

124

M

143

101*

102/157

121

161

162

104

164

113

105

130

124

145

M

142

102/157

122/123*

121

161

162

104

164

145 (4th)

105

130

124

M

143

101*

142

102/157

122*

121

161

162

104

164

145

105

130

124

M

101*

102/157

122*

121

161

162

122/123*

104

164

145 (4th)

105

130

124


October 2012




I-L

I-Q

I-W

I-Y

I-Z

I-AA

I-AG

I-F

I-G

I-H

I-J

I-AJ

I-A

I-C

I-D

I-E

Spare

Input/Output

Package Content

Function #

O-A

O-B

O-C

O-D

O-G

O-J

O-I

O-O

O-Q

O-S

Code

Group

Package

Other

Requirements

Function Name

13WUJ@

105

142

Rugged Duty

Series (RDS)

Front Loaders,

Rear Loaders,

Recycling/Packer

Trucks

13WUK@

106

170

Rugged Duty

Series (RDS)

Side Loaders

13WUL#

103

167

Rugged Duty

Series (RDS)

Street Sweeper

13WUM#

111

203

Pupil

Transportation

Series (PTS)

13WUP#

112

1484

Bus Series (B)

School/Shuttle

Transit and Intercity

Bus

Secondary Shift

Schedule

PTO Enable



Inhibit (STD)


Inhibit (Special)

Auxiliary Hold

Engine Brake &

Preselect Request



(STD)



ABS Input

Retarder Enable



Packer & PTO Enable

4th Gear Lockup for

Pump Mode

Engine Brake Enable

Sump/Retarder


Range Indicator


PTO Enable


Engine Overspeed

Indicator

Service Indicator

Retarder Indicator


M

143

101*

102/157

121

161

162

142/117

104

164

105

130

124

145

142

M

102/157

117*

101

121

161

162

104

164

113

105

130

145

124

145

M

101*

142

102/157

117*

121

161

162

104

164

145

105

124

M

143

101*

142

102/157

117*

121

161

162

104

164

145

105

130

124


October 2012




I-L

I-Q

I-W

I-Y

I-Z

I-AA

I-AG

I-F

I-G

I-H

I-J

I-AJ

I-A

I-C

I-D

I-E

Spare

Input/Output

Package Content

Function #

O-A

O-B

O-C

O-D

O-G

O-J

O-I

O-O

O-Q

O-S

Code

Group

Package

Other

Requirements

Function Name

13WUR# 13WUS% 13WUT#

100

146

99

113 mod

Dump/Constructio n with Two-Speed

Axle or Auxiliary

Transmission

(RDS)

Rugged Duty

Series (RDS)

General Purpose

Trucks Modified for

Single Input

Auto Neutral

107

119

Emergency

Vehicle Series

(EVS)

Fire (not for

Split-Shaft PTO)r

13WUU#

114

163

13WUV%

98

200

Specialty Series

(SP)

Highway Series (HS)

Specialty Vehicles

General Purpose

Trucks Modified for

Single Input

Auto Neutral

Secondary Shift

Schedule

PTO Enable



Inhibit (STD)


Inhibit (Special)

Auxiliary Hold

Engine Brake &

Preselect Request



(STD)



ABS Input

Retarder Enable



Packer & PTO Enable

4th Gear Lockup for

Pump Mode

Engine Brake Enable

Sump/Retarder


Range Indicator


PTO Enable


Engine Overspeed

Indicator

Service Indicator

Retarder Indicator


M

143

101*

102/157

142

121

161

162

104

164

145

130

145

124

M

143

101*

142

102/157

122*

121

161

162

104

164

145

105

130

124

M

143

101/142

102/157

121

161

162

104

164

105

130

164

124

145

M

143

142

102/157

121

161

162

104

164

145

105

130

124

M

102/157

117

121

161

162

104

164

145

105

124


October 2012




I-L

I-Q

I-W

I-Y

I-Z

I-AA

I-AG

I-F

I-G

I-H

I-J

I-AJ

I-A

I-C

I-D

I-E

Spare

Input/Output

Package Content

Function #

O-A

O-B

O-C

O-D

O-G

O-J

O-I

O-O

O-Q

O-S

Code

Group

Package

Other

Requirements

Function Name

13WUZ#

127

198

Emergency

Vehicle Series

(EVS)

Fire/pumper, Tank,

Aerial/Ladder

13WVB%

108

174

Emergency

Vehicle Series

(EVS)

Ambulance,

Rescue

Secondary Shift

Schedule

PTO Enable



Inhibit (STD)


Inhibit (Special)

Auxiliary Hold

Engine Brake &

Preselect Request



(STD)



ABS Input

Retarder Enable



Packer & PTO Enable

4th Gear Lockup for

Pump Mode

Engine Brake Enable

Sump/Retarder


Range Indicator


PTO Enable


Engine Overspeed

Indicator

Service Indicator

Retarder Indicator


M

142

102/157

122/123

121

161

162

104

164

145

105

130

124

M

143

101

102/157

121

161

162

104

164

113

105

130

124

145


October 2012


GAUGES

GAUGES

This chapter describes the optional gauges that are either installed or can be installed in the instrument cluster.

If the vehicle was ordered without a desired gauge, one or more can be added in the field. Programming of the

Body Controller (BC) and proper placement is critical. Certain gauges will only work in certain locations. Before adding the gauge to the vehicle, ensure that the vehicle can accept it. The outboard four gauges are the only ones that can be moved or added. They can be added by using the Diamond Logic the steps below for adding a gauge to the cluster (those without Diamond Logic

International

®

®

®

Builder software. Follow

Builder should see an

dealer). The following instructions can be followed for any of the four auxiliary gauge positions.

A

DDING

A

ND

P

ROGRAMMING

T

HE

V

EHICLE

®

Builder, obtain a copy of the electronic vehicle file either by getting it from the vehicle or from history.

b. Select the proper software feature code for the gauge to be added, and add this code to the configuration.

d. Position the gauge in the desired location in the cluster by clicking and dragging it to an open location identified by a large blue circle. If the gauge will not move to a particular position, it is not designed to work in that location.

d. Once the location of the gauge is determined, save the configuration and program the vehicle.

I

NSTALLING THE

G

AUGE

NOTE: Refer to the “How Do I – General Information” section of this electrical guide for information on how to obtain gauge, circuits, and sensor part numbers.

a. Remove the cluster shroud from the Instrument Panel (IP).

b. Remove the four screws which hold the cluster in place.

c. Tilt the cluster forward to gain access to the back of the cluster (use caution not to scratch the face of the cluster).

d. Remove all the connectors from the back of the cluster, and remove the cluster from the vehicle.

e. Remove the ten screws from the metal panel on the back of the cluster.

f. Remove the proper filler plug. See below.

g. Install the gauge using caution not to move the needle, damage the face, or get the face of the gauge dirty.

h. Connect the jumper wire in the socket directly next to the added gauge.

i. Replace the metal panel, and install in the vehicle in the reverse order of removing it.


October 2012


GAUGES

f_070

W

IRING

I

NFORMATION

The standard cluster includes:

ODOMETER DISPLAY: Miles, Trip Miles, Engine Hours, Trip Hours, Fault Code Readout (Odometer, trip odometer, and fault code readout electronic-liquid crystal display)

WARNING SYSTEM: Low Fuel, Low Oil Pressure, High Engine Coolant Temp, and Low Battery Voltage (Visual and Audible)

GAUGE CLUSTER GAUGES (6): Engine Oil Pressure (Electronic), Water Temperature (Electronic), Fuel

(Electronic), Tachometer (Electronic), Voltmeter, Speedometer

GAUGE, AIR PRESSURE: Air 1 and Air 2 Gauges; Located in Instrument Cluster (Air Chassis only)

T

ESTING


®

Builder software to steer each gauge to test values.


October 2012


GAUGES

■

INSTRUMENT CLUSTER – ADDING AIR GAUGES

This feature provides system air pressure when an air compressor is ordered with a hydraulic brake vehicle.

04SBL

AIR COMPRESSOR {Bendix Tu-Flo 550} 13.2 CFM Capacity; and Tank for Air Source on Hydraulic Chassis

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

04SBL (Auxiliary Air gauge): 595AEP

The Aux_Air_Press_Alrm_Type_Param parameter defines the number of beeps associated with the auxiliary air pressure gauge alarm.

The Aux_Air_Press_Filter_Param parameter sets the auxiliary air gauge update rate. The higher the number is, the faster the update rate. 255 is the fastest update rate available, and 1 is the slowest update rate available.

The Aux_Air_Press_Max_WL_Gen2 parameter sets the maximum point for auxiliary air in-gauge warning light.

When the auxiliary air pressure rises above this set parameter, the warning light in the gauge will illuminate. A value of 76040 is the default gauge parameter and should normally not be changed.

The Aux_Air_Press_Min_WL parameter sets the minimum point for auxiliary air in-gauge warning light. When the auxiliary air pressure falls below this set parameter, the warning light in the gauge will illuminate.

Table 66

Parameter

Aux_Air_

Press_Alrm_

Type_Param

Aux_Air_

Press_Filter_

Param

Aux_Air_

Press_Max_

WL _Gen2

Aux_Air_

Press_Min_WL

ID Description

2380

108

2392

1964

Auxiliary air pressure alarm types available

Auxiliary air gauge update rate. A value of 1 is the slowest and 255 is the fastest update rate.

Maximum threshold for auxiliary air in-gauge warning light. The default of 76040 means no minimum warning light.

Minimum threshold for auxiliary air in-gauge warning light

Default

4

255

Units

List

No_Units

Min

0

1

Max

7

255

Step

1

1

Table 67

Optional Gauges

Auxiliary Air Pressure Gauge

This feature provides engine oil temperature to the vehicle operator.

16HGG

GAUGE, OIL TEMP, ENGINE

ENGLISH Part Number

3615266C1

METRIC Part Number

3615267C1

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

16HGG (Engine Oil Temperature): 595ADW OR 595ADX (Customer cannot use both)

** Software Feature Code 595ADW is used to read engine oil temperature off the datalink.

** Software Feature Code 595ADX is used to read engine oil temperature from a hard-wired analog sensor.

The Eng_Oil_Temp_Alrm_Ty_Param parameter defines the number of beeps associated with the engine oil temperature alarm.


October 2012


GAUGES

The Eng_Oil_Temp_Filter_Param parameter sets the engine oil temperature update rate. The higher the number is, the faster the update rate. 255 is the fastest update rate available, and 1 is the slowest update rate available.

The Eng_Oil_Temp_Max_WL parameter sets the maximum point for engine oil temperature in-gauge warning light. When the oil temperature rises above this set parameter, the warning light in the gauge will illuminate.

The Eng_Oil_Temp_Min_WL parameter sets the minimum point for engine oil temperature in-gauge warning light. When the oil temperature falls below this set parameter, the warning light in the gauge will illuminate.

Table 68

Parameter

Eng_Oil_

Temp_Alrm_

Ty_Param

ID

2354

Default

4

Units

List

Min

0

Max

7

Step

1

Eng_Oil_

Temp_Filter

_Param

Eng_Oil_

Temp_ Max_WL

2274

Eng_Oil_

Temp_ Min_WL

219

2291

Description

Engine oil temperature gauge alarm type.

Engine oil temperature gauge update rate. A value of 1 is the slowest and 255 is the fastest update rate.

Maximum threshold for auxiliary air in-gauge warning light.

Minimum set point for engine oil temperature in-gauge warning light.

The default of 3226 means no minimum warning light.

255

251

3226

No_Units

F

F

1

100

100

255

300

300

1

0.03125

0.03125

Table 69

Optional Gauges

Engine Oil Temperature Gauge


3615258C1


3615259C1

16HGH

Provides Allison transmission fluid temperature information to the vehicle operator.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

16HGH (Allison Transmission Oil Temperature gauge): 595ADZ

The Trans_Oil_Temp_Alrm_Ty_Param parameter defines the number of beeps associated with the

Transmission oil temperature alarm.

The Trans_Oil_Temp_Filter_Param parameter sets the transmission oil temperature update rate. The higher the number is, the faster the update rate. 255 is the fastest update rate available, and 1 is the slowest update rate available.

The Trans_Oil_Temp_Max_WL parameter sets the maximum point for transmission oil temperature in-gauge warning light. When the oil temperature rises above this set parameter, the warning light in the gauge will illuminate.

The Trans_Oil_Temp_Min_WL parameter sets the minimum point for transmission oil temperature in-gauge warning light. When the oil temperature falls below this set parameter, the warning light in the gauge will illuminate.


October 2012


GAUGES

Table 70

Parameter

Trans_Oil_

Temp_Alrm_

Ty_Param

Trans_Oil_

Temp_

Filter_Param

ID

2356

589

Trans_Oil_

Temp_ Max_WL

2272

Trans_Oil_

Temp_ Min_WL

2273

Description

Transmission oil temperature gauge alarm type.

Transmission oil temperature gauge update rate. A value of 1 is the slowest and 255 is the fastest update rate.

Maximum set point for transmission oil temperature in-gauge warning light. The default of 3226 means no maximum warning light.

Minimum set point for transmission oil temperature in-gauge warning light. The default of 3226 means no minimum warning light.

Default

0

255

3226

3226

Units

No_Units

No_Units

F

F

Min

0

1

100

100

Max

7

255

300

300

Step

1

1

0.03125

0.03125

Table 71

Optional Gauges

Transmission Oil Temperature

Gauge


3615268C1


3615269C1

This feature provides manual transmission oil temperature to the vehicle operator. Manual transmissions should not be operated at temperatures above 250 °F (120 °C).

16HGJ

GAUGE, OIL TEMP, MANUAL TRAN

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

16HGJ (Oil Temperature gauge on a manual transmission): 595AEW

The Trans_Oil_Temp_Alrm_Ty_Param parameter defines the number of beeps associated with the

Transmission oil temperature alarm.

The Trans_Oil_Temp_Filter_Param parameter sets the transmission oil temperature update rate. The higher the number is, the faster the update rate. 255 is the fastest update rate available, and 1 is the slowest update rate available.

The Trans_Oil_Temp_Max_WL parameter sets the maximum point for transmission oil temperature in-gauge warning light. When the oil temperature rises above this set parameter, the warning light in the gauge will illuminate.

The Trans_Oil_Temp_Min_WL parameter sets the minimum point for transmission oil temperature in-gauge warning light. When the oil temperature falls below this set parameter, the warning light in the gauge will illuminate.


October 2012


GAUGES

Table 72

Parameter

Trans_Oil_

Temp_Alrm_

Ty_Param

Trans_Oil_

Temp_

Filter_Param

Trans_Oil_

Temp_ Max_WL

Trans_Oil_

Temp_ Min_WL

ID

2356

589

2272

2273

Description

Transmission oil temperature gauge alarm type.

Transmission oil temperature gauge update rate. A value of 1 is the slowest and 255 is the fastest update rate.

Maximum set point for transmission oil temperature in-gauge warning light. 3226 means no maximum warning light

.

Minimum set point for transmission oil temperature in-gauge warning light. The default of 3226 means no minimum warning light.

Table 73

Optional Gauges

Transmission Oil Temperature

Gauge

Default

4

255

250

3226

Units

No_Units

No_Units

F

F


3615268C1

Min

0

1

100

100

Max

7

255

300

300


3615269C1

Step

1

1

0.03125

0.03125

■

INSTRUMENT CLUSTER – ADDING GAUGES

Provides rear axle operating information to the vehicle operator. Rear axle temperature should not exceed 240

°F (115 °C).FEATURE CODE DESCRIPTION:

16HGL

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

16HGL (Rear Axle Temperature): 595AYA OR 595AYB (Customer cannot use both)

** Software Feature Code 595AYA is used to read rear-rear axle temperature AND forward-rear axle temperature.

** Software Feature Code 595AYB is used to read just rear-rear axle temperature.

* 595AYA (rear-rear and forward-rear axle temperature)

The Fwd_RR_Axle_Temp_Filter_Param parameter sets the forward rear axle temperature update rate. The higher the number is, the faster the update rate. 255 is the fastest update rate available, and 1 is the slowest update rate available.

The Rear_Axle_Temperature_Alarm_Gen2_Param parameter defines the number of beeps associated with the rear-rear axle temperature alarm.

The Rear_RR_Axle_Temp_Filter_Param parameter sets the rear-rear axle temperature update rate. The higher the number is, the faster the update rate. 255 is the fastest update rate available, and 1 is the slowest update rate available.

The Rear_Axle_TempC_Max_Gen2_WL parameter sets the maximum point for rear-rear axle temperature in-gauge warning light. When the rear-rear axle temperature rises above this set parameter, the warning light in the gauge will illuminate.


October 2012


GAUGES

The Rear_Axle_TempC_Min_Gen2_WL parameter sets the minimum point for rear-rear axle temperature in-gauge warning light. When the rear-rear axle temperature falls below this set parameter, the warning light in the gauge will illuminate.

The Fwd_Axle_TempC_Max_Gen2_WL parameter sets the maximum point for forward-rear axle temperature in-gauge warning light. When the forward-rear axle temperature rises above this set parameter, the warning light in the gauge will illuminate.

The Fwd_Axle_TempC_Min_Gen2_WL parameter sets the minimum point for forward-rear axle temperature in-gauge warning light. When the forward-rear axle temperature falls below this set parameter, the warning light in the gauge will illuminate.

The Fwd_Axle_Temperature_Alarm_Gen2_Param parameter defines the number of beeps associated with the forward-rear axle temperature alarm.

Table 74

Parameter

Fwd_RR_

Axle_Temp_

Filter_Param

Rear_Axle_

Temperature_

Alarm_Gen2

Rear_RR_

Axle_Temp_

Filter_Param

Rear_Axle_

TempC_

Max_Gen2_WL

Rear_RR_

Axle_TempC_M in_Gen2_WL

Fwd_Axle_

TempC_

Max_Gen2_WL

Fwd_RR_


Fwd_Axle_

Temperature_

Alarm_Gen2

ID

277

2415

519

2485

2486

2498

2499

2500

Description

Forward-rear axle temperature gauge update rate. A value of 1 is the slowest and 255 is the fastest update rate.

Rear-rear axle temperature gauge alarm type.

Rear-rear axle temperature gauge update rate. A value of 1 is the slowest and 255 is the fastest update rate.

Maximum set point for rear-rear axle temperature in-gauge warning light

Minimum set point for rear-rear axle temperature in-gauge warning light. A value of 117923 means no minimum warning light.

Maximum set point for forward-rear axle temperature in-gauge warning light

Minimum set point for forward-rear axle temperature in-gauge warning light. A value of

117923 means no minimum warning light

.

Forward-rear axle temperature gauge alarm type.

* 595AYB (just rear-rear axle temperature)

Default

255

4

255

240

100

240

100

4

Units

No_Units

No_Units

F

F

F

F

F

No_Units

Min

1

0

1

100

100

100

100

0

Max

255

7

255

300

300

300

300

7

Step

1

1

1

1

1

1

1

1

The Rear_Axle_Temperature_Alarm_Gen2_Param parameter defines the number of beeps associated with the rear-rear axle temperature alarm.

The Rear_RR_Axle_Temp_Filter_Param parameter sets the rear-rear axle temperature update rate. The higher the number is, the faster the update rate. 255 is the fastest update rate available, and 1 is the slowest update rate available.


October 2012


GAUGES

The Rear_Axle_TempC_Max_Gen2_WL parameter sets the maximum point for rear-rear axle temperature in-gauge warning light. When the rear-rear axle temperature rises above this set parameter, the warning light in the gauge will illuminate.

The Rear_Axle_TempC_Min_Gen2_WL parameter sets the minimum point for rear-rear axle temperature in-gauge warning light. When the rear-rear axle temperature falls below this set parameter, the warning light in the gauge will illuminate.

Table 75

Parameter

Rear_Axle_

Temperature_

Alarm_Gen2

Rear_RR_

Axle_Temp_

Filter_Param

Rear_Axle_

TempC_

Max_Gen2_WL

Rear_RR_


ID

2415

519

2485

2486

Description

Rear-rear axle temperature gauge alarm type.

Rear-rear axle temperature gauge update rate. A value of 1 is the slowest and 255 is the fastest update rate.

Maximum set point for rear-rear axle temperature in-gauge warning light.

Minimum set point for rear-rear axle temperature in-gauge warning light. A value of 117920 means no minimum warning light.

Default

4

255

240

100

Units

No_Units

No_Units

F

F

Min

0

1

100

100

Max

7

255

300

300

Step

1

1

1

1

Table 76

Optional Gauges

Rear-rear Axle Oil Temperature

Gauge

Forward-rear Axle Oil

Temperature Gauge


3615272C1

3615260C1


3615273C1

3615261C1

■


This feature gives a visual read-out of the amount of pressure being applied to the brake pedal.

16HGN

GAUGE, AIR APPLICATION

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

16HGN (Air application gauge): 595ANP

The LH_Brake_App_Alrm_Ty_Param parameter defines the number of beeps associated with the brake application gauge alarm.

The Brake_App_Filter_Param parameter sets the brake application gauge update rate. The higher the number is, the faster the update rate. 255 is the fastest update rate available, and 1 is the slowest update rate available.

The Brake_App_Max_WL parameter sets the maximum point for the brake application in-gauge warning light.

When the brake pressure rises above this set parameter, the warning light in the gauge will illuminate.

The Brake_App_Min_WL parameter sets the minimum point for brake application in-gauge warning light. When brake pressure falls below this set parameter, the warning light in the gauge will illuminate.


October 2012


GAUGES

The Brake_App_Max_WL_Gen2_AGSP parameter sets the maximum point for the brake application AGSP warning light. When the brake pressure rises above this set parameter, the warning light in the gauge will illuminate.

The Brake_App_Min_WL_Gen2_AGSP parameter sets the minimum point for brake application AGSP warning light. When brake pressure falls below this set parameter, the warning light in the gauge will illuminate.

Table 77

Parameter

LH_Brake_

App_ Alrm_Ty_

Param

Brake_App_

Filter_Param

Brake_App_

Max_WL

Brake_App_

Min_WL

Brake_App_

Max_WL_

Gen2_AGSP

Brake_App_

Min_WL_

Gen2_AGSP

ID Description

2348

128

2343

2337

2424

2423

Brake application gauge alarm type.

Brake application gauge update rate. A value of 1 is the slowest and 255 is the fastest update rate.

Maximum set point for brake application in-gauge warning light. A value of

38020 means no maximum warning light.

Minimum set point for brake application in-gauge warning light. A value of

38020 means no minimum warning light.

Maximum set point for brake application AGSP warning light. A value of

38020 means no maximum warning light.

Minimum set point for brake application AGSP warning light. A value of

38020 means no minimum warning light.

Default

0

255

38020

38020

150

0

Units

No_Units

No_Units psi psi psi

Table 78

Optional Gauges

Air Application Gauge

Min

0

1

0

0

0

0

Max

7

255

150

150

38020

38020


3616155C1


361656C1

Step

1

1

0.5

0.5

1

1

■


This feature gives a visual read-out of the amperage on the vehicle.

16HHT

GAUGE, Ammeter 150 Ampere (AMP)

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

16HHT (Ammeter 150 AMP Gauge): 595AEZ

The Ammeter_Alrm_Ty_Param parameter defines the number of beeps associated with the ammeter gauge alarm.


October 2012


GAUGES

The Ammeter_Filter_Param parameter sets the ammeter gauge update rate. The higher the number is, the faster the update rate. 255 is the fastest update rate available, and 1 is the slowest update rate available.

The Ammeter_Max_WL parameter sets the maximum point for the ammeter in-gauge warning light. When the amperage rises above this set parameter, the warning light in the gauge will illuminate.

The Ammeter_Min_WL parameter sets the minimum point for ammeter in-gauge warning light. When amperage falls below this set parameter, the warning light in the gauge will illuminate.

The PAM_Acc_Pos_Offset_Param parameter estimates the electrical loads measured by the PAM when the key is in the accessory position.

The PAM_Run_Pos_Offset_Param parameter estimates the electrical loads measured by the PAM when the key is in the run position.

The PAM_Xfer_Function_Slope_Param parameter sets the slope of the transfer function used to calculate the electrical load on the vehicle displayed by the ammeter.

Table 79

Parameter Default Units Min Max Step

Ammeter_

Alrm_Ty_

Param

Ammeter_

Filter_Param

Ammeter_

Max_WL

Ammeter_

Min_WL

PAM_Acc_

Pos_Offset_

Param

PAM_Run_

Pos_Offset_

Param

PAM_Xfer_

Function_

Slope_ Param

Ammeter_

Max_WL

Ammeter_

Min_WL

ID

71

72

2394

2393

1941

1940

1939

2004

2001

Description

Ammeter gauge alarm type. The number of

“beeps” is the value of this parameter divided by 5.

255 is a continuous tone.

Ammeter gauge update rate. A value of 1 is the slowest and 255 is the fastest update rate.

Maximum set point for ammeter in-gauge warning light. The default of 1676 means no maximum warning light.

Minimum set point for ammeter in-gauge warning light. The default of 1676 means no minimum warning light.

Estimation of electrical load that is not measured by the PAM when the key is in the accessory position.

Estimation of electrical load that is not measured by the PAM when the key is in the run position.

Slope of the transfer function used to calculate the electrical load on the vehicle to be displayed by the ammeter

Maximum set point for ammeter in-gauge warning light.

Minimum set point for ammeter in-gauge warning light.

0

255

1676

1676

0

5

475

150

-150

Number

Number

A

A

A

A micro Ohm

A

A

0

1

-300

-300

0

0

0

-300

-300

255

255

300

300

250

250

64255

300

300

25

1

1

1

1

1

1

1

1


October 2012


GAUGES

Table 80

Optional Gauges

Ammeter


3615264C1


--

■

INSTRUMENT CLUSTER – OMIT FAULT CODES

This is an optional feature that removes the ability to read fault codes inside the vehicle, using the cluster’s LCD display. No hardware change is needed. This is a software configurable feature.

16HKA

IP CLUSTER DISPLAY OMIT FAULT CODES — Omit display of fault codes in instrument cluster and disable blink codes (requires service tool to retrieve and view fault codes).

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

16HKA (IP Cluster Display Omit Fault Codes): 595ANV

W

IRING

I

NFORMATION


T

ESTING

1. Set Park Brake

2. Press and hold “Cruise On” switch and “Cruise Resume” switch

3. Odometer should NOT display “NO FAULTS” or a number of FAULTS.

H

OW

T

O

A

DD

T

HESE

F

EATURES

Select software feature code 595ANV using the Diamond Logic

®

Builder software (See Local Dealer)

■

INSTRUMENT CLUSTER – FAULT CODES

This feature allows the retrieval of fault codes from the LCD display in the cluster. No hardware change is needed. This is a software configurable feature.

16HKT

IP CLUSTER DISPLAY DIAGNOSTICS — Display on board diagnostics of fault codes in gauge cluster

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

16HKT (IP Cluster Display Diagnostics): 595ANW

W

IRING

I

NFORMATION


T

ESTING

1. Set Park Brake

2. Press and hold “Cruise On” switch and “Cruise Resume” switch

3. Odometer should display the number of active and past fault codes.

4. Pressing the selection button on the face of the cluster will cycle through the fault codes, or they will change to the next fault code every ten seconds.

H

OW

T

O

A

DD

T

HESE

F

EATURES

Select software feature code 595ANW using the Diamond Logic

®

Builder software (See Local Dealer)


October 2012


GAUGES


October 2012


REMOTE POWER MODULES


International

®

has developed a method of controlling loads on the vehicle, outside the cab, without running individual wires from each switch to the load. This is accomplished by an electronic device called a Remote

Power Module (RPM). This module is used to distribute and control power to various devices on the vehicle from switches inside the cab. The RPM is connected to the Body Controller (BC) via the Body Builder J1939 datalink (not the powertrain or ATA datalink). The only wires connected to the RPM are battery power (for driving the loads), datalink cable (which includes power and Ground (GND) to operate the module), and a wire for each vehicle device operated by the RPM.

■

REMOTE POWER MODULES (RPMS)

Refer to the Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Remote Power Units, Solenoid

Packs, Remote Engine Speed Controller.

There are several combinations of RPM and switch types available. Listed below are the current configurations and what types of switches are provided for them:

M

OMENTARY

S

WITCH

RPM

S

08WSK

SWITCH, BODY CIRCUITS, REAR for Body Builder; With Six Momentary Switches in Instrument Panel (IP);

One Power Module, With Six Channels, 20 Ampere (AMP) per Channel and 80 AMP Max. Output, Switches

Control the Power Modules through Multiplex Wiring, Mounted at Rear on Frame

08WSM

SWITCH, BODY CIRCUITS, MID for Body Builder, With Six Momentary Switches in IP; One Power Module with Six Channel, 20 AMP Max. per Channel and 80 AMP Max. Output, Switches Control the Power Module through Multiplex Wiring, Mounted Battery Box, Back of Cab (BOC)

08SAJ

SWITCH, BODY CIRCUITS, MID for Body Builder; 12 Momentary Switches in IP, With Two Power Modules with Six Channels, 20 AMP Max. per Channel, 80 AMP Max. Output, Switch Control Power Modules through

Multiplex Wiring, Mounted on Battery Box, BOC

08VZR

SWITCH, BODY CIRCUITS, MID for Bodybuilder, 6 Switches in Instrument Panel; One Power Module with 6

Channels, 20 Amp Max. Per Channel, 80 Amp Max Output, Switches Control Power Module Through Multiplex

Wiring, Mounted in Cab Behind Driver Seat

08VZS

SWITCH, BODY CIRCUITS, MID for Bodybuilder, 12 Switches in Instrument Panel; Two Power Modules with 6

Channels, 20 Amp Max. Per Channel, 80 Amp Max Output, Switches Control Power Module Through Multiplex

Wiring, Mounted in Cab Behind Driver Seat

N

O

S

WITCHES PROVIDED

RPM

S

60AAM

BDY INTG, RPM AUX Mounted on the Driver’s Side Frame Rail at Rear of Frame; Up to 6 Outputs and 6

Inputs, Max. 20 AMP per Channel, Max. 80 AMP Total


October 2012



60AAN

BDY INTG, RPM AUX Mounted Back of Cab; Up to 6 Outputs and Inputs, Max. 20 AMP per Channel, Max. 80

AMP Total, “(No switches included)”

60AAL

BDY INTG, RPM {SPECIAL} Mounted Inside Cab behind Driver Seat; Max. 20 AMP per Channel, Max. 80 AMP

Total; Includes Three Modules with Hardware Only

L

ATCHED

S

WITCH

RPM

S

60AAA

BDY INTG, RPM Mounted Under Cab; Up to Six Outputs and Six Inputs, Max. 20 AMP per Channel, Max. 80

AMP Total (Includes One Switch Pack with Latched Switches) Mounted on Battery Box, BOC

60AAB

BDY INTG, RPM (2) Mounted Under Cab; Up to Six Outputs and Six Inputs Each, Max. 20 AMP per Channel,

Max. 80 AMP Total per Power Module (Includes Switch Packs with Latched Switches) Mounted on Battery Box,

BOC

08WTJ

SWITCH, BODY CIRCUITS, REAR for Body Builder with Six Switches in IP (2-position Latched Switches), One

Power Module With Six Channels, 20 AMP per Channel and 80 AMP Maximum Output, Switches Control the

Power Modules Through Multiplex Wiring, Mounted at the Rear of the Frame (ROF)

60AAD

BDY INTG, RPM (2) {SPECIAL} Mounted Under Cab or on Battery Box; Max. 20 AMP per Channel, Max. 80

AMP Total per Power Module; Includes One Module with Switch Pack Containing Six Latched Switches and

One Module with Hardware Only

60AAG

BDY INTG, RPM Mounted Inside Cab behind Driver Seat; Max. 20 AMP per Channel, Max. 80 AMP Total;

Includes One Module with Switch Pack Containing Latched Switches

60AAH

BDY INTG, RPM (2) Mounted Inside Cab behind Driver Seat; Max. 20 AMP per Channel, Max. 80 AMP Total;

Includes Two Modules with 2 Switch Packs Containing Latched Switches

60AAJ

BDY INTG, RPM (3) Mounted Inside Cab behind Driver Seat; Max. 20 AMP per Channel, Max. 80 AMP Total;

Includes Three Modules with 3 Switch Packs Containing Latched Switches

60AAK

BDY INTG, RPM (2) {SPECIAL} Mounted Inside Cab behind Driver Seat; Max. 20 AMP per Channel, Max. 80

AMP Total; Includes One Module with Switch Pack Containing Six Latched Switches and One Module with

Hardware Only

60AJL

BDY INTG, REMOTE POWER MODULE Mounted Inside Cab; Up to 6 Outputs & 6 Inputs, Max. 20 AMP per

Channel, Max. 80 AMP Total; (Includes 1 Switch Pack With Latched Switches)


October 2012



60AJM

BDY INTG, REMOTE POWER MODULE (2) Mounted Inside Cab; Up to 6 Outputs & 6 Inputs each, Max. 20

AMP per Channel, Max. 80 AMP Total; (Includes Switch Packs With Latched Switches)

F

EATURE

/B

ODY

F

UNCTION

•

On the DuraStar models, codes 08SAJ, 08WSM, 60AAA, AAD, AAN and 60AAB have the RPMs mounted at the back of the battery box.

•

On the WorkStar models, codes 08SAJ, 08WSM, 60AAA, AAD, AAN and 60AAB have the RPMs mounted under the cab, left rear.

•

On either the DuraStar or WorkStar models, codes 08WSK, 08WTJ or 60AAM have the RPMs mounted on the driver’s side frame rail at the ROF.

•

On the DuraStar or WorkStar models, codes 08VZR, 08VZS, 60AAG, 60AAH, 60AAJ, 60AAK, or 60AAL have the RPMs mounted inside the cab, behind the driver’s seat.

•

On the Workstar models, codes 60AJL and 60AJM have the PRMs mounted inside the cab, behind the passenger’s seat. On the DuraStar, codes 60AJL and 60AJM are not available.

•

On WorkStar models code 60AAN is not compatible with 60AAB

Remote Power Module Internal Mounting Locations


October 2012 f_071



Picture of Sample Mounting in Cab, behind Driver’s Seat

f_072

Feature codes 08WSK, 08WSM, 08SAJ, 08VZR, 08VZS, and 08WTJ each add a 6-pack switch pack in a one-to- one relationship to the RPM feature code.

60AAA and 60AAB add switches by filling in the first empty switch location. Once the first switch pack is full, a second will be added filling in from the left to right of the switch pack.


October 2012



The table below summarizes the RPM locations and configurations by sales code and model:

Table 81

RPM

Code

08SAJ

08WSK

# of RPM’s and

Addresses

Used

2

(1, 2)

1

(4)

08WSM

08VZR

08VZS

08WTJ

60AAA

60AAB

60AAD

60AAG

60AAH

60AAJ

60AAK

60AJL (Not recommended, use 60AAG)

60AJM

(Not recommended, use 60AAH)

60AAL

60AAM

60AAN

1

(1)

1

(1)

2

(1, 2)

1

(4)

1

(1)

2

(1, 2)

2

(1, 2

1

(1)

2

(1,2)

3

(1, 2, 4)

2

(1,2)

1

2

3

(1, 2, 4)

1

(5)

1

(3)

# of

Switches

12

6

6

6

12

6

6

12

6

6

12

18

6

6

12

0

0

0

Type of

Switches

Momentary

Momentary

Momentary

Momentary

Momentary

Latched

Latched

Latched

Latched

Latched

Latched

Latched

Latched

Latched

Latched

None

None

None

Switch Configuration

Mounted in their own 6 Packs or 12 Pack Switchpack

Mounted in their own 6 Pack

Switchpack


Switchpack


Switchpack

Mounted in their own 6 Packs or 12 Pack Switchpack

Fills in the next blank switch location after factory switches










N/A

N/A

N/A

Model Location

DuraStar

WorkStar

DuraStar &

WorkStar

DuraStar

WorkStar

DuraStar &

WorkStar

DuraStar &

WorkStar

DuraStar &

WorkStar

DuraStar

WorkStar

DuraStar

WorkStar

DuraStar

WorkStar

DuraStar &

WorkStar

DuraStar &

WorkStarI

DuraStar &

WorkStarI

DuraStar &

WorkStarI

DuraStar

WorkStar

Back of Battery Box

Under Cab Left Rear

Drivers side Rear of

Frame

Back of Battery Box

Under Cab Left Rear

Inside the cab behind the driver’s seat



Frame

Back of Battery Box

Under Cab Left Rear

Back of Battery Box

Under Cab Left Rear

Back of Battery Box

Under Cab Left Rear


(Extended cab, mounted outside of cab







Not available


DuraStar

WorkStar

Not available


DuraStar &

WorkStar

DuraStar &

WorkStar

WorkStar


(Extended cab, mounted outside of cab)


Frame

Back of Cab (Not compatible with 60AAB on WorkStar)


October 2012



S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

08WSK: 595AHB

The PwrMod4_Fuse_Level1_Param sets the limit (in AMPS) of the current flowing from Output #1 of RPM #4.






The PwrMod4_Init_State1_Param parameter determines the initial state of RPM #4, output #1. If the parameter is set to 1, Output #1 of RPM #4 will be turned ON at ignition (IGN) key-on. If the parameter value is set to 0, the output will be OFF at key-on.


The PwrMod4_Init_State3_Param parameter determines the initial state of RPM #4, output #3. If the parameter is set to 1, Output #3 of RPM #4 will be turned ON at ignition (IGN) key on. If the parameter value is set to 0, the output will be OFF at key-on.





October 2012



Table 82

Parameter

PwrMod4_

Fuse_Level1_

Param

PwrMod4_

Fuse_ Level2_

Param

PwrMod4_

Fuse_ Level3_

Param

PwrMod4_

Fuse_Level4_

Param

PwrMod4_

Fuse_ Level5_

Param

PwrMod4_

Fuse_ Level6_

Param

ID

454

455

456

457

458

Description

Current Limit in amps for

Output #1 of RPM #4


Output #2 of RPM #4


Output #3 of RPM #4


Output #4 of RPM #4


Output #5 of RPM #4

Default

20

20

20

20

20

Units

A

A

A

A

A

Min

0

0

0

0

0

Max

20

20

20

20

20

Step

0.1

0.1

0.1

0.1

0.1

PwrMod4_

Init_State1_

Param

PwrMod4_

Init_State2_

Param

PwrMod4_

Init_State3_

Param

PwrMod4_

Init_State4_

Param

PwrMod4_

Init_State5_

Param

PwrMod4_

Init_State6_

Param

459

460

461

462

463

464

465


Output #6 of RPM #4

If this parameter is set to 1,

Output #1 of RPM #4 will be turned on at IGN key-on. If set to 0, output will be off at key-on.


Output #2 of RPM #4 will be turned on at ignition key-on.

If set to 0, output will be off at key-on.












If set to 0, output will be off at key-on

20

OFF

OFF

OFF

OFF

OFF

OFF

A

No_ Units

No_ Units

No_ Units

No_ Units

No_ Units

No_ Units

0

N/A

N/A

N/A

N/A

N/A

N/A

20

N/A

N/A

N/A

N/A

N/A

N/A

0.1

N/A

N/A

N/A

N/A

N/A

N/A

08WSM & 08VZR: 595AHE








October 2012



The PwrMod1_Init_State1_Param parameter determines the initial state of RPM #1, output #1. If the parameter is set to 1, Output #1 of RPM #1 will be turned ON at ignition key-on. If the parameter value is set to 0, the output will be OFF at key-on.

The PwrMod1_Init_State2_Param parameter determines the initial state of RPM #1, output #2. If the parameter is set to 1, Output #2 of RPM #1 will be turned ON at IGN key-on. If the parameter value is set to 0, the output will be OFF at key-on.






October 2012



Table 83

Parameter

PwrMod1_

Fuse_Level1_

Param

PwrMod1_

Fuse_ Level2_

Param

PwrMod1_

Fuse_ Level3_

Param

PwrMod1_

Fuse_Level4_

Param

PwrMod1_

Fuse_ Level5_

Param

PwrMod1_

Fuse_ Level6_

Param

ID

392

393

394

395

396

Description


Output #1 of RPM #1


Output #2 of RPM #1


Output #3 of RPM #1


Output #4 of RPM #1


Output #5 of RPM #1

Default

20

20

20

20

20

Units

A

A

A

A

A

Min

1

1

1

1

1

Max

20

20

20

20

20

Step

0.1

0.1

0.1

0.1

0.1

PwrMod1_

Init_State1_

Param

PwrMod1_

Init_State2_

Param

PwrMod1_

Init_State3_

Param

PwrMod1_

Init_State4_

Param

PwrMod1_

Init_State5_

Param

PwrMod1_

Init_State6_

Param

397

398

399

400

401

402

403


Output #6 of RPM #1


Output #1 of RPM #1 will be turned on at ignition key-on. If set to 0, output will be off at key-on.











20

OFF

OFF

OFF

OFF

OFF

OFF

A

No_ Units

No_ Units

No_ Units

No_ Units

No_ Units

No_ Units

1

N/A

N/A

N/A

N/A

N/A

N/A

20

N/A

N/A

N/A

N/A

N/A

N/A

0.1

N/A

N/A

N/A

N/A

N/A

N/A

08SAJ & 08VZS: 595AHE and 595AHD








October 2012






















October 2012



Table 84

Parameter

PwrMod2_

Fuse_Level1_

Param

PwrMod2_

Fuse_ Level2_

Param

PwrMod2_

Fuse_ Level3_

Param

PwrMod2_

Fuse_Level4_

Param

PwrMod2_

Fuse_ Level5_

Param

PwrMod2_

Fuse_ Level6_

Param

ID

35

36

37

38

39

Description


Output #1 of RPM #2


Output #2 of RPM #2


Output #3 of RPM #2


Output #4 of RPM #2


Output #5 of RPM #2

PwrMod2_

Init_State1_

Param

PwrMod2_

Init_State2_

Param

PwrMod2_

Init_State3_

Param

PwrMod2_

Init_State4_

Param

PwrMod2_

Init_State5_

Param

PwrMod2_

Init_State6_

Param

40

41

42

43

44

45

46

PwrMod1_

Fuse_Level1_

Param

PwrMod1_

Fuse_ Level2_

Param

PwrMod1_

Fuse_ Level3_

Param

PwrMod1_

Fuse_Level4_

Param

392

393

394

395


Output #6 of RPM #2














Output #1 of RPM #1


Output #2 of RPM #1


Output #3 of RPM #1


Output #4 of RPM #1

Default

20

20

20

20

20

20

OFF

OFF

OFF

OFF

OFF

OFF

20

20

20

20

Units

A

A

A

A

A

A

No_ Units

No_ Units

No_ Units

No_ Units

No_ Units

No_ Units

A

A

A

A

Min

1

1

1

1

1

1

N/A

N/A

N/A

N/A

N/A

N/A

1

1

1

1

Max

20

20

20

20

20

20

N/A

N/A

N/A

N/A

N/A

N/A

20

20

20

20


October 2012

Step

0.1

0.1

0.1

0.1

0.1

0.1

N/A

N/A

N/A

N/A

N/A

N/A

0.1

0.1

0.1

0.1



Parameter

PwrMod1_

Fuse_ Level5_

Param

PwrMod1_

Fuse_ Level6_

Param

ID

396

397

Description


Output #5 of RPM #1


Output #6 of RPM #1

Default

20

20

Units

A

A

Min

1

1

Max

20

20

Step

0.1

0.1

PwrMod1_

Init_State1_

Param

PwrMod1_

Init_State2_

Param

PwrMod1_

Init_State3_

Param

PwrMod1_

Init_State4_

Param

PwrMod1_

Init_State5_

Param

PwrMod1_

Init_State6_

Param

398

399

400

401

402

403






Output #3 of RPM #1 will be turned on at IGN key-on. If set to 0, output will be off at key-on







OFF

OFF

OFF

OFF

OFF

OFF

No_ Units

No_ Units

No_ Units

No_ Units

No_ Units

No_ Units

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

F

EATURE

B

ODY

F

UNCTION

60AAA provides one RPM where 60AAB provides two RPMs. Each RPM provides six load outputs for a maximum of 20 AMPS per channel and a maximum of 80 total AMPS per module. Each RPM also provides six inputs that can be either a 12 volt input or a GND active input signal.

60AAD provides two RPMs with only one 6-pack switch pack. This feature is specifically for customers that wish to use advanced logic to control the outputs of these two RPMs through special customer-created software.

60AAG provides one RPM, 60AAH provides two RPMs and 60AAJ provides three RPMs. Each RPM provides six load outputs for a maximum of 20 AMPS per channel and a maximum of 80 total AMPS per module. Each

RPM also provides six inputs that can be either a 12 volt input or a GND active input signal.

60AAK provides two RPMs with one switch a 6-pack switch pack. 60AAL provides three RPMs. These features are fir customers that wish to use advanced logic to control the outputs of the RPMs through special customer-created software.

60AJL and 60AJM provide the same functionality as 60AAG and 60AAH respectively. It is recommended that

60AAG or 60AAH be used instead of 60AJL or 60AJM.

* There are other software features that can be ordered such as PTO features that will also use RPM outputs and inputs. These features will take precedence over the RPM feature code switches and inputs/outputs. For example, an order for a PTO feature that uses switch location one and RPM input/output one comes with the

PTO switch and five other switches that would control outputs two through six.


October 2012



S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Feature code 60AAA, 60AAB, 60AAD, 60AAG, 60AAH, 60AAJ, 60AAK, 60AAL, 60AJL or 60AJM are configured by special unadvertised software feature codes. These codes are determined by the number of additional features that use the RPM resources. The following codes should be added after all other features are added to the vehicle.

60ACA = 595AJK – This feature should be added if there are features already using five RPM inputs/outputs.

60ACB = 595AJL – This feature should be added if there are features already using four RPM inputs/outputs.

60ACC = 595AJM – This feature should be added if there are features already using three RPM inputs/outputs.

60ACD = 595AJN – This feature should be added if there are features already using two RPM inputs/outputs.

60ACJ = 595AJP – This feature should be added if there are features already using one RPM input/output.

60ACK = 595AJR – This feature should be added if there no other features using any RPM inputs/outputs.

60ACV = 595AJS – This feature should be added to add the second RPM (60AAB).

The following parameters may or may not show up in certain combinations based on which of the above software feature codes are installed on the vehicle.

The TEM_Aux1_Output_Fuse_Param sets the limit (in AMPS) of the current flowing from the output labeled

Aux_Switch_1_Output of RPM #1.
























October 2012



Table 85

Parameter

TEM_Aux1_

Output_Fuse_

Param

TEM_Aux2_

Output_Fuse_

Param

TEM_Aux3_

Output_Fuse_

Param

TEM_Aux4_

Output_Fuse_

Param

TEM_Aux5_

Output_Fuse_

Param

TEM_Aux6_

Output_Fuse_

Param

TEM_Aux7_

Output_Fuse_

Param

TEM_Aux8_

Output_Fuse_

Param

TEM_Aux9_

Output_Fuse_

Param

TEM_Aux10_

Output_Fuse_

Param

TEM_Aux11_

Output_Fuse_

Param

TEM_Aux12_

Output_Fuse_

Param

ID

1990

1991

1992

1995

1999

2000

2100

2101

2102

2103

2104

2105

Description

This is the maximum current

Aux 1 output is allowed to source before the virtual fusing turns the output off.




















Aux 11output is allowed to source before the virtual fusing turns the output off.



Default

20

20

20

20

20

20

20

20

20

20

20

20

Units

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Min

0

0

0

0

0

0

0

0

0

0

0

0

Max

20

20

20

20

20

20

20

20

20

20

20

20

Step

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

F

EATURE

/B

ODY

F

UNCTION

08WTJ: 595AJG

Feature 08WTJ adds one RPM to the end of the frame to be used by itself or in combination with 60AAA (one

RPM BOC) or 60AAB (two RPMs BOC). The RPM will have six channels, 20 AMPS per channel, and 80 AMPS maximum output. There will be six, 2-position, latched switches located in the IP that will control the RPM through multiplex wiring.


October 2012



S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature code: 595AJG

Conflicts with Software features: 595AHB


RPM4_Output1 of RPM #1.











Table 86

Parameter

TEM_Aux13_

Output_Fuse_

Param

TEM_Aux14_

Output_Fuse_

Param

TEM_Aux15_

Output_Fuse_

Param

TEM_Aux16_

Output_Fuse_

Param

TEM_Aux17_

Output_Fuse_

Param

TEM_Aux18_

Output_Fuse_

Param

ID

2215

2216

2217

2218

2219

2220

Description













Default

20

20

20

20

20

20

Units

Amps

Amps

Amps

Amps

Amps

Amps

Min

0

0

0

0

0

0

Max

20

20

20

20

20

20

Step

0.1

0.1

0.1

0.1

0.1

0.1

W

IRING

I

NFORMATION

Each module receives power from a 4-gauge cable, protected by a fusible link, connected to the battery stud of the starter motor or the battery depending on the location of the RPM.


October 2012



Remote Power Module

f_073

Each generic RPM has the ability to operate up to six devices of 20 AMPS or less not to exceed 80 AMPS for the entire module. Each RPM comes with a 6-pack of switches that is inserted into the center section of the IP.

Each generic switch controls one output of the RPM. The switch mapping is one-to-one with the RPM, i.e. switch one controls output channel one on the RPM. The switch pack is connected to the switch data bus that communicates switch operation to the BC, which communicates that operation to the RPM. The RPM also has inputs on the module itself that can be programmed to control the outputs. This means that the RPM functions like a 3-way lamp switch in a home. Each in-cab switch is a momentary rocker switch that is stable in the center position. The upper section of each switch has an indicator light to provide the status of each power output channel. Pressing the upper section of the switch will latch the respective power output channel on and illuminate the indicator. Pressing the lower section of the switch will latch the power output channel off and turn the indicator off. Likewise, the output channels may be controlled remotely by using a three-position momentary single pole, double throw switch on each remote switch input. Applying battery volts to the remote switch input will turn the output channel on. Applying GND to the remote switch input will turn the output channel off. The lamp indicator on the IP switch will always display the current status of the output channel as long as the IGN key is in the IGN or accessory position. Each RPM In-cab switch operates with the key in the IGN or accessory position. The RPM remote input switches operate at any time. If a conflict exists between the switches, the off state always wins.

A maximum of three RPMs may be connected to the vehicle from the factory which allows a total of 18 devices to be controlled as long as the 80 AMPS per module is not exceeded. The modules can be relocated from their mounting position as long as the datalink cable will reach its new mounting location without the datalink cable being modified.

A

DDRESSING

RPM

S

All RPMs require jumpers to tell the system controller what RPM it is controlling. Jumpers are to be installed in a 23-way connector in location J3, shown in the figure below. No two RPMs can have the same address on a vehicle.


October 2012



J3 23–Way Connector

f_074

Instrument Panel Mounted Switch Pack

f_075

Switch Labeling: Switch packs provided with the RPM feature are general purpose “un-labeled” rocker switches. Since the functions of the rocker switches are unknown at the time of vehicle assembly, “un-labeled” rocker switches are provided so the Body Builder can customize the switches to any particular need. For switch graphic information, see the Switches chapter in this electrical guide.


October 2012



Example with RPM Output Controlled by Switch Inside Cab

f_076

Example with RPM Output Controlled by Switch Located on Chassis

f_077


October 2012



Table 87

Table 88

Pin

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

17

18

19

20

21

22

23

E

F

G

H

A

B

C

D

Pin

2

3

4

6

2

3

4

6

Signal Name Signal Direction Rating (Amps)

GND

Body Data Link

GND/Pass-Thru

Body Builder

J1939+

Datalink

Body Builder

J1939–

Datalink

Battery Input/Pass-Thru

Body Datalink

GND

Body Builder

GND/Pass-Thru

J1939+

Body Builder

Datalink

J1939–

Battery

Datalink

Input/Pass-Thru

Module Battery Feed

5

5

1 Supply Voltage Input 80

NOTE: Body datalink output is supplied with the mate to this connector which is sealed and includes a 120 ohm terminating resistor.

Fig_078 _

NOTE: No additional circuits can be added.

Signal Name

Signal Connector

Module Select Common

Module Select #1


Module Select #2


Module Select #3

Signal Direction

GND

Digital Input

GND

Digital Input

GND

Rating (Amps)

0.010

0.010

0.010

Input #1

Input #2

Input #3

Input #4

Input #5

Input #6

Output #1

Power Connector

Output #2

Output #3

Output #4

Output #5

Switch Input

Switch Input

Switch Input

Switch Input

Switch Input

Switch Input

Output

Output

Output

Output

Output

Output #6 Output

0.010

0.010

0.010

0.010

0.010

0.010

20

20

20

20

20

20


October 2012



NOTE: Refer to the Recommended Circuit Protection in the General section when selecting wire gauge and fusing.

Table 89 – Mating Connector Information

Signal Connector — 23 Way

Connector

2005482C1

Terminal

1698937C1

Plug

1688285C1

Cable Gauge

16, 18, 20

Table 90 – Mating Connector Information

Power Connector — 8 Way

Connector

3548934C1

Terminal

3535930C1

3534163C1

3535931C1

Cable Seal

3535936C1

3535937C1

3548945C1

Plug

Lock

3548943C1

Cable Gauge

16, 18

12

14

Cable Gauge

2025431C1 f_079

For Switch Product Graphic Label Kit part numbers, see the Switch chapter in this electrical guide.


October 2012



Here are some facts about the use of the RPM:

•

Each RPM provides six outputs. The loads on each output are protected by virtual fuses and are programmable in 100mA (milliAmp) increments, 20 AMP max. per channel, 80 AMP max. per module.

•

A maximum of three RPMs per vehicle may be factory-installed, and a total of seven can be added after the vehicle has been built.

•

Power is fed to the RPM through a fused link from the battery or starter lug (depending on the vehicle model) that controls lights, mirrors, solenoids, fans, etc.

•

If higher current capacity is needed, the RPM can control a high current relay and still maintain logic and diagnostic capability without having to wire to the inside of the cab.

•

The RPM outputs may be programmed to be on or off with each key-on cycle (assumes a momentary switch is used in the cab).

•

There is an input connector for the Body Builder switches.

•

A 3-way output control may be achieved by using a single pole double throw switch with the RPM inputs. The respective RPM output may be turned on by the in-cab switch and off by the remote switch, and vice versa.

The in-cab switch indicator displays the status of the RPM output.

•

The switch input actually goes to the BC so that the program rules can be checked. If all of the rules checkout, the controller will activate the channel. If the preprogrammed logic rules for this circuit are not met, the switch will flash until the desired condition is activated.

•

A 12 volt input will turn a channel on, and a GND input will turn the channel off.

•

If a latching switch is used by the TEM or Body Builder with the remote switch inputs, the channel cannot be controlled by the in-cab switch.

•

RPMs have diagnostic capability.

•

As mentioned, the fusing current can be programmed. If that current is exceeded, the circuit will be “fused” and the RPM will send that message to BC indicating which RPM and what output is over current.

•

The RPM has two 6-pin connectors.

•

The last module must have a 120–ohm terminating resistor in the datalink connector.

•

All power, GND, and datalink signals are contained in these connectors.

•

The two identical connectors located on the power input side of the module are the datalink connectors. They are pass-thru connectors that allow for the “daisy chaining” of modules. Only one connector plugs into the chassis harness.


October 2012



120–ohm Datalink Termination Connector on RPM

f_080

RPM Connectors


October 2012 f_081



H

OW

T

O

A

DD

T

HIS

F

EATURE

Three RPMs can be added to a vehicle. The RPM kit 2594132C91 contains the RPM, datalink cables, three foot power cable, 6-pack switch pack, LED indicators for the switches, and six latching switches. If momentary switches are needed, order part number 3564004C1 in the quantity needed.

Table 91 – RPM Kit Contents

Part

2588909C92

3804529P93

3558934C92

3611349P93

MIN10

3519178C91

3549776C4

3578910C1

3578733C1

3533928C1

3552005C4

2585423C91

2585651C91

2594135R1

Description

KIT, REMOTE POWER MODULE W/JMPR

MM, IP, WRG, J1939 PRIVATE RPM

HARNESS, CHASSIS WIRING* SINGLE

HARN, CTR CHSS. RPU/RPTO BOC DAT

FUSE 10A (3534209C1)

RESISTOR, ELECT TERMINATING

HOUSING, SWITCH*6-PACK DIN MULT

SWITCH, BLANK RCKR-2 POS BISTAB

LIGHT, IND, LED ON-GREEN, BRIGHT

LIGHT, IND, LED AMBER BKLGT

KIT, LIGHT* PRODUCT GRAPHIC FOR

KIT, RPM TERMINAL/SEAL 14GA

KIT, RPM TERMINAL/SEAL 12GA

MANUAL, INST RMT PWR MOD/BOC

This kit is for left-mounted battery box for DuraStar models and under cab for WorkStar models and inside the cab, for both models. If truck has right-mounted battery box, add 3558936C91. If adding two RPMs, use jumper harness 3558937C91 from first to second RPM and add 3558934C92 cable for the battery feed.

If RPM brackets are needed, the following part numbers will need to be ordered.

Quantity

1

1

6

6

1

1

1

6

1

1

1

1

1

1

DuraStar models (one or two RPMs)

RPM bracket for inside the cab – 3676154C4

•

Mounted inside the cab behind driver’s seat

RPM bracket for second BOC RPM – 3558794C1

•

Mounted under battery box

WorkStar models (one or two RPMs)

RPM bracket for inside the cab – 3676154C4

•

Mounted inside the cab behind driver’s seat

Day Cab – 3582976C2, Crew/Extended Cab – 3582983C2

•

Mounted under driver side of cab

•

3558794C1 – Mounting Bracket

Attach the mounting bracket to the underside of the vehicle cab on WorkStar models (driver’s side) and the back of the battery box if a second RPM is mounted on a DuraStar series. See figures below.

Attach the RPM to the vehicle-mounting bracket, and securely tighten the fasteners.

Install dash harness and center chassis harness as per the following instructions. The schematic diagram is provided for assistance in the installation.

Wrap the add-on harnesses to respective dash and center chassis harnesses with electrical tape or other harness wrap after the installation. Ensure harnesses are routed away from sharp edges and properly clipped for good wire harness support.


October 2012



I

NSTALLATION

I

NSTRUCTIONS

In-Cab

1. Install A5EB (1939 +) {yellow} into the BC (1602) cavity F6

2. Install A5EB (1939 -) {green} into the BC (1602) cavity F5

5. Insert A20 {lt green} into the fuse panel (1017) cavity E3.

6. Insert a 10 AMP fuse in cavity F3-E3 in the fuse panel (1017).

Engine Compartment

1. Install A5E (1939 +) {yellow} into the IP center chassis (1701) cavity 52

2. Install A5E (1939 -) {green} into the IP center chassis (1701) cavity 53

3. Insert A20 {lt green} into the IP center chassis (1701) cavity 51

4. Install N10-GR {white} into splice pack (8809) cavity C

Install a terminating resistor in the open connector in the cab, and install a terminating resistor in the last module in the datalink.

DuraStar Single RPM

f_082


October 2012



DuraStar with 2 RPMs

f_083

WorkStar Models Under Cab Mounting

Inside Cab RPMs are located behind the driver’s seat on 4000 models.

f_084


October 2012



f_085


October 2012



DuraStar Models In Cab Mounting

f_086 f_087

When more than one Remote Power Module (RPM) is installed, the Data Link wire harness must be daisy-chained using the scheme diagrammed in the figure below. Connect the 6 pin Data Link Harness (J1939) from the first RPM to either data link connector of the second. Continue connecting the data link jumper


October 2012



harness of each RPM to the next until the final RPM is reached. The last RPM in the chain will have a

Terminating Resistor inserted into the last remaining open 6 pin data link connector of the remote power module. Various lengths of data link jumper harnesses and extension harnesses are available from Navistar

Service Parts through any Navistar Dealer.

Connecting Multiple Remote Power Modules

f_089


October 2012



Installation of Switch Packs and LEDs

f_090

To install a switch in the switch pack housing, insert the switch in the proper slot and push in until the switch locking tabs are fully engaged (switches are keyed and cannot be installed upside down). f_092

Remove the rear cover of the switch pack. It is attached with a snap fit. See the attached pictures to determine which end is up on the switch pack. Install the LED lamps with the white base (part number 3578733C1) in the upper section of each switch on the switch pack housing. These are the indication of on lamps and will glow green when activated. Note that the LED lamps have a keying feature as they are installed in the switch pack circuit board. If the lamps are forced in against the proper orientation, they will not illuminate.

Install the LED lamps with the black base (part number 3533928C1) in the lower section of each switch on the switch pack housing. These are the back light lamps and will glow amber when the panel lights are on.

Reattach the rear cover and secure the wire harnesses under the cover hooks.

Locate a free switch pack opening in the central IP.

If no switch packs are present in the vehicle, remove the switch blank below the radio space and locate the

6-pin cab harness for the switch packs. Connect the cab switch harness to the left side switch pack harness (as viewed from the front). Connectors are keyed to ensure proper connection. Ensure that the switch pack is installed in the proper orientation. The green indication of on lamps must be on top when viewing the front of the switch pack.

If one 6-switch pack is already present, locate the new switch pack in the lower left switch pack area.


October 2012



Connect the second harness of the first switch pack to the input cable harness of the second switch pack.

Install the second switch pack into center IP. It is secured with a snap action.

Determine the function of each of the newly added rocker switches. Locate the set of switch labels in the parts kit. Place the labels named “on” in the upper section of each windowed rocker switch. Place the switch name in the lower portion of the rocker switch.

f_093

If an additional switch pack is being installed, it is connected to the multiplex system by “daisy chaining” its connectors to the existing switch pack (or to the cab harness if no switch pack is currently installed). It is important to connect the switch packs in the correct order. Connecting the switch packs together and to the cab harness in the wrong order will cause switch pack addressing problems.

f_094


October 2012



f_095

R

EMOVAL

/R

EPLACEMENT OF

S

WITCHES AND

S

WITCH

P

ACKS

To remove a switch pack from the panel use the DIN radio removal tool part number 2504954C1.

f_031

Insert the extraction tools (2) into the two holes on either side of a switch pack housing until the locking tabs are fully depressed. The switch pack can then be removed from the panel and the extraction tools removed.

f_096

To remove individual switches or blanks from a switch pack, squeeze the locking tabs on the rear of the switch or blank (top and bottom) and push it from the housing.

To install a switch pack in the panel, make the necessary connections then simply push the assembly into place until the locking tabs are fully engaged.

NOTE: The switch pack can be inadvertently installed upside down. To avoid this when no switches are present in the housing, make sure the white wire in the lead assemblies on the rear of the housing is towards the top.


October 2012



P

ROGRAMMING

T

HE

S

YSTEM

The RPM and switch pack system is now installed.

The electrical system must now be programmed to recognize these new components.

With the Diamond Logic

®

Builder software program, enable the appropriate 595xxx software feature codes from the beginning of this section.

The system may also be programmed at the nearest International

®

dealer. Contact the dealer for details on purchasing either of these programs.

When other body integration features are used, please refer to the body integration feature section for further directions on installing these features.

T

ESTING

08WSK, 08WSM, 08SAJ,

OR

08WTJ (

ONE

-

TO

-

ONE MAPPING

):

1. Turn key to accessory or IGN key state.

2. Activate first in-cab switch.

3. Verify that RPM output #1 is providing battery voltage.

4. Deactivate first in-cab switch.

5. Apply 12V to RPM input #1.


7. Apply GND to RPM input #1.

8. Verify that RPM output #1 shuts off.

Continue the above testing procedure for each RPM switch location.

If any RPM outputs have been programmed to turn on automatically when the key is turned on, (see programmable parameters) then turn the key to the on position and verify that those outputs are providing battery voltage.

T

ESTING

60AAA

OR

60AAB:

1. Turn key to accessory or IGN key-state.

2. Activate first in-cab switch.


4. Deactivate first in-cab switch.

Continue the above testing procedure for each RPM switch location.


October 2012



■

SWITCH BODY CIRCUITS FRAME MTG REAR

Feature 08WTJ adds 1 RPM to the end of the frame to be used by itself or in combination with 60AAA (1 RPM

BOC) or 60AAB (2 RPMs BOC). The Remote Power Module will have 6 channels, 20A per channel, and 80A maximum output. There will be 6, 2–position, switches located in the Instrument Panel, that will control the

RPM through multiplex wiring.

08WTJ

SWITCH, BODY CIRCUITS, REAR for Bodybuilder with 6 switches in instrument panel (2–position switches), one power module with 6 channels, 20 amp per channel and 80 amp maximum output. Switches control the power modules through multiplex wiring, mounted at the rear of the frame.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature code: 595AJG

Conflicts with Software features: NONE

Table 92

Parameter

Name

TEM_

Aux13_

Output_Fuse_

Param

TEM_

Aux14_

Output_Fuse_

Param

TEM_

Aux15_

Output_Fuse_

Param

TEM_

Aux16_

Output_Fuse_

Param

TEM_

Aux17_

Output_Fuse_

Param

TEM_

Aux18_

Output_Fuse_

Param

ID Description

PV-TEM-

Aux-13

Default setting for

TEM_Aux13_Output_Fuse

Param

PV-TEM-

Aux-14

Default setting for


Param

PV-TEM-

Aux-15

Default setting for


Param

PV-TEM-

Aux-16

Default setting for


Param

PV-TEM-

Aux-17

Default setting for


Param

PV-TEM-

Aux-18

Default setting for


Param

Default

Settings

20

20

20

20

20

20

Units Min Value Max Value

Amps

Amps

Amps

Amps

Amps

Amps

0

0

0

0

0

0

20

20

20

20

20

20

Step

0.1

0.1

0.1

0.1

0.1

0.1

W

IRING

I

NFORMATION

Refer to current remote power module.

T

ESTING

Refer to current remote power module.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Select software feature code 595AJG using ICAP or the Diamond Logic

®

Builder software (See Local

Dealer)

•

Programmable Parameters must be set using ICAP or the Diamond Logic

®

Builder software (See Local

Dealer)

•

Refer to current remote power module for further installation instructions.


October 2012



Listed below is a listing of parts that may be required depending on how the vehicle was equipped at the factory.

Table 93

Part Number

3595804F91

6 of 3533928C1

6 of 3578733C1

6 of 3578910C1

Description

Consists of the following:

Light, Indicator, LED backlight (Amber)

Light, Indicator, LED on (Green) 1.0 CAN

Switch, Electronic, Blank Rocker — 2 POS


October 2012


SWITCHES AND SWITCH LABEL PART

NUMBERS AND INFORMATION

SWITCHES AND SWITCH LABEL PART NUMBERS AND INFORMATION

f_097

Most switches are rocker actuators that do not require hard wiring. See the Switch Actuators for Multiplex

Systems Table below. The switches are used in switch pack modules (6 or 12 switches) that connect to the multiplex system through the switch housing cable harnesses. Push button switches for the cluster are also available. See Push Buttons Table below.

If the original vehicle has a three switch pack with only one or two switch locations full, adding another switch is acceptable. Once three switch locations are full, adding more would require the purchase of a six switch pack.

To identify a 3 or 6-pack, remove the switch pack from the center console using the radio removal tool. A

3-pack has wires on the left side only; a 6-pack has wires on the left and right side.

In the Switch Actuator Table below, the first column references the part numbers of the new replacement switch, and columns 2 and 3 are the replacement LED’s part numbers. Column 4 is the switch description.

Columns 5, 6, and 7 describe the switch functions. Position Number reflects the number of positions where the switch can physically be placed. Position On denotes the position of the switch for activation. Switch Action indicates whether the switch is momentary (spring-loaded, switch returns to a specific state) or if the switch is latching (switch stays in the selected state).

NOTE: Switches are no longer packaged with LEDs (Light Emitting Diodes). LEDs must be ordered separately.

Refer to the Table below to locate the proper LED part numbers. Each switch usually requires two LEDs that are installed from the rear side of the switch pack assembly (see the Switches section). If the switch has an on indicator, a green LED will be located in the upper portion. An amber LED is required in the lower portion providing for nighttime viewing. If a switch does not contain an on indicator, then an amber LED should be installed in the upper as well as the lower section.


October 2012




■

SWITCH ACTUATORS FOR MULTIPLEX SYSTEM

LED part numbers: 3578733C1 (green) = 1 3533928C1 (amber) = 2

* = User may use any LED color they see fit.

Table 94 – Switch Actuators for Multiplex System

1 2 3 4

New Part # Indicator LED Back Light LED

3563061C1 2 2

3560046C1

3560047C1

1

2

2

2

3560048C1

3560659C1

3560961C1

3561702C1

1

1

1

1

2

2

2

2

3563062C1

3563063C1

3563064C1

3563065C1

3563066C1

3563068C1

3563069C1

3563070C1

3563072C1

3563073C1

3563074C1

3563075C1

3563076C1

3563079C1

3563080C1

3563111C1

3563113C1

3563114C1

3582129C1

3587551C1

3593177C1

3597367C1

3597368C1

3598282C1

3606678C1

3621122C1

3622543C1

3809914C1

3813770C1

3564004C1

3578910C1

3579027C1

2589880C91

2589590C91

2589883C91

2589881C91

2589882C91

3533950C1

2585638C1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

*

*

*

*

*

1

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

Description

Head Light Switch

Engine Compression Brake On/Off On/Off

Engine Compression Brake Selector

Fan Override

Transfer Case Hi/Neut/Low

Blower Road Switch

Auxiliary Transmission

Dimmer Switch

Work Light Switch

Fog Light Switch

Exhaust Brake Switch

Plow Light Switch

2 Speed Axle Hi/Low

Front Axle Switch

Auto Neutral Switch

Power Divider Lock

Diff Lock

Air Suspension Dump

5th Wheel Slide

PTO On/Off

Air Assist

Transfer Case Hi/Low

Wet Tank Drain

Primary Tank Drain

Mirror Heat

PTO, Xfer Case

Lift Gate

Forward Rear Differential Lock

Rear-Rear Differential Lock

Eng Spd

120VAC

Traction Control Mud/Snow

Traction Control Off Road

Parked Regen

Engine Brake On/Variable/Off

*Window Rocker Blank (3 Position)



Blue Rocker Blank (2-Position)

Red Rocker Blank (2-Position)

Yellow Rocker Blank (2-Position)

Orange Rocker Blank (2-Position)

White Rocker Blank (2-Position)

Plug, Filler Switch Blank for 6/12 packs

Switch, Rocker Blank

5 6 7

2

2

3

3

2

3

3

2

2

2

2

2

2

2

2

3

2

3

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

Position # Position On Switch Action

3 Mid/Up Latching

2

3

Up

All

Latching

Latching

2

3

2

3

Up

All

Up/Down

All

Latching

Latching

Latching

Latching

Up/Down

Up/Down

Up

Up

Up

Up/Hi

Up

Down

Momentary

Latching

Latching

Latching

Latching

Latching

Latching

Momentary

Up

Up

Up

Up

Up

Up

Up

Up/Hi

Up

Up

Up

Up

Up

Up

Up

Up

Latching

Latching

Latching

Latching

Momentary

Latching

Momentary

Latching

Momentary

Momentary

Momentary

Latching

Momentary

Latching

Latching

Latching

Up

Up

Up

Up

Up/Mid

Up

Up

Up

Up

Up

Up

Up

Up

Momentary

Latching

Latching

Momentary

Latching

Momentary

Latching

Momentary

Latching

Latching

Latching

Latching

Latching

3 ALL Latching

NOTE: Blank switches have two clear square windows on them and require a stick-on graphic to identify function and allow for custom switches. The graphic labels can be purchased under part numbers in the Switch

Graphic Label Kits Table below.

*These blank switches are normally to be used with Remote Power Modules (RPMs) or advanced logic functions.


October 2012




■

PUSH BUTTONS — LEFT SIDE OF CLUSTER TABLE

Table 96 – Warning Lights

Part Number

3587032C1

3596344C1

3587033C1

3587034C1

3587024C1

3587031C1

Description

Green Indicator Housing Less LED

Green 3 Candle Power LED

Amber Indicator Housing Less LED

Amber 3 Candle Power LED

Red Indicator Housing Less LED

Red 3 Candle Power LED f_098 f_099

S

WITCH

P

ACK AND

RPM S

WITCH

L

ABEL

G

RAPHICS

A package of the first five switch label sheets is provided for usage by the Body Builder to finish the labeling of the switches. There are also seven additional sheets at this time with more labels available from Navistar (see the Switch section of this manual for a list of all labels offered from Navistar). If the Body Builder requires a label name not already provided by International

®

, a custom label may be designed by following the specification of the switch label appliqué drawing below. Supply of custom labels is the responsibility of the Body Builder.

Switch Labeling: Switch packs provided with the RPM feature are general purpose “un-labeled” rocker switches. Since the functions of the rocker switches are unknown at the time of vehicle assembly, “un-labeled” rocker switches are provided so the Body Builder can customize the switches to any particular need.


October 2012




Switch Label Dimensions in Millimeters

f_100

The supplier for the windowed rocker labels is:

ECI Screenprint

135 S. Main St.

P.O. Box 116

Thomaston, CT 06787

Telephone: 860-283-9849

Web site: eciscreenprint.com

When contacting ECI Screenprint, instruct them to create the labels in the same format and style as the

Navistar sheets to ensure product consistency and the factory fit and finish that is achieved by using the

Navistar graphics.


October 2012




110 V INVT

12 VOLT OUTLET

120VAC POWER

A/C

A/C HEAT

AIR COMPR

AIR HORN

ALLEY

ALLEY LIGHTS

ALT FLASH

AMB POWER

ARROW BOARD

ARROW LEFT

ARROW RIGHT

ARROW SPLIT

ATF PUMP

AUTO

AUTO CHAINS

AUTOMATIC

AUX 1

AUX 2

AUX 3

AUX ENGINE

AUX HEAT

AUX LIGHT

AUX PTO

Table 97 – Legend

Sheet

Sheet 1 – 5

Sheet 1

Sheet 2

Sheet 3

Sheet 4

Sheet 5

Sheet 6

Kit Part No.

3552005C4

Table 98 – Labels – Page 1

2588422C1

(BLANK)

First Label

Left Alley

Mangr Cancel

Aux 1

On

Raise Bed

Self Test

Sheet 4

Quantity of 8

Sheet 2

Sheet 4

Sheet 7

Sheet 4

Sheet 4

Sheet 2

Sheet 2

Sheet 4

Sheet 9

Sheet 5

Sheet 7

Sheet 9

Sheet 9

Sheet 9

Sheet 10

Sheet 11

Sheet 11

Sheet 6

Sheet 13

Sheet 3

Sheet 3

Sheet 3

Sheet 6

Sheet 11

Sheet 11

Sheet 2

AUX WARN

AXLE 1 DOWN

AXLE 1 UP

AXLE 2 DOWN

AXLE 2 UP

B LOAD GATE

BACK ALARM

BACKUP LIGHT

BAR LIGHTS

BATH ASSIST

BATH CONFIRM

BATH LIGHT

BATT SAVE

BATTERY ON

BEACON LIGHT

BED UP

BELLY VALVE

BIN LIGHT

BLOWER

BODY LOWER

BODY N/STOW

BODY OVRHT

BODY RAISE

BODY UP

BOOM

BOOM DOWN

BOOM LEFT

Sheet

Sheet 7

Sheet 8

Sheet 9

Sheet 10

Sheet 11

Sheet 12

Sheet 13

Sheet 2

Sheet 3

Sheet 3

Sheet 3

Sheet 3

Sheet 7

Sheet 3

Sheet 2

Sheet 5

Sheet 13

Sheet 13

Sheet 13

Sheet 5

Sheet 7

Sheet 2

Sheet 5

Sheet 7

Sheet 1

Sheet 3

Sheet 11

Sheet 9

Sheet 9

Sheet 11

Sheet 11

Sheet 3

Sheet 3

Sheet 3

Kit Part No.

2589327C1

2590999C1

2591000C1

2593674C1

2593676C1

2593677C1

2597868C1

BOOM N/STOW

BOOM RIGHT

BOOM STOW

BOOM UP

BOOST DOWN

BOOST OPERATE

BOOST UP

BOTTOM LOAD

BOX UP

BRAKE INTLCK

BRAKE LOCK

BRK INT OVRIDE

CAB BACKUP

CAB ROTO

CAB STROBE

CABIN LIGHTS

CAMERA LIGHT

CARGO LIGHT

CEILING LIGHT

CENTER DOME

CHARGE PSI LOW

CHARGR POWER

CHASER FLASH

CHECK ELEC

CHECK FAULTS

CHECK HYBRID

CHUTES

First Label

Left Cot

Night Strobe

Hyd Filter

Tank1 Open

Door

Estop

Front

Sheet 5

Sheet 3

Sheet 3

Sheet 3

Sheet 9

Sheet 9

Sheet 9

Sheet 7

Sheet 3

Sheet 7

Sheet 2

Sheet 7

Sheet 6

Sheet 1

Sheet 1

Sheet 5

Sheet 3

Sheet 1

Sheet 13

Sheet 11

Sheet 9

Sheet 12

Sheet 9

Sheet 3

Sheet 12

Sheet 9

Sheet 8


CHUTES DOWN

CHUTES LOCK

CHUTES UNLOCK

CHUTES UP

CITY HORN

CLEAR LIGHTS

CLEAR WARN

CLOSE

CLOSE DOOR

CLOSE GATE

CLOSE WINDOW

CODE AMBER

CODE BLUE

CODE GREEN

CODE RED

COLOR LIGHTS

COMPRS PTO

Sheet 8

Sheet 8

Sheet 8

Sheet 8

Sheet 2

Sheet 7

Sheet 1

Sheet 9

Sheet 5

Sheet 7

Sheet 9

Sheet 2

Sheet 2

Sheet 2

Sheet 2

Sheet 5

Sheet 13


DECK LIGHT

DEFROST FAN

DEFUEL VALVE

DFROST FAN 1

DFROST FAN 2

DIESEL GEN

DIESEL HEATER

DIESEL PUMP

DIESEL REEL

DIGGER

DIVIDER DOWN

DIVIDER UP

DO NOT MOVE

DOCK LIGHTS

DOME LIGHT

DOOR

DOOR DOWN

October 2012

Sheet 1

Sheet 7

Sheet 7

Sheet 13

Sheet 13

Sheet 13

Sheet 13

Sheet 11

Sheet 11

Sheet 13

Sheet 5

Sheet 5

Sheet 2 &12

Sheet 10

Sheet 1

Sheet 11

Sheet 12

EMERG SHTOFF

EMERG STOP

ESPAR HEAT

ESTOP

EXHST FAN

EXT SPEAKR

EXTEND

FAN

FAN 1

FAN 2

FAN HIGH

FAN LOW

FAST IDLE

FILL VALVE

FILTER BYPASS

FLOOD LIGHT

FLOOR HEATER

Sheet 11

Sheet 6

Sheet 4

Sheet 12

Sheet 2

Sheet 11

Sheet 8

Sheet 4

Sheet 11

Sheet 11

Sheet 2

Sheet 2

Sheet 10

Sheet 3

Sheet 6

Sheet 2

Sheet 5




COMPT 1 CLOSE

COMPT 1 OPEN

COMPT 2 CLOSE

COMPT 2 OPEN

COMPT 3 CLOSE

COMPT 3 OPEN

COMPT LIGHT

CONVEYOR

COOL

COORDINATOR

CRANE

CRANE ACTIVE

CRANE DOWN

CRANE EXTEND

CRANE LEFT

CRANE LIGHT

CRANE PTO

CRANE RETRACT

CRANE RIGHT

CRANE UP

CRUISE

DEAD MN SWITCH

Sheet 12

Sheet 12

Sheet 12

Sheet 12

Sheet 12

Sheet 12

Sheet 1

Sheet 3

Sheet 5

Sheet 11

Sheet 4

Sheet 11

Sheet 8

Sheet 8

Sheet 8

Sheet 6

Sheet 13

Sheet 8

Sheet 8

Sheet 8

Sheet 9

Sheet 7

DOOR LIGHT

DOOR OPEN

DOOR UP

DOWN

DRAIN VALVE

DRIVE LIGHT

DRIVER ALLEY

DRIVER DOME

DRUM CHRGE

DRUM DISCHRG

DRUM START

DRUM STOP

DUMP CLOSE

DUMP OPEN

DUMP POWER

DUMP VALVE

ELECT HORN

ELECT MAGNET

ELECT SUCTN

EMERG MASTER

EMERG OVRIDE

EMERG PANIC

Sheet 12

Sheet 2

Sheet 12

Sheet 5

Sheet 3

Sheet 2

Sheet 1

Sheet 13

Sheet 8

Sheet 8

Sheet 8

Sheet 8

Sheet 10

Sheet 10

Sheet 7

Sheet 9

Sheet 2

Sheet 12

Sheet 3

Sheet 2

Sheet 13

Sheet 3

FLOOR LIGHTS

FLOOR UNLOAD

FLORES LIGHT

FLOW 1 CLOSE

FLOW 1 OPEN

FLOW 2 CLOSE

FLOW 2 OPEN

FOG LIGHTS

FRONT

FRONT A/C

FRONT ALARM

FRONT CENTER

FRONT FLASH

FRONT LIGHT

FRONT SCENE

FRONT STROBE

FRONT SWEEP

FRONT UNITY

FRONT WARN

FRONT WORK

FRT OW NOZZLE

FT LF ARM DN

Sheet 5

Sheet 9

Sheet 1

Sheet 6

Sheet 6

Sheet 6

Sheet 6

Sheet 11

Sheet 13

Sheet 5

Sheet 13

Sheet 5

Sheet 1

Sheet 1

Sheet 7

Sheet 1

Sheet 12

Sheet 13

Sheet 1

Sheet 13

Sheet 7

Sheet 6


FT LF ARM UP

FT RT ARM DN

FT RT ARM UP

GAS PUMP

GAS REEL

GATE DOWN

GATE OPEN

GATE UP

GEN RUN

GPM FLOW

GROUND LIGHT

HAZARD LIGHT

HEAT

HEAT 1

HEAT 2

HEATED MIRROR

HEATER 1

HEATER 2

HEATER 3

HEATER 4

HEV OFF

HI FLO HOSE

HI THROTL

HIGH

HIGH IDLE

HIGH PRES

HIGH RAIL

HIGH WATER

HOOD OPEN

HOOK DOWN

HOOK UP

HOPPER

HOPPER DOWN

HOPPER LIGHT

HOPPER UP

HOSE LIGHTS

Sheet 13

Sheet 13

Sheet 13

Sheet 13

Sheet 9

Sheet 11

Sheet 7

Sheet 4 & 5

Sheet 3

Sheet 9

Sheet 4

Sheet 7

Sheet 9

Sheet 8

Sheet 8

Sheet 8

Sheet 8

Sheet 4

Sheet 8

Sheet 7

Sheet 6

Sheet 6

Sheet 6

Sheet 11

Sheet 11

Sheet 9

Sheet 5

Sheet 9

Sheet 2

Sheet 6

Sheet 1

Sheet 11

Sheet 5

Sheet 11

Sheet 11

Sheet 11


HYD OIL HI TEMP

HYD OIL LOW

HYD OVRIDE

HYD PUMP

HYD SHUTDN

IN REVERSE

INJECT SYSTEM

INTERNL VALVE

INTSEC LIGHTS

LADDER

LADDER DOWN

LADDER LIGHTS

LADDER N/STOW

LADDER PTO

LADDER RACK

LADDER UP

LAMP OUT

LAMP TEST

LASER LIGHTS

LCR 11 POWER

LEFT ALLEY

LEFT CEILING

LEFT CENTER

LEFT CHUTE

LEFT COMPT

LEFT COT

LEFT DOME

LEFT DOOR

LEFT EVAC

LEFT FLOOD

LEFT FRONT

LEFT HOSE

LEFT PTO

LEFT PTO ON

LEFT READ

LEFT REAR

October 2012

Sheet 9

Sheet 12

Sheet 5

Sheet 10

Sheet 1

Sheet 13

Sheet 5

Sheet 7

Sheet 6

Sheet 7

Sheet 11

Sheet 8

Sheet 6

Sheet 1

Sheet 5

Sheet 12

Sheet 12

Sheet 12

Sheet 11

Sheet 5

Sheet 6

Sheet 6

Sheet 8

Sheet 11

Sheet 8

Sheet 9

Sheet 11

Sheet 11

Sheet 1

Sheet 8

Sheet 10

Sheet 10

Sheet 7

Sheet 7

Sheet 7

Sheet 10

LEFT WARN

LEFT WING

LF DUMP CLOSE

LF DUMP OPEN

LF WEEDSEEKER

LIFT

LIFT ENABLE

LIFT EXTEND

LIFT GATE

LIGHT BAR

LIGHT BOARD

LIGHT TOWER

LO FLO HOSE

LOAD

LOAD MANGR

LOCK

LOCK DOOR

LOCK WINDOW

LOW

LOW PRES

LOW THROTL

LOW VOLTS

LOWER

LOWER BED

LOWER BOX

LOWER IDLE

LOWER LIFT

LOWER PLW LTS

LOWER WARN

LOWER WORK

MACHINE

MANGR CANCEL

MANUAL

MAP LIGHT

MASTER

MASTER HEATER


Sheet 4

Sheet 9

Sheet 4 &5

Sheet 9

Sheet 7

Sheet 2

Sheet 5

Sheet 5

Sheet 3

Sheet 7

Sheet 12

Sheet 13

Sheet 1

Sheet 1

Sheet 2

Sheet 2

Sheet 11

Sheet 1

Sheet 2

Sheet 13

Sheet 1

Sheet 3

Sheet 6

Sheet 6

Sheet 6

Sheet 5

Sheet 13

Sheet 11

Sheet 3 &5

Sheet 1

Sheet 2

Sheet 7

Sheet 11

Sheet 11

Sheet 2

Sheet 9

HOSE REEL

HYD ENABLE

HYD FILTER



Sheet 11

Sheet 8

Sheet 9

LEFT SCENE

LEFT SPRAY

LEFT SWEEP

Sheet 1

Sheet 10

Sheet 12

MASTER POWER

MASTER THROTL

MEDIUM IDLE

Sheet 12

Sheet 2

Sheet 10

MESSG WAIT

METEOR LIGHT

METER POWER

MID START

MID STOP

MIDDLE

MIXER

MTROIL PUMP

NEED REGEN

NEON LIGHTS

NEUTRAL

NIGHT STROBE

NO DATA LOGGED

NO DATA LOGGING

NOT LEVEL

NOZZLE N/STOW

OIL LEVEL

OK TO HI IDLE

OK TO PUMP

OK TO THROTL

ON

OPEN

OPEN DOOR

OPEN GATE

OPEN WINDOW

OPTI COM

OUTRIG DOWN

OUTRIG N/STOW

OUTRIG UP

OVER LOAD

OVER RIDE

OVER TEMP

OXYGEN

OXYGEN LIGHT

PA POWER

PACKER LEFT

Packer On


Sheet 8

Sheet 4

Sheet 10

Sheet 8

Sheet 8

Sheet 13

Sheet 6

Sheet 11

Sheet 12

Sheet 5

Sheet 11

Sheet 8

Sheet 8

Sheet 13

Sheet 7

Sheet 13

PACKER RIGHT

PANEL LIGHT

PASS ALLEY

PERM LIGHT

PLC POWER

PLOW DOWN

PLOW LEFT

PLOW LIGHT

PLOW RIGHT

PLOW UP

POLE LIGHT

POWER

POWER WINDOW

PRESSURE

PRIMRY WARN

PRINTR POWER

Sheet 4

Sheet 2

Sheet 2

Sheet 6

PTO

PTO 1

PTO 2

PTO 3

Sheet 4

Qty of 24

PTO CURB

Sheet 9

Sheet 5

Sheet 3

Sheet 9

Sheet 1

Sheet 3

Sheet 5

Sheet 3

PTO DIESEL

PTO DRIVER

PTO GAS

PTO GEN

PTO OVRIDE

PTO PASNGR

PTO PUMP

PTO STREET

Sheet 9

Sheet 9

Sheet 9

Sheet 2

Sheet 2

Sheet 6 &13

Sheet 11

Sheet 11

PUMP

PUMP & ROLL

PUMP ENG’D

PUMP HI

PUMP LO

PUMP ONE

PUMP PANEL

PUMP TWO

Sheet 10

Sheet 10

Sheet 12

Sheet 10

Sheet 2

Sheet 6

Sheet 12

Sheet 2

Sheet 10

Sheet 3

Sheet 2

Sheet 2

Sheet 10

Sheet 10

Sheet 6

Sheet 2

Sheet 6

Sheet 11

Sheet 12

Sheet 1

Sheet 1

Sheet 12

Sheet 3

Sheet 6

Sheet 3

Sheet 6

Sheet 3

Sheet 13

Sheet 5

Sheet 9

Sheet 10

Sheet 1

Sheet 11

Sheet 2

Sheet 12

Sheet 7 & 12

Sheet 12

PURGE

PUSHER DOWN

PUSHER UP

QUICK RAISE

RADIO REMOTE

RAISE BED

RAISE BOX

RAISE IDLE

RAISE LIFT

RAMP ENABLE

REAR

REAR A/C

REAR ALERT

REAR ALLEY

REAR CAMERA

REAR CENTER

REAR CHUTE

REAR CNTRL

REAR COMPT

REAR DELIVRY

REAR FLASHR

REAR FLOOD

REAR GATE

REAR LIGHT

REAR MOOD

REAR SCENE

REAR STROBE

REAR SWEEP

REAR UNITY

REAR WARN

REAR WORK

REEL GATE

REFER FUEL

REFER TEMP

REGEN ON

REMOTE OVRIDE

RESET

Sheet 2

Sheet 1

Sheet 6

Sheet 1

Sheet 11

Sheet 1

Sheet 1

Sheet 12

Sheet 13

Sheet 1

Sheet 13

Sheet 6

Sheet 9

Sheet 9

Sheet 12

Sheet 8

Sheet 11

Sheet 10

Sheet 8

Sheet 8

Sheet 13

Sheet 8

Sheet 5

Sheet 3

Sheet 7

Sheet 12

Sheet 13

Sheet 13

Sheet 5

Sheet 5

Sheet 1

Sheet 5

Sheet 5

Sheet 7

Sheet 9

Sheet 7

Sheet 10


RETRACT

RF POWER

RIGHT ALLEY

RIGHT CEILING

RIGHT CENTER

RIGHT CHUTE

RIGHT COMPT

RIGHT COT

RIGHT DOME

RIGHT DOOR

RIGHT FLOOD

RIGHT FRONT

Sheet 8

Sheet 10

Sheet 1

Sheet 13

Sheet 5

Sheet 7

Sheet 6

Sheet 7

Sheet 11

Sheet 8

Sheet 1

Sheet 5


SECND WARN

SELF TEST

SENSOR POWER

SHAKER

SHRED POWER

SHUT DOWN

SIDE DELVRY

SIDE EVAC

SIDE GATE

SIDE WARN

SIREN

SIREN BRAKE

October 2012

Sheet 1

Sheet 6

Sheet 10

Sheet 3

Sheet 9

Sheet 9

Sheet 10

Sheet 7

Sheet 6

Sheet 1

Sheet 2

Sheet 2

SWIVEL DOWN

SWIVEL UP

TAG DOWN

TAG UP

TAIL GATE

TANK 1 CLOSED

TANK 1 OPEN

TANK 2 CLOSED

TANK 2 OPEN

TANK 3 CLOSED

TANK 3 OPEN

TANK 4 CLOSED

Sheet 9

Sheet 9

Sheet 3&12

Sheet 3&12

Sheet 8

Sheet 10

Sheet 10

Sheet 10

Sheet 10

Sheet 10

Sheet 10

Sheet 10




RIGHT HOSE

RIGHT PTO

RIGHT PTO ON

RIGHT READ

RIGHT REAR

RIGHT SCENE

RIGHT SPRAY

RIGHT SWEEP

RIGHT WARN

RIGHT WING

ROAD MODE

ROOF AC

ROOF LIGHT

ROTO LIGHT

RR DUMP CLOSE

RR DUMP OPEN

RR LF ARM DN

RR LF ARM UP

RR OW NOZZLE

RR RT ARM DN

RR RT ARM UP

RT DUMP CLOSE

RT DUMP OPEN

RT WEED SEEKER

SANDER

SANDER ROTO

Sheet 12

Sheet 12

Sheet 12

Sheet 11

Sheet 5

Sheet 1

Sheet 10

Sheet 12

Sheet 1

Sheet 3

Sheet 6

Sheet 13

Sheet 1

Sheet 2

Sheet 6

Sheet 6

Sheet 6

Sheet 6

Sheet 7

Sheet 6

Sheet 6

Sheet 6

Sheet 6

Sheet 6

Sheet 3

Sheet 3

SIREN HORN

SLOW FLASH

SLOW IDLE

SPARE

SPOT LIGHT

SPRAY FILL

SPREDR

SPREDR LIGHT

START

START GEN

START REGEN

STEP HEATER

STEP LIGHT

STEP LT CANCEL

STOP

STOP CONFIRM

STOP GEN

STOP HYBRID

STOP REGEN

STOP REQST

STROBE BAR

STROBE LIGHT

SUMMER

SUSP DUMP

SUSP KNEEL

SUSP RAISE

Sheet 2

Sheet 9

Sheet 10

Sheet 3

Sheet 4

Sheet 7

Sheet 5

Sheet 2

Sheet 6

Sheet 7

Sheet 12

Sheet 7

Sheet 1

Sheet 1

Sheet 6

Sheet 13

Sheet 7

Sheet 9

Sheet 12

Sheet 13

Sheet 1

Sheet 1

Sheet 8

Sheet 7

Sheet 13

Sheet 7 & 13

TANK 4 OPEN

TANK 5 CLOSED

TANK 5 OPEN

TANK 6 CLOSED

TANK 6 OPEN

TANK 7 CLOSED

TANK 7 OPEN

TANK 8 CLOSED

TANK 8 OPEN

TANK EMPTY

TANK HEAT

TANK VENTS

TARP UNWIND

TARP WIND

T-GATE DOWN

T-GATE UP

THROTL

TIRE PRES

TOOL CIRCUIT

TOWER DOWN

TOWER POWER

TOWER UP

TRAFFC CNTRL

TRAILER ACTIVE

TRANS HEAT

TRAP LIGHT

Sheet 10

Sheet 10

Sheet 10

Sheet 10

Sheet 10

Sheet 10

Sheet 10

Sheet 10

Sheet 10

Sheet 5

Sheet 9

Sheet 10

Sheet 3

Sheet 3

Sheet 8

Sheet 8

Sheet 13

Sheet 9

Sheet 13

Sheet 10

Sheet 7

Sheet 10

Sheet 10

Sheet 8

Sheet 10

Sheet 3


TRUCK

TTP CLOSED

TTP OPEN

TV MONITOR

U WING NOZZLE

UNLOAD

UNLOCK

UNLOCK DOOR

UNLOCK WINDOW

UP

UPPER PLW LTS

UPPER WARN

UPPER WORK

VAC OFF

Sheet 2

Sheet 12

Sheet 12

Sheet 5

Sheet 7

Sheet 11

Sheet 9

Sheet 4

Sheet 9

Sheet 5

Sheet 13

Sheet 1

Sheet 1

Sheet 12

VAC ON

VACUUM

VAN DOWN

VAN UP

VAPOR PUMP

VAPOR VALVE

VOLUME

WARN 1

WARN 2

WARN 3

WATER

WATER CANNON

WATER J-STICK

WATER PUMP

Sheet 12

Sheet 8

Sheet 5

Sheet 5

Sheet 11

Sheet 7

Sheet 10

Sheet 12

Sheet 12

Sheet 12

Sheet 8

Sheet 13

Sheet 13

Sheet 5

WELDER LIGHT

WHEEL CHAIR

WHEEL CHOCK

WIG WAG

WIGWAG FLASH

WINCH

WINCH IN

WINCH OUT

WINDOW AJAR

WING LIGHTS

WINTER

WINTER SUMMER

WORK LIGHT

XFER CASE

Sheet 13

Sheet 5

Sheet 6

Sheet 2

Sheet 9

Sheet 3

Sheet 7

Sheet 7

Sheet 11

Sheet 7

Sheet 8

Qty of 2

Sheet 8

Sheet 1

Sheet 3


October 2012





October 2012 f_101





October 2012 f_102





October 2012 f_103




f_104


October 2012


POWER FEATURES USING REMOTE POWER

MODULES

POWER FEATURES USING REMOTE POWER MODULES

■

DUAL OUTPUT LATCHED SWITCH 40 AMPS

This feature provides one two-positioned latched rocker switch that controls one auxiliary load with a 40 AMP maximum. This feature was designed for owners who have a load that requires a RPM output of greater than

20 AMPS. Two RPM outputs are required, and power would only be available in IGN or accessory key-state.

60ACE

BDY INTG, SWITCH DUAL OUTPUT 2 Position Latched Rocker, Backlit, with “ON” Indicator Mounted on Dash, for 1; Auxiliary Load 40 AMP Maximum; Power Available Only in “Ignition (IGN)” or “Accessory” Position;

Controls Two Remote Power Modules (RPMs) (requires two RPM outputs)

Through programmable parameters, the owner can send the amount of current desired to the two outputs. This allows the owner to customize the amperage supplied to the RPM output based on their specific needs.

* Please use the Diamond Logic

®

Builder software to determine pin and switch locations for RPM inputs and outputs and to set programmable parameters (refer to pin and switch location section)

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

*Software feature codes can be added through the Diamond Logic


®

®


Builder software.

Required software feature code: 595AKA

Software features that must be removed: NONE

The TEM_Dual1_Output1_Fuse_Param is programmed to allow a specified amount of current to go to the

RPM output 1. If the current exceeds this specified amount, the virtual fusing shuts the output off.

The TEM_Dual1_Output2_Fuse_Param is programmed to allow a specified amount of current to go to the

RPM output 2. If the current exceeds this specified amount, the virtual fusing shuts the output off.

Table 101

Parameter ID

TEM_Dual1_

Output1_

Fuse_Param

1988

TEM_Dual1_

Output2_

Fuse_Param

1989

Description


Dual 1 Output 1 is allowed to source before the virtual fusing turns the output off.


Dual 1 Output 2 is allowed to source before the virtual fusing turns the output off.

Default

20

20

Units

A

A

Min

0

0

Max

20

20

Set

0.1

0.1

W

IRING

I

NFORMATION

This feature requires the customer to supply the wiring that runs from the pins labeled

DUAL_OUTPUT_SWITCH_Output1 and DUAL_OUTPUT_SWITCH_Output2, on the brown 8-pin RPM output connector, to the customer-installed feature that requires the load.


September 2012



MODULES

f_105

T

ESTING

1. Depress the switch.

2. Verify that the desired voltage is being pulled from the RPM outputs labeled

DUAL_OUTPUT_SWITCH_Output1 and DUAL_OUTPUT_SWITCH_Output2 (as programmed by the

Diamond Logic

®

Builder software).

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature code 595AKA MUST be enabled using the Diamond Logic

®


•

Programmable parameters must be set using the Diamond Logic

®


•

Install the switch in the in-cab switch pack

•

Customer must supply wiring from the RPM output

■

ONE INTERLOCKED LATCHED SWITCH DISENGAGE AT 30 MPH

This feature provides a 2-position latched rocker switch that controls one auxiliary load of 20 AMPS maximum and requires one RPM output. Output will be defaulted to turn off when vehicle speed reaches 30 MPH. The output will only be available in IGN or accessory key-state. This feature is used for applications such as a rear shining light. If the operator forgets to turn the light off before he drives away, the light will shut off when the driver hits 30 MPH.

The owner can interlock the switch with certain programmable conditions. These conditions can be set as programmable parameters using the Diamond Logic® Builder software. These parameters are listed and explained below.

60ACG

BDY INTG, SWITCH, INTERLOCKED 2 Position Latched Rocker, Backlit, with “ON” Indicator Mounted on

Dash for 1; Auxiliary Load 20 Ampere (AMP) Maximum; Output will disengage when Vehicle Exceeds 30 MPH,

Programmable; Power Available Only in “Ignition (IGN)” or “Accessory” Position (requires one Remote Power

Module (RPM) output)


®

Builder software to determine pin and switch locations for RPM inputs and outputs and to set programmable parameters (refer to pin and switch location section).


September 2012



MODULES

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

*Software feature codes can be added through the Diamond Logic


®

®


Builder software.

14

15

16

Required software feature code: 595AKB


Setting

6

7

4

5

8

9

2

3

0

1

10

11

12

13

* TEM_Aux1_Misc_Interlock_Param

This parameter (TEM_Aux1_Misc_Interlock_Param) is the master parameter for this feature. The setting for this parameter selects the interlocking condition for the output. The following table indicates which interlocking condition corresponds to which setting for the parameter. To select the interlocking condition simply set the value of this parameter to the corresponding setting on the table.

Table 102

Interlocking Condition

Apply no interlocks to this output

Activate this output when the park brake is set AND the switch is on

Activate this output when the park brake is not set AND the switch is on

Activate this output when a door is open AND the switch is on

Activate this output when all doors are closed AND the switch is on

Activate this output when the PTO is engaged AND the switch is on (Requires a PTO feature)

Activate this output when the PTO is not engaged AND the switch is on (Requires a PTO feature)

Activate this output when the engine is running AND the switch is on

Activate this output when the engine is not running AND the switch is on

Activate this output when the vehicle speed exceeds the value set in TEM_Aux_1_Speed_Interlock_Param AND the switch is on

Activate this output when the vehicle speed is less than the value set in TEM_Aux_1_Speed_Interlock_Param AND the switch is on

Activate this output when the vehicle is stopped AND the switch is on

Activate this output when the vehicle is moving AND the switch is on

Activate this output when the transmission gear is higher than TEM_Aux1_Gear_Interlock_Param AND the switch is on (Requires

Automatic Transmission)

Activate this output when the transmission gear is lower than TEM_Aux1_Gear_Interlock_Param AND the switch is on (Requires


Activate this output when the transmission is in neutral AND the switch is on (Requires Automatic Transmission)

Activate this output when the transmission is not in neutral AND the switch is on (Requires Automatic Transmission)


September 2012



MODULES

Drop Down List of Possible Parameters for TEM_Aux1_Misc_Interlock_Param

f_106

* TEM_Aux1_Interlock_Latches_Off

Normally, if the output is deactivated because the interlocking condition is not met, the output will re-activate as soon as the interlocking condition is re-established as long as the switch is still on. If this behavior is not desirable, the parameter TEM_Aux1_Interlock_Latches_Off parameter can be set. When it is set and the output is deactivated because the interlocking condition is not met, the output will not reactivate when the interlocking condition is re-established even if the switch is still on. To re-activate the output in this case, the switch must be re-cycled (flipped off and then on again).

* TEM_Aux1_Speed_Interlock_Param

If TEM_Aux1_Misc_Interlock_Param is set to 9 or 10, the speed-interlock parameter

(TEM_Aux1_Speed_Interlock_Param) must also be set. This parameter must be set to the actual speed to use in the condition selected by TEM_Aux1_Misc_Interlock_Param (default unit for this parameter is MPH). The speed parameter is only used if TEM_Aux1_Misc_Interlock_Param is set to 9 or 10.

Example: If you want the output to only come on when the vehicle is traveling over 15 MPH, you would set

TEM_Aux1_Misc_Interlock_Param to 9 and set TEM_Aux1_Speed_Interlock_Param to 15 MPH.

* TEM_Aux1_Gear_Interlock_Param

If TEM_Aux1_Misc_Interlock_Param is set to 13 or 14 and the vehicle has an automatic transmission, the gear-interlock parameter (TEM_Aux1_Gear_Interlock_Param) must also be set. This parameter must be set to the transmission gear to use in the condition selected by TEM_Aux1_Misc_Interlock_Param. The transmission gear is set as follows:


September 2012



MODULES

Table 103

Setting

125

126

127

128

125 + x

Transmission Gear

Transmission in Neutral

Transmission is in the 1st forward gear

Transmission is in the 2nd forward gear

Transmission is in the 3rd forward gear

Transmission is in the xth forward gear

124

123

125 – y

Transmission is in the 1st reverse gear

Transmission is in the 2nd reverse gear

Transmission is in the yth reverse gear

The transmission gear parameter is only used if TEM_Aux1_Misc_Interlock_Param is set to 13 or 14.

Example: For the output to only come on when the vehicle transmission is in a reverse gear, set

TEM_Aux1_Misc_Interlock_Param to 10 and TEM_Aux1_Gear_Interlock_Param to 125.

* TEM_Aux1_w_Ilocks_Output_Fuse

This parameter is the value at which the output will fuse (shut off). The allowable values are from 1 to 20

Amperes.

Table 104

Parameter

TEM_Aux1_

Interlock_

Latches_Off

TEM_Aux1_

Speed_

Interlock_

Param

TEM_Aux1_

Gear_

Interlock_

Param

TEM_Aux1_ w_Ilocks_

Output_Fuse

TEM_Aux1_

Misc_ Interlock_

Param

ID

2006

2007

Description

If this is set, when the output is turned off due to an interlock, it will remain off until the switch is recycled.

The speed parameter for the TEM Aux

#1 with Interlocks feature.

2008

2009

2033

The transmission gear parameter for the

TEM Aux #1 with Interlocks feature (124 is reverse, 125 is neutral, 126 is 1st gear, 127 is second gear etc.).

Fuse parameter for the TEM Single output with interlocks feature.

Miscellaneous or control parameter used for setting the interlock for the auxiliary 1 with interlocks.

Default

Off

30

0

20

10

Units

On/Off

Mph

Number

A

List

Min

0

0

0

Max

100

250

20

Set

1

1

0.1

W

IRING

I

NFORMATION

The wiring out of the pin labeled INTERLOCKED_SWITCH_AUX1_Output on the Brown 8-pin RPM output connector is customer supplied.


September 2012



MODULES

f_107

T

ESTING

2. Verify that the RPM output labeled INTERLOCKED_SWITCH_AUX1_Output is obtaining the desired voltage (as programmed by the Diamond Logic

®

Builder software).

3. Verify the functionality of the 30 Mph interlock by violating the parameter and determine that the output shuts off.

4. Test all other interlocks by violating the programmable parameters to see if the output shuts off.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature code 595AKB MUST be enabled using the Diamond Logic

®


•

Programmable Parameters must be set using the Diamond Logic

®

Builder software (see local dealer)

•

The 2-position latched rocker switch must be installed in the in-cab switch pack

•

Customer must install the wiring from the RPM output.


September 2012



MODULES

■

TWO INTERLOCKED LATCHED SWITCH DISENGAGE AT 30 MPH

This feature provides TWO 2-position Latched Rocker switches that control two auxiliary loads, each having a

20 AMP maximum and requiring a total of two RPM outputs. Outputs are defaulted to disengage when vehicle speed reaches 30 MPH. The outputs will only be available in IGN or accessory key-state. This feature is used for applications such as a rear shining light. If the operator forgets to turn the light off before he drives away, the light will shut off when the driver hits 30 MPH.

The owner can interlock the switch with certain programmable conditions. These conditions can be set as programmable parameters using the Diamond Logic

®

Builder software. These parameters are listed and explained below.

60ACH

BDY INTG, SWITCH, INTERLOCKED (2) 2 Position Latched Rockers, Backlit, with “ON” Indicator Mtd on

Dash, for 2; Auxiliary Load each 20 AMP Maximum; Outputs will Disengage when Vehicle Exceeds 30 MPH,

Programmable; Power Available Only in “IGN” or “Accessory” Position (requires two RPM outputs)

** This feature includes two copies of the functionality provided by 60ACG; e.g., two outputs with two switches.

Each one of these outputs is exactly the same as that provided by 60ACG. The two outputs in this feature are completely autonomous (independent of each other). Each of the two outputs has its own set of five parameters as is mentioned in the description for 60ACG.


®


S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

*Software feature codes can be added through the Diamond Logic parameters are also programmable through the Diamond Logic

®

®


Builder software.

Required software feature codes: 595AKB, 595AKC





September 2012



MODULES

Table 105

Setting

6

7

4

5

8

2

3

0

1

9

10

11

12

13

14

15

16











Activate this output when the vehicle speed exceeds the value set in

TEM_Aux_1_Speed_Interlock_Param AND the switch is on

Activate this output when the vehicle speed is less than the value set in




Activate this output when the transmission gear is higher than TEM_Aux1_Gear_Interlock_Param AND the switch is on (Requires Automatic Transmission)

Activate this output when the transmission gear is lower than TEM_Aux1_Gear_Interlock_Param AND the switch is on (Requires Automatic Transmission)

Activate this output when the transmission is in neutral AND the switch is on (Requires Automatic

Transmission)

Activate this output when the transmission is not in neutral AND the switch is on (Requires Automatic

Transmission)


f_106


September 2012



MODULES






Example: For the output to only come on when the vehicle is traveling over 15 MPH, set




Table 106

Setting

125



126

127

128

125 + x





124

123

125 – y









Amperes.




September 2012



MODULES

Table 107

Setting

2

3

0

1

4

5

6

7

8

9

10

11

12

13

14

15

16








Activate this output when the PTO is not engaged AND the switch is on

(Requires a PTO feature)









Activate this output when the transmission gear is higher than

TEM_Aux1_Gear_Interlock_Param AND the switch is on (Requires Automatic

Transmission)

Activate this output when the transmission gear is lower than

TEM_Aux1_Gear_Interlock_Param AND the switch is on (Requires Automatic

Transmission)

Activate this output when the transmission is in neutral AND the switch is on

(Requires Automatic Transmission)

Activate this output when the transmission is not in neutral AND the switch is on (Requires Automatic Transmission)


f_106


September 2012



MODULES










Table 108

Setting

125



126

127

128

125 + x





124

123

125 – y





Example: For the output to only come on when the vehicle transmission is in a reverse gear, you would set




Amperes.


September 2012



MODULES

Table 109

Parameter

TEM_Aux1_

Interlock_

Latches_Off

TEM_Aux1_

Speed_

Interlock_

Param

TEM_Aux1_

Gear_

Interlock_

Param

TEM_Aux1_ w_Ilocks_

Output_Fuse

TEM_Aux1_

Misc_ Interlock_

Param

TEM_Aux2_

Interlock_

Latches_Off

TEM_Aux2_

Speed_

Interlock_

Param

TEM_Aux2_

Gear_

Interlock_

Param

TEM_Aux2_ w_Ilocks_

Output_Fuse

TEM_Aux2_

Misc_ Interlock_

Param

ID

2006

2007

2008

2009

2033

2010

2011

2012

2013

2034

Description


The speed parameter for the TEM Aux #1 with Interlocks feature.

The transmission gear parameter for the TEM

Aux #1 with Interlocks feature (124 is reverse,

125 is neutral, 126 is 1st gear, 127 is second gear etc.).




The speed parameter for the TEM Aux #2 with Interlocks feature.






Default

Off

30

0

20

10

Off

30

0

20

10

Units

On/Off

Mph

Number

A

List

On/Off

Mph

Number

A

List

Min

0

0

0

0

0

0

Max

100

250

20

100

250

20

Set

1

1

0.1

1

1

0.1

W

IRING

I

NFORMATION




September 2012



MODULES

f_110

T

ESTING

2. Verify that the RPM output labeled INTERLOCKED_SWITCH_AUX1_Output is obtaining the desired voltage (as programmed by the Diamond Logic

®

Builder software).


4. Test all other interlocks can by violating the programmable parameters to see if the output shuts off

5. Depress the second switch.

6. Verify that the RPM output labeled INTERLOCKED_SWITCH_AUX2_Output is obtaining the desired voltage (as programmed by the Diamond Logic® Builder software).

7. Verify the functionality of the 30 MPH interlock by violating the parameter and determine that the output shuts off.


H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature code 595AKB and 595AKC MUST be enabled using the Diamond Logic

®

Builder software

(see local dealer).

•


®


•

The 2-position latched rocker switch must be installed in the in-cab switch pack

•

Customer must install the wiring from the RPM outputs.


September 2012



MODULES

■

ONE MOMENTARY ROCKER SWITCH/REMOTE SWITCH CAPABILITY

This feature provides a three-way switch control function for a RPM output. An in-cab, 3-position momentary switch is connected to a RPM output. In addition, a customer-supplied, remote-mounted momentary switch may be used to control the same RPM output. This switch must be active at 12 volts and must use Ground

(GND) to deactivate the output. Thus, a three-way switch control action may be performed with these two switch inputs. The RPM output may be turned off or on from either switch; however, an off command from either switch takes precedence and will turn the RPM output off. This feature is useful when a lamp or other load requires control from both in the cab and from a remote location on the body.

60ACS

BDY INTG, SWITCH MOMNTRY 3POS Rocker, Backlit, with “ON” Indicator Mounted on Dash, Latching

Software, for 1 Auxiliary Load 20 amp. Maximum; Power Available Only in “Ignition” or “Accessory” Position,

Output Also Controlled by a Customer Remote Mounted Switch (requires 1 Remote Power Module input and 1 output)

The in-cab switch provides a green lamp in the top section of the switch to indicate when the RPM output is on.

The RPM provides an active high output that will source up to 20 AMPS at battery voltage levels. The output current level may be limited through programmable parameters between .1 and 20 AMPS in .1 AMP increments. This virtual fusing level is controlled in software and mimics the performance of an SAE fuse.

The RPM output may be activated with the in-cab switch provided that the IGN key is in the accessory or IGN position. The RPM output may also be activated with the remote switch input with IGN key off or on. It is important to turn off RPM outputs that have been enabled remotely before leaving a parked vehicle with the

IGN key off. Otherwise, the system will remain active and drain the batteries.

60AAA or 60AAB is a prerequisite feature that must be ordered along with 60ACS. 60ACS uses a single momentary switch in place of one of the latching switches that is provided with 60AAA and 60AAB. For example, instead of the six latching switches that are provided with 60AAA, a vehicle with 60ACS will have a switch pack of five latching switches and one momentary switch.


®


S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

*Software feature codes can be added through the Diamond Logic® Builder. Programmable parameters are also programmable through the Diamond Logic

®

Builder.

Required software feature code: 595AKD

Conflicts with software features: NONE

The TEM_Aux1_w_Ext_Sw_Fuse_Level parameter sets the amount of current that flows through auxiliary output 1. If current rises above this level, fusing takes place and the RPM output is shut down.

By turning the TEM_Aux1_w_Ext_Switch_Init_State parameter on, the Body Controller (BC) forces the RPM output to be on whenever the truck’s key-state is turned from off to accessory or IGN.


September 2012



MODULES

Table 110

Parameter

TEM_Aux1_ w_Ext_Sw_

Fuse_Level

TEM_Aux1_ w_Ext_Switch_

Init_State

ID

1998

2032

Description

This is the level above which the RPM will fuse the TEM Auxiliary output with external switch.

This programmable parameter sets the initial State of RPM channel used with

TEM Auxiliary with external switch #1.

Default

20

Off

Units

A

On/Off

Min

0

NA

Max

20

NA

Step

0.1

NA

W

IRING

I

NFORMATION

Customer may mount a switch and install the wiring into the pin labeled 3POS_SWITCH_AUX1_Input in the black 23-pin RPM input connector. Installation of the remote switch is optional with this feature (see Diamond

Logic

®

Builder for input pin location).

Customer must install wiring from the pin labeled 3POS_SWITCH_AUX1_Output brown 8-pin RPM output connector to the electrical load that is to be controlled (see Diamond Logic

®

Builder for output pin location).

f_111

T

ESTING

1. This feature allows the customer the ability to activate the output when the IGN key is turned from OFF to

ACCESSORY or IGN. This functionality is obtained by turning programmable parameters

(TEM_Aux1_w_Ext_Switch_Init_State ON.

2. Activate the first remote Body Builder installed switch to 12 volts by using a momentary switch action.

3. Verify that the RPM output labeled 3POS_SWITCH_AUX1_Output is providing the battery volts at rated current levels (as programmed in Diamond Logic® Builder).

4. Verify that the green switch indicator light comes on.

5. Verify that the RPM input labeled 3POS_SWITCH_AUX1_Input is receiving battery volts from the customer-mounted switch (as programmed in Diamond Logic

®

Builder).

6. Deactivate the first remote Body Builder installed switch by providing a momentary switch action to GND.


September 2012



MODULES

7. Verify that the RPM output goes OFF.

8. Activate the in-cab switch.

9. Verify that the RPM output labeled 3POS_SWITCH_AUX1_Output is providing the battery volts (as programmed in Diamond Logic

®

Builder).


11. Deactivate the in-cab switch.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Select software feature code 595AKD using Diamond Logic

®

Builder (see local dealer).

•

Programmable Parameters must be set using the Diamond Logic

®

Builder (see local dealer)

•

The 3-position momentary switch with latching software must be installed in the in-cab switch pack.

•

The customer must install wiring from the RPM output to the load they wish to control.

•

The customer may mount a remote switch and install the wiring into the RPM input.

■

TWO MOMENTARY ROCKER SWITCHES/REMOTE SWITCH CAPABILITY

This feature provides three-way switch control function for two RPM outputs. Each RPM output is controlled by an in-cab, 3-position momentary switch and a 3-position momentary Body Builder-installed, remote-mounted switch. These customer-installed, remote-mounted switches must be active at 12 volts and must use GND to deactivate the output. Each in-cab, 3-position momentary switch is connected to a RPM output. In addition, each customer-supplied, remote-mounted momentary switch may be used to control the respective RPM outputs. Thus, three-way switch control action may be performed. The RPM outputs may be turned off or on from either the respective in-cab switch or the respective Body Builder switch; however, an off command from either switch takes precedence and will turn the RPM output off. This feature is useful when a lamp or other load requires control from both in the cab and from a remote location on the body.

The in-cab switches provide green lamps in the top section of the switches to indicate when the RPM outputs are on. The RPM provides active high outputs that will source up to 20 AMPS at battery voltage levels. The output current level may be limited through programmable parameters between .1 and 20 AMPS in .1 AMP increments. This virtual fusing level is controlled in software and mimics the performance of an SAE fuse.

The RPM outputs may be activated with the respective in-cab switches provided that the IGN key is in the accessory or IGN position. The RPM outputs may also be activated with the remote switch inputs with IGN key off or on. It is important to turn off RPM outputs that have been enabled remotely before leaving a parked vehicle with the IGN key off. Otherwise, the system will remain active and drain the batteries.

60ACT

BDY INTG, SWITCH MOMNTRY 3POS Rocker, Backlit, with “ON” Indicator Mounted on Dash, Latching

Software, for 2; Auxiliary Load 20 AMP Maximum; Power Available Only in “IGN” or “Accessory” Position,

Output Also Controlled by a Customer Remote-Mounted Switch (requires two RPM inputs and two outputs)

60AAA or 60AAB is a prerequisite feature that must be ordered along with 60ACT. 60ACT uses two momentary switches in place of two latching switches that are provided with 60AAA and 60AAB. For example, instead of the six latching switches that are provided with 60AAA, a vehicle with 60ACT will have a switch pack of four latching switches and two momentary switches.


®

Builder to determine pin and switch locations for RPM inputs and outputs and to set programmable parameters (refer to pin and switch location section)


September 2012



MODULES

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

*Software feature codes can be added through Diamond Logic

®

Builder. Programmable parameters are also programmable through Diamond Logic® Builder.

Required software feature code: 595AKE


The TEM_Aux1_w_Ext_Sw_Fuse_Level parameter sets the amount of current that flows through Auxiliary output 1. If current rises above this level, fusing takes place and the RPM output is shut down.

By turning the TEM_Aux1_w_Ext_Switch_Init_State parameter on, the BC forces the RPM auxiliary output 1 to be on whenever the truck’s key-state is turned from off to accessory or IGN.

The TEM_Aux2_w_Ext_Sw_Fuse_Level parameter sets the amount of current that flows through auxiliary output 2. If current rises above this level, fusing takes place and the RPM output is shut down.


Table 111

Parameter

TEM_Aux1_ w_Ext_Sw_

Fuse_Level


Init_State

ID

1998

2032

TEM_Aux2_ w_Ext_Sw_

Fuse_Level


Init_State

2106

2142

Description

This is the level above which the

RPM will fuse the TEM Auxiliary output with external switch.

This programmable parameter sets the initial State of RPM channel used with TEM Auxiliary with external switch #1.


RPM will fuse the TEM Auxiliary output #2 with external switch.


Default

20

Off

20

Off

Units

A

On/Off

A

On/Off

Min

0

NA

0

NA

Max

20

NA

20

NA

Step

0.1

NA

0.1

NA

W

IRING

I

NFORMATION

•


Logic

®


•


Logic

®


•


®


•


®



September 2012



MODULES

f_112

T

ESTING

1.

This feature allows the customer the ability to activate the output when the IGN key is turned from off to accessory or IGN. This functionality is obtained by turning the programmable parameters

(TEM_Aux1_w_Ext_Switch_Init_State and TEM_Aux2_w_Ext_Switch_Init_State) on.


3. Verify that the RPM output labeled 3POS_SWITCH_AUX1_Output is providing the battery volts at rated current levels (as programmed in Diamond Logic

®

Builder).



®

Builder).

6. Deactivate the first remote Body Builder-installed switch by providing a momentary switch action to GND.


8. Activate the first in-cab switch.


®

Builder).


11. Deactivate the first in-cab switch.

12. Activate the second remote Body Builder installed switch to 12 volts by using a momentary switch action.


®

Builder).



®

Builder).


September 2012



MODULES

16. Deactivate the second remote Body Builder installed switch by providing a momentary switch action to

GND.


18. Activate the second in-cab switch.


®

Builder).


21. Deactivate the second in-cab switch.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Select software feature code 595AKE using Diamond Logic

®


•

Programmable parameters must be set using Diamond Logic

®


•


•

The customer must install wiring from the RPM outputs to the loads that are to be controlled

•

The customer may mount a switch (12 volts active and GND de-active) and install the wiring into the RPM inputs (Use the Diamond Logic® Builder software to determine switch and pin location assignments).

■

THREE MOMENTARY ROCKER SWITCHES/REMOTE SWITCH CAPABILITY

60ACU

BDY INTG, SWITCH MOMNTRY 3POS (3) Rocker, Backlit, with “ON” Indicator Mounted on Dash, Latching

Software, for 3; Auxiliary Load 20 AMP Maximum; Power Available Only in “IGN” or “Accessory” Position,

Output Also Controlled by a Customer Remote-Mounted Switch (requires three RPM inputs and three outputs)

This feature provides three-way switch control function for three RPM outputs. Each RPM output is controlled by an in-cab, 3-position momentary switch and a 3-position momentary Body Builder-installed, remote-mounted switch. These customer-installed, remote-mounted switches must be active at 12 volts and must use GND to deactivate the output. Each in-cab, 3-position momentary switch is connected to a RPM output. In addition, each customer-supplied, remote-mounted momentary switch may be used to control the respective RPM outputs. Thus, three-way switch control action may be performed. The RPM outputs may be turned off or on from either the respective in-cab switch or the respective Body Builder switch; however, an off command from either switch takes precedence and will turn the RPM output off. This feature is useful when a lamp or other load requires control from both in the cab and from a remote location on the body.

The in-cab switches provide green lamps in the top section of the switches to indicate when the RPM outputs are on. The RPM provides active high outputs that will source up to 20 AMPS at battery voltage levels. The output current level may be limited through programmable parameters between .1 and 20 AMPS in.1 AMP increments. This virtual fusing level is controlled in software and mimics the performance of an SAE fuse.

The RPM outputs may be activated with the respective in-cab switches provided that the IGN key is in the accessory or IGN position. The RPM outputs may also be activated with the remote switch inputs with IGN key off or on. It is important to turn off RPM outputs that have been enabled remotely before leaving a parked vehicle with the IGN key off. Otherwise, the system will remain active and drain the batteries.

60AAA or 60AAB is a prerequisite feature that must be ordered along with 60ACU. 60ACU uses three momentary switches in place of three latching switches that are provided with 60AAA and 60AAB. For example, instead of the six latching switches that are provided with 60AAA, a vehicle with 60ACU will have a switch pack of three latching switches and three momentary switches.


®



September 2012



MODULES

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

*Software feature codes can be added through theDiamond Logic also programmable through the Diamond Logic

®

Builder.

®

Builder. Programmable Parameters are

Required software feature code: 595AKG








Table 112

Parameter

TEM_Aux1_ w_Ext_Sw_

Fuse_Level


Init_State

ID

1998

2032

TEM_Aux2_ w_Ext_Sw_

Fuse_Level


Init_State

2106

2142

TEM_Aux3_ w_Ext_Sw_

Fuse_Level


Init_State

2107

2143

Description










Default

20

Off

20

Off

20

Off

Units

A

On/Off

A

On/Off

A

On/Off

Min

0

NA

0

NA

0

NA

Max

20

NA

20

NA

20

NA

Step

0.1

NA

0.1

NA

0.1

NA

W

IRING

I

NFORMATION

•


Logic

®


•


Logic

®



September 2012



MODULES

•


Logic

®


•


®


•


®


•


®


f_113

T

ESTING

1. This feature allows the customer the ability to activate the output when the IGN key is turned from off to accessory or IGN. This functionality is obtained by turning programmable parameters

(TEM_Aux1_w_Ext_Switch_Init_State, TEM_Aux2_w_Ext_Switch_Init_State or

TEM_Aux3_w_Ext_Switch_Init_State) on.



®

Builder).



®

Builder).


September 2012



MODULES

6. Deactivate the first remote Body Builder installed switch by providing a momentary switch action to GND.


8. Activate the first in-cab switch.


®

Builder).


11. Deactivate the first in-cab switch.

12. Activate the second remote Body Builder installed switch to 12 volts by using a momentary switch action.


®

Builder).



®

Builder).

16. Deactivate the second remote Body Builder installed switch by providing a momentary switch action to

GND.


18. Activate the second in-cab switch.


®

Builder).


21. Deactivate the second in-cab switch.

22. Activate the third remote Body Builder installed switch to 12 volts by using a momentary switch action.


®

Builder).



®

Builder).

26. Deactivate the third remote Body Builder installed switch by providing a momentary switch action to GND.


28. Activate the third in-cab switch.


®

Builder).


31. Deactivate the third in-cab switch.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Select software feature code 595AKG using Diamond Logic

®


•

Programmable parameters must be set using Diamond Logic

®


•


•

The customer must install wiring from the RPM outputs to the loads that are to be controlled

•

The customer may mount a switch (12 volts active and GND de-active) and install the wiring into the RPM inputs (use Diamond Logic

®

Builder to determine switch and pin location assignments).


September 2012


INDICATOR LIGHTS AND ALARMS


■

TWO INDICATOR LIGHTS AND AUDIBLE ALARMS PROGRAMMABLE MODE FOR

VARIOUS SWITCH ACTIONS (WASTE SOLUTION)

60AJC

BDY INTG, INDICATOR LIGHTS (2) One for Gate Open and One for Rear Alert, Includes Audible Alarm,

Programmable Mode for Various Switch Action (requires 2 Remote Power Module (RPM) inputs).

This feature provides a custom alarm package designed for the Refuse/Waste Applications. It provides both an audible and visual alarm for Gate Open and Rear Alert. Red indicator lights are located in prime viewing area of the driver in the switch pack. Audible alarm provides a second level of warning to the driver to indicate the status of these two equipment options.

The gate open indicator light is ON constant when the gate open input is active with the park brake set. If the park brake is released, with the gate open input active, the gate open indicator shall flash at 0.6-second intervals, accompanied by an audible alarm. Flexibility is provided through programmable parameters to establish whether the inputs are active high (12V) or active low (GND). See the Diamond Logic

®

Builder software to set programmable parameters.

Rear Alert provides the operator the capability to communicate from the rear of the vehicle to the cab. A customer-mounted switch is wired into the black 23-pin RPM input connector (See the Diamond Logic

®

Builder software for pin location). The ignition (IGN) switch must be in “ignition” for this feature to function.

Programmable Parameters allow the customer to establish whether the input is active at 12 volts or active at

GND. When the operator activates the customer-mounted switch, the rear alert light in the gauge cluster illuminates and an audible alarm sounds.

Switch Pack Display of “Gate Open” and “Rear

Alert” Indicator Lights

f_114


October 2012



P

ROGRAMMABLE

P

ARAMETERS

Required software feature codes: (595AMD or 595AMC**) and 595AKP

** Software feature code 595AMD should be used with an automatic transmission, whereas software feature code 595AMC should be used for a truck with a manual transmission.


The TEM_Tail_Gate_Input_Active_State parameter sets the voltage level that determines when the Gate Open alert should be active.

0 = Input active when open circuit

1 = Input active when grounded

3 = Input active when at 12V

When the TEM_Tail_Gate_Park_Brake_Inhibit parameter is turned ON, the tailgate alert will only alert when the

Park Brake is released.

The TEM_Tail_Gate_Transmission_Interlock parameter indicates the action of the tailgate alert based on transmission gear.

0 = Ignores Gear

1 = Alert will only activate if the transmission is NOT in reverse

2 = Alert will only activate if transmission is in reverse

3 = Alert will activate for the tailgate sensor or if the transmission is in reverse

The TEM_Rear_Alert_Input_Active_State parameter sets the voltage level that determines when the rear alert should be active.




The TEM_Tail_Gate_Alarm_Timeout parameter determines the length of time that the audible alarm will beep continuously after the gate is opened and the park brake is released. If this parameter is set to 0, the audible alarm will beep continuously as long as the gate open indicator is illuminated. Once the audible alarm has stopped continuous beeping (as set by the TEM_Tail_Gate_Alarm_Timeout parameter) and the gate open indicator remains illuminated, the TEM_Tail_Gate_Alarm_Period parameter determines the length of time between individual beeps of the audible alarm.


October 2012



Table 113

Parameter

TEM_Tail_

Gate_Input_

Active_State

TEM_Tail_

Gate_Park_

Brake_Inhibit

TEM_Tail_

Gate_

Transmission_

Interlock

TEM_Rear_

Alert_Input_

Active_State

TEM_Tail_

Gate_Alarm_

Period

TEM_Tail_

Gate_Alarm_

Timeout

ID

2160

2165

2167

2168

2172

2175

Off – Indicates a 0 is set in for this parameter

On – Indicates a 1 is set for the parameter

Description

This parameter is used to set the voltage level that indicates when the tail gate alert should be active.

Default

3

Units

List

When set, the tailgate alert will only alert if the park brake is not set.

Off On/Off

This parameter is used to determine how the tailgate alert acts based upon the transmission.

This parameter is used to set the voltage level that indicates when the rear alert should be active.

Once the audible alarm has stopped continuous beeping and the gate open indicator remains illuminated, this parameter determines the length of time between individual beeps of the audible alarm.

This parameter determines the length of time that the audible alarm will beep continuously. If this parameter is set to 0, the audible alarm will beep continuously as long as the gate open indicator is illuminated.

0

3

20

10

List

List s s

Min

0

0

10

10

Max

3

3

60

60

Step

1

1

W

IRING

I

NFORMATION

**If the truck has a manual transmission, to interlock indicator lights and alarm with the transmission, splice a wire off of the reverse light circuit and run that wire into a pin on the black 23-pin RPM input connector (see the

Diamond Logic

®

Builder software for correct pin and switch locations). This wire will indicate to the Body

Controller (BC) that the truck is in reverse. This is only required if the customer wishes to interlock the functionality of the indicator lights and audible alarm with reverse (and they have a manual transmission).

•

The customer must run a wire from the tailgate switch to the pin labeled Tail_Gate_Open_Input on the black

23-pin input connector on the RPM (See the Diamond Logic

®

Builder software for correct pin locations).

•

The customer must run a wire from the rear alert switch to the pin labeled Rear_Alert_Switch_Input on the black 23-pin input connector on the RPM (See the Diamond Logic

®



October 2012



f_115

T

ESTING

1. Set park brake.

3. Verify that the input labeled Tail_Gate_Open_Input is receiving the correct voltage (as programmed in the

Diamond Logic

®

Builder software).

4. Verify that the red “Gate Open” indicator light in the switch pack comes on.

5. Release park brake.

6. Verify that indicator light flashes and audible alarm sounds and works according to the set programmable parameters seen above.

8. Reset park brake.

9. Activate Rear Alert switch.

10. Verify that the input labeled Rear_Alert_Switch_Input is receiving the correct voltage (as programmed in the Diamond Logic

®

Builder software).

11. Verify that the red “Rear Alert” indicator light in the switch pack comes on and an audible alarm sounds.


October 2012



H

OW

T

O

A

DD

T

HIS

F

EATURE

For an Automatic Transmission

•

Requires Warning Assy. 3587024C1 and LED 3587031C1 be added to the switch pack if this feature is added aftermarket

•

Software feature codes 595AKP and 595AMD must be enabled using the Diamond Logic

®

Builder software

(see local dealer). NOTE: these features can be added individually in the field.

•

Set programmable parameters for software feature codes using the Diamond Logic

®

Builder software (See

Local Dealer).

•

Install the wiring from tailgate switch into a pin on the black 23-pin input connector on the RPM (See the

Diamond Logic

®

Builder software for pin locations).

•

Install the wiring from rear alert switch into a pin on the black 23-pin input connector on the RPM (See the

Diamond Logic

®


•

Customer must install indicator light labels in switch pack (indicator graphics or suitable substitutes can be used from the graphics sheets that come with the RPM kit).

F

OR A

M

ANUAL

T

RANSMISSION

•

Requires Warning Assy. 3587024C1 and LED 3587031C1 be added to the switch pack if this feature is added aftermarket.

•

Software feature codes 595AKP and 595AMC must be enabled using the Diamond Logic

®

Builder software

(see local dealer).

•


®


Local Dealer).

•

Install the wiring from tailgate switch into a pin on the black 23-pin input connector on the RPM (See the

Diamond Logic

®


•

Install the wiring from rear alert switch into a pin on the black 23-pin input connector on the RPM (See the

Diamond Logic

®


•

Splice a wire into the backup light circuit and run that wire into a pin on the black 23-pin input connector on the RPM (See the Diamond Logic

®


•

Customer must install indicator light labels in switch pack (indicator graphics or suitable substitutes can be used from the graphics sheets that come with the RPM kit).

■

BODY INTEGRATED, INDICATOR LIGHTS (UTILITY SOLUTIONS)

60AJD

BDY INTG, INDICATOR LIGHTS (2) One for Boom Out of Stow, One for Outriggers Deployed, Includes Audible

Alarm and Interlock to Parking Brake, Programmable Mode for Various Switch Actions (requires 2 RPM inputs)

This feature provides a custom alarm package designed for the Utility Application. It provides both an audible and visual alarm for Boom Out Of Stow and Outriggers Not Stowed. Red indicator lights are in viewing area of the driver in the switch pack. Audible alarm provides a second level of warning to the driver to indicate the status of these two equipment options. Indicator lights are ON constant when either the boom or outrigger inputs are active with the park brake set. If the park brake is released, with either input active, the respective indicator shall flash at 0.6-second intervals, accompanied by an audible alarm.


October 2012



Switch Pack Display of “Outrig Out” and “Boom Up”

f_116

P

ROGRAMMABLE

P

ARAMETERS

Required software feature codes: 595AKR, 595AKS

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

If the TEM_Boom_Not_Stowed_Alarm_Inhibit parameter is turned on, the audible alarm for the boom-not-stowed will be disabled.

If the TEM_Outrig_Deploy_Alarm_Inhibit parameter is turned on, the audible alarm for the outriggers deployed warning light will be disabled.

The TEM_Consol_Boom_Not_Stow_Param parameter sets the active state of the Remote Power Module Input connected to the Boom switch. This active state indicates when the Boom is out of stow.




The TEM_Consol_Outrig_Deployed_Param parameter sets the active state of the RPM input connected to the outrigger switch. This active state indicates when the outriggers are down.





October 2012



Table 114

Parameter

TEM_Boom_

Not_Stowed_

Alarm_Inhibit

TEM_Outrig_

Deploy_Alarm_

Inhibit

TEM_ Consol_

Boom_Not_

Stow_Param

TEM_Consol_

Outrig_

Deployed_

Param

ID

2061

2074

2150

2151



Description

If this parameter is set, the audible alarm for the boom-not- stowed warning light will be inhibited.

If this parameter is set, the audible alarm for the outriggers deployed warning light will be inhibited.

Default

Off

Off

Units

On/Off

On/Off

Active state for the RPM input connected to the boom switch(es)

1 List

Active state on the RPM input for the outriggers deployed warning light.

1 List

Min

0

0

Max

3

3

Step

W

IRING

I

NFORMATION

•

The customer must run a wire from the customer-mounted “Outriggers out of Stow” switch to the pin labeled

Outrig_Not_Stow_Input on the black 23-pin input connector on the RPM (see the Diamond Logic

®


•

The customer must run a wire from the customer-mounted “Boom out of Stow” switch to the pin labeled

Boom_Not_Stow_Input on the black 23-pin input connector on the RPM (see the Diamond Logic

®



October 2012



f_117

T

ESTING

1. Set the park brake.

2. Take boom out of stow.

3. Verify that the RPM input labeled Boom_Not_Stow_Input is receiving the correct active state voltage (as programmed in the Diamond Logic

®

Builder software).

4. Verify that the boom up indicator light is on constantly.

5. Take off the parking brake (with boom still out of stow).

6. Verify that the boom up indicator light is now flashing and the audible alarm is sounding.

7. Set park brake and put boom back in stow.

8. Put outriggers down.

9. Verify that the RPM input labeled Outrig_Not_Stow_Input is receiving the correct active state voltage (as programmed or the Diamond Logic

®

Builder software).

10. Verify that the outrig out indicator light is on constantly.

11. Take off the parking brake (with outriggers still down).

12. Verify that the outrig out indicator light is now flashing and the audible alarm is sounding.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Requires Warning Assy. 3587024C1 and LED 3587031C1 be added to the instrument cluster if this feature is added aftermarket.

•

Software feature codes 595AKR and 595AKS must be enabled using the Diamond Logic

®

Builder software

(see local dealer). NOTE: these features can be added individually in the field.

•

Set the programmable parameters for the required software feature codes using the Diamond Logic

®


•

Customer must install wiring from the customer-mounted boom switch into a pin on the black 23-pin RPM input connector (see the Diamond Logic

®



October 2012



•

Customer must install wiring from the customer-mounted outriggers switch into a pin on the black 23-pin

RPM input connector (see the Diamond Logic

®


•

Customer must install indicator light labels (indicator graphics or suitable substitutes can be used from the graphics sheets that come with the RPM kit).

■

DUMP BOX INDICATOR LIGHTS AND ALARM

60AJK

INDICATOR LIGHTS (2), One for Body Up, One for Gate Open, Includes Audible Alarm, Programmable Mode for Various Switch Actions (Requires 2 RPM Inputs).

This feature provides the operator of Dump Box Applications with visual and audible warning indications for a raised dump box body and open dump gate using Body Builder-installed switches. The visual indications that are provided for this feature are a “Body Up” light and a “Gate Open” light. Red indicator lights are located in prime viewing area of the driver in the switch pack. Audible alarm provides a second level of warning to the driver to indicate the status of these two equipment options.

The “Gate Open” indicator light is on constant when the gate open input is active with the park brake set. If the park brake is released, with the gate open input active, the gate open indicator shall flash at 0.6 second intervals, accompanied by an audible alarm. Flexibility is provided through programmable parameters to establish whether the inputs are active high (12V) or active low (GND). See the Diamond Logic

®

Builder software to set programmable parameters.

For both the “BODY UP” and “GATE OPEN” indications, the associated light will illuminate continuously and the associated audible alarm (default off) will sound when the corresponding input has entered an active state on the condition that the park brake is set and the vehicle speed is less than or equal to 10 MPH.

For both the “BODY UP” and “GATE OPEN” indications, the associated light will illuminate in a slow flashing manner and the associated audible alarm (default of five fast beeps) will sound when the corresponding input is in an active state and either the park brake has been released or the vehicle speed has exceeded 10 MPH.

Both the “BODY UP” and “GATE OPEN” lights will be off when the RPM input is inactive.


October 2012 f_118



S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature codes: 595AKT and 595AKU


The TEM_Body_Up_Input_Active_State parameter indicates the state that the BC will read as active for the customer-installed switch for the dump body up function (as it goes into the RPM input). This active state will be used to tell the BC when the dump body has been raised up.

The TEM_Tail_Gate_Input_Active_State parameter indicates the state that the BC will read as active for the customer-installed switch for the dump gate open function (as it goes into the RPM input). This active state will be used to tell the BC when the dump body has been raised opened.

The TEM_Body_Up_Alarm_Beeper parameter allows the customer to set the alarm type for the condition when the dump body has been raised (active) and either the park brake has been released or the vehicle speed has exceeded 10 MPH. The default alarm type is five fast beeps.

The TEM_Gate_Alarm_Beeper parameter allows the customer to set the alarm type for the condition when the dump gate has been opened (active) and either the park brake has been released or the vehicle speed has exceeded 10 MPH. The default alarm type is five fast beeps.

The TEM_Body_Up_Beeper parameter allows the customer to set the alarm type for the condition when the dump body has been raised (active) and both the park brake is set and the vehicle speed is equal to or less than 10 MPH. The default alarm type is off.

The TEM_Gate_Open_Beeper parameter allows the customer to set the alarm type for the condition when the dump gate has been opened (active) and both the park brake is set and the vehicle speed is equal to or less than 10 MPH. The default alarm type is off.

Table 115

Units Min Max Step Parameter

TEM_Body_

Up_Alarm_

Beeper

TEM_Body_

Up_Beeper

TEM_Body_

Up_Input_

Active_ State

TEM_Gate_

Alarm_ Beeper

TEM_Gate_

Open_ Beeper

TEM_Tail_

Gate_Input_

Active_State

ID

2259

Description

Allows the selection of one of four beeper cadences 0 = Off, 1 = 5 fast beeps, 2 = 3 slow beeps, 3 = continuous beeps

2260

207

Allows the selection of one of four beeper cadences 0 = Off, 1 = 5 fast beeps, 2 = 3

4 slow beeps, 3 = continuous beeps

2261

2262

2263

2160

This parameter selects the active state of the BODY UP RPM input. 0 = Open, 1 =

GND, 3 = 12 volts

Allows selection of one of four beeper cadences 0 = Off, 1 = 5 fast beeps, 2 = 3 slow beeps, 3 = continuous beeps

Allows the selection of one of four beeper cadences 0 = Off, 1 = 5 fast beeps, 2 = 3 slow beeps, 3 = continuous beeps

This parameter is used to set the voltage level that indicates when the tailgate alert should be active. 0 = Open, 1 = GND, 3 =

12V

Default

1

0

3

1

0

3

List

List

List

List

List

List

0

0

0

0

0

0

3

3

3

3

3

3

1

1

1

1

1

1


October 2012



f_119

W

IRING

I

NFORMATION

The customer must run a wire from the customer-mounted “Gate Open” switch to the pin labeled

Tail_Gate_Open_Input on the black 23-pin input connector on the RPM (see the Diamond Logic

®


The customer must run a wire from the customer-mounted “Body Up” switch to the pin labeled

TEM_Body_Up_Signal on the black 23-pin input connector on the RPM (see the Diamond Logic

®


T

ESTING

1. Set park brake.

3. Verify that the input labeled TEM_Tail_Gate_Input_Active_State input is receiving the correct voltage (as programmed in the Diamond Logic

®

Builder software).

4. Verify that the Red “Gate Open” indicator light in the switch pack comes on.

5. Release park brake.

6. Verify that indicator light flashes and audible alarm sounds and works according to the set programmable parameters seen above.


10. Verify that the input labeled TEM_Body_Up_Input_Active_State is receiving the correct voltage (as programmed in the Diamond Logic

®

Builder software).

11. Verify that the red “Body Up” indicator light in the switch pack comes on, and an audible alarm sounds.



October 2012



H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Requires Warning Assy. 3587024C1 and LED 3587031C1 be added to the instrument cluster if this feature is added aftermarket.

•

Software feature codes 595AKT and 595AKU must be enabled using Diamond Logic

®


Local Dealer). NOTE: these features can be added individually in the field.

•


®


Local Dealer).

•

Customer must install wiring from the customer-mounted body switch into a pin on the black 23-pin RPM input connector (see the Diamond Logic

®


•

Customer must install wiring from the customer-mounted tailgate switch into a pin on the black 23-pin RPM input connector (see the Diamond Logic

®


•


■

DASH INDICATOR LIGHTS

60AJR

BDY INTG, DASH INDICATOR LIGHT, Red (1)

60AJS


60AJT


60AJU


60AJZ

BDY INTG, DASH INDICATOR LIGHT, Yellow (1)

60AKA


60AKB


60AKC


60AJV

BDY INTG, DASH INDICATOR LIGHT, Green (1)

60AJW


60AJX



October 2012



60AJY


These features give the ability to order the indicator lights and associated LED’s for body integration out of the factory. A total of eighteen indicators may be ordered in any combination with the exception that only one code may be ordered for each color. (For example, only one code from 60AJR, 60AJS, 60AJT, or 60AJU may be ordered to get 1, 2, 3 or 6 red lights). These indicators are installed in the Diamond Logic

®

switchpacks. They are not associated with any input or electrical function and must be used with Advanced Logic.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature codes:

Sales code 60AJR – 595BHL

Sales code 60AJS – 595BHM

Sales code 60AJT – 595BHN

Sales code 60AJU – 595BHP

Sales code 60AJZ – 595BHR

Sales code 60AKA – 595BHS

Sales code 60AKB – 595BHT

Sales code 60AKC – 595BHU

Sales code 60AJV – 595BHV

Sales code 60AJW – 595BHW

Sales code 60AJX – 595BHX

Sales code 60AJY – 595BHY

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

None


October 2012



Indicator Light Included

f_120

Location: Center Multiplex Switch

Panel in Dash

T

ESTING

1. Create Advanced Logic in Diamond Logic

®

Builder to turn each light ON using RPM inputs for each light to be tested.

2. Use indicator lights as outputs

3. Apply template to vehicle

4. Program the vehicle with the template created

5. Turn on RPM inputs as needed and check indicator lights

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature codes must be enabled using Diamond Logic

®

Builder software (See Local Dealer). NOTE: these features can be added individually in the field.

•



October 2012


BODY BUILDER INTEGRATION HARNESS


■

BODY INTEGRATION, I/O EXPANSION HARNESS

60ABM

BDY INTG, RPM I/O HARNESS, Includes a Harness with 6 Input Blunt Cut wires and 6 Output Blunt Cut Wires, for use with one RPM.

60ABN

BDY INTG, RPM I/O HARNESS, Includes 2 Harnesses with 6 Input Blunt Cut wires and 6 Output Blunt Cut

Wires, for use with two RPMs.

These features provide the I/O RPM connectors, terminals and blunt cut wires for TEMs which significantly reduces labor installation and material content previously available with just the connector. The included wires are approximately 3 feet long and ease connecting the RPM to vehicle wiring.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

For wiring information for this feature, see Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories,

Aux Inputs and Drivers.

T

ESTING

Use Diamond Logic

®

Builder software to program and test drivers and inputs.

■

BODY INTEGRATION, I/O EXPANSION HARNESS

60ACW

BODY INTG, I/O EXPANSION HARNESS (for Diamond Logic

®

Builder only) includes a harness with five blunt-cut wires routed on lower left of IP. Two GND active inputs and two (0.5 AMP) relay driver outputs (GND active) are provided.

This feature is an input/output expansion feature for Diamond Logic

®

Builder to be utilized by Body Builders.

This expansion feature provides the following: (2) digital inputs, (2) 0.5 AMP relay driver outputs, (1) ZVR on the BC as well as an expansion overlay harness that is part of the IP harness. The expansion overlay harness grants access to these inputs, outputs, and ZVR by providing blunt-cut wires that are strapped to the main IP harness trunk near the J1939 diagnostic connector on the interior of the cab. The overlay harness was designed to be long enough to allow the wires to be inserted into the 72-way pass thru connector if desired.

Additionally, there are two (0.5 AMP) relay driver outputs not included in the overlay harness which are available only through the advanced logic capabilities of Diamond Logic

®

Builder.

When this feature is added to the vehicle, the BC pins will not show up on the connector view of DLB until they are written to with Advanced Logic. 595AKH must be turned on and the inputs/outputs must be used in

Advanced Logic to show up on the connector view of DLB. The following pins are NOT assigned with 595AKH

Diamond Logic

®

must be used to assign these pins.

Description Of Each Digital Input

- GND active inputs,

Digital input 1: pin F14 of BC connector #1602

Digital input 2: pin F12 of BC connector #1602


October 2012



Refer to #1602 connector pinout for pinout description.

Description Of Each Relay Driver Output

- 0.5 AMP relay driver output (Active Low),

Relay driver output 1: pin E1 of the BC connector #1601




Refer to Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Aux Inputs and Drivers.

Description of ZVR

•

Allows for the return of DC current from an external sensor or switch.

CAUTION:

CAUTION – Do not connect any additional electrical loads to ZVR. Adding non-approved electrical loads may adversely affect total electrical operation.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

A

DDED

595AKH

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

There are no customer or Body Builder programmable features associated with this feature.

W

IRING

I

NFORMATION

For wiring information for this feature, see Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories,

Aux Inputs and Drivers.

T

ESTING

Use Diamond Logic

®

Builder software to program and test drivers and inputs.

H

OW

T

O

A

DD

T

HIS

F

EATURE

Add the feature code 595AKH with Diamond Logic

®

Builder. Create advanced logic using the GND active inputs and/or the 0.5 AMP relay driver outputs (Active Low). View the connectors tab in Diamond Logic

®

Builder to verify the pin assignments and connect to these circuits.

■

BODY BUILDER WIRING

08HAT

BODY BUILDER WIRING Includes Wires Installed through the Dash Panel and End in Engine Compartment, In

Cab Wire Ends Will Have ESC Input Terminals, Engine Compartment Wire Ends will have Sealed Connectors.

Feature code 08HAT provides 8 wires from the cab through the 76 way pass-through connector located on the left (driver’s) side of the dash extending 685 mm into the engine compartment for ease of connecting accessory equipment in the engine compartment to the ESC. This feature provides these circuits from the ESC without compromising the cab seal or having to drill additional holes in the cab. The wires are terminated in a sealed connector in the engine compartment and the other ends have ESC input pin termination inside the cab compartment. This will significantly reduce labor and material costs for the bodybuilder.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None


October 2012



W

IRING

I

NFORMATION

A 76-pin connector is provided inside the cab compartment. The pins in the following table will be used to connect the 8 auxiliary wires.

Table 116

Pin Number Circuit Number

56

57

58

59

52

53

54

55

RBTEM1

RBTEM2

RBTEM3

RBTEM4

RBTEM5

RBTEM6

RBTEM7

RBTEM8

Terminals for the 76-Way Connector are part no. 3549418C1.

Gauge

16

16

16

16

16

16

16

16

Color

Gray

Gray

Gray

Gray

Gray

Gray

Gray

Gray f_190


October 2012



Table 117 – 12-Way Output Connector

Connector Part No.

Description

Terminal Part

Connector Lock Part

3601924C1

Connector, Body, 12–Way 16

Socket Deutsch

1651969R1 – 16 Gauge

3601925C1

1689499C1

Connector, Body, 12-Way 16

Pin Deutsch

N/A

N/A f_191

■

JUNCTION BLOCK STUD

08WZG

JUNCTION BLOCK Stud, 100 Amp Battery Feed, protected by a Fusable Link, Stud to be used for Body

Builder Feeds Inside Cab.

This feature is a battery feed point provided inside the cab. The connection will provide up to 100 amps for body builder use. The circuit feeds off of the mega fuse on the left side of the dash panel and is protected by a fusible link connection. A 3/8” stud is provided on the left side of the instrument panel behind the gauge cluster.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

None


October 2012


(PTO) POWER TAKE OFF


■

PTO ACCOMMODATION CABLE SHIFT

60ABA

BDY INTG, PTO ACCOMMODATION for Monitoring Cable Shift Engaged PTO, With Indicator Light and

Audible Alarm in Gauge Cluster (requires one Remote Power Module (RPM) input)

This feature utilizes a customer-mounted PTO feedback switch wired to a RPM input to drive an indicator light in the gauge cluster that allows the operator to determine that the PTO is engaged. An audible alarm is used to warn the operator when the PTO is engaged during unsafe vehicle operating conditions such as when the park brake is released or the engine speed is too high. Operating limits are established through programmable parameters that are set in the Body Controller (BC). The RPM input also drives a PTO hourmeter to allow the operator to measure stationary PTO hours for maintenance records and fuel tax purposes. To view the PTO hourmeter, press the gauge cluster display selector button momentarily until the text portion of the display indicates “PTO Hour.”

A Cable-Shifted PTO is a gear-to-gear engagement type mechanism. Very specific transmission operating modes are required to allow safe engagement of a Cable-Shifted PTO. In essence, the PTO gear in the transmission must be stopped before engagement of a Cable-Shifted PTO should be attempted. The clutch must be depressed with the vehicle parked in order to engage the PTO for a manual transmission. An automatic transmission must be in any driving gear with vehicle parked in order to engage a Cable-Shifted

PTO.

For Hybrid Electric Vehicles only, there is an additional feature code (595BBA) which must be added to make this type of PTO operable in an Eaton hybrid system.

The PTO alarms are controlled by programmable parameters set in the BC. Factory default settings for these programmable parameters are listed in the tables below.

Please use the Diamond Logic

®

Builder software to determine pin locations for RPM inputs (refer to the

CONNECTOR screen view) and to set programmable parameters (refer to the FEATURE screen view).

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS



®

®


Builder software. Body Builders must set programmable parameters that are appropriate for their PTO application.

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES

595AJT (Use 595BJS or 595BJT instead of 595AJT on vehicles with 2010 compliant engines), 595AJU,

595BBA (Hybrid Electric Vehicles only)

C

ONFLICTS

W

ITH

S

OFTWARE

F

EATURES

595AJZ, 595AJV, 595AJW, 595AJX, 595AJY, 595AMZ, 595BAM

A

LARMS

If TEM_PTO_Air_Pres_Alarms parameter is turned on, then an audible alarm will sound in the cab if the primary air pressure drops below the value specified by TEM_PTO_Air_Pres_Alarm_Limit.

If TEM_PTO_Eng_Run_Alarms is turned on, then an alarm will sound if the PTO is engaged while the engine is turned off.

If TEM_PTO_Eng_Spd_Alarms is turned on, then an alarm will sound if the PTO is engaged and the engine speed is over the value set by TEM_PTO_Eng_Spd_Alarm_Limit


October 2012



If TEM_PTO_Non_Neut_Alarms is turned on, then an audible alarm will sound if the PTO is engaged and the transmission is taken out of neutral

If TEM_PTO_Pk_Brake_Alarms is turned on, then an audible alarm will sound if the PTO is engaged and the park brake is released

If TEM_PTO_Veh_Spd_Alarms is turned on, then an audible alarm will sound if the PTO is engaged and the vehicle speed is over the value set by TEM_PTO_Veh_Spd_Alarm_Limit

Table 117 PTO Alarms

Parameter

TEM_PTO_Air_

Pres_Alarms

TEM_PTO_Air_

Pres_Alarm_Limit

TEM_PTO_

Eng_Run_ Alarms

TEM_PTO_

Eng_Spd_

Alarm_Limit

TEM_PTO_

Eng_Spd_ Alarms

ID

2138

2139

2137

2136

2135



Description

If this parameter is 1, an alarm will sound if the

PTO is engaged and the air pressure is below

TEM_PTO_Air_Pres_Alarm_Limit

Default

Off

See TEM_PTO_Air_Pres_Alarms 0 psi

If this Parameter is 1, an alarm will sound if the

PTO is engaged and the engine is turned off

Off

See TEM_PTO_Eng_ Spd_Alarms 1400 RPM

On

Min

NA

0

NA

0

NA

Max

NA

500

NA

5000

NA

Step

NA

1

NA

0.1

NA

TEM_PTO_

Non_Neut_ Alarms

TEM_PTO_

Pk_Brake_ Alarms

TEM_PTO_

Veh_Spd_ Alarms

TEM_PTO_

Veh_Spd_

Alarm_Limit

2132

2131

2133

2134


PTO is engaged and the engine speed is over

TEM_PTO_Eng_ Spd_Alarm_Limit.


PTO is engaged and transmission is taken out of neutral.


PTO is engaged and the park brake is released


PTO is engaged and the vehicle speed is over

TEM_PTO_Veh_ Spd_Alarm_Limit.

See TEM_PTO_Veh_ Spd_Alarms

Off

Off

On

5 MPH

NA

NA

NA

3

NA

NA

NA

100

NA

NA

NA

1

O

THER

P

ARAMETERS

The TEM_RPM_PTO_Engaged_Param parameter indicates the active state that the Body Controller (BC) will read as active for the TEM PTO feedback switch. This active state will be used to indicate when the PTO is engaged.




Table 118

Parameter

TEM_PTO_Air_

Pres_Alarms

ID

2147

Description

Active State for the TEM PTO engagement feedback switch.

Default

1

Min

List

Max

List

Step

List

W

IRING

I

NFORMATION


®

Builder software to determine pin locations for RPM inputs.

•

The wiring to the RPM input is customer supplied.

•

A wire must be connected from the Body Builder-installed PTO feedback switch to the pin labeled

PTO_Feedback_Switch in the black 23-pin RPM input connector (J3).


October 2012



Diagram of Cable Shift PTO System

f_121

RPM C

ONNECTOR

I

NFORMATION

HPV Wire Terminal Kits are REQUIRED to allow Body Builders to create wire harnesses for the RPM connectors.

HPV terminal kits are pre-made kits that include six power output terminals and seals for the brown 8-way connector and six terminals for the black 23-way connector.

Table 114

HPV Kits

RPM Terminal Kit 12 Gauge


Part Number

2585651C91

2585423C9

NOTE: The following connectors are optional because they are already provided with the RPMs.

This information is given so that the Body Builder could purchase connectors in the event that the original connectors were damaged or lost, or so that the Body Builder can pre-fabricate a wire harness.


October 2012



Table 115 – 8-Way RPM Output Connector (Brown) and 23-Way RPM Input Connector (Black)


Description

Terminal Part

Cable Seal Part

Connector Lock Part

CPA Lock

Cavity Plug

3548934C1 2585981C91

Connector, Body, Brown 8–Way RPM Output Connector, Body, Black 23-Way RPM Input Kit

3534163C1 – 12 Gauge

3535931C1 – 14 Gauge

3535930C1 – 16 & 18 Gauge

1698937C1

3548945C1 – 12 & 14 Gauge

3535937C1 – 16 & 18 Gauge

3548943C1

3573833C1

3535938C1

N/A

N/A

N/A

Built into the connector

RPM Mounting Location on a DuraStar Model Truck

f_122


October 2012



RPM Mounting Location on a WorkStar Model Truck

F_123

T

ESTING

Verify that the RPM input labeled PTO_Feedback_Switch (pin position specified by the Diamond Logic

®

Builder software) is receiving the correct voltage (12V or Ground (GND)) as specified by the programmable parameter 2147 in the Diamond Logic

®

Builder software.

Make certain that the PTO indicator light in the gauge cluster illuminates by engaging the PTO.

The audible alarm can be tested by activating a vehicle condition that will sound the alarm based upon the settings of the programmable parameters. For example, if the park brake interlock is programmed on, release the park brake and engage the PTO. The audible alarms should sound with continuous beeps.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature codes 595AJT (595BJS or 595BJT on vehicles with 2010 compliant engines) and 595AJU must be enabled on the vehicle using the Diamond Logic

®

Builder software (see Local Dealer)

•


®

Builder software to make sure that software feature codes 595ACZ, 595AJV,

595AJW, 595AJX, 595AJY, and 595AMZ are NOT enabled on the vehicle (see local dealer).

•


®

Builder software (see

Local Dealer)

•

Connect a wire from a Body Builder-installed PTO feedback switch to the pin labeled PTO_Feedback_Switch in the black 23-pin connector on the RPM as defined by the Diamond Logic

®

Builder software program for this particular vehicle.

•

Perform the PTO testing procedure that is listed above.


October 2012



■

PTO ACCOMMODATION MUNCIE® POWERFLEX* LECTRA-SHIFT

Refer to the circuit diagram manual for PTO Accommodation for Lectra-Shift.

60ABB

BDY INTG, PTO ACCOMMODATION for Muncie Lectra-Shift PTO Engagement and Disengagement, With

Switch Mounted on Dash; Includes Indicator Light and Audible Alarm in Gauge Cluster (requires one RPM input and one output)

This feature provides a center stable, momentary rocker switch in a cab switch pack that drives a RPM output and a 40 Ampere (AMP) relay that are used to engage and disengage the Muncie® Lectra-Shift PTO. The high current relay output is engaged momentarily to shift in the PTO gear mechanism. Once engaged, the RPM output is activated to keep the PTO gear in the engaged position. This feature utilizes a customer-mounted

PTO feedback switch wired to a RPM input to drive an indicator light in the gauge cluster that allows the operator to determine that the PTO is engaged. An audible alarm is used to warn the operator when the PTO is engaged during unsafe vehicle operating conditions such as when the park brake is released or the engine speed is too high. Operating limits are established through programmable parameters that are set in the BCM.

The RPM input also drives a PTO hourmeter to allow the operator to measure stationary PTO hours for maintenance records and fuel tax purposes. To view the PTO hourmeter, press the gauge cluster display selector button momentarily until the text portion of the display indicates “PTO Hour.”

The Lectra-Shift is a gear-to-gear engagement PTO mechanism. Very specific transmission operating modes are required to allow safe engagement of a Lectra-Shift PTO. In essence, the PTO gear in the transmission must be stopped before engagement of the Lectra-Shift PTO should be attempted. The clutch must be depressed with the vehicle parked in order to engage the Lectra-Shift PTO for a manual transmission. An automatic transmission must be in any driving gear with vehicle parked in order to engage the Lectra-Shift

PTO. Engagement, disengagement and re-engagement parameters should be set according to the type of transmission on which the Lectra-Shift is mounted.



Through programmable parameters, the vehicle can be programmed to customize the number of times that an operator can request a PTO engagement per key cycle. The customer can also customize the maximum time allowed to engage the solenoid per attempt, and the length of time between a failed engagement attempt and the next time the operator can attempt to engage the PTO.


®



S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Required software feature codes: 595AJT (Use 595BJS or 595BJT instead of 595AJT on vehicles with 2010 compliant engines), 595AJU, 595AJV, 595AJZ, 595BBA (Hybrid Electric Vehicles only)

Software feature codes that must be removed: 595AJW, 595AJX, 595AJY, 595AMZ, 595BAM

E

NGAGEMENT

These parameters set rules that must be met in order for the PTO to be engaged.

If TEM_PTO_Brake_Engmnt_Inhib parameter is turned on, then the brake pedal must be depressed in order for the PTO to engage.

If TEM_PTO_Cltch_Engmnt_Inhib parameter turned on, then the clutch pedal must be depressed for the PTO to engage.


October 2012



If TEM_PTO_Eng_Run_Engmnt_Inhib parameter is turned on, then the engine has to be running in order for the PTO to be engaged.

If TEM_PTO_Eng_Spd_Engmnt_Inhib parameter is turned on, then the PTO cannot be engaged if the engine speed is over a certain threshold, which is defined as a programmable parameter in

TEM_PTO_Eng_Spd_Engmnt_Limit

If TEM_PTO_Neut_Engmnt_Inhib parameter is turned on, then the PTO can only be engaged if the transmission is NOT in Neutral or Park

If TEM_PTO_Non_Neut_Engmnt_Inhib parameter is turned on, then the transmission must be in Neutral or

Park for the PTO to be engaged.

If TEM_PTO_Pk_Brake_Engmnt_Inhib parameter is turned on, then the Park Brake must be set in order for the

PTO to be engaged.

If TEM_PTO_Veh_Spd_Engmnt_Inhib parameter is turned on, then the PTO cannot be engaged if the Vehicle

Speed is over the value prescribed by TEM_PTO_Veh_Spd_Engmnt_Limit.

If TEM_PTO_Mast_Switch_Engmnt_Inhib parameter is turned on, then the PTO will not be engaged if the vehicle master switch is not ON.


October 2012



Table 121

Parameter

TEM_PTO_

Brake_Engmnt_

Inhib

TEM_PTO_

Cltch_Engmnt_

Inhib

TEM_PTO_

Eng_Run_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Limit

TEM_PTO_

Neut_Engmnt_

Inhib

TEM_PTO_

Non_Neut_

Engmnt_Inhib

TEM_PTO_Pk_

Brake_Engmnt_

Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Limit

TEM_PTO_Mast_

Switch_Engmnt_

Inhib

ID

2095

2094

If this Parameter is 1, the PTO will not be engaged when the clutch pedal is not depressed

2096

If this Parameter is 1, the PTO will not be engaged if the engine is not running

2092

If this Parameter is 1, the PTO will not be engaged if the engine speed is over the value set in TEM_PTO_Eng_ Spd_Engmnt_ Limit

2093

2089

2088

2087

If this Parameter is 1, the PTO will only be engaged if the Transmission is not in Neutral or

Park

If this Parameter is 1, the PTO will not be engaged if the Transmission is not in Neutral or

Park

If this Parameter is 1, the PTO will not be engaged if the Park Brake is not set.

2090

If this Parameter is 1, the PTO will not be engaged if the vehicle speed is over the value set in TEM_PTO_Veh_ Spd_Engmnt_ Limit

2091

2099



Description Default

If this Parameter is 1, the PTO will not be engaged if the brake pedal is not depressed

Off

See TEM_PTO_Eng_ Spd_Engmnt_ Inhib

See TEM_PTO_Veh_ Spd_Engmnt_ Inhib

If this Parameter is 1, the PTO will not be engaged if the vehicle master switch is not ON

Off

Off

On

1000 RPM

On

Off

Off

Off

0

Off

D

ISENGAGEMENT

These parameters set the conditions under which the PTO will be disengaged.

Min

NA

NA

NA

NA

100

NA

NA

NA

NA

1

NA

Max

NA

NA

NA

NA

5000

NA

NA

NA

NA

100

NA

Step

NA

NA

NA

NA

1

NA

NA

NA

NA

1

NA

If TEM_PTO_Eng_Run_Disengages parameter is turned on, then the PTO will be disengaged if the engine is turned off.

If TEM_PTO_Eng_Spd_Disengages parameter is turned on, then the PTO will be disengaged if the engine speed rises above the value set by TEM_PTO_Eng_Spd_DisEng_Limit.

If TEM_PTO_ Non_Neut _Disengages parameter is turned on, then the PTO will be disengaged if the transmission is taken out of neutral.

If TEM_PTO_Pk_Brake_Disengages parameter is turned on, then the PTO will be disengaged if the Park Brake is released.

If TEM_PTO_Veh_Spd_Disengages parameter is turned on, then the PTO will be disengaged if the vehicle speed is over the valued specified by TEM_PTO_Veh_Spd_DisEng_Limit.

If TEM_PTO_Ext_Input_Disengages is turned on, then the PTO will be disengaged if the external input designated for this purpose is active.

If TEM_PTO_Mast_Switch_Disengages is turned on, then the PTO will be disengaged if the vehicle master switch is not ON.


October 2012



Table 122

Parameter

TEM_PTO_

Eng_Run_

Disengages

TEM_PTO_

Eng_Spd_

DisEng_Limit

TEM_PTO_

Eng_Spd_

Disengages

TEM_PTO_

Non_Neut_

Disengages

TEM_PTO_

Pk_Brake_

Disengages

TEM_PTO_

Veh_Spd_

Disengages

TEM_PTO_

Veh_Spd_

DisEng_Limit

TEM_PTO_Ext_

Input_Disengages

TEM_PTO_Mast_

Switch_Disengages

ID

2113

2108

2110

2111



Description

2114

If this Parameter is 1, the PTO will be disengaged if the engine is turned off.

See TEM_PTO_ Eng_Spd_ Disengages

2112

If this Parameter is 1, the PTO will be disengaged if the engine speed is over the value set in

TEM_PTO_Eng_ Spd_DisEng_ Limit

2109

If this Parameter is 1, the PTO will be disengaged if the transmission is taken out of neutral.

If this Parameter is 1, the PTO will be disengaged if the Park Brake is released.

If this parameter is 1, the PTO will be disengaged if the vehicle speed is over the value set in

TEM_PTO_Veh_ Spd_DisEng_ Limit.

See TEM_PTO_Veh_ Spd_Disengages

2117

2118

If this Parameter is 1m the PTO will be disengaged if the external input designated for this purpose is active

If this Parameter is 1, the PTO will be disengaged if the vehicle master switch is not ON

Default

Off

1400 RPM

On

Off

Off

On

5 MPH

Off

Off

Min

N/A

0

N/A

N/A

N/A

N/A

N/A

N/A

R

E

-E

NGAGEMENT

These parameters set the conditions under which the PTO can be re-engaged.

3

Max

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

N/A

Step

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

NOTE: All re-engagement parameters should be set to 0 with Lectra-Shift PTOs to prevent gear grind and damage to the transmission.

If TEM_PTO_Eng_Run_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to engine stopping) when the engine is restarted.

If TEM_PTO_Eng_Spd_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to engine overspeed) when the engine speed falls below

TEM_PTO_Eng_Spd_Engmnt_Limit.

If TEM_PTO_Key_State_Allow_ReEng parameter is turned on, then the PTO will be allowed to reengage when the key state is returned to run.

If TEM_PTO_Non_Neut_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to transmission out of neutral) when the transmission is placed back into neutral.

If TEM_PTO_Pk_Brake_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to park brake released) when the park brake is reapplied.

If TEM_PTO_Veh_Spd_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to the vehicle being over the vehicle speed value) when the vehicle speed is falls

TEM_PTO_Veh_Spd_Engmnt_Limit.

If TEM_PTO_Mast_Switch_Allow_ReEng is turned on, then the PTO will be reengaged after a disengage due to the master switch being turned off when the master switch is turned on again.

If TEM_PTO_Ext_Input_Allow_ReEng is turned on, then the PTO will be reengaged after a disengage due to the designated external input when the external input is no longer active.


October 2012



Table 123

Parameter

TEM_PTO_

Eng_Run_

Allow_ReEng

TEM_PTO_

Eng_Spd_

Allow_ReEng

TEM_PTO_Key_

State_ Allow_

ReEng

TEM_PTO_

Non_Neut_

Allow_ReEng

ID

2122

2120



Description

If this Parameter is 1, the PTO will be reengaged after disengagement due to the engine stopping when the engine is restarted.

If this Parameter is 1, the PTO will be reengaged after disengagement due to engine overspeed when the engine speed is below

TEM_PTO_Eng_ Spd_Engmnt_ Limit.

Default

Off

Off

2069

If this parameter is set, the PTO will be allowed to reengage when the key state is returned to run.

TEM_PTO_

Pk_Brake_

Allow_ReEng

TEM_PTO_

Veh_Spd_

Allow_ReEng

TEM_PTO_Mast_

Switch_Allow_ReEn g

TEM_PTO_Ext_

Input_Allow_ReEng

2148

2149

2119

2123

2121

If this Parameter is 1, the PTO will be reengaged after disengagement due to transmission out of neutral when the transmission is placed back into neutral.

If this Parameter is 1, the PTO will be reengaged after disengagement due to park brake released when the park brake is reapplied.

If this Parameter is 1, the PTO will be reengaged after disengagement due to vehicle overspeed when the vehicle speed is below

TEM_PTO_Veh_ Spd_Engmnt_ Limit.

If this Parameter is 1, the PTO will be reengaged after a disengage due to the master switch being turned off when the master switch is turned on again

If this Parameter is 1, the PTO will be reengaged after a disengage due to the designated external input when the external input is no longer active

Off

Off

Off

Off

Off

Off

Min

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Max

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Step

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A

LARMS

These parameters utilize the gauge cluster to sound an alarm to the driver when certain programmable parameters are violated.

If TEM_PTO_Air_Pres_Alarms parameter is turned on, then an alarm will sound if the PTO is engaged and the air pressure is below the value set by TEM_PTO_Air_Pres_Alarm_Limit.

If TEM_PTO_Eng_Spd_Alarms parameter is turned on, then an alarm will sound if the PTO is engaged and the engine speed is over the value set by TEM_PTO_Eng_Spd_Alarm_Limit.

If TEM_PTO_Non_Neut_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the transmission is taken out of neutral.

If TEM_PTO_Pk_Brake_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the park brake is released.

If TEM_PTO_Veh_Spd_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the vehicle speed is about the value set by TEM_PTO_Veh_Spd_Alarm_Limit.


October 2012



Table 124 – PTO Alarms

Parameter

TEM_PTO_Air_

Pres_Alarms

TEM_PTO_Air_

Pres_Alarm_Limit

TEM_PTO_

Eng_Run_ Alarms

TEM_PTO_

Eng_Spd_

Alarm_Limit

TEM_PTO_

Eng_Spd_ Alarms

ID

2138

2139

2137

2136



Description



Default

Off

SeeTEM_PTO_Air_Pres_Alarms 0 psi



Off

See TEM_PTO_Eng_ Spd_Alarms 1400 RPM

Min

N/A

0

N/A

0

Max

N/A

500

N/A

5000

Step

N/A

1

N/A

0.1

TEM_PTO_

Non_Neut_ Alarms

TEM_PTO_

Pk_Brake_ Alarms

TEM_PTO_

Veh_Spd_ Alarms

TEM_PTO_

Veh_Spd_

Alarm_Limit

2135

2132

2131

2133











2134 See TEM_PTO_Veh_ Spd_Alarms

On

Off

Off

On

5 mph

N/A

N/A

N/A

N/A

3

N/A

N/A

N/A

N/A

100

N/A

N/A

N/A

N/A

1

O

THER

P

ARAMETERS

The TEM_PTO_Retaining_Solenoid_Fuse parameter is the fusing value for the Remote Power Module output feeding the retaining coil that holds the electric solenoid in the engaged position. If current exceeds this value, the BC will turn off the output.

The TEM_PTO_Lectra_Shift_Max_Retries parameter allows the customer to establish the maximum number of times that the operator can request a PTO engagement per key cycle.

The TEM_PTO_Lectra_Shift_Retry_Time parameter sets the time between a failed engagement attempt and the time that the operator can attempt to engage the PTO again.

The TEM_PTO_Allowed_Engagement_Time parameter sets the maximum time allowed for the solenoid to make one engagement attempt.

The TEM_RPM_PTO_Engaged_Param parameter indicates the state that the BC will read as active for the

TEM PTO feedback switch (as it goes into the RPM input). This active state will be used to tell the BC when the

PTO is engaged.





October 2012



Table 125

Parameter

TEM_PTO_

Retaining_

Solenoid_Fuse

TEM_PTO_

Lectra_Shift_

Max_Retries

TEM_PTO_

Lectra_Shift_

Retry_Time

TEM_PTO_

Allowed_

Engagement_ Time

TEM_RPM_

PTO_Engaged_

Param

ID

2022

2058

2059

2057

2147



Description

Fuse value for the TEM PTO Single Polarity engagement retaining solenoid power.

Default

20 Amps

The maximum number of times a PTO engagement request is allowed to be issued in a key cycle.

0 Retries

Time frame for retry counting in Lectra- Shift engagement algorithm.

600

Seconds

Time allowed for engagement of the Lectra- Shift

PTO.

3 Seconds


1

Min

0

0

0

0

List

Max

20

65535

600

10

List

Step

0.1

1

1

0.1

List

W

IRING

I

NFORMATION


®



•

When a vehicle is ordered from Navistar with this feature, a 3-pin connector is provided which mates with the connector from the Muncie Lectra-Shift Solenoid. This connector is located in the transmission/engine harness located above the transmission. The customer is responsible for connecting two wires from this connector to the RPM connectors.

•

The white wire is pre-wired from a relay to the Lectra-Shift connector. This wire is for the engagement coil.

•

The red wire is for the holding coil in the solenoid. The red wire must be connected to the brown 8-pin RPM output connector pin labeled PTO_Lectra-Shift_Retaining_Solenoid_Output.

•

The black wire is for the PTO feedback switch. The customer must wire from this pin into the black 23-pin

RPM input connector pin labeled PTO_Feedback_Switch.

•

When the customer has completed the wiring from the connector, plug the 3-pin connector into the connector provided by the Muncie Solenoid (See the Figure below).

•

The customer is responsible for providing GND to the solenoid.


October 2012



Lectra-Shift PTO Solenoid Connectors

f_124

Navistar Supplied Harness for Lectra-Shift PTO

f_125


October 2012



Diagram of Lectra-Shift PTO System

f_126

RPM C

ONNECTOR

I

NFORMATION



Table 126

HPV Kits



Part Number

2585651C91

2585423C91


This information is given so that the Body Builder could purchase connectors in the event that the original connectors were damaged or lost, or so that the Body Builder can pre-fabricate a wire harness.



Description

Terminal Part

Cable Seal Part

Connector Lock Part

CPA Lock

Cavity Plug

3548934C1 2585981C91


3534163C1 – 12 Gauge

3535931C1 – 14 Gauge

3535930C1 – 16 & 18 Gauge

1698937C1

3548945C1 – 12 & 14 Gauge

3535937C1 – 16 & 18 Gauge

3548943C1

3573833C1

3535938C1

N/A

N/A

N/A



October 2012




f_122



October 2012 f_123



T

ESTING

1. Depress the PTO switch in the cab to the ON position. Ensure that all PTO interlock conditions are enabled.

2. Verify that the pin labeled PTO_Lectra-Shift_Retaining_Solenoid_Output of the Brown 8-way Remote

Power Module output connector has battery voltage levels present.

3. Verify that the Remote Power Module Input labeled PTO_Feedback_Switch (Pin position specified by the

Diamond Logic

®

Builder software) is receiving the correct voltage (12V or GND) as specified by the customer in the Diamond Logic

®

Builder software.

4. Make certain that the switch indicator lights are functioning by engaging the PTO and verifying that the green light in the top section of the switch illuminates.

5. Make certain that the PTO indicator light in the gauge cluster is functioning by engaging the PTO.

6. The audible alarm can be tested by activating a vehicle condition that will sound the alarm based upon the settings of the programmable parameters. For example, if the park brake interlock is programmed on, release the park brake and engage the PTO. The audible alarms should sound with continuous beeps.

H

OW

T

O

A

DD

T

HIS

F

EATURE

A. If vehicle does not have a Remote Power Module installed, follow the Remote Power Module installation procedure listed in this document.

B. If the vehicle already has a Remote Power Module, follow the procedure listed below to add specific wiring for Lectra-Shift.


®

Builder software to determine pin locations for RPM inputs and outputs (refer to the CONNECTOR screen view) and to set programmable parameters (refer to the FEATURE screen view).

•

Software feature codes 595AJT (Use 595BJS or 595BJT instead of 595AJT on vehicles with 2010 compliant engines), 595AJU, 595AJV, and 595AJZ must be enabled on the vehicle using the Diamond Logic

®


•


®

Builder software to make sure that software feature codes 595AJW, 595AJX,

595AJY, and 595AMZ are NOT enabled on the vehicle (see local dealer).

•


®


Local Dealer)

•

Connect a wire from the pin labeled PTO_Lectra-Shift_Retaining_Solenoid_Output pin the brown 8-pin RPM output connector to the coil on the solenoid.

•

Connect a wire from a Body Builder-installed PTO feedback switch to the pin labeled PTO_Feedback_Switch in the black 23-Pin RPM input connector.

•

Connect a wire from Body Controller connector 1600 Pin E11 (Blue Connector) to a 40A relay to provide power for PTO Engagement.


f_129

WARNING: Batteries expel explosive gases. Keep sparks, flames, burning cigarettes or other ignition (IGN) sources away at all times. Always wear safety glasses and a face shield when working near batteries to prevent personal injury and/or property damage.

Open hood and disconnect batteries on the vehicle.

I

N

C

AB

I

NTERIOR INSTALLATION

:

Remove BC kick panel to access the BC.

1. Locate an 18 gauge wire long enough to reach from the BC Connector 1601 to the 76-way dash panel connector 1700.


October 2012



2. Disconnect connector 1700 outside the cab on the dash panel.

3. Terminate one end of the wire with a BC terminal and insert it into connector 1601 pin E11.

4. Terminate the other end of the wire with a 76-way wire terminal and insert it into cavity 12 of connector

1700.

5. Install dash switch.

a.

Ensure the switch assigned to the Lectra-Shift is a center stable momentary switch.

b. If the switch is not a momentary switch, use a DIN removal tool and remove the affected switch pack from the Instrument Panel (IP). Install a momentary switch in the position assigned to the PTO switch.

Re-install the switch pack in the IP.

6. Re-install the BC kick panel.

E

XTERIOR

W

IRING

A

ND

F

USE

/R

ELAY

I

NSTALLATION

1.

Position an in-line 40 AMP fuse and relay near the mega-fuse in the engine compartment.

2.

Terminate an 18 gauge wire with a terminal and insert one end into connector 1700 pin 12.

3.

Terminate the other end with a relay socket terminal and connect it to the 40 AMP relay coil terminal 86.

4.

Connect a second 18 gauge wire from the 40 AMP relay coil terminal 85 to the GND stud on the dash panel using a ring terminal.

5.

Connect a 10 gauge wire from the battery side of the mega-fuse to one side of the in-line fuse.

6.

Connect a 10 gauge wire from the other side of the in-line fuse to the moving contact of the 40 AMP relay.

7.

Connect a 10 gauge wire from the normally open relay contact to the white wire of the Lectra-Shift supplied wire harness.

8.

Tie-wrap the in-line fuse and relay to the center chassis harness. Ensure that the terminals of the relay and fuse are pointed down to prevent water intrusion.

9.

Route the harness down along the engine harness next to the Engine Control Module (ECM) above the clutch linkage; follow the portion of the transmission/engine harness coming out of the engine ECM. Tape or tie-wrap the single white Lectra-Shift pull-in coil wire to the transmission/engine harness.

10. Connect the red wire to the brown 8-pin RPM output connector pin labeled

PTO_Lectra_Shift_Retaining_Solenoid_Output.

11. Connect the black wire to the black 23-pin RPM input connector pin labeled PTO_Feedback_Switch.

12. Reconnect vehicle batteries.

13. Test the PTO operation.

■

PTO ACCOMMODATION FOR ELECTRIC OVER HYDRAULIC PTO

60ABE

BDY INTG, PTO ACCOMMODATION for Electric over Hydraulic PTO, With Switch Mounted on Dash, Includes

Audible Alarm and Indicator Light in Gauge Cluster (Requires one RPM input and one output). This feature does Not Include Solenoids.

This feature provides a latched switch in a switch pack to drive one RPM output to engage an Electric over

Hydraulic PTO.

This feature utilizes a customer-mounted PTO feedback switch wired to a RPM input to drive an indicator light in the gauge cluster that allows the operator to determine that the PTO is engaged. An audible alarm is used to warn the operator when the PTO is engaged during unsafe vehicle operating conditions such as when the park brake is released or the engine speed is too high. Operating limits are established through programmable parameters that are set in the BC. The RPM input also drives a PTO hourmeter to allow the operator to measure stationary PTO hours for maintenance records and fuel tax purposes. To view the PTO hourmeter,


October 2012



press the gauge cluster display selector button momentarily until the text portion of the display indicates “PTO

Hour.”




®



S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS



®

®



R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES


595AJW, 595AJZ, 595BBA (Hybrid Electric Vehicles only)

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

595AJV, 595AJX, 595AJY, 595AMZ, 595BAM

E

NGAGEMENT



If TEM_PTO_Cltch_Engmnt_Inhib parameter is turned on, then the clutch pedal must be depressed for the

PTO to engage.




If TEM_PTO_Neut_Engmnt_Inhib parameter is turned on, then the PTO can only be engaged if the

Transmission is NOT in Neutral or Park

If TEM_PTO_Non_Neut_Engmnt_Inhib parameter is turned on, then the Transmission must be in Neutral or



PTO to be engaged.



If TEM_Air_Pres_Engmnt_Inhib parameter is turned on, then the PTO cannot be engaged if the Vehicle

Primary Air Pressure is under the value prescribed be TEM_Air_Pres_Engmnt_Limit.

If TEM_PTO_Mast_Switch_Engmnt_Inhib parameter is turned on, the PTO will not be engaged if the vehicle master switch is not ON.


October 2012



Table 128

Parameter

TEM_PTO_

Brake_Engmnt_

Inhib

TEM_PTO_

Cltch_Engmnt_

Inhib

TEM_PTO_

Eng_Run_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Limit

TEM_PTO_

Neut_Engmnt_

Inhib

TEM_PTO_

Non_Neut_

Engmnt_Inhib

TEM_PTO_Pk_

Brake_Engmnt_

Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Limit

ID

2095

2094


2096


2092


2093

2089

2088

2087


Park


Park


2090


2091





Off



Off

Off

On

1000 RPM

Off

Off

Off

On

3 MPH

Min

N/A

N/A

N/A

N/A

100

N/A

N/A

N/A

N/A

1

TEM_Air_Pres_

Engmnt_Inhib

TEM_Air_Pres_

Engmnt_Limit

TEM_PTO_Mast_

Switch_Engmnt_

Inhib

2097

2098

2099

If this Parameter is 1, the PTO will not be engaged if the Vehicle Primary Air Pressure is under the value prescribed by

TEM_Air_Pres_Engmnt_Limit

See TEM_PTO_Air_Pres_Engmnt_Inhib

If this Parameter is 1, the PTO will not be engaged if the primary vehicle air pressure is below TEM_PTO_Air_Pres_Engmnt_Limit

Off

0

Off

D

ISENGAGEMENT


N/A

1

N/A

Max

N/A

N/A

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

500

N/A

Step

N/A

N/A

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A

1

N/A







October 2012



If TEM_PTO_Air_Pres_Disenages is turned on, then the PTO will be disengaged if the primary air pressure is below the value set in TEM_PTO_Air_DisEng_Limit.


IF TEM_PTO_Mast_Switch_Disengages is turned on, then the PTO will be disengaged if the vehicle master switch is not ON.

Table 129

Parameter

TEM_PTO_

Eng_Run_

Disengages

TEM_PTO_

Eng_Spd_

DisEng_Limit

TEM_PTO_

Eng_Spd_

Disengages

TEM_PTO_

Non_Neut_

Disengages

TEM_PTO_

Pk_Brake_

Disengages

TEM_PTO_

Veh_Spd_

Disengages

TEM_PTO_

Veh_Spd_

DisEng_Limit

TEM_PTO_Air_

Pres_Disengages

TEM_PTO_Air_

Pres_DisEng_Limit

TEM_PTO_Ext_

Input_Disengages

TEM_PTO_Mast_

Switch_Disengages

ID

2113

2111



Description

2114



2112



2109


2108


2110

If this Parameter is 1, the PTO will be disengaged if the vehicle speed is over the value set in



2115

2116

If this Parameter is 1, the PTO will be disengaged if the primary air pressure is below the value set in TEM_PTO_Air_Pres_DisEng_Limit

See TEM_PTO_Air_Pres_Disengages

2117

2118

If this Parameter is 1, the PTO will be disengaged if the external input designated for this purpose is active


Default

Off

1800 RPM

On

Off

Off

Off

0 MPH

0

0

Off

Off

Min

N/A

0

N/A

N/A

N/A

N/A

3

N/A

0

N/A

N/A

Max

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

500

N/A

N/A

Step

N/A

1

N/A

N/A

N/A

N/A

1

N/A

1

N/A

N/A

R

E

-E

NGAGEMENT

These parameters set the conditions under which the PTO can be reengaged.




If TEM_PTO_Ext_Input_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to the designated external input being in active state) when the external input is no longer in active state.



October 2012





If TEM_PTO_Veh_Spd_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to the vehicle being over the vehicle speed value) when the vehicle speed falls below



If TEM_PTO_Air_Pres_Allow_ReEng is turned on, then the PTO will be reengaged after a disengage due to low vehicle air pressure when the primary air pressure is over the value set in

TEM_PTO_Air_Pres_Engmnt_Limit.

Table 130

Parameter

TEM_PTO_

Eng_Run_

Allow_ReEng

TEM_PTO_

Eng_Spd_

Allow_ReEng

TEM_PTO_

Ext_Input_

Allow_ReEng

TEM_PTO_

Key_State_

Allow_ReEng

TEM_PTO_

Non_Neut_

Allow_ReEng

TEM_PTO_

Pk_Brake_

Allow_ReEng

TEM_PTO_

Veh_Spd_

Allow_ReEng

TEM_PTO_Mast_

Switch_Allow_

ReEng

TEM_PTO_Air_

Pres_Allow_ReEng

ID

2122

2120

2121



Description




If this Parameter is 1, the PTO will be reengaged after disengagement due to the designated external input when the external input is no longer active.

Default

Off

On

Off

2069


Off

2148

2149

2119

2123

2124





If this Parameter is 1, the PTO will be reengaged after a disengage due to the master switch being turned off when the master switch is turned on again.

If this Parameter is 1, the PTO will be reengaged after a disengage due to low vehicle air pressure when the primary air pressure is over

TEM_PTO_Air_Pres_Engmnt_Limit

Off

Off

Off

Off

Off

Min

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Max

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Step

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A


October 2012



A

LARMS

These parameters set the conditions in which an audible alarm in the gauge cluster will sound.


If TEM_PTO_Eng_Run_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the engine is turned off.


If TEM_PTO_Non_Neut_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the transmission is taken out of neutral

If TEM_PTO_Pk_Brake_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the park brake is released

If TEM_PTO_Veh_Spd_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the vehicle speed is about the value set by TEM_PTO_Veh_Spd_Alarm_Limit.


Parameter

TEM_PTO_Air_

Pres_Alarms

TEM_PTO_Air_

Pres_Alarm_Limit

TEM_PTO_

Eng_Run_ Alarms

TEMP_PTO_Eng_

Spd_Alarm_Limit

TEM_PTO_

Eng_Spd_ Alarms

TEM_PTO_

Non_Neut_ Alarms

TEM_PTO_

Pk_Brake_ Alarms

TEM_PTO_

Veh_Spd_ Alarms

TEM_PTO_Veh_

Spd_Alarm_Limit

ID

2138



Description



TEM_PTO_Air_Pres_Alarm_Limit

Default

Off

See TEM_PTO_Air_Pres_Alarms 0 psi 2139

2137

2136

2135

2132

2131

2133

2134



See TEM_PTO_Eng_Spd_Alarms

Off

1400 RPM











See TEM_PTO_Veh_Spd_Alarms

Off

Off

Off

Off

5 mph

Min

N/A

0

N/A

0

N/A

N/A

N/A

N/A

3

Max

N/A

500

N/A

5000

N/A

N/A

N/A

N/A

100

Step

N/A

1

N/A

0.1

N/A

N/A

N/A

N/A

1


October 2012



O

THER

P

ARAMETERS

These parameters allow the customer to program the active state of the Remote Power Module Input and set the maximum current of the Remote Power Module Output.

The TEM_RPM_PTO_Engaged_Param parameter 2147 indicates the state that the BC will read as active for the TEM PTO feedback switch (as it goes into the RPM input). This active state will be used to indicate when the PTO is engaged.




The TEM_Hyd_PTO_Engagement_Out_Param parameter sets the current at which the BC will fuse the

Remote Power Module output that drives the engagement of the PTO. This is used to define the maximum amount of current that can flow through the Remote Power Module output.

Table 132

Parameter

TEM_RPM_PTO_

Engaged_ Param

TEM_Hyd_PTO_

Engagement_

Out_Param

ID

2147

1993



Description


Default

1

This is the fuse level of the Hydraulic PTO FET

(Field Effect Transistor).

20 Amps

Min

List

0

Max

List

20

Step

List

0.1

W

IRING

I

NFORMATION


®



•

All wiring to RPM inputs and outputs is customer supplied.

•

One wire must be connected from the pin labeled PTO_Output in the brown 8-pin RPM output connector to the coil on the hydraulic solenoid. This wire drives the engagement and disengagement of the solenoid. The customer supplies a GND wire for the hydraulic solenoid.

•

A second wire must be connected from the Body Builder-installed PTO feedback switch (GND active) to the pin labeled PTO_Feedback_Switch in the black 23-pin RPM input connector. This feedback switch is used to determine whether or not the PTO is engaged by determining if the switch is in the active state. If the switch is indeed in the active state and the PTO is running, then an indicator light in the gauge cluster will be on.

When the switch is not in the active state, the indicator light will not be on.

•

The switch provided is labeled PTO.


October 2012



Overview of Electric Over Hydraulic PTO System

f_130

RPM C

ONNECTOR

I

NFORMATION



Table 133

HPV Terminal Kits



Part Number

2585651C91

2585423C91


This information is given so that the Body Builder can purchase connectors in the event that the original connectors are damaged or lost, or so that the Body Builder can pre-fabricate a wire harness.



Description

Terminal Part

Cable Seal Part

Connector Lock Part

CPA Lock

Cavity Plug

3548934C1 2585981C91


3534163C1 – 12 Gauge

3535931C1 – 14 Gauge

3535930C1 – 16 & 18 Gauge

1698937C1

3548945C1 – 12 & 14 Gauge

3535937C1 – 16 & 18 Gauge

3548943C1

3573833C1

3535938C1

N/A

N/A

N/A



October 2012




f_127


f_123


October 2012



T

ESTING

1.

To determine if the PTO is working, depress the PTO switch in the cab to the on position. Ensure that all interlock conditions are enabled.

2.

Verify that the pin labeled PTO_Output of the brown 8-way Remote Power Module output connector has the battery voltage levels present.

3.

Verify that the RPM input labeled PTO_Feedback_Switch (pin position specified by the Diamond Logic

®

Builder software) is receiving the correct voltage (12V or GND) as specified by the programmable parameter in the Diamond Logic

®

Builder software.

4.

Make certain that the indicator light in the top section of the PTO switch illuminates by engaging the PTO.

5.

Make certain that the PTO indicator light in the gauge cluster illuminates by engaging the PTO.

6.

The Audible Alarm can be tested by violating the set programmable parameters and determining if the

Alarm sounds. For example: If the park brake interlock is programmed ON, release the park brake and engage the PTO. The audible alarm should sound with continuous beeps.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature codes 595AJT (Use 595BJS or 595BJT instead of 595AJT on vehicles with 2010 compliant engines), 595AJU, 595AJW, and 595AJZ must be enabled on the vehicle using the Diamond Logic

®


•


®

Builder software to make sure that software feature codes 595AJV, 595AJX,

595AJY, and 595AMZ are NOT enabled on the vehicle (see local dealer).

•


®


Local Dealer)

•

Connect a wire from the pin labeled PTO_Output in the brown 8-pin RPM output connector, to the coil on the solenoid.

•

Connect a wire from a Body Builder-installed PTO feedback switch to the pin labeled PTO_Feedback_Switch in the black 23-Pin RPM input connector.

•


Constant Engagement Hydraulic Pump

Another use of 60ABE is to control a dump valve on a constantly engaged hydraulic pump. In this case the operator would use the RPM (address 1) output A to activate and deactivate the dump valve. This dump valve is used to control hydraulic pressure in the system, reducing wear on the system and increasing fuel economy.

■

PTO ACCOMMODATION ELECTRIC OVER AIR NON-CLUTCHED

60ABK

BDY INTG, PTO ACCOMMODATION. Accommodation for Electric over Air, Non-Clutched PTO Engagement and Disengagement, Does not Include Air Solenoid, With Switch Mounted on Dash, Includes Audible Alarm and Indicator Light in Gauge Cluster (requires one RPM input and one output)

This feature provides a momentary switch in the in-cab switch pack to drive a RPM output to engage an Electric over Air, Non-Clutched PTO.

A RPM input is used to drive an indicator light in the gauge cluster to indicate when the PTO is engaged. An audible alarm sounds when certain programmable parameters are violated. The RPM input also drives a PTO hourmeter to allow the operator to measure stationary PTO hours for maintenance records and fuel tax purposes. To view the hourmeter, press the gauge cluster selection button momentarily until the text portion of the display indicates “PTO Hour.”

The Non-Clutched air-shifted PTO is a gear-to-gear engagement mechanism. Very specific transmission operating modes are required to allow safe engagement of the PTO. In essence, the PTO gear in the transmission must be stopped before engagement of the PTO should be attempted. The clutch must be depressed with the vehicle parked in order to engage the PTO for a manual transmission. An automatic


October 2012



transmission must be in any driving gear with vehicle parked in order to engage the PTO. Engagement, disengagement, and re-engagement parameters should be set according to the type of transmission where the

Non-Clutched PTO is mounted.

For Hybrid Electric Vehicles only, there is an additional feature code (595BBA) which must be added to make this type of PTO operable in the hybrid system.

The PTO alarms are controlled by programmable parameters set in the BCM. Through these programmable parameters, the vehicle owner can customize the functionality of the PTO. Factory default settings for these programmable parameters are listed in the tables below.


®


All re-engagement parameters for Non-Clutched PTOs are defaulted OFF. These parameters are defaulted to

OFF because reengaging a Non-Clutched PTO automatically (after it has disengaged) could cause the gears to grind and damage the PTO.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS



®

®



Required software feature codes: 595AJT (Use 595BJS or 595BJT instead of 595AJT on vehicles with 2010 compliant engines), 595AJU, 595AJX, 595AJZ, 595BBA (Hybrid Electric Vehicles only)

Software feature codes that must be removed: 595AJV, 595AJW, 595AJY, 595AMZ, 595BAM

E

NGAGEMENT


If TEM_PTO_Air_Pres_Engmnt_Inhib parameter is turned on, the PTO cannot be engaged if the primary vehicle air pressure is below the programmable parameter set by TEM_PTO_Air_Pres_Engmnt_Limit.



PTO to engage.





Transmission is NOT in Neutral or Park.




PTO to be engaged.





October 2012



Table 135

Parameter

TEM_PTO_

Air_Pres_

Engmnt_Inhib

TEM_PTO_

Air_Pres_

Engmnt_Limit

TEM_PTO_

Brake_Engmnt_

Inhib

TEM_PTO_

Cltch_Engmnt_

Inhib

TEM_PTO_

Eng_Run_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Limit

TEM_PTO_

Neut_Engmnt_

Inhib

TEM_PTO_

Non_Neut_

Engmnt_Inhib

TEM_PTO_Pk_

Brake_Engmnt_

Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Limit

TEM_PTO_Mast_

Switch_Engmnt_

Inhib

ID

2097

2098

2095

2094


2096


2092


2093

2089

2088

2087


Park


Park


2090


2091

2099



Description

If this Parameter is 1, the PTO will not be engaged if the primary vehicle air pressure is below TEM_PTO_Air_ Pres_Engmnt_ Limit

Default

On

See TEM_PTO_Air_ Pres_Engmnt_ Inhib




If this Parameter is 1, the PTO will not be engaged if the vehicle master switch is not ON.

90 psi

Off

Off

Off

On

1000 RPM

Off

Off

Off

On

3 MPH

Off

D

ISENGAGEMENT


Min

N/A

1

N/A

N/A

N/A

N/A

100

N/A

N/A

N/A

N/A

1

N/A

Max

N/A

500

N/A

N/A

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

Step

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A

If TEM_PTO_Air_Pres_Disengages parameter is turned on, then the PTO will be disengaged if the primary air pressure is below the value set in TEM_PTO_Air_Pres_DisEng_Limit.






October 2012






Table 136



Description Default Parameter

TEM_PTO_

Air_Pres_

DisEng_Limit

TEM_PTO_

Air_Pres_

Disengages

TEM_PTO_

Eng_Run_

Disengages

TEM_PTO_

Eng_Spd_

DisEng_Limit

TEM_PTO_

Eng_Spd_

Disengages

TEM_PTO_

Non_Neut_

Disengages

TEM_PTO_

Pk_Brake_

Disengages

TEM_PTO_

Veh_Spd_

Disengages

TEM_PTO_

Veh_Spd_

DisEng_Limit

TEM_PTO_Ext_

Input_Disengages

TEM_PTO_Mast_

Switch_Disengages

ID

2116

2115

If this Parameter is 1, the PTO will be disengaged if the primary air pressure is below the value set in TEM_PTO_Air_ Pres_DisEng_ Limit.

2114


2113

2111

See TEM_PTO_Air_ Pres_Disengages


2112



2109


2108


2110




2117

2118



80 psi

On

Off

1800 RPM

On

Off

Off

Off

0 MPH

Off

Off

Min

0

N/A

N/A

0

N/A

N/A

N/A

N/A

3

N/A

N/A

Max

500

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

N/A

Step

1

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

R

E

-E

NGAGEMENT


All re-engagement parameters should be set to 0 with non-clutched air-shifted PTOs to prevent gear grind and damage to the transmission.

If TEM_PTO_Air_Pres_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to low air pressure) when the primary air pressure rises about the value specified by






October 2012









If TEM_PTO_Ext_Input_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after a disengage due to the designated external input being in active state) when the external input is no longer in active state.

Table 137

Parameter

TEM_PTO_

Air_Pres_

Allow_ReEng

TEM_PTO_

Eng_Run_

Allow_ReEng

TEM_PTO_

Eng_Spd_

Allow_ReEng

TEM_PTO_

Key_State_

Allow_ReEng

TEM_PTO_

Non_Neut_

Allow_ReEng

TEM_PTO_

Pk_Brake_

Allow_ReEng

TEM_PTO_

Veh_Spd_

Allow_ReEng

TEM_PTO_Ext_

Input_Allow_ReEng

TEM_PTO_Mast_

Switch_Allow_

ReEng

ID

2124

2122

2120



Description

If this Parameter is 1, the PTO will be reengaged after disengagement due to low vehicle air pressure when the primary air pressure is over

TEM_PTO_Air_ Pres_Engmnt_ Limit.




Default

Off

Off

Off

2069


Off

2148

2149

2119

2121

2123







Off

Off

Off

Off

Off

Min

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Max

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Step

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A


October 2012



A

LARMS



If TEM_PTO_Eng_Run_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the engine is turned off.


If TEM_PTO_Non_Neut_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the transmission is taken out of neutral.

If TEM_PTO_Pk_Brake_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the park brake is released.

If TEM_PTO_Veh_Spd_Alarms parameter is turned on, then an audible alarm will sound if the PTO is engaged and the vehicle speed is over the value set by TEM_PTO_Veh_Spd_Alarm_Limit.


Parameter

TEM_PTO_

Air_Pres_ Alarms

TEM_PTO_Air_

Pres_Alarm_Limit

TEM_PTO_

Eng_Run_ Alarms

TEM_PTO_

Eng_Spd_ Alarms

TEMP_PTO_Eng_

Spd_Alarm_Limit

TEM_PTO_

Non_Neut_ Alarms

TEM_PTO_

Pk_Brake_ Alarms

TEM_PTO_

Veh_Spd_ Alarms

TEM_PTO_Veh_

Spd_Alarm_Limit

ID

2138



Description

If this Parameter is 1, an alarm will sound if the primary air pressure is below TEM_PTO_Air_

Pres_Alarm_Limit.

Default

Off

See TEM_PTO_Air_Pres_Alarms 0 psi 2139

2137

2135

2136

2132

2131

2133

2134







Off

Off

1400 RPM









Off

Off

Off

5 mph

Min

N/A

0

N/A

N/A

0

N/A

N/A

N/A

3

Max

N/A

500

N/A

N/A

5000

N/A

N/A

N/A

100

Step

N/A

1

N/A

N/A

0.1

N/A

N/A

N/A

1

O

THER

P

ARAMETERS

These parameters allow the customer to program the active state of the RPM input and set the maximum current of the RPM output.

The TEM_RPM_PTO_Engaged_Param parameter 2147 indicates the state that the BC will read as active for the TEM PTO feedback switch (as it goes into the RPM input). This active state will be used to indicate when the PTO is engaged.





October 2012



The TEM_Hyd_PTO_Engagement_Out_Param parameter 1993 sets the current at which the BC will fuse the

RPM output that drives the engagement of the PTO. This is used to define the maximum amount of current that can flow through the RPM output.

Table 139

Parameter

TEM_RPM_

PTO_Engaged_

Param

TEM_Hyd_ PTO_

Engagement_

Out_Param

ID

2147





1

1993 This is the fuse level of the Hydraulic PTO FET.

20 Amps

Min

List

0

Max

List

20

Step

List

0.1

W

IRING

I

NFORMATION


®


•


•

One wire must be connected from the pin labeled PTO_Output in the Brown 8-pin RPM output connector, to the coil on the air solenoid. This wire drives the engagement and disengagement of the solenoid. The customer supplies a GND wire for the air solenoid.

•

A second wire must be connected from the Body Builder-installed PTO feedback switch (GND active) to the pin labeled PTO_Feedback_Switch in the black 23-pin RPM input connector. This switch is used to determine whether or not the PTO is engaged by determining if the switch is in the active state. If the switch is indeed in the active state and the PTO is running, then an indicator light in the gauge cluster will be on.

When the switch is not in the active state, the indicator light will not be on.

•

The switch provided is not labeled; therefore the customer will have to install a PTO label for the switch from the bag of switch labels provided with the vehicle. The customer should use the Diamond Logic

®

Builder software to determine the location of the in-cab switch.


October 2012



Diagram of Electric Over Air (Non-Clutched) PTO System

f_131

RPM C

ONNECTOR

I

NFORMATION

HPV kits are REQUIRED to allow Body Builders to wire in and out of the RPM connectors.

HPV kits are pre-made kits that include terminals and seals for BOTH RPM connectors.

Table 140

HPV Kits



Part Number

2585651C91

2585423C91


This information is given so that the Body Builder can purchase connectors in the event that the original connectors are damaged or lost, or so that the Body Builder can pre-fabricate a harness.



Description

Terminal Part

Cable Seal Part

Connector Lock Part

CPA Lock

Cavity Plug

3548934C1 2585981C91


3534163C1 – 12 Gauge

3535931C1 – 14 Gauge

3535930C1 – 16 & 18 Gauge

1698937C1

3548945C1 – 12 & 14 Gauge

3535937C1 – 16 & 18 Gauge

3548943C1

3573833C1

3535938C1

N/A

N/A

N/A

Included


October 2012




f_127


f_123


October 2012



T

ESTING

1. To determine if the PTO is working, depress the PTO switch in the cab to the on position. Ensure that all interlock conditions are enabled.

2. Verify that the pin labeled PTO_Output of the brown 8-way RPM output connector has the battery voltage levels present.

3. Verify that the RPM input labeled PTO_Feedback_Switch (Pin position specified by the Diamond Logic

®

Builder software) is receiving the correct voltage (12V or GND) as specified by the customer in the

Diamond Logic

®

Builder software.

4. Make certain that the indicator light in the top section of the PTO switch illuminates by engaging the PTO.

5. Make certain that the PTO indicator light in the gauge cluster illuminates by engaging the PTO.

6. The audible alarm can be tested by violating the set programmable parameters and determining if the alarm sounds. For example: If the park brake interlock is programmed ON, release the park brake and engage the PTO. The audible alarm should sound with continuous beeps.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature codes 595AJT (Use 595BJS or 595BJT instead of 595AJT on vehicles with 2010 compliant engines), 595AJU, 595AJX, 595AJZ and 595BBA (for Hybrids only) must be enabled on the vehicle using the Diamond Logic

®

Builder software (see Local Dealer).

•


®

Builder software to make sure that software feature codes 595AJV, 595AJW,

595AJY, and 595AMZ are NOT enabled on the vehicle (see Local Dealer)

•


®


Local Dealer)

•

Connect a wire from the pin labeled PTO_Output in the Brown 8-pin RPM output connector to the coil on the solenoid.

•

Connect a wire from a Body Builder-installed PTO feedback switch to the pin labeled PTO_Feedback_Switch in the Black 23-Pin RPM input connector.

•


■

PTO ACCOMMODATION ELECTRIC OVER AIR CLUTCHED

60ABL

BDY INTG, PTO ACCOMMODATION. Accommodation for Electric over Air, Clutched PTO Engagement and

Disengagement, Does not Include Air Solenoid, With Switch Mounted on Dash, Includes Audible Alarm and

Indicator Light in Gauge Cluster (requires one RPM input and one output)

This feature provides a latched switch in the in-cab switch pack to drive a RPM output that provides power to engage and disengage the Electric over Air, Clutched PTO. A RPM input is used to drive an indicator light in the gauge cluster, allowing the operator to discern whether or not the PTO is engaged. An audible alarm sounds when certain programmable parameters are violated. The RPM input also drives a PTO hourmeter to allow the operator to measure stationary PTO hours for maintenance records and fuel tax purposes. To view the hourmeter, press the gauge cluster selection button momentarily until the text portion of the display indicates

“PTO Hour.”


This PTO feature is a rule-based option. The operation of the PTO is governed by rules of engagement, disengagement, re-engagement, and alarms. These rules are defined through programmable parameters.

Through these programmable parameters, the vehicle owner can customize the functionality of the PTO.

Factory default settings for these programmable parameters are listed in the tables below.


®



October 2012



S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS



®

®



R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES


595AJY, 595AJZ, 595BBA (Hybrid Electric Vehicles only)

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

595AJV, 595AJW, 595AJX, 595AMZ, 595BAM

E

NGAGEMENT





PTO to engage.





Transmission is NOT in Neutral or Park




PTO to be engaged.





October 2012



Table 142

Parameter

TEM_PTO_

Air_Pres_

Engmnt_Inhib

TEM_PTO_

Air_Pres_

Engmnt_Limit

TEM_PTO_

Brake_Engmnt_

Inhib

TEM_PTO_

Cltch_Engmnt_

Inhib

TEM_PTO_

Eng_Run_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Limit

TEM_PTO_

Neut_Engmnt_

Inhib

TEM_PTO_

Non_Neut_

Engmnt_Inhib

TEM_PTO_Pk_

Brake_Engmnt_

Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Limit

TEM_PTO_Mast_

Switch_Engmnt_

Inhib

ID

2097

2098

2095

2094


2096


2092


2093

2089

2088

2087


Park


Park


2090


2091

2099



Description


Default

On





If this Parameter is 1, the PTO will not be engaged if the vehicle master switch is not ON.

90 psi

Off

Off

Off

On

1000 RPM

Off

Off

Off

On

3 MPH

Off

D

ISENGAGEMENT


Min

N/A

1

N/A

N/A

N/A

N/A

100

N/A

N/A

N/A

N/A

1

N/A

Max

N/A

500

N/A

N/A

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

Step

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A







October 2012






Table 143




TEM_PTO_

Air_Pres_

DisEng_Limit

TEM_PTO_

Air_Pres_

Disengages

TEM_PTO_

Eng_Run_

Disengages

TEM_PTO_

Eng_Spd_

DisEng_Limit

TEM_PTO_

Eng_Spd_

Disengages

TEM_PTO_

Non_Neut_

Disengages

TEM_PTO_

Pk_Brake_

Disengages

TEM_PTO_

Veh_Spd_

Disengages

TEM_PTO_

Veh_Spd_

DisEng_Limit

TEM_PTO_Ext_

Input_Disengages

TEM_PTO_Mast_

Switch_Disengages

ID

2116

2115

If this Parameter is 1, the PTO will be disengaged if the primary air pressure is below the value set in TEM_PTO_Air_ Pres_DisEng_Limit.

2114


2113

2111


See TEM_PTO_ Eng_Spd_Disengages

2112


TEM_PTO_Eng_ Spd_DisEng_Limit

2109


2108


2110


TEM_PTO_Veh_ Spd_DisEng_Limit.


2117

2118



80 psi

On

Off

1800 RPM

On

Off

Off

Off

0 MPH

Off

Off

Min

0

N/A

N/A

0

N/A

N/A

N/A

N/A

3

N/A

N/A

Max

500

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

N/A

Step

1

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

R

E

-E

NGAGEMENT









October 2012









Table 144

Parameter

TEM_PTO_

Air_Pres_

Allow_ReEng

TEM_PTO_

Eng_Run_

Allow_ReEng

TEM_PTO_

Eng_Spd_

Allow_ReEng

TEM_PTO_

Key_State_

Allow_ReEng

TEM_PTO_

Non_Neut_

Allow_ReEng

TEM_PTO_

Pk_Brake_

Allow_ReEng

TEM_PTO_

Veh_Spd_

Allow_ReEng

TEM_PTO_Ext_

Input_Allow_ReEng

TEM_PTO_Mast_

Switch_Allow_

ReEng

ID

2124

2122

2120



Description






Default

Off

Off

On

2069


Off

2148

2149

2119

2021

2023






If this Parameter is 1, the PTO will be reengaged after a disengage due to the engine stopping when the engine is restarted

Off

Off

Off

Off

Off

Min

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Max

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Step

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A

LARMS



If TEM_PTO_Eng_Run_Alarms parameter is turned on, then an audible alarm will sound in the cab if the PTO is engaged and the engine is turned off.


October 2012



If TEM_PTO_Eng_Spd_Alarms parameter is turned on, then an alarm will sound in the cab if the PTO is engaged and the engine speed is over the value set by TEM_PTO_Eng_Spd_Alarm_Limit.

If TEM_PTO_Non_Neut_Alarms parameter is turned on, then an audible alarm will sound in the cab if the PTO is engaged and the transmission is taken out of neutral.

If TEM_PTO_Pk_Brake_Alarms parameter is turned on, then an audible alarm will sound in the cab if the PTO is engaged and the park brake is released

If TEM_PTO_Veh_Spd_Alarms parameter is turned on, then an audible alarm will sound in the cab if the PTO is engaged and the vehicle speed is about the value set by TEM_PTO_Veh_Spd_Alarm_Limit.

Table 145

Parameter

TEM_PTO_

Air_Pres_ Alarms

TEM_PTO_Air_

Pres_Alarm_Limit

TEM_PTO_

Eng_Run_ Alarms

TEM_PTO_

Eng_Spd_ Alarms

ID

2138

2139

2137

2135



Description


Pres_Alarm_Limit.

Default

Off



PTO is engaged and the engine is turned off.




Off

Off

Min

N/A

0

N/A

N/A

Max

N/A

500

N/A

N/A

Step

N/A

1

N/A

N/A

TEMP_PTO_Eng_

Spd_Alarm_Limit

TEM_PTO_

Non_Neut_ Alarms

TEM_PTO_

Pk_Brake_ Alarms

TEM_PTO_

Veh_Spd_ Alarms

TEM_PTO_Veh_

Spd_Alarm_Limit

2136

2132

2131

2133

2134










1400 RPM

Off

Off

Off

5 mph

0

N/A

N/A

N/A

3

5000

N/A

N/A

N/A

100

0.1

N/A

N/A

N/A

1

O

THER

P

ARAMETERS

These parameters allow the customer to program the active state of the RPM input and set the maximum current of the RPM output.

The TEM_RPM_PTO_Engaged_Param parameter 2147 indicates the state that the BC will read as active for the TEM PTO feedback switch (As it goes into the RPM input). This active state will be used to indicate when the PTO is engaged.




The TEM_Hyd_PTO_Engagement_Out_Param parameter 1993 sets the current at which the BC will fuse the

Remote Power Module output that drives the engagement of the PTO. This is used to define the maximum amount of current that can flow through the Remote Power Module output.


October 2012



Table 146

Parameter

TEM_RPM_

PTO_Engaged_

Param

TEM_Hyd_ PTO_

Engagement_

Out_Param

ID

2147





1

1993 This is the fuse level of the Hydraulic PTO FET.

20 Amps

Min

List

0

Max

List

20

Step

List

0.1

W

IRING

I

NFORMATION


®


•


•

One wire must be connected from the pin labeled PTO_Output in the Brown 8-pin RPM output connector to the coil on the air solenoid. This wire drives the engagement and disengagement of the solenoid. The customer supplies a GND wire for the air solenoid.

•

A second wire must be connected from the Body Builder-installed PTO feedback switch (GND active) to the pin labeled PTO_Feedback_Switch in the Black 23-pin RPM input connector. This switch used to determine whether or not the PTO is engaged by checking if the switch is in the active state. If the switch is indeed in the active state and the PTO is running, then an indicator light in the gauge cluster will be on. When the switch is not in the active state, the indicator light will not be on.

•

The switch provided is labeled PTO.

Diagram of Electric Over Air (Clutched) PTO System

f_132

RPM C

ONNECTOR

I

NFORMATION

HPV kits are REQUIRED to allow Body Builders to wire in and out of the RPM connectors.

HPV kits are pre-made kits that include terminals and seals for BOTH RPM connectors.


October 2012



Table 147

HPV Kits



Part Number

2585651C91

2585423C91


This information is given so that the Body Builder can purchase connectors in the event that the original connectors are damaged or lost, or so that the Body Builder can pre-fabricate a harness.



Description

Terminal Part

Cable Seal Part

Connector Lock Part

CPA Lock

Cavity Plug

3548934C1 2585981C91


3534163C1 – 12 Gauge

3535931C1 – 14 Gauge

3535930C1 – 16 & 18 Gauge

1698937C1

3548945C1 – 12 & 14 Gauge

3535937C1 – 16 & 18 Gauge

3548943C1

3573833C1

3535938C1

N/A

N/A

N/A

Included



f_127

October 2012




f_123

T

ESTING

1. To determine if the PTO is working, depress the PTO switch in the cab to the on position. Ensure that all interlock conditions are enabled.

2. Verify that the pin labeled PTO_Output of the Brown 8-way Remote Power Module output connector has the battery voltage levels present.

3. Verify that the Remote Power Module Input labeled PTO_Feedback_Switch (Pin position specified by the

Diamond Logic

®

Builder software) is receiving the correct voltage (12V or GND) as specified by the customer in the Diamond Logic

®

Builder software.

4. Make certain that the indicator light in the top section of the PTO switch illuminates by engaging the PTO.

5. Make certain that the PTO indicator light in the gauge cluster illuminates by engaging the PTO.

6. The audible alarm can be tested by violating the set programmable parameters and determining if the alarm sounds. For example, if the park brake interlock is programmed ON, release the park brake and engage the PTO. The audible alarm should sound with continuous beeps.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature codes 595AJT (Use 595BJS or 595BJT instead of 595AJT on vehicles with 2010 compliant engines), 595AJU, 595AJY, 595AJZ and 595BBA (for Hybrids only) must be enabled on the vehicle using the

Diamond Logic

®

Builder software (see Local Dealer).

•


®

Builder software to make sure that software feature codes 595AJV, 595AJW,

595AJX, and 595AMZ are NOT enabled on the vehicle (see Local Dealer)

•


®


Local Dealer)

•

Connect a wire from the pin labeled PTO_Output in the Brown 8-pin RPM output connector to the coil on the solenoid.

•

Connect a wire from a Body Builder-installed PTO feedback switch to the pin labeled PTO_Feedback_Switch in the Black 23-Pin RPM input connector.

•



October 2012



■

THREE INTERLOCKED LATCHED SWITCHES DISENGAGE AT 30 MPH WITH PTO

ACCOMMODATION

60AKG

BDY INTG, PTO ACCOMODATION for (3) Rocker Switches, (1) PTO Switch, (2) Generic Switches to Control

(3) 30 amp relays, With Programmable Interlocks, for Body Builder Hook up in the Engine Compartment Left

Side, Recommended for Automatic Transmissions

This feature provides TWO 2-position Latched Rocker switches that control two auxiliary loads requiring a total of two RPM outputs. Outputs are defaulted to disengage when vehicle speed reaches 30 MPH. The outputs will only be available in IGN or accessory key-state. This feature is used for applications such as a rear shining light. If the operator forgets to turn the light off before he drives away, the light will shut off when the driver hits

30 MPH.

The owner can interlock the switch with certain programmable conditions. These conditions can be set as programmable parameters using the Diamond Logic

®

Builder software. These parameters are listed and explained below.

This feature includes two copies of the functionality provided by 60ACG; e.g., two outputs with two switches.

Each one of these outputs is exactly the same as that provided by 60ACG. The two outputs in this feature are completely autonomous (independent of each other). Each of the two outputs has its own set of four parameters (the five mentioned in the description for 60ACG with the exception of the RPM fuse parameters).

This feature also provides the customer with the ability to control a customer-supplied PTO with an in-dash switch. Programmable parameters allow customers to customize the functionality of their PTO.


®


S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software feature codes can be added through the Diamond Logic parameters are also programmable through the Diamond Logic

®

®


Builder software.

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES

595BHZ, 595BKY, 595AJZ

Conflicts with Software features: 595 AKB, 595AKC, 595AJV, 595AJW, 595AJX, and 595AJY

TEM_Aux1_Misc_Interlock_Param



October 2012



Table 149

Setting

2

3

0

1

4

5

6

7

8

9

10

11

12

13

14

15

16


















TEM_Aux1_Gear_Interlock_Param AND the switch is on (Requires Automatic Transmission)



Activate this output when the transmission is in neutral AND the switch is on (Requires


Activate this output when the transmission is not in neutral AND the switch is on (Requires



* TEM_Aux1_Interlock_Latches_Off f_106


October 2012











Table 150

Setting

125



126

127

128

125 + x





124

123

125 – y




The transmission gear parameter is only used if

TEM_Aux1_Misc_Interlock_Param is set to 13 or 14.






October 2012



Table 151

Setting

2

3

0

1

4

5

6

7

8

9

10

11

12

13

14

15

16





















Activate this output when the transmission is in neutral AND the switch is on (Requires


Activate this output when the transmission is not in neutral AND the switch is on (Requires



f_106


October 2012












Table 152

Setting

125



126

127

128

125 + x





124

123

125 – y




The transmission gear parameter is only used if

TEM_Aux1_Misc_Interlock_Param is set to 13 or 14.

Example: For the output to only come on when the vehicle transmission is in a reverse gear, you would set



October 2012



Table 153

Parameter

TEM_Aux1_

Interlock_

Latches_Off

TEM_Aux1_

Speed_ Interlock_

Param

ID

2006

2007



Description


The speed parameter for the TEM Aux #1 with

Interlocks feature.

TEM_Aux1_ Gear_

Interlock_ Param

TEM_Aux1_ Misc_

Interlock_ Param

TEM_Aux2_

Interlock_

Latches_Off

TEM_Aux2_

Speed_ Interlock_

Param

2008

2033

2010

2011






The speed parameter for the TEM Aux #2 with

Interlocks feature.

TEM_Aux2_ Gear_

Interlock_ Param

TEM_Aux2_ Misc_

Interlock_ Param

2012

2034





Default

Off

30

0

10

Off

30

0

10

Min

On/Off

Mph

Number

List

On/Off

Mph

Number

List

E

NGAGEMENT

*These parameters set rules that must be met in order for the PTO to be engaged.

Max

0

0

0

0

Step

100

250

100

250




PTO to engage.




If TEM_PTO_Neut_Engmnt_Inhib parameter is turned on, then the PTO can only be engaged if the transmission is NOT in Neutral or Park.



If TEM_PTO_Pk_Brake_Engmnt_Inhib parameter is turned on, then the park brake must be set in order for the

PTO to be engaged.

If TEM_PTO_Veh_Spd_Engmnt_Inhib parameter is turned on, then the PTO cannot be engaged if the vehicle speed is over the value prescribed by TEM_PTO_Veh_Spd_Engmnt_Limit.


October 2012



Table 154

Parameter

TEM_PTO_

Air_Pres_

Engmnt_Inhib

TEM_PTO_

Air_Pres_

Engmnt_Limit

TEM_PTO_

Brake_Engmnt_

Inhib

TEM_PTO_

Cltch_Engmnt_

Inhib

TEM_PTO_

Eng_Run_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Limit

TEM_PTO_

Neut_Engmnt_

Inhib

TEM_PTO_

Non_Neut_

Engmnt_Inhib

TEM_PTO_Pk_

Brake_Engmnt_

Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Limit

ID

2097

2098

2095

2094


2096


2092


2093

2089

2088

2087


Park


Park


2090


2091



Description


Default

On





90 psi

Off

Off

Off

On

1000 RPM

Off

Off

Off

On

3 MPH

D

ISENGAGEMENT


Min

N/A

1

N/A

N/A

N/A

N/A

100

N/A

N/A

N/A

N/A

1

Max

N/A

500

N/A

N/A

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

Step

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

N/A

N/A

1








October 2012



Table 155

Parameter

TEM_PTO_

Air_Pres_

DisEng_Limit

TEM_PTO_

Air_Pres_

Disengages

TEM_PTO_

Eng_Run_

Disengages

TEM_PTO_

Eng_Spd_

DisEng_Limit

TEM_PTO_

Eng_Spd_

Disengages

TEM_PTO_

Non_Neut_

Disengages

TEM_PTO_

Pk_Brake_

Disengages

TEM_PTO_

Veh_Spd_

Disengages

TEM_PTO_

Veh_Spd_

DisEng_Limit

ID

2116

2115


2114


2113




2112



2109


2108


2110



2111




80 psi

On

Off

1800 RPM

On

Off

Off

Off

0 MPH

R

E

-E

NGAGEMENT


Min

0

N/A

N/A

0

N/A

N/A

N/A

N/A

3

Max

500

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

Step

1

N/A

N/A

1

N/A

N/A

N/A

N/A

1












October 2012



Table 156

Parameter

TEM_PTO_

Air_Pres_

Allow_ReEng

TEM_PTO_

Eng_Run_

Allow_ReEng

TEM_PTO_

Eng_Spd_

Allow_ReEng

TEM_PTO_

Key_State_

Allow_ReEng

TEM_PTO_

Non_Neut_

Allow_ReEng

TEM_PTO_

Pk_Brake_

Allow_ReEng

TEM_PTO_

Veh_Spd_

Allow_ReEng

ID

2124

2122

2120



Description






Default

Off

Off

On

2069


Off

2148

2149

2119





Off

Off

Off

Min

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Max

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Step

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A

LARMS

This feature does not provide any PTO feedback indications or alarms. If this functionality is required, add the feature described in the chapter for 16WLM PTO Feedback and Alarms.

W

IRING

I

NFORMATION

The wiring out of the pin labeled TEM_PTO_Relay_Driver_Command should be connected to the F2 pin on the

J4 (1601) connector.

The wiring out of the pin labeled Interlocked_switch_relay1_output should be connected to the F6 pin on the J4

(1601) connector.

The wiring out of the pin labeled Interlocked_switch_relay2_output should be connected to the F7 pin on the J4

(1601) connector.


October 2012



f_135

T

ESTING

2. Verify that the output labeled Interlocked_switch_relay1_output is obtaining the desired voltage (as programmed by the Diamond Logic

®

Builder software).



5. Depress the second switch.

6. Verify that the RPM output labeled Interlocked_switch_relay2_output is obtaining the desired voltage (as programmed by the Diamond Logic

®

Builder software).

7. Verify the functionality of the 30 MPH interlock by violating the parameter and determine that the output shuts off.


9. Depress the In-cab PTO switch to the ON position.

10. Verify that all enabled interlock conditions are met.


October 2012



H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature codes 595BHZ, 595BKY and 595AJZ MUST be enabled using the Diamond Logic

®


•

Software feature codes 595AJU, 595AJV, 595AJW, 595AJX, and 595AJY must NOT be enabled on the truck.

•

Three (3) 2-position latched rocker switches (P/N 3578910C1) must be installed in the in-cab switch pack in the position specified by the Diamond Logic

®

Builder software.

•

Three (3) green LED indicator lights (P/N 3578733C1) must be installed behind the upper portion of each switch.

•

Three (3) amber LED indicator lights (P/N 3533928C1) must be installed behind the lower portion of each switch.

•

Three (3) relays, gen. control, 4-pin micro (P/N 3600329C1) must be installed with the proper pin connections to the J4 connector described above.

•


®


•

Set desired “Engagement”, “Disengagement”, and “Re-engagement” programmable parameters.

■

PTO CONTROL

13XAA

PTO CONTROL, DASH MOUNTED For Customer Provided PTO; Includes Switch, Electric/Air Solenoid, Piping and Wiring

13WDH

WIRING, TRANS, BODY BUILDER, Installed Wiring for Transmission/PTO Controls, for Allison 2000, 2100,

2200, 2400, 2500 Series Transmission Only. NOTE: See the Automatic Transmission Interfaces section of this manual for connector reference information and connector location.

13WDN

PTO CONTROL, DASH MOUNTED for Customer Provided PTO; Includes 2 Independent Illuminated Switches,

2 Electric/Air Solenoids, Piping and Wiring

This feature provides the customer with the ability to control a customer-supplied PTO(s) with a single

(13XAA)/two (13WDN) in-dash switch(es) and a single (13XAA)/two (13WDN) air solenoid(s). This feature provides all the software and wiring to the air solenoid located inside the driver’s side frame rail next to the transmission. Customer must supply and route air plumbing to the PTO. Programmable parameters allow customers to customize the functionality of their PTO.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES

(

FOR ALL MODELS OTHER THAN

L

INE

H

AUL AND

P

RO

S

TAR

):

595AJZ and 595AMZ

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

595AJU, 595AJV, 595AJW, 595AJX, and 595AJY

NOTE: The parameters for 13XAA for the Line Haul and ProStar models are listed further down.

E

NGAGEMENT




October 2012





PTO to engage.








PTO to be engaged.




October 2012



Table 157

Parameter

TEM_PTO_

Air_Pres_

Engmnt_Inhib

TEM_PTO_

Air_Pres_

Engmnt_Limit

TEM_PTO_

Brake_Engmnt_

Inhib

TEM_PTO_

Cltch_Engmnt_

Inhib

TEM_PTO_

Eng_Run_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Limit

TEM_PTO_

Neut_Engmnt_

Inhib

TEM_PTO_

Non_Neut_

Engmnt_Inhib

TEM_PTO_Pk_

Brake_Engmnt_

Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Limit

TEM_PTO_Mast_

Switch_Engmnt_

Inhib

ID

2097

2098

2095

2094


2096


2092


2093

2089

2088

2087


Park


Park


2090


2091

2099



Description


Default

On






90 psi

Off

Off

Off

On

1000 RPM

Off

Off

Off

On

3 MPH

Off

D

ISENGAGEMENT


Min

N/A

1

N/A

N/A

N/A

N/A

100

N/A

N/A

N/A

N/A

1

N/A

Max

N/A

500

N/A

N/A

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

Step

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A







October 2012






Table 158




TEM_PTO_

Air_Pres_

DisEng_Limit

TEM_PTO_

Air_Pres_

Disengages

TEM_PTO_

Eng_Run_

Disengages

TEM_PTO_

Eng_Spd_

DisEng_Limit

TEM_PTO_

Eng_Spd_

Disengages

TEM_PTO_

Non_Neut_

Disengages

TEM_PTO_

Pk_Brake_

Disengages

TEM_PTO_

Veh_Spd_

Disengages

TEM_PTO_

Veh_Spd_

DisEng_Limit

TEM_PTO_Ext_

Input_Disengages

TEM_PTO_Mast_

Switch_Disengages

ID

2116

2115


2114


2113

2111



2112



2109


2108


2110




2117

2118



80 psi

On

Off

1800 RPM

On

Off

Off

Off

0 MPH

Off

Off

Min

0

N/A

N/A

0

N/A

N/A

N/A

N/A

3

N/A

N/A

Max

500

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

N/A

Step

1

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

R

E

-E

NGAGEMENT









October 2012









Table 159

Parameter

TEM_PTO_

Air_Pres_

Allow_ReEng

TEM_PTO_

Eng_Run_

Allow_ReEng

TEM_PTO_

Eng_Spd_

Allow_ReEng

TEM_PTO_

Key_State_

Allow_ReEng

TEM_PTO_

Non_Neut_

Allow_ReEng

TEM_PTO_

Pk_Brake_

Allow_ReEng

TEM_PTO_

Veh_Spd_

Allow_ReEng

TEM_PTO_Ext_

Input_Allow_ReEng

TEM_PTO_Mast_

Switch_Allow_

ReEng

ID

2124

2122

2120



Description






Default

Off

Off

On

2069


Off

2148

2149

2119

2121

2123







Off

Off

Off

Off

Off

Min

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Max

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Step

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

W

IRING

I

NFORMATION

Customer must supply and route air plumbing from the Navistar-provided air solenoid (Located inside the driver’s side frame rail, adjacent to the Transmission) to the PTO.


October 2012



f_136

T

ESTING



3. Verify that the Navistar-provided air solenoid is supplying air pressure at the solenoid output.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature codes 595AJZ and 595AMZ must be added to the truck using the Diamond Logic

®

Builder software.

•

Software feature codes 595AJU, 595AJV, 595AJW, 595AJX, and 595AJY must NOT be enabled on the truck.

•


•

Add a latched switch (P/N 3578910C1) in the in-cab switch pack in the position specified by the Diamond

Logic

®

Builder software.

•

If the truck does not already have a 4-pack solenoid base, the customer should order a 4-pack base (part number 2505594C1) and an air solenoid (part number 2506711C91).

•

Add wiring as per the Electrical Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Air

Solenoid.


October 2012



■

PTO CONTROL ONLY FOR LINE HAUL AND PROSTAR MODELS, DASH MOUNTED FOR

CUSTOMER PROVIDED PTO; INCLUDES SWITCH, ELECTRIC/AIR SOLENOID, PIPING

AND WIRING

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES

595ADD for post 2007 clusters and pre 2010 clusters – 595BKJ or 595BNP is required to be added for 2010 clusters.

Software feature 595BNP is similar to 595BKJ, but has 42 parameters available.

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

595AEB for post 2007 clusters and pre 2010 clusters – 595BKK or 595BNN is required to be removed for 2010 clusters.

These parameters set the conditions under which the PTO will be engaged and disengaged.

Software Feature Codes: 595ADD or 595BKJ

P

ARAMETERS

PTOa_Vehicle_Speed_Enable – Set to 0 to ignore the vehicle speed. Set to 1 to require the vehicle to be below a specified vehicle speed for the PTO to engage. Please use PTOa_Vehicle_Speed_Range to specify the appropriate vehicle speed if this parameter is set to 1.

PTOa_Engine_Speed_Enable – Set to 0 to ignore the engine speed. Set to 1 to require the vehicle to be below a specified engine speed for the PTO to be engaged. Please use PTOa_Engine_Speed_Range to specify the appropriate engine speed if this parameter is set to 1.

PTOa_Engine_Speed_Alarm_Enable – Set to 0 to not have an alarm based on engine speed. Set to 1 to have a speed that an alarm will sound when the PTO is engaged and the engine speed is greater than the set value.

Please use PTOa_Engine_Speed_Alarm_Range to specify the appropriate engine speed if this parameter is set to 1.

Vehicle_Speed_Alarm_Enable PTOa_– Set to 0 to not have an alarm based on vehicle speed. Set to 1 to have a speed limit that an alarm will sound when the PTO is engaged and the vehicle speed is greater than the set value. Please use PTOa_Vehicle_Speed_Alarm_Range to specify the appropriate vehicle speed if this parameter is set to 1.

PTOa_Clutch_Pedal – Set to 0 to ignore the clutch pedal or if the vehicle does not have a clutch pedal. Set to 1 to ensure that the clutch pedal is depressed for engagement.

PTOa_Engine_Running – Set to 0 to ignore the engine. Set to 1 to ensure that the engine is running to engage and disengage if the engine stops running.

PTOa_Engine_Speed_Range – Set to a speed that the engine has to be below for the PTO to engage. The

PTO will disengage if the engine speed becomes greater than the set value. If engine speed is required for

PTO operation, please use PTOa_Engine_Speed_Enable to enable this interlock.

PTOa_Park_Brake – Set to 0 to ignore the park brake. Set to 1 to ensure that the park brake is set for engage and disengage if the park brake is released.

PTOa_Engine_Speed_Alarm_Range – Set to the speed that the vehicle has to be below for the PTO to engage. The PTO will disengage if the vehicle speed becomes greater than the set value. If vehicle speed is required for PTO operation, please use PTOa_Vehicle_Speed_Enable parameter to enable this interlock.

PTOa_Vehicle_Speed_Alarm_Range.


October 2012



PTOa_Transmission_Neutral – NOTE: this parameter will only work for vehicles with automated manual transmissions. Set to 0 to ignore the transmission state. Set to 1 to ensure that the transmission is in neutral for engagement.

Table 160

Parameter

PTOa_Vehicle_

Speed_Enable

PTOa_Engine_

Speed_Enable

PTOa_Engine_

Speed_Alarm_

Enable

Vehicle_Speed_

Alarm_Enable

PTOa

PTOa_Clutch_

Pedal

PTOa_Engine_

Running

PTOa_Engine_

Speed_Range

PTOa_Vehicle_

Speed_Range

PTOa_Engine_

Speed_Alarm_

Range

PTOa_Vehicle_

Speed_Alarm_

Range

PTOa_

Transmission_

Neutral

ID

2242

2243

2244

2267

2333

2334

2336

PTOa_Park_Brake 2338

2339

2340

2342

2355



Description

Set to 1 to require the vehicle to be below a specified vehicle speed for the PTO to engage. Please use

PTOa_Vehicle_Speed_Range to specify the appropriate vehicle speed if this parameter is set to 1..

Set to 1 to require the vehicle to be below a specified engine speed for the PTO to be engaged. Please use

PTOa_Engine_Speed_Range to specify the appropriate engine speed if this parameter is set to 1.

Set to 1 to have a speed that an alarm will sound when the PTO is engaged and the engine speed is greater than the set value. Please use

PTOa_Engine_Speed_Alarm_Range to specify the appropriate engine speed if this parameter is set to 1.

Set to 1 to have a speed limit that an alarm will sound when the PTO is engaged and the vehicle speed is greater than the set value. Please use

PTOa_Vehicle_Speed_Alarm_Range to specify the appropriate vehicle speed if this parameter is set to 1.

Set to 1 to ensure that the clutch pedal is depressed for engagement.

Set to 1 to ensure that the engine is running to engage and disengage if the engine stops running.

Set to a speed that the engine has to be below for the

PTO to engage. The PTO will disengage if the engine speed becomes greater than the set value. If engine speed is required for PTO operation, please use

PTOa_Engine_Speed_Enable to enable this interlock.

Set to 1 to ensure that the park brake is set for engage and disengage if the park brake is released.

Set to the speed that the vehicle has to be below for the PTO to engage. The PTO will disengage if the vehicle speed becomes greater than the set value. If vehicle speed is required for PTO operation, please use PTOa_Vehicle_Speed_Enable parameter to enable this interlock.

If an engine speed alarm is required for PTO operation, please use PTOa_Engine_Speed_Alarm_Enable parameter to enable this alarm.

Set to a speed limit that an alarm will sound when the

PTO is engaged and the vehicle speed is greater than the set value. If the vehicle alarm is required for PTO operation, please use

PTOa_Vehicle_Speed_Alarm_Enable to enable this alarm.

NOTE, this parameter will only work for vehicles with automated manual transmissions. Set to 1 to ensure that the transmission is in neutral for engagement.

Default

On

Off

Off

Off

Off

Off

300

On

3

300

3

On

Min

N/A

N/A

N/A

N/A

N/A

N/A

300

N/A

3

300

3

N/A

Max

N/A

N/A

N/A

N/A

N/A

N/A

3000

N/A

100

3000

100

N/A

Step

N/A

N/A

N/A

N/A

N/A

N/A

10

N/A

1

10

1

N/A


October 2012



S

OFTWARE

F

EATURE

C

ODES

595BNP (2010 Clusters, 42 Parameters)

P

ARAMETERS

E

NGAGEMENT





PTO to engage.








PTO to be engaged.




October 2012



Table 161

Parameter

TEM_PTO_

Air_Pres_

Engmnt_Inhib

TEM_PTO_

Air_Pres_

Engmnt_Limit

TEM_PTO_

Brake_Engmnt_

Inhib

TEM_PTO_

Cltch_Engmnt_

Inhib

TEM_PTO_

Eng_Run_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Limit

TEM_PTO_

Neut_Engmnt_

Inhib

TEM_PTO_

Non_Neut_

Engmnt_Inhib

TEM_PTO_Pk_

Brake_Engmnt_

Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Limit

TEM_PTO_Mast_

Switch_Engmnt_

Inhib

ID

2097

2098

2095

2094

2096

2092

2093

2089

2088

2087

2090

2091

2099



Description

If this Parameter is 1, the PTO will not be engaged if the primary vehicle air pressure is below

TEM_PTO_Air_ Pres_Engmnt_ Limit

Default

On





If this Parameter is 1, the PTO will not be engaged if the engine speed is over the value set in

TEM_PTO_Eng_ Spd_Engmnt_ Limit


If this Parameter is 1, the PTO will only be engaged if the Transmission is not in Neutral or Park

If this Parameter is 1, the PTO will not be engaged if the Transmission is not in Neutral or Park


If this Parameter is 1, the PTO will not be engaged if the vehicle speed is over the value set in

TEM_PTO_Veh_ Spd_Engmnt_ Limit



90 psi

Off

Off

Off

On

1000 RPM

Off

Off

Off

On

3 MPH

Off

D

ISENGAGEMENT


Min

N/A

1

N/A

N/A

N/A

N/A

100

N/A

N/A

N/A

N/A

1

N/A

Max

N/A

500

N/A

N/A

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

Step

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A







October 2012






Table 162




TEM_PTO_

Air_Pres_

DisEng_Limit

TEM_PTO_

Air_Pres_

Disengages

TEM_PTO_

Eng_Run_

Disengages

TEM_PTO_

Eng_Spd_

DisEng_Limit

TEM_PTO_

Eng_Spd_

Disengages

TEM_PTO_

Non_Neut_

Disengages

TEM_PTO_

Pk_Brake_

Disengages

TEM_PTO_

Veh_Spd_

Disengages

TEM_PTO_

Veh_Spd_

DisEng_Limit

TEM_PTO_Ext_

Input_Disengages

TEM_PTO_Mast_

Switch_Disengages

ID

2116

2115

2114

2113

2112

2109

2108

2110

2111

2117

2118


If this Parameter is 1, the PTO will be disengaged if the primary air pressure is below the value set in

TEM_PTO_Air_ Pres_DisEng_ Limit.



If this Parameter is 1, the PTO will be disengaged if the engine speed is over the value set in TEM_PTO_Eng_

Spd_DisEng_ Limit


If this Parameter is 1, the PTO will be disengaged if the

Park Brake is released.

If this Parameter is 1, the PTO will be disengaged if the vehicle speed is over the value set in TEM_PTO_Veh_

Spd_DisEng_ Limit.




80 psi

On

Off

1800 RPM

On

Off

Off

Off

0 MPH

Off

Off

Min

0

N/A

N/A

0

N/A

N/A

N/A

N/A

3

N/A

N/A

Max

500

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

N/A

Step

1

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

R

E

-E

NGAGEMENT









October 2012









Table 163

Parameter

TEM_PTO_

Air_Pres_

Allow_ReEng

TEM_PTO_

Eng_Run_

Allow_ReEng

TEM_PTO_

Eng_Spd_

Allow_ReEng

TEM_PTO_

Key_State_

Allow_ReEng

TEM_PTO_

Non_Neut_

Allow_ReEng

TEM_PTO_

Pk_Brake_

Allow_ReEng

TEM_PTO_

Veh_Spd_

Allow_ReEng

TEM_PTO_Ext_

Input_Allow_ReEng

TEM_PTO_Mast_

Switch_Allow_

ReEng

ID

2124

2122

2120

2069



Description

If this Parameter is 1, the PTO will be reengaged after disengagement due to low vehicle air pressure when the primary air pressure is over TEM_PTO_Air_

Pres_Engmnt_ Limit.


If this Parameter is 1, the PTO will be reengaged after disengagement due to engine overspeed when the engine speed is below TEM_PTO_Eng_ Spd_Engmnt_

Limit.

Default

Off

Off

On


Off

2148

2149

2119

2121

2123



If this Parameter is 1, the PTO will be reengaged after disengagement due to vehicle overspeed when the vehicle speed is below TEM_PTO_Veh_ Spd_Engmnt_

Limit.



Off

Off

Off

Off

Off

Min

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Max

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Step

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A

LARMS





October 2012







Table 164

Parameter

TEM_PTO_

Air_Pres_Alarms

TEM_PTO_Air_

Pres_Alarm_Limit

TEM_PTO_

Eng_Run_ Alarms

TEM_PTO_

Eng_Spd_ Alarms

ID

2138

2139

TEMP_PTO_Eng_

Spd_Alarm_Limit

TEM_PTO_

Non_Neut_ Alarms

TEM_PTO_

Pk_Brake_ Alarms

TEM_PTO_

Veh_Spd_ Alarms

TEM_PTO_Veh_

Spd_Alarm_Limit

2132

2131

2133

2134



Description


Pres_Alarm_Limit.

Default

Off


2137

2135

2136

If this Parameter is 1, an alarm will sound if the PTO is engaged and the engine is turned off.

If this Parameter is 1, an alarm will sound if the PTO is engaged and the engine speed is over



Off

Off

1400 RPM

If this Parameter is 1, an alarm will sound if the PTO is engaged and transmission is taken out of neutral.

If this Parameter is 1, an alarm will sound if the PTO is engaged and the park brake is released

If this Parameter is 1, an alarm will sound if the PTO is engaged and the vehicle speed is over



Off

Off

Off

5 mph

Min

N/A

0

N/A

N/A

0

N/A

N/A

N/A

3

Max

N/A

500

N/A

N/A

5000

N/A

N/A

N/A

100

Step

N/A

1

N/A

N/A

0.1

N/A

N/A

N/A

1

W

IRING

I

NFORMATION



October 2012



f_136

T

ESTING




H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature codes 595ADD must be added to the truck using the Diamond Logic

®

Builder software for post 2007 clusters and pre 2010 clusters. For 2010 clusters add code 595BKJ.

•

Software feature codes 595AEB must NOT be enabled on the truck for post 2007 clusters and pre 2010 clusters. For 2010 clusters remove code 595BKK, 595BNN.

•


•

Add a latched switch (P/N 3578910C1) in the in-cab switch pack in the position specified by the Diamond

Logic

®

Builder software.

•

If the truck does not already have a 4-pack solenoid base, the customer should order a 4-pack base (part number 2505594C1) and an air solenoid (part number 2506711C91).

•


Solenoid.

13WDN - PTO CONTROL Only for Line Haul and ProStar models, DASH MOUNTED For Customer Provided

PTO; Includes Switch, Electric/Air Solenoid, Piping and Wiring.

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES

595AEB for post 2007 and pre 2010 clusters - 595BKK or 595BNN is required to be added for 2010 clusters.

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

595ADD for post 2007 and pre 2010 clusters – 595BKJ or 595BNP is required to be removed for 2010 clusters

S

OFTWARE FEATURE CODES

595AEB

OR

595BKK - P

ROGRAMMABLE

P

ARAMETERS

* These parameters set the conditions under which the PTO will be engaged and disengaged.


October 2012



PTOb_Clutch_Pedal – Set to 0 to ignore the clutch pedal or if the vehicle does not have a clutch pedal. Set to 1 to ensure that the clutch pedal is depressed for engagement.

PTOb _Engine_Running – Set to 0 to ignore the engine. Set to 1 to ensure that the engine is running to engage and disengage if the engine stops running.

PTOb_Engine_Speed_Range – Set to a speed that the engine has to be below for the PTO to engage. The


PTO operation, please use PTOb_Engine_Speed_Enable to enable this interlock.

PTOb_Transmission_Neutral – NOTE: this parameter will only work for vehicles with automated manual transmissions. Set to 0 to ignore the transmission state. Set to 1 to ensure that the transmission is in neutral for engagement.

PTOb_Park_Brake – Set to 0 to ignore the park brake. Set to 1 to ensure that the park brake is set for engage and disengage if the park brake is released.

PTOb_Vehicle_Speed_Range – Set to the speed that the vehicle has to be below for the PTO to engage. The

PTO will disengage if the vehicle speed becomes greater than the set value. If vehicle speed is required for

PTO operation, please use PTOb_Vehicle_Speed_Enable parameter to enable this interlock.

PTOb_Engine_Speed_Enable – Set to 0 to ignore the engine speed. Set to 1 to require the vehicle to be below a specified engine speed for the PTO to be engaged. Please use PTOa_Engine_Speed_Range to specify the appropriate engine speed if this parameter is set to 1.

PTOb_Engine_Speed_Alarm_Enable – Set to 0 to not have an alarm based on engine speed. Set to 1 to have a speed that an alarm will sound when the PTO is engaged and the engine speed is greater than the set value.


PTOb_Vehicle_Speed_Enable – Set to 0 to ignore the vehicle speed. Set to 1 to require the vehicle to be below a specified vehicle speed for the PTO to engage. Please use PTOa_Vehicle_Speed_Range to specify the appropriate vehicle speed if this parameter is set to 1.

PTOb_Vehicle_Speed_Alarm_Enable _– Set to 0 to not have an alarm based on vehicle speed. Set to 1 to have a speed limit that an alarm will sound when the PTO is engaged and the vehicle speed is greater than the set value. Please use PTOb _Vehicle_Speed_Alarm_Range to specify the appropriate vehicle speed if this parameter is set to 1.

PTOb_Engine_Speed_Alarm_Range – Set to the speed that the vehicle has to be below for the PTO to engage. The PTO will disengage if the vehicle speed becomes greater than the set value. If vehicle speed is required for PTO operation, please use PTOb_Vehicle_Speed_Enable parameter to enable this interlock.

PTOb_Vehicle_Speed_Alarm_Range - Set to a speed limit that an alarm will sound when the PTO is engaged and the vehicle speed is greater than the set value. If the vehicle alarm is required for PTO operation, please use PTOb_Vehicle_Speed_Alarm_Enable to enable this alarm.

PTOa_Vehicle_Speed_Enable – Set to 0 to ignore the vehicle speed. Set to 1 to require the vehicle to be below a specified vehicle speed for the PTO to engage. Please use PTOa_Vehicle_Speed_Range to specify the appropriate vehicle speed if this parameter is set to 1.

PTOa_Engine_Speed_Enable – Set to 0 to ignore the engine speed. Set to 1 to require the vehicle to be below a specified engine speed for the PTO to be engaged. Please use PTOa_Engine_Speed_Range to specify the appropriate engine speed if this parameter is set to 1.

PTOa_Engine_Speed_Alarm_Enable – Set to 0 to not have an alarm based on engine speed. Set to 1 to have a speed that an alarm will sound when the PTO is engaged and the engine speed is greater than the set value.



October 2012



PTOa_Vehicle_Speed_Alarm_Enable _– Set to 0 to not have an alarm based on vehicle speed. Set to 1 to have a speed limit that an alarm will sound when the PTO is engaged and the vehicle speed is greater than the set value. Please use PTOa_Vehicle_Speed_Alarm_Range to specify the appropriate vehicle speed if this parameter is set to 1.

PTOa_Clutch_Pedal – Set to 0 to ignore the clutch pedal or if the vehicle does not have a clutch pedal. Set to 1 to ensure that the clutch pedal is depressed for engagement.

PTOa_Engine_Running – Set to 0 to ignore the engine. Set to 1 to ensure that the engine is running to engage and disengage if the engine stops running.

PTOa_Engine_Speed_Range – Set to a speed that the engine has to be below for the PTO to engage. The


PTO operation, please use PTOa_Engine_Speed_Enable to enable this interlock.

PTOa_Park_Brake – Set to 0 to ignore the park brake. Set to 1 to ensure that the park brake is set for engage and disengage if the park brake is released.

PTOa_Vehicle_Speed_Range - Set to the speed that the vehicle has to be below for the PTO to engage. The

PTO will disengage if the vehicle speed becomes greater than the set value. If vehicle speed is required for

PTO operation, please use PTOa_Vehicle_Speed_Enable parameter to enable this interlock.

PTOa_Engine_Speed_Alarm_Range – Set to the speed that the vehicle has to be below for the PTO to engage. The PTO will disengage if the vehicle speed becomes greater than the set value. If vehicle speed is required for PTO operation, please use PTOa_Vehicle_Speed_Enable parameter to enable this interlock.

PTOa_Vehicle_Speed_Alarm_Range - Set to a speed limit that an alarm will sound when the PTO is engaged and the vehicle speed is greater than the set value. If the vehicle alarm is required for PTO operation, please use PTOa_Vehicle_Speed_Alarm_Enable to enable this alarm.

PTOa_Transmission_Neutral – NOTE: this parameter will only work for vehicles with automated manual transmissions. Set to 0 to ignore the transmission state. Set to 1 to ensure that the transmission is in neutral for engagement.


October 2012



Table 165

Parameter ID

PTOb_Clutch_Pedal 2017

PTOb_Engine_

Running

PTOb_Engine_

Speed_Range

PTOb_Transmission

_Neutral

PTOb_Park_Brake

PTOb_Vehicle_

Speed_Range

PTOb_Engine_

Speed_Enable

PTOb_Engine_

Speed_Alarm

PTOb_Vehicle_

Speed_Enable

PTOb_Vehicle_

Speed_Alarm_

Enable

2018

2019

2020

2021

2031

2050

2051

2052

2053



Description



Set to a speed that the engine has to be below for the PTO to engage. The PTO will disengage if the engine speed becomes greater than the set value. If engine speed is required for PTO operation, please use

PTOb_Engine_Speed_Enable to enable this interlock.



Set to the speed that the vehicle has to be below for the PTO to engage. The

PTO will disengage if the vehicle speed becomes greater than the set value. If vehicle speed is required for PTO operation, please use

PTOb_Vehicle_Speed_Enable parameter to enable this interlock.


PTOb_Engine_Speed_Range to specify the appropriate engine speed if this parameter is set to 1.


PTOb_Engine_Speed_Alarm_Range to specify the appropriate engine speed if this parameter is set to 1.


PTOb_Vehicle_Speed_Range to specify the appropriate vehicle speed if this parameter is set to 1.


PTOb_Vehicle_Speed_Alarm_Range to specify the appropriate vehicle speed if this parameter is set to 1.

Default

Off

On

300

Off

On

3

On

Off

On

Off

Min

N/A

N/A

300

N/A

N/A

3

N/A

N/A

N/A

N/A

Max

N/A

N/A

3000

N/A

N/A

100

N/A

N/A

N/A

N/A

Step

N/A

N/A

10

N/A

N/A

1

N/A

N/A

N/A

N/A


October 2012



Parameter

PTOb_Engine_

Speed_Alarm_

Range

PTOb_Vehicle_

Speed_Alarm_

Range

PTOa_Vehicle_

Speed_Enable

PTOa_Engine_

Speed_Enable

PTOa_Engine_

Speed_Alarm_

Enable

PTOa_Clutch_

Pedal

PTOa_Engine_

Running

PTOa_Engine_

Speed_Range

PTOa_Park_Brake

ID

2140

2141

2242

2243

2244

Vehicle_Speed_

Alarm_Enable PTOa

2267

2333

2334

2336

2338



Description

Set to a speed that an alarm will sound when the PTO is engaged and the engine speed is greater than the set value. If an engine speed alarm is required for PTO operation, please use

PTOb_Engine_Speed_Alarm_Enable parameter to enable this alarm.

Set to a speed limit that an alarm will sound when the PTO is engaged and the vehicle speed is greater than the set value. If the vehicle alarm is required for

PTO operation, please use

PTOb_Vehicle_Speed_Alarm_Enable to enable this alarm.


PTOa_Vehicle_Speed_Range to specify the appropriate vehicle speed if this parameter is set to 1..


PTOa_Engine_Speed_Range to specify the appropriate engine speed if this parameter is set to 1.


PTOa_Engine_Speed_Alarm_Range to specify the appropriate engine speed if this parameter is set to 1.


PTOa_Vehicle_Speed_Alarm_Range to specify the appropriate vehicle speed if this parameter is set to 1.



Set to a speed that the engine has to be below for the PTO to engage. The PTO will disengage if the engine speed becomes greater than the set value. If engine speed is required for PTO operation, please use

PTOa_Engine_Speed_Enable to enable this interlock.


Default

300

3

On

Off

Off

Off

Off

Off

300

On

Min

300

3

N/A

N/A

N/A

N/A

N/A

N/A

300

N/A

Max

3000

100

N/A

N/A

N/A

N/A

N/A

N/A

3000

N/A

Step

10

1

N/A

N/A

N/A

N/A

N/A

N/A

10

N/A


October 2012



Parameter

PTOa_Vehicle_

Speed_Range

PTOa_Engine_

Speed_Alarm_

Range

PTOa_Vehicle_

Speed_Alarm_

Range

PTOa_

Transmission_

Neutral

ID

2339

2340

2342

2355



Description

Set to the speed that the vehicle has to be below for the PTO to engage. The

PTO will disengage if the vehicle speed becomes greater than the set value. If vehicle speed is required for PTO operation, please use

PTOa_Vehicle_Speed_Enable parameter to enable this interlock.

If an engine speed alarm is required for


PTOa_Engine_Speed_Alarm_Enable parameter to enable this alarm.

Set to a speed limit that an alarm will sound when the PTO is engaged and the vehicle speed is greater than the set value. If the vehicle alarm is required for


PTOa_Vehicle_Speed_Alarm_Enable to enable this alarm.


Default

3

300

3

On

S

OFTWARE

F

EATURE

C

ODES

595BNN (2010 Clusters, 42 Parameters)

Min

3

300

3

N/A

P

ARAMETERS

E

NGAGEMENT


Max

100

3000

100

N/A

Step

1

10

1

N/A




PTO to engage.








PTO to be engaged.



October 2012




If TEM_PTOb_Air_Pres_Engmnt_Inhib parameter is turned on, the PTO cannot be engaged if the primary vehicle air pressure is below the programmable parameter set by TEM_PTOb_Air_Pres_Engmnt_Limit.

If TEM_PTOb_Brake_Engmnt_Inhib parameter is turned on, then the brake pedal must be depressed in order for the PTO to engage.

If TEM_PTOb_Cltch_Engmnt_Inhib parameter is turned on, then the clutch pedal must be depressed for the

PTO to engage.

If TEM_PTOb_Eng_Run_Engmnt_Inhib parameter is turned on, then the engine has to be running in order for the PTO to be engaged.

If TEM_PTOb_Eng_Spd_Engmnt_Inhib parameter is turned on, then the PTO cannot be engaged if the engine speed is over a certain threshold, which is defined as a programmable parameter in

TEM_PTOb_Eng_Spd_Engmnt_Limit

If TEM_PTOb_Neut_Engmnt_Inhib parameter is turned on, then the PTO can only be engaged if the transmission is NOT in Neutral or Park.

If TEM_PTOb_Non_Neut_Engmnt_Inhib parameter is turned on, then the transmission must be in Neutral or


If TEM_PTOb_Pk_Brake_Engmnt_Inhib parameter is turned on, then the park brake must be set in order for the PTO to be engaged.

If TEM_PTOb_Veh_Spd_Engmnt_Inhib parameter is turned on, then the PTO cannot be engaged if the vehicle speed is over the value prescribed by TEM_PTOb_Veh_Spd_Engmnt_Limit.

If TEM_PTOb_Mast_Switch_Engmnt_Inhib parameter is turned on, then the PTO will not be engaged if the vehicle master switch is not ON.


October 2012



Table 166

Parameter

TEM_PTO_

Air_Pres_

Engmnt_Inhib

TEM_PTO_

Air_Pres_

Engmnt_Limit

TEM_PTO_

Brake_Engmnt_

Inhib

TEM_PTO_

Cltch_Engmnt_

Inhib

TEM_PTO_

Eng_Run_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Inhib

TEM_PTO_

Eng_Spd_

Engmnt_Limit

TEM_PTO_

Neut_Engmnt_ Inhib

TEM_PTO_

Non_Neut_

Engmnt_Inhib

TEM_PTO_Pk_

Brake_Engmnt_

Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Inhib

TEM_PTO_

Veh_Spd_

Engmnt_Limit

TEM_PTO_Mast_

Switch_Engmnt_

Inhib

TEM_PTOb_

Air_Pres_

Engmnt_Inhib

TEM_PTOb_

Air_Pres_

Engmnt_Limit

TEM_PTO_

Brake_Engmnt_

Inhib

TEM_PTOb_

Cltch_Engmnt_

Inhib

TEM_PTOb_

Eng_Run_

Engmnt_Inhib

ID

2097

2098

2095

2094

2096

2092

2093

2089

2088

2087

2090

2091

2099

2711

2712

2676

2677

2678



Description

If this Parameter is 1, the PTO will not be engaged if the primary vehicle air pressure is below TEM_PTO_Air_

Pres_Engmnt_ Limit

Default

On

See TEM_PTO_Air_ Pres_Engmnt_

Inhib

90 psi

Min

N/A

1




Off

Off

Off

If this Parameter is 1, the PTO will not be engaged if the engine speed is over the value set in TEM_PTO_Eng_

Spd_Engmnt_ Limit

See TEM_PTO_Eng_ Spd_Engmnt_

Inhib

On

1000 RPM

If this Parameter is 1, the PTO will only be engaged if the Transmission is not in

Neutral or Park

If this Parameter is 1, the PTO will not be engaged if the Transmission is not in

Neutral or Park


If this Parameter is 1, the PTO will not be engaged if the vehicle speed is over the value set in TEM_PTO_Veh_

Spd_Engmnt_ Limit

See TEM_PTO_Veh_ Spd_Engmnt_

Inhib

Off

Off

Off

On

3 MPH


If this Parameter is 1, the PTO will not be engaged if the primary vehicle air pressure is below TEM_PTO_Air_

Pres_Engmnt_ Limit

See TEM_PTO_Air_ Pres_Engmnt_

Inhib




Off

On

90 psi

Off

Off

Off

N/A

N/A

N/A

N/A

100

N/A

N/A

N/A

N/A

1

N/A

N/A

1

N/A

N/A

N/A

Max

N/A

500

N/A

N/A

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

N/A

500

N/A

N/A

N/A


October 2012

Step

N/A

1

N/A

N/A

N/A

1

N/A

N/A

N/A

1

N/A

N/A

N/A

N/A

N/A

1

N/A

N/A



Parameter

TEM_PTOb_

Eng_Spd_

Engmnt_Inhib

ID

2679



Description

If this Parameter is 1, the PTO will not be engaged if the engine speed is over the value set in TEM_PTO_Eng_

Spd_Engmnt_ Limit

Default

On

Min

N/A

TEM_PTOb_

Eng_Spd_

Engmnt_Limit

TEM_PTOb_

Neut_Engmnt_

Inhib

TEM_PTOb_

Non_Neut_

Engmnt_Inhib

TEM_PTOb_Pk_

Brake_Engmnt_

Inhib

2680

2681

2682

2683

See TEM_PTO_Eng_ Spd_Engmnt_

Inhib

If this Parameter is 1, the PTO will only be engaged if the Transmission is not in

Neutral or Park

If this Parameter is 1, the PTO will not be engaged if the Transmission is not in

Neutral or Park


1000 RPM

Off

Off

Off

100

N/A

N/A

N/A

TEM_PTOb_

Veh_Spd_

Engmnt_Inhib

2684

If this Parameter is 1, the PTO will not be engaged if the vehicle speed is over the value set in TEM_PTO_Veh_

Spd_Engmnt_ Limit

On N/A

TEM_PTOb_

Veh_Spd_

Engmnt_Limit

TEM_PTOb_Mast_

Switch_Engmnt_

Inhib

2685

2714

See TEM_PTO_Veh_ Spd_Engmnt_

Inhib


3 MPH

Off

1

N/A

D

ISENGAGEMENT


Max

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

Step

N/A

1

N/A

N/A

N/A

N/A

1

N/A









If TEM_PTOb_Air_Pres_Disengages parameter is turned on, then the PTO will be disengaged if the primary air pressure is below the value set in TEM_PTO_Air_Pres_DisEng_Limit.

If TEM_PTOb_Eng_Run_Disengages parameter is turned on, then the PTO will be disengaged if the engine is turned off.


October 2012



If TEM_PTOb_Eng_Spd_Disengages parameter is turned on, then the PTO will be disengaged if the engine speed rises above the value set by TEM_PTOb_Eng_Spd_DisEng_Limit.

If TEM_PTOb_ Non_Neut _Disengages parameter is turned on, then the PTO will be disengaged if the transmission is taken out of neutral.

If TEM_PTOb_Pk_Brake_Disengages parameter is turned on, then the PTO will be disengaged if the Park

Brake is released.

If TEM_PTOb_Veh_Spd_Disengages parameter is turned on, then the PTO will be disengaged if the vehicle speed is over the valued specified by TEM_PTOb_Veh_Spd_DisEng_Limit.

If TEM_PTOb_Ext_Input_Disengages is turned on, then the PTO will be disengaged if the external input designated for this purpose is active.

If TEM_PTOb_Mast_Switch_Disengages is turned on, then the PTO will be disengaged if the vehicle master switch is not ON.

Table 167

ID



Description Default Min Max Step Parameter

TEM_PTO_

Air_Pres_

DisEng_Limit

TEM_PTO_

Air_Pres_

Disengages

TEM_PTO_

Eng_Run_

Disengages

TEM_PTO_

Eng_Spd_

DisEng_Limit

TEM_PTO_

Eng_Spd_

Disengages

TEM_PTO_

Non_Neut_

Disengages

TEM_PTO_

Pk_Brake_

Disengages

TEM_PTO_

Veh_Spd_

Disengages

TEM_PTO_

Veh_Spd_

DisEng_Limit

TEM_PTO_Ext_

Input_Disengages

TEM_PTO_Mast_

Switch_Disengages

TEM_PTOb_

Air_Pres_

DisEng_Limit

2116

2115

2114

2113

2112

2109

2108

2110

2111

2117

2118

2719


If this Parameter is 1, the PTO will be disengaged if the primary air pressure is below the value set in TEM_PTO_Air_

Pres_DisEng_ Limit.



Spd_DisEng_ Limit




Spd_DisEng_ Limit.

80 psi

On

Off

See TEM_PTO_ Eng_Spd_ Disengages 1800 RPM





On

Off

Off

Off

0 MPH

Off

Off

80 psi

0

N/A

N/A

0

N/A

N/A

N/A

N/A

3

N/A

N/A

0

500

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

N/A

500

1

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A

1


October 2012



Parameter

TEM_PTOb_

Air_Pres_

Disengages

ID

2716



Description

If this Parameter is 1, the PTO will be disengaged if the primary air pressure is below the value set in TEM_PTO_Air_

Pres_DisEng_ Limit.

Default

On

Min

N/A

TEM_PTOb_

Eng_Run_

Disengages

TEM_PTOb_

Eng_Spd_

DisEng_Limit

2686

2687


Off

See TEM_PTO_ Eng_Spd_ Disengages 1800 RPM

N/A

0

TEM_PTOb_

Eng_Spd_

Disengages

TEM_PTOb_

Non_Neut_

Disengages

TEM_PTOb_

Pk_Brake_

Disengages

2688

2689

2690


Spd_DisEng_ Limit



On

Off

Off

N/A

N/A

N/A

TEM_PTOb_

Veh_Spd_

Disengages

2691


Spd_DisEng_ Limit.

Off N/A

TEM_PTOb_

Veh_Spd_

DisEng_Limit

2692 See TEM_PTO_Veh_ Spd_Disengages 0 MPH 3

TEM_PTOb_Ext_

Input_Disengages

TEM_PTOb_Mast_

Switch_Disengages

2772

2718



Off

Off

N/A

N/A

R

E

-E

NGAGEMENT


Max

N/A

N/A

5000

N/A

N/A

N/A

N/A

100

N/A

N/A

Step

N/A

N/A

1

N/A

N/A

N/A

N/A

1

N/A

N/A










October 2012







If TEM_PTOb_Air_Pres_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to low air pressure) when the primary air pressure rises about the value specified by

TEM_PTOb_Air_Pres_Engmnt_Limit.

If TEM_PTOb_Eng_Run_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to engine stopping) when the engine is restarted.

If TEM_PTOb_Eng_Spd_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to engine overspeed) when the engine speed falls below

TEM_PTOb_Eng_Spd_Engmnt_Limit.

If TEM_PTOb_Key_State_Allow_ReEng parameter is turned on, then the PTO will be allowed to reengage when the key state is returned to run.

If TEM_PTOb_Non_Neut_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to transmission out of neutral) when the transmission is placed back into neutral.

If TEM_PTOb_Pk_Brake_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to park brake released) when the park brake is reapplied.

If TEM_PTOb_Veh_Spd_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after disengagement due to the vehicle being over the vehicle speed value) when the vehicle speed falls below

TEM_PTOb_Veh_Spd_Engmnt_Limit.

If TEM_PTOb_Ext_Input_Allow_ReEng parameter is turned on, then the PTO will be reengaged (after a disengage due to the designated external input being in active state) when the external input is no longer in active state.

If TEM_PTOb_Mast_Switch_Allow_ReEng is turned on, then the PTO will be reengaged after a disengage due to the master switch being turned off when the master switch is turned on again.


October 2012



Table 168

Parameter

TEM_PTO_

Air_Pres_

Allow_ReEng

TEM_PTO_

Eng_Run_

Allow_ReEng

TEM_PTO_

Eng_Spd_

Allow_ReEng

TEM_PTO_

Key_State_

Allow_ReEng

TEM_PTO_

Non_Neut_

Allow_ReEng

TEM_PTO_

Pk_Brake_

Allow_ReEng

TEM_PTO_

Veh_Spd_

Allow_ReEng

TEM_PTO_Ext_

Input_Allow_ReEng

TEM_PTO_Mast_

Switch_Allow_

ReEng

TEM_PTOb_

Air_Pres_

Allow_ReEng

TEM_PTOb_

Eng_Run_

Allow_ReEng

TEM_PTOb_

Eng_Spd_

Allow_ReEng

TEM_PTOb_

Key_State_

Allow_ReEng

TEM_PTOb_

Non_Neut_

Allow_ReEng

ID

2124

2122

2120

2069

2148

2149

2119

2121

2123

2713

2693

2694

2696

2697



Description


Pres_Engmnt_ Limit.


If this Parameter is 1, the PTO will be reengaged after disengagement due to engine overspeed when the engine speed is below TEM_PTO_Eng_

Spd_Engmnt_ Limit.




If this Parameter is 1, the PTO will be reengaged after disengagement due to vehicle overspeed when the vehicle speed is below TEM_PTO_Veh_

Spd_Engmnt_ Limit.




Pres_Engmnt_ Limit.


If this Parameter is 1, the PTO will be reengaged after disengagement due to engine overspeed when the engine speed is below TEM_PTO_Eng_

Spd_Engmnt_ Limit.



Default

Off

Off

On

Off

Off

Off

Off

Off

Off

Off

Off

On

Off

Off

Min

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A


October 2012

Max

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Step

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A



Parameter

TEM_PTOb_

Pk_Brake_

Allow_ReEng

TEM_PTOb_

Veh_Spd_

Allow_ReEng

TEM_PTOb_Ext_

Input_Allow_ReEng

TEM_PTOb_Mast_

Switch_Allow_

ReEng

ID

2698

2699

2771

2715



Description


If this Parameter is 1, the PTO will be reengaged after disengagement due to vehicle overspeed when the vehicle speed is below TEM_PTO_Veh_

Spd_Engmnt_ Limit.



Default

Off

Off

Off

Off

Min

N/A

N/A

N/A

N/A

Max

N/A

N/A

N/A

N/A

Step

N/A

N/A

N/A

N/A

A

LARMS








If TEM_PTOb_Air_Pres_Alarms parameter is turned on, then an audible alarm will sound in the cab if the primary air pressure drops below the value specified by TEM_PTOb_Air_Pres_Alarm_Limit.

If TEM_PTOb_Eng_Run_Alarms parameter is turned on, then an audible alarm will sound in the cab if the PTO is engaged and the engine is turned off.

If TEM_PTOb_Eng_Spd_Alarms parameter is turned on, then an alarm will sound in the cab if the PTO is engaged and the engine speed is over the value set by TEM_PTO_Eng_Spd_Alarm_Limit.

If TEM_PTOb_Non_Neut_Alarms parameter is turned on, then an audible alarm will sound in the cab if the

PTO is engaged and the transmission is taken out of neutral.

If TEM_PTOb_Pk_Brake_Alarms parameter is turned on, then an audible alarm will sound in the cab if the PTO is engaged and the park brake is released

If TEM_PTOb_Veh_Spd_Alarms parameter is turned on, then an audible alarm will sound in the cab if the PTO is engaged and the vehicle speed is about the value set by TEM_PTO_Veh_Spd_Alarm_Limit.


October 2012



Table 169

Parameter

TEM_PTO_

Air_Pres_ Alarms

TEM_PTO_Air_Pres

_Alarm_Limit

TEM_PTO_

Eng_Run_ Alarms

TEM_PTO_

Eng_Spd_ Alarms

TEMP_PTO_Eng_

Spd_Alarm_Limit

TEM_PTO_

Non_Neut_ Alarms

TEM_PTO_

Pk_Brake_ Alarms

TEM_PTO_

Veh_Spd_ Alarms

TEM_PTO_Veh_

Spd_Alarm_Limit

TEM_PTOb_

Air_Pres_ Alarms

TEM_PTOb_Air_

Pres_Alarm_Limit

TEM_PTOb_

Eng_Run_ Alarms

TEM_PTOb_

Eng_Spd_ Alarms

TEMP_PTOb_Eng_

Spd_Alarm_Limit

TEM_PTOb_

Non_Neut_ Alarms

TEM_PTOb_

Pk_Brake_ Alarms

TEM_PTOb_

Veh_Spd_ Alarms

ID

2138

2139

2137

2135

2136

2132

2131

2133

2134

2700

2701

2702

2704

2703

2705

2706

2708



Description

If this Parameter is 1, an alarm will sound if the primary air pressure is below

TEM_PTO_Air_ Pres_Alarm_Limit.

Default

Off


Min

N/A

0


If this Parameter is 1, an alarm will sound if the PTO is engaged and the engine speed is over TEM_PTO_Eng_

Spd_Alarm_Limit.


Off

Off

1400 RPM



If this Parameter is 1, an alarm will sound if the PTO is engaged and the vehicle speed is over TEM_PTO_Veh_

Spd_Alarm_Limit.


If this Parameter is 1, an alarm will sound if the primary air pressure is below

TEM_PTO_Air_ Pres_Alarm_Limit.

See TEM_PTOb_Air_Pres_Alarms

Off

Off

Off

5 mph

Off

0 psi


If this Parameter is 1, an alarm will sound if the PTO is engaged and the engine speed is over TEM_PTO_Eng_

Spd_Alarm_Limit.

See TEM_PTOb_Eng_Spd_Alarms

Off

Off

1400 RPM



If this Parameter is 1, an alarm will sound if the PTO is engaged and the vehicle speed is over TEM_PTO_Veh_

Spd_Alarm_Limit.

See TEM_PTOb_Veh_Spd_Alarms

Off

Off

Off

5 mph

N/A

N/A

0

N/A

N/A

N/A

3

N/A

0

N/A

N/A

0

N/A

N/A

N/A

3

Max

N/A

500

N/A

N/A

5000

N/A

N/A

N/A

100

N/A

500

N/A

N/A

5000

N/A

N/A

N/A

Step

N/A

1

N/A

N/A

0.1

N/A

N/A

N/A

1

N/A

1

N/A

N/A

0.1

N/A

N/A

N/A

TEM_PTOb_Veh_

Spd_Alarm_Limit

2709 100 1

W

IRING

I

NFORMATION



October 2012



f_137

T

ESTING

1. Depress the In-cab PTO 1 or PTO 2 switch to the ON position.



H

OW

T

O

A

DD

T

HIS

F

EATURE

•

Software feature codes 595AEB must be added to the truck using the Diamond Logic

®

Builder software for post 2007 and pre 2010 clusters – Code 595BKK or 595BNN must be added for 2010 clusters.

•

Software feature codes 595ADD must NOT be enabled on the truck for post 2007 and pre 2010 clusters –

Code 595BJKKJ, BNP must be removed for 2010 clusters.

•


•

Add two latched switches (P/N 3578910C1) in the in-cab switch pack in the position specified by the

Diamond Logic

®

Builder software.

•

If the truck does not already have a 4-pack solenoid base, the customer should order a 4-pack base (part number 2505594C1) and two air solenoids (part number 2506711C91).

•


Solenoid.


October 2012



■

PTO HOURMETER

16WLM

HOURMETER, PTO for Customer Provided PTO; Indicator Light and Hourmeter in Gauge Cluster Includes

Return Wire for PTO Feedback Switch

This feature provides the customer with a wire (Circuit K88B 14 gauge, light green – cut blunt – located in the transmission harness) to be wired into a PTO body builder-installed feedback switch. Also included in this feature is a PTO indicator light in the gauge cluster and a PTO hourmeter, which allows the operator to measure stationary PTO hours for maintenance records and fuel tax purposes. To view the hourmeter, press the gauge cluster selection button momentarily until the text portion of the display indicates “PTO Hour”.

This feature cannot be used if 16HGJ (Optional Transmission Oil Temperature Gauge for a MANUAL

Transmission) is utilized.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

A

DDED

595AJU and (595AYN, for pre-2010 OR 595BJT for post-2010)

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

NOT B

E

E

NABLED

595AEW

The BC_PTO_Engaged_Param parameter defines the voltage that will be read as the active state for the PTO engagement feedback switch.




Table 170

Parameter

BC_PTO_

Engaged_ Param

ID




2199 Active State for the PTO engagement feedback switch. No_Units

Min

N/A

Max

NA

Step

NA

W

IRING

I

NFORMATION

The customer must wire the Navistar-provided PTO engagement feedback return wire (14 gauge, Light Green) into the PTO feedback switch which should be a GND active switch.


October 2012



f_138

T

ESTING

1. Customer should apply the correct active state voltage (as programmed in the Diamond Logic

®

Builder software) to the Navistar-provided PTO engagement feedback wire.

2. Verify that the PTO indicator light in the gauge cluster comes on and stays on as long as the active state voltage is applied.

H

OW

T

O

A

DD

T

HIS

F

EATURE

•

The customer must enable software feature code 595AJU and 595AYN using the Diamond Logic

®

Builder software.

•

The customer must make sure that software feature code 595AEW is NOT enabled using the Diamond

Logic

®

Builder software.

•

The customer must set BC_PTO_Engaged_Param to desired active state for the PTO feedback switch.

•

When adding this feature to a vehicle, alternate wiring methods must be performed. It is not possible to add a wire to connector 1702 pin 13 as described by the electrical circuit diagram manual. The dash panel grommet is sealed, and additional wires may not be added.

•

In order to add this feature, connect an 18 gauge wire to the PTO feedback switch, and terminate it in an open wire terminal cavity in connector 1700 or 1701.

•

Add another 18 gauge wire in the corresponding cavity on the cab harness connector, and terminate it in the

BC Connector 1600 terminal pin B7.


October 2012


REMOTE ENGINE SPEED CONTROL

FEATURES

REMOTE ENGINE SPEED CONTROL FEATURES

■

REMOTE MOUNTED ENGINE CONTROL

12VXY

ENGINE CONTROL, REMOTE MOUNTED Provisions for: Includes module and connector for Body Builder installation of remote engine speed control with SAE J1939 communication with MaxxForce electronic engines.

12VZA

ENGINE CONTROL, REMOTE MOUNTED Provision for, Includes Wiring for Body Builder Installation of PTO

Controls, With Ignition Switch Control for International

®

post 2007 Emissions Electronic Engines

12VZB

ENGINE CONTROL, REMOTE MOUNTED for PTO with MaxxForce 11 & 13 Engines

Feature codes 12VZA, 12VZB and 12VXY are available to control engine speed from outside the cab. 12VZA and 12VZB are hardwired remote engine speed control solutions and Remote Engine Speed Control Module

(RESCM) feature code 12VXY utilizes the Diamond Logic

®

Electrical System to control engine speed. The operation of the engine control features behaves exactly the same whether the body builder switches are hardwired (12VZA) or multiplexed (12VXY).

Feature code 12VXY is an accommodation for a Remote Engine Speed Control Module (RESCM). This feature also provides a public J1939 datalink to the Body Controller (BC) from the RESCM. The feature has associated software (595AHA) that is programmed into the BC, which allows it to control the engine remotely through the

RESCM.

There are programmable parameters that are used by 12VXY both in the BC and the Engine Control Module

(ECM). The parameters in the BC are listed below and the parameters in the ECM allow the selection of disabling the cab controls, engine speed presets, stationary or variable speed control, etc. The ECM parameters are programmed with either the Master Diagnostics or ServiceMaxx software.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

(12VXY

ONLY

)

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES

595AHA

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

The Remote_Accelerator_Enable parameter is used to enable or disable the remote accelerator function within the RESCM feature. If the parameter is set to 1, the remote accelerator function is enabled. If the parameter is set to 0, the remote accelerator function is disabled.

The RESCM_Require_Park_Brake parameter is used to enable or disable the park brake interlock within the

RESCM feature. If the parameter is set to 1, the park brake interlock is enabled. If the parameter is set to 0, the park brake interlock is disabled.


October 2012



FEATURES

Table 161

Parameter

Remote_

Accelerator_

Enable

RESCM_

Require_Park_

Brake

ID

1870

2240

Description

Enables the remote accelerator.

Enables the park brake interlock for

RESCM.

Default

1

1

Units

None

None

Min

-

-

Max

1

1

Step

1

1


October 2012



FEATURES

RESCM W

IRING

I

NFORMATION

Remote Engine Speed Control Module (RESCM) Overview Diagram

f_140


October 2012



FEATURES

P

RESET

T

HROTTLE

I

NFORMATION

Remote Throttle Installation with Preset Engine Control Using the Remote

Engine Speed Controller (RESCM)

f_141


October 2012



FEATURES

Split Shaft Throttle Information

Remote Throttle Installation with Split Shaft Engine Control Using the Remote

Engine Speed Controller (RESCM)

f_142


October 2012



FEATURES

R

EMOTE

T

HROTTLE

P

EDAL

I

NFORMATION

Remote Throttle Installation with a Remote Throttle Pedal Control Using the

Remote Engine Speed Controller (RESCM)

f_143


October 2012



FEATURES

Location of Body Builder Wiring on

12VZA or 12VZB

f_144

RESCM Located on Battery Box on

DuraStar Models

RESCM Located Under Cab on WorkStar

Models

f_145


October 2012



FEATURES

The following page shows the connectors associated with the different sales feature codes for the Engine Body

Builder connectors on both the I6 and IBB Navistar products. The connectors can be located in the engine compartment near the megafuse above the driver side wheel well.

On the IBB connectors, both the he male and female connectors and terminals are used in the same way as the transmission Body Builder connectors.


October 2012



FEATURES

f_147


October 2012



FEATURES

f_148


October 2012



FEATURES

f_149

T

ESTING

12VXY is tested and programmable parameters are set with Master Diagnostics or ServiceMaxx Software packages.


October 2012



FEATURES

■

THROTTLE, HAND CONTROL, STATIONARY, VARIABLE SPEED

12VXT

THROTTLE, HAND CONTROL Engine Speed Control; Electronic, Stationary, Variable Speed; Mounted on

Steering Wheel

Stationary Variable Speed feature 12VXT allows the equipment operator to feather engine speed up or down to make fine adjustments to engine speed to achieve the desired functionality. The vehicle must be in a stationary position. Application examples are Fire (to throttle up to get a certain water flow), Utility Bucket, Crane, and

Digger Derrick.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

No software in the Body Controller (BC) is required.

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

W

IRING

I

NFORMATION

No additional wiring is associated with this feature.

T

ESTING

This feature is added by programming the Engine Control Module (ECM) for stationary, variable speed control.

Refer to the Body Builder Book CT-471 (PBB-71000A) for engine ECM programming functionality.

■

THROTTLE, HAND CONTROL, STATIONARY PRE-SET

12VXU

THROTTLE, HAND CONTROL Engine Speed Control for PTO; Electronic, Stationary Pre-Set, Two Speed

Settings; Mounted on Steering Wheel

Stationary Preset Speed feature 12VXU allows the user to operate auxiliary equipment at two pre-determined engine speed settings while in a stationary position. Application examples are Garbage Packer, Recovery,

Sewer Suckers, and other applications that are meant to run at a set speed.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

No software in the BC is required.

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

W

IRING

I

NFORMATION


T

ESTING

This feature is added by programming the Engine Control Module (ECM) for stationary, pre-set speed control.



October 2012



FEATURES

■

THROTTLE, HAND CONTROL, MOBILE, VARIABLE SPEED

12VXV

THROTTLE, HAND CONTROL Engine Speed Control for PTO; Electronic, Mobile (Range 2 to 20 MPH),

Variable Speed; Mounted on Steering Wheel

Mobile Variable Speed feature 12VXV allows the equipment operator to feather engine speed up or down to make fine adjustments to engine speed to achieve the desired functionality. The vehicle is moving; however, the accelerator and brake pedals are inoperative. Speed is controlled through the steering wheel controls.

Application examples are Concrete Mixer, Asphalt Spreader, Dump (dumping gravel, etc.), and other applications that require fine control of engine speed while the vehicle is moving.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

No software in the BC is required.

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E

R

EMOVED

None

W

IRING

I

NFORMATION


T

ESTING

This feature is added by programming the Engine Control Module (ECM) for mobile, variable speed control.


■

REMOTE MOUNTED ENGINE CONTROL

FEATURE CODE DESCRIPTION:

12VZA & 12VZB

ENGINE CONTROL, REMOTE MOUNTED Provision for; Includes Wiring for Body Builder Installation of PTO

Controls; With Ignition (IGN) Switch Control for International

®

post 2007 Emissions Electronic Engines

This feature is an accommodation for remote engine speed control using hard wires directly into the ECM for

International

®

post 2007 emission electronic engines. This feature provides 13 blunt-cut wires on the V8 and 2 connectors on the I6 in the engine compartment above the steering shaft. These wires can be spliced to Body

Builder-supplied switches and throttle control devices to control the engine speed.

There are no programmable Body Controller (BC) parameters that are used by this function. The programmable parameters are located in the ECM of the engine.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

No BC features

For proper ECM parameter programming, see the Body Builder book CT-471 PBB-71000.

W

IRING

I

NFORMATION

The new connector associated with sales feature code 12VZA is illustrated below. The connector can be located in the engine compartment near the megafuse above the driver side wheel well.


October 2012



FEATURES

T

ESTING

12VZA & 12VZB is tested and programmable parameters are set via the Master Diagnostics or ServiceMaxx

Software package.

ECM Engine Harness

f_150

If the Engine Harness is not provided, the following diagrams show how to hard-wire this feature.


October 2012



FEATURES

12VZA & 12VZB W

IRING

I

NFORMATION

12VZA & 12VZB Hard Wire ECM Engine Control Overview

Diagram

f_151


October 2012



FEATURES

12VZA

AND

12VZB C

IRCUIT

D

IAGRAM AND PIN

L

OCATIONS

12VZA and 12VZB Circuit Diagram and Pin Locations

(Reference Table for Preset Throttle, Variable Throttle,

Split Shft Operations, and Remote Throttle)

f_152


October 2012



FEATURES

P

RESET

T

HROTTLE

I

NFORMATION

Remote Installation for Preset Engine Control Using the Hard Wired ECM

Inputs

f_153


October 2012



FEATURES

V

ARIABLE

T

HROTTLE

I

NFORMATION

Remote Installation for Engine Control Using the Hard Wired ECM

Inputs

f_154


October 2012



FEATURES

S

PLIT

S

HAFT

O

PERATION

W

ITH

V

ARIABLE

T

HROTTLE

Remote Throttle Installation for Split Shaft Control Using the

Hard Wire ECM Inputs

f_155


October 2012



FEATURES

R

EMOTE

T

HROTTLE

P

EDAL

Remote Throttle Installation with a Remote Throttle Pedal

Cotnrol Using the Hard Wire ECM Inputs

f_156


October 2012



FEATURES

■

REMOTE THROTTLE CONTROL INTERLOCKED TO PARK BRAKE APPLIED —

RECOMMENDED APPLICATION: RECOVERY

60AJA

BDY INTG, THROTTLE CONTROL Accommodation for Single Customer-Mounted External Engine Speed

Control Switch, Programmable Mode for Various Switch Actions and Engine Speed Control Option; Useable

Only While Vehicle is Stopped and the Park Brake is Applied (requires one Remote Power Module (RPM) input)

Truck Equipment Manufacturer (TEM) or customer-mounted single remote center stable, momentary switch; when the operator moves the switch to the up position, the switch supplies 12 volts to the RPM input to activate

Remote engine speed control preset-1; when the operator returns the switch to the center position or stable position, the engine will remain at preset-1 until the operator moves the switch to the down position; in the down position, the switch then supplies a Ground (GND) to the RPM input to deactivate Remote engine speed control preset-1; when the operator returns the switch to the center position or stable position, the engine will remain at idle.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AKJ

C

ONFLICTS

W

ITH

S

OFTWARE

F

EATURES

595AKK, 595AKL, 595AKM, 595AKN

A

CTIVATION

P

ARAMETERS

:

1. Momentary 12 volt input to RPM

2. Park brake applied

3. Transmission in neutral or park or clutch pedal not depressed

4. Vehicle speed is less than one MPH

5. Engine running and at idle

6. Optional PTO feedback is true.

D

EACTIVATION

P

ARAMETERS

:

1. Momentary GND input to RPM

2. Park brake not applied

3. Transmission not in neutral or park or clutch pedal depressed

4. Vehicle speed is greater than one MPH.

5. Engine not running

7. Optional PTO feedback not true

F

EATURE

O

RDERING

N

OTES

1. This feature requires one RPM input.

2. If 60AJA is ordered, 12VXU must also be ordered which requires entering TEM or customer-requested

Remote engine speed control preset-1 RPMs.

3. TEM or customer must supply single pull, double throw, center stable, momentary switch and all associated wiring from switch to RPM.


October 2012



FEATURES

4. The optional PTO interlock is defaulted off; this interlock only works with International

®

pre-engineered

PTO features. If the TEM or customer has one of the International

®

pre-engineered PTO features and needs to have this interlock turned on, this will require an additional parameter change by someone who is at least Diamond Logic

®

Builder Level 2 or 3 certified.

H

OW

T

O

I

NSTALL

T

HIS

F

EATURE

Software Installation:

1. Use Diamond Logic

®

Builder to install Body Controller (BC) software feature code 595AKJ, and set the feature code parameters to the following settings: a. 595AKJ – Set parameter 2035 to 1. Reference feature configuration programmable parameters.

b. 595AKJ – Set parameter 2158 to 3. Reference feature configuration programmable parameters.

c. 595AKJ – Set parameter 2036 to on for optional PTO interlock. Reference feature configuration programmable parameters.


®

Builder to remove BC software feature codes 595AKK, 595AKL, 595AKM, and

595AKN.

3. Use Master Diagnostics to program Engine control module: PTO in-cab control: on

4. Use Master Diagnostics to program Engine control module: PTO in-cab mode: stationary pre-set

5. Use Master Diagnostics to program Engine control module: PTO Power Take Off mode: remote and in-cab operation

6. Use Master Diagnostics to program Engine control module: PTO Preset-1 RPM set (700.00 to 2800.00)

(Note: this is the RPM the customer or TEM has requested)

P

ROGRAMMABLE

P

ARAMETERS

1. 2036 TEM_Ext_Eng_Spd_Ctrl_PTO_Ilock; This parameter sets the optional PTO interlock mode on or off.

If set on, the Remote engine speed control preset-1 will be interlocked to all International

®

pre-engineered

PTO features that use a center panel switch. This means that the remote engine speed control will only be allowed to operate if the PTO is being requested to engage. If this parameter is not set, the engine speed control will operate regardless of the PTO request.

a. On b. Off

2. 2035 TEM_Ext_Eng_Spd_Control_Mode; This parameter sets the mode of operation for the TEM external engine speed control feature and should be set to 1.

a. 1, 12 volts on the engine speed control input causes engine to ramp to preset-1. GND on the same input causes the engine to return to idle.

3. 2158 TEM_Ext_ Eng_Spd_ Ctrl_Active_State; This is the active state for the external engine speed control switch input to the RPM and should be set to 3.

a. 3, 12 volts – The input is connected to 12 volts through a switch.


October 2012



FEATURES

Table 162

Parameter

TEM_Ext_

Eng_Spd_

Ctrl_PTO_ Ilock

TEM_Ext_

Eng_Speed_

Control_ Mode

TEM_Ext_

Eng_Spd_

Ctrl_Active_

State

ID

2036

2035

Description

If this parameter is a one, external engine speed controls will be interlocked to PTO request.

This parameter sets the mode of operation for the TEM external engine speed control feature.

2158

This is the active state for the external engine speed control switch.

Default

0

1

3

Units

On/Off

List

List

Min

0

0

0

Max

1

3

1

Step

1

1

3

H

ARDWARE

I

NSTALLATION

1. Reference the connectors tab within Diamond Logic

®

Builder to verify the correct RPM input pin on the black 23-pin connector. The pin is named Remote_Engine_Speed_Sw_Input.

2. Connect an 18 gauge wire to input pin, and run this wire to the center pole on the switch.

3. Connect one of the remaining switch poles to a 12 volt power source.

4. Connect the only remaining switch pole to a chassis GND source.

Input connector part number – 2005482C1

Input terminal part number – 1698937C1


October 2012



FEATURES

60AJA W

IRING

I

NFORMATION f_157

Feature Testing

1. Stationary Remote engine speed control preset-1 Activation; Start engine, set park brake, transmission in neutral or park, vehicle speed is less than one MPH, and take the switch to the up position, or supply 12 volts on the input pin labeled Remote_Engine_Speed_Sw_Input, or use Diamond Logic

®

Builder to force the RPM input pin to the 12 volt state.

2. Verify the RPM input labeled Remote_Engine_Speed_Sw_Input (pin position specified Diamond Logic

®

Builder software) is receiving GND as long as the switch is closed.

3. Verify that the engine ramps to the first preset speed.

4. If engine does not ramp to the first preset speed, check engine programming to verify that the correct engine speed control parameters are set.

5. Deactivate the remote engine speed control switch (release GND).


®

Builder software) is an open circuit when switch is in the center stable position.

7. Verify that the engine returns to idle.


October 2012



FEATURES

■


RECOMMENDED APPLICATION: VARIOUS

60AJE

BDY INTG, THROTTLE CONTROL Accommodation for On Demand Engine Speed for Single

Customer-Mounted Pressure Switch, Programmable Mode for Various Switch Actions, Useable Only While

Vehicle is Stopped and the Park Brake is Applied (requires one RPM input)

TEM or customer-mounted single remote momentary, latched switch or normally open pressure switch; when the operator moves the switch to the up position or the switch closes, the switch supplies GND or 12 volts to the

RPM input which starts ramping the engine to Engine Speed Preset-1, the engine will continue to ramp to the

Engine Speed Preset-1 as long as the switch continues to supply either GND or 12 volts to the RPM input; when the operator moves the switch to the down position or the switch opens, the switch removes the GND or

12 volt RPM input to deactivate Remote engine speed control preset-1 returning the engine to idle.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AKK

C

ONFLICTS

W

ITH

S

OFTWARE

F

EATURES

595AKJ, 595AKL, 595AKM, 595AKN

A

CTIVATION

P

ARAMETERS

:

1.

Momentary or latched GND or 12 volt input to RPM

2.

Park brake applied

3.

Transmission in neutral or park or clutch pedal not depressed

4.

Vehicle speed is less than one MPH

5.

Engine running and at idle

6.

Optional PTO feedback is true.

D

EACTIVATION

P

ARAMETERS

:

1.

No GND or 12 volt input to RPM

2.

Park brake not applied

3.

Transmission not in neutral or park or clutch pedal depressed

4.

Vehicle speed is greater than one MPH.

5.

Engine not running

6.

Service brake depressed

7.

Optional PTO feedback not true

F

EATURE

O

RDERING

N

OTES


2. If 60AJE is ordered, 12VXU must also be ordered which requires entering TEM or customer-requested


3. TEM or customer must supply single momentary, latched or normally open pressure switch and all associated wiring from switch to RPM.



®

®

pre-engineered

pre-engineered PTO features and needs to have this interlock turned on, this will require an additional parameter change by someone who is


October 2012



FEATURES

at least Diamond Logic

®


H

OW

T

O

I

NSTALL

T

HIS

F

EATURE

Software Installation


®

Builder to install Body Controller (BC) software feature code 595AKK, and set the feature code parameters to the following settings: a. 595AKK – Set parameter 2035 to 3. Reference feature configuration programmable parameters.

b. 595AKK – Set parameter 2158 to 3 for 12 volt input or 1 for GND input. Reference feature configuration programmable parameters.

c. 595AKK – Set parameter 2036 to on for optional PTO interlock. Reference feature configuration programmable parameters.


®

Builder to remove BC software feature codes 595AKJ, 595AKL, 595AKM, and

595AN.





(Note: this is the RPM the customer or TEM has requested).

P

ROGRAMMABLE

P

ARAMETERS



®

pre-engineered


a. On b. Off


a. 3, Engine will ramp for only as long as the engine speed control input is held in its active state.

3. 2158 TEM_Ext_ Eng_Spd_ Ctrl_Active_State; This is the active state for the external engine speed control switch input to the RPM and should be set to 3 or 1.


b. 1, GND – The input is connected to GND through a switch.


October 2012



FEATURES

Table 163

Parameter

TEM_Ext_

Eng_Spd_

Ctrl_PTO_ Ilock

TEM_Ext_

Eng_Speed_

Control_ Mode

TEM_Ext_

Eng_Spd_

Ctrl_Active_

State

ID

2036

2035

Description



2158


Default

0

3

1

Units

On/Off

List

List

Min

0

0

0

Max

1

3

1

Step

1

1

3

H

ARDWARE

I

NSTALLATION


®

Builder to verify the correct RPM input pin on the black 23-pin connector. The pin is named Remote_Engine_Speed_Sw_Input.

2. Connect an 18 gauge wire to input pin, and run this wire to one pole on the switch.

3. Connect the remaining switch pole to a 12 volt or GND power source.




October 2012



FEATURES

60AJE W

IRING

I

NFORMATION f_156

F

EATURE

T

ESTING

1. Stationary Remote engine speed control preset-1 Activation; Start engine, set park brake, transmission in neutral or park, vehicle speed is less than one MPH, and take the switch to the closed position, or supply

12 volts or GND on the input pin labeled Remote_Engine_Speed_Sw_Input, or use Diamond Logic

®

Builder to force the RPM input pin to the 12 volt or GND state.


® software) is receiving GND or 12 volts as long as the switch is closed.





®

Builder software) is an open circuit when switch is in the down or open position.



October 2012



FEATURES

■


RECOMMENDED APPLICATION: UTILITY

60AJG

BDY INTG, THROTTLE CONTROL Accommodation for Single Customer-Mounted External Engine Speed

Control Switch, for Utility Applications, Programmable Mode for Various Switch Actions and Engine Speed

Control Option, Only with Vehicle Stopped and Park Brake is Applied (requires one RPM input)

TEM or customer-mounted single remote, momentary switch; when the operator moves the switch to the up position or the switch closes for the first time, the switch supplies the GND or 12 volts to the RPM input which activates Engine Speed Preset-1; when the operator moves the switch to the down position or the switch opens, the engine will remain at Engine Speed Preset-1; when the operator moves the switch to the up position or the switch closes for the second time, Remote engine speed control preset-1 is deactivated returning the engine to idle.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AKL

C

ONFLICTS

W

ITH

S

OFTWARE

F

EATURES

595AKJ, 595AKK, 595AKM, 595AKN

A

CTIVATION

P

ARAMETERS

1.

First momentary GND or 12 volt input to RPM

2.

Park brake applied

3.


4.


5.


6.


D

EACTIVATION

P

ARAMETERS

:

1.

Second momentary GND or 12 volt input to RPM

2.


3.


4.


5.

Engine not running

6.


7.


F

EATURE

O

RDERING

N

OTES


2. If 60AJG is ordered, 12VXU must also be ordered which requires entering TEM or customer-requested


3. TEM or customer must supply single momentary switch and all associated wiring from switch to RPM.



®

®

pre-engineered


®



October 2012



FEATURES

H

OW

T

O

I

NSTALL

T

HIS

F

EATURE



®

to install Body Controller (BC) software feature code 595AKL, and set the feature code parameters to the following settings: a. 595AKL – Set parameter 2035 to 2. Reference feature configuration programmable parameters.

b. 595AKL – Set parameter 2158 to 3 for 12 volt input or 1 for GND input. Reference feature configuration programmable parameters.

c. 595AKL – Set parameter 2036 to on for optional PTO interlock. Reference feature configuration programmable parameters.


®

Builder to remove BC software feature codes 595AKK, 595AKJ, 595AKM, and

595AKN.






P

ROGRAMMABLE

P

ARAMETERS



®

pre-engineered


a. On b. Off


a. 3, Pulling the engine speed control input momentarily to its active state causes the engine to ramp to preset-1; another momentary active state causes the engine to return to idle.

3. 2158 TEM_Ext_ Eng_Spd_ Ctrl_Active_State; This is the active state for the external engine speed control switch input to the RPM and should be set to 3 or 1.


b. 1, GND – The input is connected to GND through a switch.

Table 164

Parameter

TEM_Ext_

Eng_Spd_

Ctrl_PTO_ Ilock

TEM_Ext_

Eng_Speed_

Control_ Mode

TEM_Ext_

Eng_Spd_

Ctrl_Active_

State

ID

2036

2035

Description



2158


Default

0

2

1

Units

On/Off

List

List

Min

0

0

0

Max

1

3

1

Step

1

1

3


October 2012



FEATURES

H

ARDWARE

I

NSTALLATION


®

to verify the correct RPM input pin on the black

23-pin connector. The pin is named Remote_Engine_Speed_Sw_Input.


3. Connect the remaining switch pole to a 12 volt or GND power source.



60AJG W

IRING

I

NFORMATION f_156

F

EATURE

T

ESTING


12 volts or GND on the input pin labeled Remote_Engine_Speed_Sw_Input, or use Diamond Logic

®

Builder to force the RPM input pin to the 12 volt or GND state.


®

Builder software) is receiving GND or 12 volts as long as the switch is closed.


4.

If engine does not ramp to the first preset speed, check engine programming to verify that the correct engine speed control parameters are set.


October 2012



FEATURES



® software) is an open circuit when switch is in the down or open position.


■


RECOMMENDED APPLICATION: UTILITY

60AJH

BDY INTG, THROTTLE CONTROL for Dual Function Input, for Utility Applications, Remote Throttle Control

When Engine is Running, and Activating Output for Emergency Power When the Engine is Not Engaged;

Useable Only When Vehicle is Stopped and Park Brake is Applied (requires one RPM input and output)

Stationary Remote engine speed control preset-1 interlocked to park brake and transmission in neutral or park and vehicle speed and engine running or optional PTO interlock; when engine is not running, the GND input will turn on a 12 volt, 20 Ampere (AMP) RPM out used to control emergency pump.

TEM or customer-mounted single remote, momentary or normally open pressure switch; when the operator moves the switch to the up position or the switch closes for the first time, the switch supplies a GND to the RPM input which activates Engine Speed Preset-1; when the operator moves the switch to the down position or the switch opens, the engine will remain at Engine Speed Preset-1; when the operator moves the switch to the up position or the switch closes for the second time, the switch supplies a GND to the RPM input which deactivates Remote engine speed control preset-1 returning the engine to idle; when the engine is not running and the operator moves the switch to the up position and holds or the switch closes and holds, the switch will supply a GND signal to the RPM input which then turns on a 12 volt, 20 AMP RPM output used for emergency pump control.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AKM

C

ONFLICTS

W

ITH

S

OFTWARE

F

EATURES

595AKJ, 595AKK, 595AKL, 595AKN

A

CTIVATION

P

ARAMETERS

, P

RESET

-1

1.

First momentary GND input to RPM

2.

Park brake applied

3.


4.


5.


6.


D

EACTIVATION

P

ARAMETERS

, P

RESET

-1:

1.

Second momentary GND input to RPM

2.


3.


4.


5.

Engine not running

6.



October 2012



FEATURES

7.


A

CTIVATION

P

ARAMETERS

, E

MERGENCY

P

UMP

:

1.

Hold GND input to RPM

2.

Park brake applied

3.


4.

Vehicle speed is less than one MPH.

5.

Engine not running

6.

Optional PTO feedback is true

F

EATURE

O

RDERING

N

OTES

1. This feature requires one RPM input, one 12 volt, 20 AMP RPM output.

2. If 60AJH is ordered, 12VXU must also be ordered which requires entering TEM or customer-requested


3. TEM or customer must supply single momentary or normally open pressure switch and all associated wiring from switch to RPM.

H

OW

T

O

I

NSTALL

T

HIS

F

EATURE



®

to install Body Controller (BC) software feature code 595AKM, and set the feature code parameters to the following settings: a. 595AKM – Set Parameter 2060, fusing value for the output driving the emergency pump in the combination remote engine speed control emergency pump feature.

b. 595AKM – Set parameter 2035 to 2. Reference feature configuration programmable parameters.

c. 595AKM – Set parameter 2158 to 1 for GND input. Reference feature configuration programmable parameters.

d. 595AKM – Set parameter 2036 to on for optional PTO interlock. Reference feature configuration programmable parameters.


®

to remove BC software feature codes 595AKK, 595AKJ, 595AKL, and 595AKN.

3.

Use Master Diagnostics to program Engine control module: PTO in-cab control: on





P

ROGRAMMABLE

P

ARAMETERS

1. 2060 TEM_Emergency_Pump_Fuse; fusing value for the output driving the emergency pump in the combination remote engine speed control emergency pump feature



®

pre-engineered


a. On b. Off


October 2012



FEATURES


a. 2, Pulling the engine speed control momentarily to its active state causes engine to ramp to preset-1; another momentary active state causes the engine to return to idle.


a. 1, GND – The input is connected to GND through a switch.

Table 165

Parameter

TEM_

Emergency_ pump_Fuse

TEM_Ext_Eng_

Spd_Ctrl_PTO_

Ilock

TEM_Ext_Eng_

Spd_Control_M ode

TEM_Ext_Eng_

Spd_Ctrl_Active

_State

ID

2060

2036

2035

2158

Description

Fusing value for the output driving the emergency pump in the combination remote engine speed control emergency pump feature




Default

0

0

2

1

Units

A

On/Off

List

List

Min

0

0

0

0

Max

20

1

3

3

Step

0.1

1

1

1

H

ARDWARE

I

NSTALLATION


®




®

to verify the correct RPM output pin on the brown connector. The pin is named Utility_Emergency_Pump_Output.


4. Connect the remaining switch pole to a GND power source.

5. Connect emergency pump relay to RPM output connector using 12 gauge wire.




October 2012



FEATURES

60AJH W

IRING

I

NFORMATION

Figure 140 f_160

F

EATURE

T

ESTING


® software) is receiving GND as long as the switch is closed.





®

Builder software) is an open circuit when switch is in the down or open position.


7. Verify 12 volts 20 AMPS on RPM output connector labeled Utility_Emergency_Pump_Output.


October 2012



FEATURES

■


RECOMMENDED APPLICATION: REFUSE

60AJJ

BDY INTG, THROTTLE CONTROL Accommodation for Single Customer-Mounted Momentary Switch, for

Refuse Applications, Programmable Mode Various Switch Actions, Useable Only While Vehicle is Stopped and the Park Brake is Applied (requires one RPM input)

TEM or customer-mounted single remote, latched switch; when the operator moves the switch to the up position or the switch closes, the switch supplies 12 volts to the RPM input which activates Engine Speed

Preset-1, the engine will stay at Engine Speed Preset-1 as long as the switch continues to supply 12 volts to the

RPM input; when the operator moves the switch to the down position or the switch opens, the switch removes the 12 volt RPM input to deactivate Remote engine speed control preset-1 returning the engine to idle.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AKN

C

ONFLICTS

W

ITH

S

OFTWARE

F

EATURES

595AKJ, 595AKK, 595AKL, 595AKM

A

CTIVATION

P

ARAMETERS

:

1.

Latched switch that supplies 12 volt input to RPM

2.

Park brake applied

3.


4.


5.


6.


D

EACTIVATION

P

ARAMETERS

:

1.

No 12 volt input to RPM

2.


3.


4.


5.

Engine not running

6.


7.


F

EATURE

O

RDERING

N

OTES


2. If 60AJJ is ordered, 12VXU must also be ordered which requires entering TEM or customer-requested


3. TEM or customer must supply single latched switch and all associated wiring from switch to RPM.


®

pre-engineered


®


®

Level 2 or 3 certified.


October 2012



FEATURES

H

OW

T

O

I

NSTALL

F

EATURE



®

Builder to install Body Controller (BC) software feature code 595AKN, and set the feature code parameters to the following settings: a. 595AKN – Set parameter 2035 to 3. Reference feature configuration programmable parameters.

b. 595AKN – Set parameter 2158 to 3 for 12 volt input. Reference feature configuration programmable parameters.

c. 595AKN – Set parameter 2036 to on for optional PTO interlock. Reference feature configuration programmable parameters.


®

to remove BC software feature codes 595AKJ, 595AKK, 595AKL, and 595AKM.






P

ROGRAMMABLE

P

ARAMETERS



®

pre-engineered


a. On b. Off


a. 3, Engine will ramp for only as long as the engine speed control input is held in its active state.



Table 166

Parameter

TEM_Ext_

Eng_Spd_

Ctrl_PTO_ Ilock

TEM_Ext_

Eng_Speed_

Control_ Mode

TEM_Ext_

Eng_Spd_

Ctrl_Active_

State

ID

2036

2035

Description



2158


Default

0

3

1

Units

On/Off

List

List

Min

0

0

0

Max

1

3

1

Step

1

1

3

H

ARDWARE

I

NSTALLATION


®




October 2012



FEATURES


3. Connect the remaining switch pole to a 12 volt power source.



60AJJ W

IRING

I

NFORMATION f_156

F

EATURE

T

ESTING


12 volts on the input pin labeled Remote_Engine_Speed_Sw_Input, or use Diamond Logic

®

to force the

RPM input pin to the 12 volt.


® software) is receiving 12 volts as long as the switch is closed.


4.

If engine does not ramp to the first preset speed, check engine programming to verify that the correct engine speed control parameters are set.

5. Deactivate the remote engine speed control switch (release 12 volts).


® software) is an open circuit when switch is in the down or open position.



October 2012



FEATURES

■

REMOTE ENGINE SPEED CONTROL – CATERPILLAR AND CUMMINS ENGINES

Caterpillar and Cummins engine controllers must be programmed using the appropriate diagnostic/programming software for these functions to operate properly. Please see a certified Caterpillar or

Cummins dealer for proper installation and functionality of these features.

R

EMOTE

E

NGINE

S

PEED

C

ONTROL

F

EATURES

A

VAILABLE WITH

C

ATERPILLAR

E

NGINES

Feature codes 12VYC and 12VXY are not available on Caterpillar engines. The following features are available to the Body Builder by directly wiring to the engine controller:

•

Vehicle Speed

•

Engine Speed

•

Remote PTO On/Off

•

Remote PTO Ramp Up/Ramp Down

•

Frequency Output Signals for Driving Off-board Engine Warning Lights

•

Remote Throttle (Pedal) Control

Remote Engine Speed Control Features Available with 2004 Cummins Engines

Vehicle speed on a Cummins engine can be accessed on a datalink or via a second vehicle speed sensor added to the transmission.

■

ACCESSORY WIRING

12VYL

ACCESSORY WIRING, SPECIAL For Road Speed Wire Coiled Under Instrument Panel for Customer Use

This feature provides a vehicle speed signal source from the engine ECM. This speedometer output is calibrated to 30,000 pulses per mile.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software feature codes can be added through the Diamond Logic also programmable through the Diamond Logic

®

software.

®

software. Programmable parameters are

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODES

None

C

ONFLICTS

W

ITH

S

OFTWARE FEATURES

None

P

ROGRAMMABLE

P

ARAMETERS

None

W

IRING

I

NFORMATION

The Road Speed Wire is coiled under the instrument panel.

T

ESTING

Specific testing requirements depend upon the customer application.


October 2012



FEATURES


October 2012


REMOTE AIR SOLENOID MODULE


■

TEM AIR SOLENOIDS

Refer to Circuit Diagram Manual S08322, Chapter 10, Chassis Accessories, Air Solenoid.

■ ■

Normally Closed

08WGA

SOLENOID, AIR for Customer Use; Provides (1) Normally Closed Pilot Air Source, Approx. 4 CFM, Includes

Switch in Cab; Air Available Only With Key in “Ignition (IGN)” or “Accessory” Position; Air Will Exhaust with Key in “Off” Position

08WGB


Switch in Cab; Air Available Only With Key in “IGN” or “Accessory” Position; Air Will Exhaust with Key in “Off”

Position

08WGC



Position

08WGD



Position

08WKM


Switch in Cab; Air Available Only With Key in “Ignition” or “Accessory” Position; Air Will Exhaust with key in

“Off” Position

■ ■

Normally Open

08WGP

SOLENOID, AIR for Customer Use; Provides (5) Normally Open Pilot Air Source, Approx. 4 CFM, Includes

Switch in Cab; Air Exhausted Only With Key in “IGN” or “Accessory” Position; Air Will be Supplied with Key in

“Off” Position

08WGR

SOLENOID, AIR for Customer Use; Provides (6) Normally Open Pilot Air Source, Approx. 4 CFM, Includes

Switch in Cab; Air Exhausted Only With Key in “IGN” or “Accessory” Position; Air Will be Supplied with Key in

“Off” Position

These air solenoids provide Instrument Panel (IP)-mounted, rocker switches and normally closed and/or normally open air solenoids that allow the operator to control up to four normally closed or five or six normally open body-mounted air accessories from the cab. Note: these air solenoids are to be used as a pilot air source and are not to be used as an air supply. All of the air solenoid feature codes include windowed latching rocker switches and do not include any interlock features. Product graphics are included for application to each switch window.


October 2012



The air solenoids will turn off and the air will be exhausted for normally closed solenoids, and air pressure will be maintained with the normally open solenoids with the IGN key turned off. Take precautions to ensure that equipment controlled by these solenoids will not cause personal injury when the IGN key is turned off.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

B

E INSTALLED

B

ASED

O

N

T

HE

F

EATURE

C

ODE

B

EING

I

NSTALLED

08WGA — 595AHX; 08WGB — 595AHY; 08WGC — 595AHZ; 08WGD — 595AJA; 08WGP — 595AKZ;

08WGR — 595AJC; 08WKM --- 595BBD

S

OFTWARE

F

EATURE

C

ODES

T

HAT

M

UST

N

OT

B

E

E

NABLED

None

W

IRING

I

NFORMATION

Use the Diamond Logic® Builder software to determine switch locations of the air solenoid switches.

Customer supplies air plumbing from the air solenoids to the desired air-controlled accessory.

There are several positions where the solenoid packs may be mounted.

f_161

(1) The first 4-pack is mounted on the inboard side of the driver’s side frame rail in front of the rear cab crossmember.

(2) The second and third 4-packs for a 6x4 suspension are mounted on the forward rear suspension crossmember.

(3) The second and third 4-packs for a 4x2 suspension are located on the passenger side frame rail in front of the rear suspension crossmember.

(4) A 6x4 or SS 4x2 can have a fourth 4-pack which mounts on the passenger side frame rail in front of the forward rear suspension crossmember.


October 2012



f_162

T

ESTING

Directions For 4-Pack

This procedure can be used for each auxiliary air solenoid added to the vehicle.

1. Activate the in-cab auxiliary air solenoid switch.

2. Verify that the particular air solenoid either provides air pressure for normally closed or exhausts the air for normally open solenoids.

3. Verify that the proper pin in the air solenoid 4-pack connector has battery voltage.

4. Pin A for all air solenoids should have continuity with the negative battery stud.

H

OW

T

O

A

DD

T

HESE

F

EATURES

See the “How Do I – General Information” section of this electrical guide.

Feature codes 595AHX, 595AHY, 595AHZ, 595AJA, 595AKZ, or 595AJC must be added depending on the number and type of air outputs desired.

Use the Diamond Logic® Builder software to determine correct in-cab switch location(s) for the switches controlling the air outputs.


October 2012



Below is a listing of parts that may be required depending on how the vehicle was equipped at the factory.

Table 167

Part Number

3610975C1

3610976C1

3610977C1

3610978C1

3610973C1

3610974C1

2506711C91

2506712C91

2506713C91

3549776C4

3549777C4

Description

Support, 4-pack Solenoid (Bracket for 7700 w /Chalmers or HMX suspension)

Support, 8-pack Solenoid (Bracket holds 2 4-pack solenoids for 7700 w /Chalmers or HMX suspension)

Support, 4-pack Solenoid (Bracket for 7700 w/ Hendrickson Air suspension w/ 3/8 frame rails)

Support, 8-pack Solenoid (Bracket holds 2 4-pack solenoids for 7700 w/ Hendrickson Air suspension w/ 3/8 frame rails)

Support, 4-pack Solenoid (All other 6x4 vehicles)

Support, 8-pack Solenoid (Bracket holds 2 4-pack solenoids for all other 6x4 vehicles)

Kit, Air Brake Solenoid N.C. (includes labels and O-rings)

Kit, Air Brake Solenoid N.O. (includes labels and O-rings)

Kit, Air Horn Solenoid (includes labels and O-rings)

Housing, Switch 6-Pack DIN Multiplex

Housing, Switch 12-Pack DIN Multiplex

S

CENARIOS

F

OR

A

DDING

A

IR

S

OLENOIDS

The vehicle has a 4-pack with unused solenoid locations.

Add the solenoid to the solenoid pack, and add the appropriate rocker to the switch pack. See the Switch Pack section for switch information, and use the Diamond Logic

®

Builder software in conjunction with Circuit

Diagram Manual S08322, Chapter 10, Chassis Accessories, Air Solenoid for terminal and connector information. The BC will have to be programmed for the additional solenoid and switch. Add solenoids per the view below. f_163

The vehicle does not have any solenoid switch pack.

A 4-pack and solenoid(s) will have to be added. The solenoids are controlled by the BC. There is no multiplexing from the BC to the solenoid pack. See the Switch Pack section for switch information and use the

Diamond Logic

®

Builder software in conjunction with Circuit Diagram Manual S08322, Chapter 10, Chassis

Accessories, Air Solenoid for terminal and connector information.

The vehicle has a 4-pack, but it is full.

Use the same procedure that was used above for a vehicle that already has a solenoid pack that is completely full. A total of two 4-packs may be added to DuraStar and 8000 series vehicles. Four total 4-packs may be added to WorkStar series vehicles. Additional 4-packs are required to be wired per Circuit Diagram Manual

S08322, Chapter 10, Chassis Accessories, Air Solenoid.

The BC will have to be programmed for the additional air features to work properly.


October 2012



■

SWITCH, AIR HORN, PASSENGER, FIRE TRUCK

08WEE

SWITCH, AIR HORN, PASSENGER Fire Truck Application; Switch Located in Instrument Panel (IP) Close to

Passenger; Driver Also To Activate Switch at Steering Wheel

The passenger side air horn switch provides a method for an individual to activate the vehicle air horn from the passenger seat. The feature consists of a hard wired momentary switch that is located in the lower right corner of the central IP. This second rocker switch is used in conjunction with the air horn switch that is located in the steering wheel.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

The air horn software feature code 595ALD must be enabled on the vehicle Body Controller (BC) using the

Diamond Logic® Builder software (see local dealer).

There are no programmable parameters associated with this feature.

W

IRING

I

NFORMATION

Both the hard wired rocker switch in the IP and the air horn switch in the steering wheel are connected to a single input on the BC connector 1602 Pin F8. The air solenoid is driven from the BC output connector 1602 Pin

E12.

Air Horn Switch Part Number 3551415C1

f_164

T

ESTING

S

YSTEM

O

PERATION

1. Turn the Ignition (IGN) key to the accessory position.

2. Momentarily depress the air horn switch in the steering wheel. Note that the air horn sounds.

3. Momentarily depress the air horn rocker switch. Note that the air horn sounds.

H

OW

T

O

A

DD

T

HIS

F

EATURE

1. Remove the central IP trim piece.


October 2012



Center Panels to Remove

f_165

2. Locate an open switch position in the lower right corner of the IP.

3. Use a switch hole punching tool to cut a hole in the plastic plate of the central IP plate.

4. Remove the storage box or 12-pack of switches located above plastic plate. Use a scribe or other marker tool to outline the hard wired switch openings in the steel plate located behind the plastic switch plate.

5. Drill a pilot hole in the center of the desired switch location.

6. Use the switch punch to open the hole in the plastic plate. The recommended method to create a rectangular switch slot is to use a Green Lee Punch (part number ZTSE4426 from SPX).

7. Insert the air horn switch in the plastic plate.

8. Wire the mating switch connector as Circuit Diagram Manual S08322, Chapter 4 Cab Accessories, Horn –

Electric.

9. Attach the switch connector to the air horn switch.

10. Reinstall the plastic switch plate and central IP trim piece.


October 2012



General Circuit Diagram for Adding the Passenger Side Air

Horn Switch

f_166


October 2012




October 2012


REMOTE START/STOP


■


Refer to the circuit diagram in S08322, Chapter 10, Chassis Accessories, Remote Start/Stop.

60ABC

BDY INTG, REMOTE START/STOP To Start and Stop Vehicle Engine

The Remote Start/Stop feature provides the operator with the ability to remotely start or stop the engine from a single ground (GND) active switch closure located on the vehicle body equipment. The vehicle park brake must be set, and the hood of the vehicle must be closed. The vehicle must also be equipped with an automatic transmission and must be in neutral. This feature requires the customer to provide the GND active switch as well as the wiring from that switch into the Remote Start/Stop connector located in the middle of the chassis.

The customer will also provide the terminals and seals for the International

®

-provided connector.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AKW

S

OFTWARE

F

EATURE

C

ODE

T

HAT

M

UST

B

E

R

EMOVED

595AKV

If TEM_Rem_Start_Stop_PTO_Ilock is turned on, then the operator can only use Remote Start/Stop when the in-cab, International

®

PTO switch is in the ON position.

The TEM_Rem_Start_Stop_Crank_Delay_Gen2 parameter determines how long the engine will wait before starting once the remote start/stop feature is activated.

Table 168

Parameter

TEM_Rem_

Start_Stop_

PTO_Ilock

TEM_Rem_

Start_Stop_

Crank_Delay_

Gen2

ID

2192

2438

Description

If this parameter is set, the remote start/stop functionality will not function unless the PTO switch is in the on position.

This is the time that the remote start/stop feature delays before starting to crank the engine.

Default

Off

0.5

Units

On/Off

S

Min

N/A

0.1

Max

N/A

1

Step

N/A

0.01

W

IRING

I

NFORMATION

•

When 60ABC is ordered on a truck, a connector (# 9778) is provided for the TEM to wire into for Remote

Start/Stop. This connector is located in the mid-chassis harness. The mid-chassis harness is located approximately halfway between the rear axle (or forward-rear axle for trucks with tandem rear axles) and the back of the cab on the driver’s side frame rail. The customer should wire into the circuit with the Dark Blue wire (# N104CA).

•

The customer must provide a GND active momentary switch that is wired into the mid-chassis Remote

Start/Stop connector.

•

The customer must also order the terminals and seals (based on their wire gauge) for the

International

®

-provided connector so that the customer can wire the switch into the connector.

Table 169

Customer Wire Gauge

12AWG

14AWG

16AWG

Terminal Part Numbers

1673748C1

0587577C1

0587577C1

Seal Part Numbers

0589390C1

0589391C1

1652325C1


October 2012



Remote Start Stop Connector in Mid-Chassis Harness

f_167

T

ESTING

1. When starting and stopping the engine, make sure that the Body Builder switch is providing a GND signal to the mid-chassis wire. The vehicle ignition (IGN) key must be in the ON position and the hood must be closed.

2. If the engine is running, a momentary switch closure of the body builder-supplied switch will stop the engine.

3. If the engine is stopped, push and hold the body builder-supplied switch until the vehicle starts.

H

OW

T

O

A

DD

T

HIS

F

EATURE

Refer to the circuit diagram in S08322, Chapter 10, Chassis Accessories, Remote Start/Stop for proper circuit and connector/pin information.


October 2012



■

REMOTE START/STOP WITH EMERGENCY PUMP

Refer to the circuit diagram in S08322, Chapter 10, Chassis Accessories, Remote Start/Stop.

60ABD

BDY INTG, REMOTE START/STOP To Start and Stop Vehicle Engine, Will Start Emergency Pump Motor,

Programmable Time Intervals

The Remote Start/Stop feature provides the ability to remotely start or stop the engine from a single GND active switch closure located on the vehicle body equipment. This feature operates in two modes, namely the remote start/stop mode and the emergency pump mode. The vehicle park brake must be set and the hood of the vehicle must be closed. The vehicle must also be equipped with an automatic transmission and must be in neutral. The user may engage the same switch to control an emergency pump solenoid/motor combination, if the vehicle engine cannot be restarted.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AKV

S

OFTWARE

F

EATURE

C

ODE

T

HAT

M

UST

B

E

R

EMOVED

595AKW

If TEM_Rem_Start_Stop_PTO_Ilock is turned on, then the operator can only use Remote Start/Stop when the in-cab, International

®

PTO switch is in the ON position.

If the engine shuts off unexpectedly or will not start, 60ABD provides the operator with the ability to use an emergency pump solenoid/motor. The TEM_Remote_Engine_Stop_Time parameter sets the time to hold the switch down, after the engine has unexpectedly shut off, before the emergency pump activates. Also, if the truck is stopped remotely and the remote switch is held in the active position, the emergency pump will start by holding the switch for the time set by the TEM_Remote_Engine_Stop_Time parameter.

The TEM_Rem_Start_Stop_Crank_Delay_Gen2 parameter determines how long the engine will wait before starting once the remote start/stop feature is activated

Table 170

Parameter

TEM_Rem_

Start_Stop_

PTO_Ilock

TEM_ Remote_

Engine_Stop_

Time

TEM_Rem_

Start_Stop_

Crank_Delay_

Gen2

ID

2192

2072

2438

Description

If this parameter is set, the remote start/stop functionality will not function unless the PTO switch is in the on position.

Time allotted to stop the engine for the remote engine start stop with emergency pump feature.

This is the time that the remote start/stop feature delays before starting to crank the engine.

Default

Off

5

0.5

Units

On/Off

S

S

Min

N/A

-

0.1

Max

N/A

6-

1

Step

N/A

0.01

0.01

W

IRING

I

NFORMATION

•

When 60ABD is ordered on a truck, two mid-chassis wires with a connector (# 9778) are provided for the

TEM to wire into for Remote Start/Stop with emergency pump. This connector is located in the mid-chassis harness. The mid chassis harness is located approximately halfway between the rear axle (or forward-rear axle for trucks with tandem rear axles) and the back of the cab on the driver’s side frame rail.

•

The first wire is the wire used to stop and start the engine (# N104CA). It is a dark blue wire.

•

The second wire is used to control an emergency pump (#N59CA). It is a grey wire.

•

The customer must also order the terminals and seals (based on their wire gauge) for the

International

®

-provided connector so that the customer can wire the switch into the connector.


October 2012



Table 171

Customer Wire Gauge

12AWG

14AWG

16AWG

Terminal Part Numbers

1673748C1

0587577C1

0587577C1

Seal Part Numbers

0589390C1

0589391C1

1652325C1

•

The customer must provide a GND active momentary switch that is wired into the mid-chassis connector.

•

If the customer orders 60ABD but decides not to use an emergency pump, the customer should simply use the Diamond Logic

®

Builder software to enable software feature code 595AKW, and remove software feature code 595AKV.

Navistar does not suggest adding a remote start on vehicles with manual transmissions.

f_168

T

ESTING

1. When starting and stopping the engine, make sure that the Body Builder switch is providing a GND signal to the mid-chassis wire. The vehicle IGN key must be in the ON position and the hood must be closed.

2. If the engine is running, a momentary switch closure of the body builder-supplied switch will stop the engine.

3. If the engine is stopped, push and hold the body builder-supplied switch until the vehicle starts.

4. If the engine will not start, release the start/stop switch momentarily, activate the switch again, and hold it until the emergency pump control wire supplies GND to the emergency pump relay. The emergency pump will remain ON as long as the switch is active.

H

OW

T

O

A

DD

T

HIS

F

EATURE

Refer to the circuit diagram in S08322, Chapter 10, Chassis Accessories, Remote Start/Stop for proper circuit and connector/pin information.


October 2012


LIFT GATE ACCOMMODATION PACKAGE


■

POWER SOURCE FOR LIFT GATE

08WJA

POWER SOURCE, SPECIAL for Customer-Installed Lift Gate; 200 AMP max, includes 2 gauge power cable to end-of-frame, switch on Instrument Panel (IP), with a time out feature, battery discharge protection, controlling a mag switch which provides power

08WJB

POWER SOURCE, for Customer-Installed Lift Gate; heavy duty, includes 0 gauge power cable to end-of-frame, switch on IP, with a time out feature, battery discharge protection, controlling a mag switch which provides power

08WJH

POWER SOURCE, SPECIAL Special Socket; Dual Pole Terminal, for Power Lift Gate Feed, Battery Feed Thru

150 Amp Circuit Breaker To Operate Lift Gate On Trailer

08WCM

POWER SOURCE, SPECIAL Special Socket; Single Terminal, for Power Lift Gate Feed, Battery Feed Thru

150 Amp Circuit Breaker, To Operate Lift Gate On Trailer, Includes a 15’ Power Cable Coiled in Cab

Feature code 08WJA or 08WJB provides a factory-installed, dedicated power source for lift gate operation. This feature includes an IP-mounted master switch, which illuminates when the system is turned on, and an optional

“AUX” button on the key fob to enable or disable the lift gate. The purpose of the in-cab master switch and the

“AUX” button on the key fob is to help prevent unauthorized use of the lift gate. These switches also activate a

60 minute timer in the BC that will disable the lift gate after 60 minutes. For continued use of the lift gate, the master switch or the aux button on the key fob must be used to activate the system for an additional ten minutes. A Battery Protection Module, activated by the BC 60 minute timer, and a 200 AMP mag switch, mounted in or at the battery box, enables power to the lift gate motor. A circuit protected cable from the battery to the mag switch and a heavy gauge wire routed from the mag switch to the end of frame, to provide power to the lift gate motor is also provided.

This feature will provide battery discharge protection for users who operate the lift gate with or without the engine running. Without the engine running, key off, the Battery Protection Module will constantly monitor battery voltage and shut down the lift gate operation before battery voltage reaches a state of charge that will not allow the vehicle to restart. With the key switch in any position except start or off, an audible alarm will also sound in the cab during certain low voltage conditions. In addition to battery voltage monitoring, this feature has time out functionality from the BC to automatically disable the lift gate after a selected time. The default time out is 60 minutes. A road speed interlock from the BC is provided that activates above approximately 2 MPH. If activated, the indicator light in the switch flashes and the lift gate is disabled by the BC which prevents the lift gate from being operated while the vehicle is in motion. The lift gate master switch, or the aux button on the key fob, must be activated again to continue use of the lift gate after vehicle has stopped.

The lift gate shall be activated for 60 minutes when the key switch is in any position and the lift gate switch is pressed to the momentary on position (up position), or key fob aux button is pressed, and the vehicle speed is lower than 2 MPH and voltage conditions are met.

The lift gate shall be deactivated when any of the following conditions are met:

1. The lift gate switch is pressed to the momentary off position (down position), or the push button is cycled depending on the programmable feature on the vehicle.

2. The aux button on the key fob is pressed.


October 2012



3. The voltage is lower than the safe voltage value, and the shutdown override time expires or the vehicle speed is greater than 2 MPH.

4. The programmable time limit, set at 60 minutes, has been reached.

A cable accommodation is required to fit body van length of 14-26 feet. An additional 40 inch cable length is provided for ease of installation.

Design accommodation for a lift gate with maximum current draw of up to 200 AMPS for code 08WJA and 200+

AMPS for code 08WJB is available.

This feature can work with the work light feature but cannot work with the work light Remote Keyless Entry

(RKE) key fob feature.

S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Software feature codes can be added through the Diamond Logic parameters are also programmable through the Diamond Logic

®

®


software.

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AYM for lift gate with rocker switch or 595AGN for lift gate with push button switch in the left side cluster switch B location. Be careful: 595AGN “LIFT GATE WIRING PAK Push Button B” may conflict with other “B” located switch features like Lamp Check (595AZY).

S

OFTWARE

F

EATURES

T

HAT

M

UST

B

E

R

EMOVED

595ABT

The Lift_Gate_Alarm_Time parameter is programmed to allow the operation of the lift gate for a period of 60 seconds. At the end of 60 seconds, the master switch or the aux button on the key fob must be used to reactivate the system.

The Lift_Gate_Enable_Timeout parameter is programmed to allow continual operation of the lift gate, in 10 minute increments, with the master switch or aux button on the key fob after the time out period of 60 minutes.

The Lift_Gate_Enable_Hi_Current parameter will set an alarm if amperage load goes above the programmed value.

The Lift_Gate_Enable_Lo_Current parameter will set an alarm if amperage load goes below the programmed value.

The Lift_Gate_Enable_OC_Current parameter will set an alarm if amperage load goes below the programmed value.

The Lift_Gate_Enable_Timeout parameter can be adjusted to vary the amount of time, in ten minute increments, that the lift gate will remain enabled. If this value is set to 6, the lift gate will remain enabled for 60 minutes from the time that it is enabled.

The Lift_Gate_Disable_Threshold parameter will disable the lift gate feature if the voltage falls below this threshold voltage.


October 2012



Table 172

Parameter

ift_Gate_

Alarm_Time

Lift_Gate_

Enable_Hi_

Current

Lift_Gate_

Enable_Lo_

Current

Lift_Gate_

Enable_OC_

Current

Lift_Gate_

Enable_Timeou t

Lift_Gate_Disab le_Threshold

ID

2249

2234

2233

Description

Lift Gate Alarm Time Value

Lift Gate Enable High Current


Work Light Low Current Detection

Level (AMPS)

2232

2235

2239

Lift Gate Enable Open Circuit


Amount of time, in 10 minute increments, that the lift gate will remain enabled.

Voltage threshold below which the lift gate is disabled

Default

60

10

0.3

0.3

60

11.5

Units

s

A

A

A

Min

V

Min

1

0

0

0

10

11.5

Max

120

10

10

10

240

13.8

Step

1

0.1

0.1

0.1

10

0.1

W

IRING

I

NFORMATION

For 08WJA and 08WJB

Please refer to Circuit Diagram Manual S08337, Chapter 10, Chassis Accessories, Power Source, Customer

Installed Lift Gate.

For 08WJA

The Body Builder will be required to cut the 2 straplocks securing the power cable and route and clip the power cable to the lift gate motor. Then trim the power cable to length and add a lug terminal for securing cable to the lift gate motor. Two product graphics, from the plastic bag for Body Builders, need to be installed on the van body in the approximate locations shown.

For 08WJB

The Body Builder will be required to route a 0 gauge cable from the mag switch, back along the frame to the lift gate motor.

Code 08WJB is identical to code 08WJA with the following exceptions:

Added – 3598246C91 Cable Assy, Lift Gate Feed with “0” gauge cable and 3-10 Awg fusible links.

Removed – 3592398C91 Cable Assy, Lift Gate Feed with “2” gauge cable and 2-10 Awg fusible links.

Also the 3592400C93-REF “2” gauge Cable Assy, Lift Gate – 33.5 feet Ref – Cut to length is changed to “0” gauge cable. The Body Builder will be required to remove the “2” gauge cable from the mag switch, back along the frame to the lift gate motor and replace it with the “0” gauge cable.


October 2012



Harness Routing Diagram

f_169


October 2012



Warning Label Locations Diagram

f_170

T

ESTING

1.

The body builder or lift gate installer must bring the batteries up to a full charge before trying to test the system for functionality.

2. With the batteries at a full charge, voltage in the 12.6 to 12.9 range and the lift gate power controlled by the

Battery Protection System, the system will operate as described in the above section.

H

OW

T

O

A

DD

T

HIS

F

EATURE


®

software to add the following software feature:

R

EQUIRED

S

OFTWARE

F

EATURE

C

ODE

595AYM for lift gate with rocker switch or 595AGN for lift gate with push button switch

S

OFTWARE

F

EATURES

T

HAT

M

UST

B

E

R

EMOVED

595ABT

H

ARDWARE

Please refer to Circuit Diagram Manual S08337, Chapter 10, Chassis Accessories, Customer Installed Lift Gate for circuit locations and routing and an International

®

dealer for parts information.


October 2012




October 2012


POWERPACK 3 PRIMARY AND TEMPORARY

MOUNT FEATURES

POWERPACK 3 PRIMARY AND TEMPORARY MOUNT FEATURES

■

POWERPACK 3 PRIMARY AND TEMPORARY MOUNT FEATURES

60AAC

BDY INTG, POWER INVERTER 3000 Watt Dynamic (With Engine Running); On/Off Switch in Instrument Panel

(IP); Includes 120 volt AC Wiring; Connection for Customer-Mounted Power Outlet

60AAE

BDY INTG, POWER INVERTER Temporary Mount on Frame Rail for Customer Installation; 3000 Watt

Dynamic (With Engine Running); On/Off Switch in IP; Includes 120 volt AC Wiring Connection for

Customer-Mounted Power Outlet

WARNING: Shock hazard. Only trained technicians should service high voltage components. High voltage circuits and components contain voltage levels that may cause equipment damage, electric shock, and/or deadly electrocution if handled incorrectly.

WARNING: DO NOT OPEN the PowerPack 3. Hazardous voltages exist internally even after the PowerPack 3 is removed from the vehicle. Only a Qualified Technician may perform service inside the PowerPack 3. Failure to follow this warning may result in property damage, personal injury, or death.

WARNING: The alternator may generate high voltage, particularly at high rpm, which can be harmful. Do not touch the 3–phase output terminals. Failure to follow this warning may result in property damage, personal injury or death.

WARNING: The alternator output is a hazardous 3–phase AC voltage — Do not cut the cable or touch the terminals. Failure to follow this warning could result in property damage, personal injury, or death.

The PowerPack 3 Inverter system is an advanced Power Generation and Power Management system to provide both DC power and an on-board 120 volt AC power source. The PowerPack 3 system is integrated with the Diamond Logic

®

Electrical system. The DC portion of the system provides 14 volts DC at a maximum of

100 Amperes (AMPS) to charge the vehicle batteries. The AC portion of the system provides a 120 Volts AC single, phase 60 Hertz output at a maximum of 25 AMPS. The system may be ordered from International

®

, factory-installed either mounted in the battery box or as a temporary mounted inverter module behind the cab.

The body upfitter is tasked with mounting the inverter in a body compartment with the temporary mount.

The PowerPack system consists of an inverter module, a special 3-phase 42 volt AC alternator, a multiplexed switch in the cab, and associated wiring harness. The engine must be running in order for the PowerPack system to generate AC or DC voltages. The 120 volt AC output is only functional when the vehicle is stationary with the park brake set. The 120 volt AC output contains a Ground (GND) fault interrupter device and a weather sealed power plug.

CAUTION:

If 120 volts AC Shore power is integrated into the body wiring, the shore power connection must never be directly connected to the PowerPack 3 AC output.


October 2012



MOUNT FEATURES

f_171

PowerPack 3 Block Diagram


October 2012



MOUNT FEATURES

Battery Box Mounted PowerPack 3

f_172

Remote Mount PowerPack 3

f_173


October 2012



MOUNT FEATURES

AC Derating Curve

f_174

DC Derating Curve

f_175


October 2012



MOUNT FEATURES

U

SING

P

OWER

P

ACK

3 W

ITH

R

EMOTE

E

NGINE

S

PEED

C

ONTROL

PowerPack 3 provides full power output for the 120 volt AC section at an engine RPM of 935 or greater. The

PowerPack 3 inverter module uses special datalink commands to raise the engine RPM to 935 when the 120 volt AC rocker switch is turned on. Since the engine cannot respond to both datalink commands and direct

Engine Control Module (ECM) hard wired engine speed control commands, the body upfitter must use specific alternative wiring methods to permit remote engine speed control from remote body locations as well as allow

PowerPack 3 to raise engine speed as required. Vehicles equipped with PowerPack 3 may not be used with the feature 12VZA which provides remote engine speed control through hard wires connected directly to the engine ECM. The following alternative features are compatible with PowerPack 3 and may be used to achieve various engine speed control functions.

•

Preset or variable engine speed control using the steering wheel cruise control switches

•

Preset variable or remote pedal/throttle using the Remote Engine Speed Control Module (RESCM). Requires

Body Controller (BC) feature 595AHA

•

Preset 1 using Remote Power Module (RPM) inputs; i.e., feature code 60AJE

•

Preset or variable engine speed control using Diamond Logic

®

Advanced Ladder Logic

When the PowerPack 3 AC output is turned off and no other form of remote engine speed control is requested, the engine will be at an idle speed of approximately 700 RPM. If the PowerPack 3 AC switch is turned on, the engine speed shall be increased to 935 RPM. If another form of remote engine speed control is activated, the

PowerPack 3 will release engine speed control to that input. When the remote engine speed request is removed, the engine will return to 935 RPM until the PowerPack is turned off.

B

ODY

C

ONTROLLER

: S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Stationary Mode

Software feature code 595AZU must be enabled on the vehicle Body Controller using the Diamond Logic

®


Parameter PPE3_param_incrThrottle_rqst_enable will enable the automatic throttle request. This will automatically ramp the engine to the value set in parameter 2344 when the PowerPack is requested on.

Parameter PPE3_param_incrThrottle_startDelay is the amount of time that the PowerPack will wait to turn on.

This is to allow the engine to ramp to the operating RPM before the PowerPack is activated.

Parameter PPE3_param_incrThrottle_targetRPMs is the target RPM for the engine to ramp to when the

PowerPack is activated.

Parameter PPE3_param_incrThrottle_timeout is the amount of time that the inverter is inhibited from coming back on due to inadequate engine speed.

Table 173

Parameter

PPE3_param_ incrThrottle_ rqst_enable

Units

On/Off

Min

0

Max

1

Step

1

PPE3_param_ incrThrottle_ startDelay

PPE3_param_ incrThrottle_ targetRPMs

PPE3_param_ incrThrottle_ timeout

ID

2357

2399

Description

If this is true, then the automatic throttle increase request has been enabled.

This parameter allows the throttle to ramp to the target RPM prior to enabling the PPE. The logic for this parameter is that a maximum load on the PPE would turn off the inverter if the alternator RPMs are not at target.

Default

1

2

2344

2345

This is the target RPM rate for the throttle increase feature.

The amount of time until the inverter is inhibited because the engine speed is not at an adequate level

935

5

Seconds

RPM

Seconds

0

900

0

5

2000

30

0.1

1

0.1


October 2012



MOUNT FEATURES

W

IRING

I

NFORMATION

WARNING: All electrical connections to the PowerPack 3 must be made by a qualified electrician. Failure to follow this warning could result in property damage, personal injury, or death.

A Hubbell Watertight Safety-Shroud male plug (Hubbell part number HBL2611SW) is needed to connect to the

AC output plug to mate with the PowerPack supplied Hubbell Watertight Safety-Shroud female socket (Hubbell part number HBL2613SW). These plugs are available at electrical and industrial supply houses.

Using this part combination will allow for a weather resistant connection to the PowerPack 3 unit. Alteration of the AC output plug, failure to use the correct male plug, or removal of the supplied socket will not guarantee a watertight connection.

The AC output from the PowerPack 3 is wired to a Ground Fault Circuit Interrupter (GFCI) to ensure protection against GND fault conditions. Be aware that standard duplex GFCI and non-GFCI receptacles need to be protected with a circuit breaker, usually rated for 15 or 20 AMPS.

PowerPack 3 Inverter/Regulator Component Detail

f_176

PowerPack 3 Kit, Left Side under Cab for vehicles built after March 2007.

PowerPack 3 Kit, Right Side under Cab for vehicles built after March 2007.

PowerPack 3 Kit, Remote Mount for vehicles built after March 2007.

Fuse, 58 volt, 10 amp: Alternator Field Wire fuse. Navistar Part Number: 2590768C1

T

ESTING

S

YSTEM

O

PERATION

•

Start engine; ensure that the park brake is set.

•

Verify that the batteries are being charged. The voltmeter should be reading greater than 13.5 volts.

•

Depress 120 VAC rocker switch in IP.

•

Verify that the engine ramps to 935 RPM.

•

Verify green light in rocker switch is on solid within five seconds.

•

Verify 120 volt AC output voltage.


October 2012



MOUNT FEATURES

f_177

P

OWER

P

ACK

3 T

ROUBLESHOOTING

If the PowerPack 3 output does not power up or shuts down during vehicle operation, follow these steps to troubleshoot the system:

1. Set the 120VAC ON/OFF switch to OFF position, and ensure interlocks are satisfied, as described above, correcting as necessary.

2. Attempt to restart the PowerPack 3 by pressing the ON switch.

3. If the unit continues to shut-down, (blinking green light in the rocker switch) disconnect any AC loads before restarting the PowerPack 3.

4. Check for green light on GFCI. If there is a red light press the reset button on GFCI.

5. Press the 120VAC switch to OFF, check the 30-Amp circuit breaker, and reset if necessary.

6. Wait several minutes to allow the system alternator and PowerPack 3 unit to cool, and then attempt to restart.

7. If the unit does not restart, then turn the vehicle’s ignition OFF, and then back ON again. This will restart the

PowerPack 3 output protection circuits.

8. If the above steps fail to restart the PowerPack 3 unit, then have the system serviced by a qualified technician.

NOTE: If the unit does not restart, the problem could be caused by overheating or other circuit protection devices. If the PowerPack 3 circuit breaker or the GFCI device is tripped, the green light in rocker switch will continue to show an indication that AC power is ON. Be advised to check these other elements of the system if

120 volt AC power is not present as expected.


October 2012



MOUNT FEATURES

Table 174 – Diagnostic Indications Using the In-Cab Rocker Switch or Diamond Logic

®

(Pre-2007 Vehicles)

SPN

168

168

168

168

168

168

168

168

168

168

639

FMI

2

3

3

4

4

6

8

16

16

17

14

Byte 7

0

0

0

0

0

0

0

0

0

0

37

Byte 8 Switch Indicator

Blink Rate

0

0

0

0

0

0

0

0

0

0

255

Fast

Fast

Slow

Fast

Slow

Slow

Fast

Fast

Slow

Fast

Fast

Condition Description/Comments/Probable Cause(s)

Communication fault from ESC to the PowerPack. Check for open circuit or short in J1939 datalink. If switch is not blinking, verify vehicle is programmed for PowerPack feature and the switchpack is operating correctly.

DC module over voltage on vehicle DC bus. System detected voltage over 15 volts. Remove any external power supply/charger from vehicle

AC module over voltage condition on high voltage DC bus. Likely an internal failure for AC output. AC has been shut down. DC output remains on.

DC module under voltage condition on vehicle DC bus. System detected low DC voltage. This could be due to insufficient power from the alternator. Check the 3 phase wires from the alternator to the

PowerPack.

AC module under voltage condition on high voltage DC bus. System detected low internal voltages. This could be due to insufficient input power from the alternator. Check the 3 phase wires from the alternator to the PowerPack.

AC module has shut down due to overload condition. AC overloaded, remove some or all of AC load.

Phase missing fault/alternator fault. One of the three 3-phase wires has an open circuit. Check the 3 phase wires from the alternator to the PowerPack.

DC module over temperature condition. PowerPack is experiencing extremely high internal temperatures. AC and DC has been shut down. Allow the system to cool down.

AC module over temperature condition. PowerPack has detected high internal temperatures although less severe. AC inverter has shut down, but DC output remains on. Shut the system down to all it to cool down or remove some of the loads.

PowerPack Fuse Open. Check DC battery charging connections from

PowerPack. Check 150A fuse.

Communication fault between PowerPack and the ESC. Check for open circuit or short in J1939 datalink. Also, check the ignition circuit to the PowerPack module


October 2012



MOUNT FEATURES


®

(2007 Vehicles and post-2007)

SPN FMI Byte 7

520467

168

520664

168

520644

520771

115

520774

520773

520772

639

9

3

3

4

4

6

2

0

0

31

9

0

0

0

0

0

0

0

0

0

0

37


Blink Rate

0

0

0

0

0

0

0

0

0

0

255

Fast

Fast

Slow

Fast

Slow

Slow

Fast

Fast

Slow

Fast

Fast






PowerPack.









NOTE: A complete aftermarket parts kit is under development. The PowerPack 3 kit part number is not available at this time.

H

OW

T

O

A

DD

T

HIS

F

EATURE

1. Remove power from batteries.

a. Remove the lid from the battery box.

b. Remove all battery cables from the batteries and battery box, starting with the negative terminals.

2. Replace the 3 battery box with a 4 battery box.

a. Remove cab steps from the battery box.

b. Remove the front side of the battery box.

c. Remove all batteries.

d. Remove old battery box from the frame rail.

e. Remove any options that may be on box, and transfer to new box.


October 2012



MOUNT FEATURES

f. Attach new 4 battery box to the frame rail. Some new mounting holes may need drilled in the frame rail.

Re-use existing holes as much as possible.

g. Add cover hold downs, and add new box to frame, 777937C1 retainers, 934871R1 nuts, 30278R1 screws, 30264R1 washers.

h. Put batteries in the two forward locations of the 4 battery box.

i. Install the PowerPack 3 Inverter Module in the most rearward location of the battery box. Align the PP3 module such that the mounting stud on the rear panel of the module projects through the rear of the battery box.

j. Ensure that the PP3 harnesses are carefully routed through the openings in the rear panel of the battery box without kinking or pinching.

k. Attach the battery box hold down bracket to secure the batteries and the PP3 Inverter Module.

l. Attach the retainer nut to the PP3 module stud on the back side of the battery box.

m. Attach vent tubes to each battery, and route out of battery box.

Sample Inverter on Installation on the Driver’s Side of the Vehicle

f_172

3. Add new alternator.

a. Remove air filter and cover turbo intake to prevent items from falling into intake.

b. Remove serpentine belt and old alternator.

c. Tie off old cables.

1. Seal terminal ends with heat shrink tube, fold back onto trunk of harness, and tape to trunk of harness.

d. Attach the Leece-Neville alternator (part number 3606039C91) to the engine. Transfer belt pulley from old alternator to the new alternator.

e. Check alternator mounting bolt torque. DO NOT OVER TORQUE.


October 2012



MOUNT FEATURES

1. Alternator to bracket mounting bolts 30 to 35 lb ft f. Add new alternator harness overlay.

1. Route the PP3 harness next to existing engine harness to the starter; then follow battery cables to the battery box.

2. At base of battery box, route inverter cables to back of battery box by going under the frame rail.

g. Use tie wraps, every 12 inches, to attach the alternator harness to the battery cables.

A

LTERNATOR

H

ARNESS

The harness from the PowerPack 3 to the alternator must be properly routed and securely fastened to avoid any hot or sharp areas and to prevent cable movement. Failure to use the proper size wire can result in overheating conditions that could cause fire, personal injury, and void of warranty.

h. Add Ignition (IGN) lead to the in-cab fuse relay panel.

1. Connect an 18 gauge wire from the PowerPack 3 IGN feed connector to the dash pass thru connector 1702 pin 5.

2. Connect an 18 gauge wire from the dash pass thru connector 1702 pin 5 to an IGN feed in the cab fuse/relay panel cavity G2-H2 (see fuse box detail).

3. Add 10 AMP fuse to fuse locations G2-H2.

4. Connect to inverter overlay harness (connector 9740 at the center of valve cover). Strap lock the connector to the main center chassis harness.

5. Remove terminating resistor from J1939 datalink back bone harness (connector 7801M located on the top center of the engine valve cover). Connect the PP3 J1939 datalink harness (connector

7801M) to J1939 inverter (connector 7801N). Save J1939 terminator resistor assembly.

6. Strap harness to existing harnesses.

Keep clear of sharp edges or anything that can rub or damage wire insulation.

4. Connect harness wires to the alternator.

a. Attach 3-Phase AC output ring terminal wires to bolt studs on the back of alternator. 80-120 in lb

(inch-pounds, NOT foot-pounds) Three phase wire attachment order to the alternator does not matter.

b. Attach field coil wires to the top of alternator using two nuts 15-20 in lb (inch- pounds, NOT foot-pounds).

3-Phase and Field Wire Alternator Connections

5. Make connections from the PowerPack 3 wire harness to the inverter module.

a. At back of the battery box: f_178


October 2012



MOUNT FEATURES

1. Connect 3-Phase AC alternator connectors (9741, 9742, and 9743) which are large 4 gauge, 1-pin connectors. Ensure the connectors are fully mated with a positive click of the male connector into the female connector.

2. Connect inverter IGN connector (7899) 1-pin connector.

3. Connect inverter J1939 connector (7801R) 3-pin connector.

4. Connect field voltage connector (9740) 2-pin connector.

b. Connect terminating resistor connector to (7801L) located on inverter harness near inverter connection to the J1939 data bus connector.

6. Secure PowerPack 3 harness to the chassis harness.

a. Keep harness clear of sharp edges or anything that can rub or damage wire insulation. Use tie wraps every 12 inches to attach the PP3 alternator harness to battery cables.

8. Remove cloth from air intake, and reinstall air filter.

WARNING: Shock Hazard. Never make electrical connections to a “live” unit. Make the connections to the

PowerPack 3 first and the batteries last. Failure to follow this warning may result in property damage, personal injury or death.

Step 1: Make sure that the batteries are disconnected from the vehicle.

Step 2: Install the in-line fuse on the positive battery terminal or within 18 inches of the battery or DC wiring bus system.

Step 3: Route, but DO NOT connect, the positive DC (red) input cable from the PowerPack 3 to the in-line fuse on the battery or DC wiring bus system. Make sure to protect all cables from where they contact hard or sharp edges.

Step 4: Connect the PowerPack 3 to the battery in THIS order.

A. Install washers and nuts, and torque terminal nuts. (120 inch-pounds)

B. Connect red cables to the positive battery posts.

C. Connect black cables to the negative battery posts.

Step 5: Verify that all connections are tight and the cables are secure.

G

ENERAL

C

ABLE

I

NSTALLATION

T

IPS

:

WARNING: Fire and Explosion Hazard. Double check the polarity of the DC input connections. Reverse polarity may severely damage the PowerPack 3. Fire and/or explosion of the batteries may also occur as a result of reversed polarity. Failure to follow this warning may result in property damage, personal injury or death.

DC cables should be as short as possible. The optional installation kit includes all DC cables. The PowerPack

3 is polarity sensitive, and careful attention must be paid to the polarity. The black DC cable must be connected to the battery negative (-) and the negative (-) PowerPack 3 terminal, located under the top cover (orange).

The red DC cable must be connected to the fuse which is connected to the positive (+) battery connection and the positive (+) PowerPack 3 terminal, located under the red cover.


October 2012



MOUNT FEATURES

Fuse Wiring

f_179

Route the AC power wiring separately from the DC wiring and low voltage wiring such as audio and video signal wires with as much physical separation from the AC wires as possible.

WARNING: Fire Hazard. Make sure all connections are tight and properly made. Failure to follow this warning may result in property damage, personal injury or death.

CAUTION: An in-line 150 AMP DC fuse is REQUIRED on the positive battery cable to properly protect the

PowerPack 3 and batteries. Failure to properly fuse the input leads to the PowerPack 3 can result in damage to the unit.

10. Add switch to switch pack.

R

EMOVAL

/R

EPLACEMENT OF

S

WITCHES AND

S

WITCH

P

ACKS

To remove a switch pack from the IP, use the DIN radio removal tool part number 2504954C1.

f_031

Insert the extraction tools (2) into the two holes on either side of a switch pack housing until the locking tabs are fully depressed. The switch pack can then be removed from the panel and the extraction tools removed.

f_096

To remove individual switches or blanks from a switch pack, squeeze the locking tabs on the rear of the switch or blank (top and bottom) and push it from the housing.


October 2012



MOUNT FEATURES

To install a switch pack in the panel, make the necessary connections, and then simply push the assembly into place until the locking tabs are fully engaged.

NOTE: The switch pack can be inadvertently installed upside down. To avoid this when no switches are present in the housing, make sure the white wire in the lead assemblies on the rear of the housing are towards the top.

f_092

To install a switch in the switch pack housing, insert the switch in the proper slot, and push in until the switch locking tabs are fully engaged (switches are keyed and cannot be installed upside down).

LED I

NSTALLATION

The LEDs are installed from the rear of the switch housing (snap fit rear cover must first be removed). The amber backlight LED (part number 3533928C1) must be installed in the lower position and the green indicator

LED (part number 3578733C1) in the upper position. The LEDs can be identified by the color of the base – black for the amber LED and white for the green LED.

To install an LED, insert it into the hole in the printed wiring board and, with a small flat blade screwdriver, turn the LED clockwise until locked. Replace the rear cover when complete.

11. Program Vehicle.

a. Using DLB, activate feature 0595AJU “BC PROG, INVERTER ON In-Cab Multiplex Switch enables 3kw

Inverter.” b. After 0595AJU is activated, use DLB to locate position for 120 volt on switch location. Make note of location for switch install. Exit DLB.

c. Use Master Diagnostics to program the engine for proper operation with PowerPack 3

Open Master Diagnostics. Turn IGN key on. Open com port, go to view >session>basic plus session. Right click add/delete parameters, delete all currently selected parameters from “Selected Parameters” window. In the available parameters window, double click on:

PTO Power Take Off mode

PTO in-cab control

PTO remote pedal

If PTO in-cab control is on, set Power Take Off mode to remote and in-cab operation.

If in-cab control is off, then set PTO mode to remote operation only.

Set remote pedal on.

Default ramp rate 100.

Right click, enter password, right click, then program all.

Cycle IGN key from off to on.


October 2012



MOUNT FEATURES

12. Checking system operation a. Start engine, and ensure that the park brake is set.

b. Verify that the batteries are being charged. Voltmeter should be reading greater than 13.5 volts.

c. Depress 120 VAC rocker switch in IP.

d. Verify that the engine ramps to 935 RPM.

e. Verify green light in rocker switch is on solid within 5 seconds.

f. Check 120 volt AC output voltage.

■

POWERPACK 3 FOR MOBILE OPERATION

60AKD

BDY INTG, AUX POWER GEN HYBRID (1) 5000 Watt, Eaton, On/Off (APG) Button on Shift Selector, Mounted

Inside Rail, Back of Cab, Includes (3) 120 Volt AC Power Outlets, (to be mounted by body builder)

60AKE

BDY INTG, AUX POWER GEN HYBRID (1) 5000 Watt, Eaton, On/Off (APG) Button on Shift Selector, Mounted

Left Side Outside Rail, Back of Cab, Includes (3) 120 Volt AC Power Outlets, (to be mounted by body builder)

As an added feature to the International

®

Hybrid offerings, International

®

has announced the release of the

Auxiliary Power Generator. The APG enhances the current Eaton Hybrid Power Systems capabilities by offering our customers a convenient way to produce exportable power without the need for a separate source of power generation. Currently, the only vocation approved for this unit is the Utility segment. The addition of the APG enhances the Utility application’s reduction in emissions as well as the associated fuel savings.

f_180

P

ROGRAMMABLE

P

ARAMETERS

None

L

OCATION

60AKD mounted Inside Rail, Back of Cab; 60AKE mounted Left Side Outside Rail, Back of Cab

A

PPLICATION

R

ECOMMENDATION

Optional Equipment – Any application that requires mobile power at a work site, such as Utility, Recovery,

Construction or Rescue applications.


October 2012



MOUNT FEATURES

■

POWERPACK 3 FOR MOBILE OPERATION

60AJN

BDY INTG, POWER INVERTER 3000 Watt Dynamic (With Engine Running); On/Off Switch in Instrument Panel

(IP); Includes 120 volt AC Wiring; Connection for Customer-Mounted Power Outlet

60AJP

BDY INTG, POWER INVERTER Mobile and Stationary; Temp Mount on Frame Rail for Customer Installation;

3000 Watt, On/Off Switch in Instrument Panel, Includes 120 Volt AC Wiring Connection for Customer Mounted

Power Outlet, Body Company Must be a Certified PowerPack 3 Installer or Warranty will be VOID.

WARNING: Shock hazard. Only trained technicians should service high voltage components. High voltage circuits and components contain voltage levels that may cause equipment damage, electric shock, and/or deadly electrocution if handled incorrectly.

WARNING: DO NOT OPEN the PowerPack 3. Hazardous voltages exist internally even after the PowerPack 3 is removed from the vehicle. Only a Qualified Technician may perform service inside the PowerPack 3. Failure to follow this warning may result in property damage, personal injury, or death.

WARNING: Shock Hazard. The alternator may generate high voltage, particularly at high rpm, which can be harmful. Do not touch the 3–phase output terminals. Failure to follow this warning may result in property damage, personal injury or death.

WARNING: Shock Hazard. The alternator output is a hazardous 3–phase AC voltage — Do not cut the cable or touch the terminals. Failure to follow this warning could result in property damage, personal injury, or death.

The PowerPack 3 Inverter system is an advanced Power Generation and Power Management system to provide both DC power and an on-board 120 volt AC power source. The PowerPack 3 system is integrated with the Diamond Logic

®

Electrical system. The DC portion of the system provides 14 volts DC at a maximum of

100 Amperes (AMPS) to charge the vehicle batteries. The AC portion of the system provides a 120 VAC single phase 60 Hertz output at a maximum of 25 AMPS. The system may be ordered from International

®

, factory-installed either mounted in the battery box or as a temporary mounted inverter module behind the cab.

The body builder is tasked with mounting the inverter in a body compartment with the temporary mounted feature.

The PowerPack system consists of an inverter module, a special 3-phase 42 volt AC alternator, a multiplexed switch in the cab, and associated wiring harness. The engine must be running in order for the PowerPack system to generate AC or DC voltages. The 120 volt AC output is only functional when the vehicle is stationary with the park brake set. The 120 volt AC output contains a Ground (GND) fault interrupter device and a weather sealed power plug.

CAUTION: If 120 volts AC Shore power is integrated into the body wiring, the shore power connection must never be directly connected to the PowerPack 3 AC output.


October 2012


.


MOUNT FEATURES

f_171

PowerPack 3 Block Diagram


October 2012



MOUNT FEATURES

Battery Box Mounted PowerPack 3

f_172

Remote Mount PowerPack 3

f_173


October 2012



MOUNT FEATURES

AC Derating Curve

f_174

DC Derating Curve

f_175


October 2012



MOUNT FEATURES

U

SING

P

OWER

P

ACK

3 W

ITH

R

EMOTE

E

NGINE

S

PEED

C

ONTROL

PowerPack 3 provides full power output for the 120 volt AC section at any engine speed. Vehicles equipped with the mobile version of PowerPack 3 may be used with any of the following engine speed control functions.

•

Preset or variable engine speed control using the steering wheel cruise control switches

•

Preset variable or remote pedal/throttle using the Remote Engine Speed Control Module (RESCM). Requires

Body Controller (BC) feature 595AHA

•

Preset 1 using Remote Power Module (RPM) inputs; i.e., feature code 60AJE

•

Preset or variable engine speed control using Diamond Logic

®

Advanced Ladder Logic

•

12VZA which provides remote engine speed control through hard wires connected directly to the engine

ECM.

B

ODY

C

ONTROLLER

: S

OFTWARE

F

EATURE

C

ODES

/P

ROGRAMMABLE

P

ARAMETERS

Mobile Operation

Software feature code 595BAH must be enabled on the vehicle Body Controller using the Diamond Logic

® software (see local dealer).

Parameter: PPE3_Stationary or Mobile: In Stationary mode the AC function can be used only while the trucked is parked with the park brake set. Mobile operation enables 120 AC anytime the engine is running. These features are defaulted to Mobile Operation.

Parameter: PPE3_Auto ON or Manual ON: Allows the AC power to turn ON automatically each time the vehicle is started. These features are defaulted to AUTO ON.

Parameter: PPE3_Auto Restart: Allows the PowerPack to restart should there be an over current situation. The number restart retries and duration before the restart is also programmable. These features are defaulted to

Auto Restart ON with 3 retries with 40 seconds between retries.

Parameter: PPE3_ReStart_Attempts: Number of times the PowerPack will attempt to re-start the system after an overload. These features are defaulted to 3 retries.

Parameter: PPE3_ReStart_Delay: The amount of time between re-start attempts should there be an over current situation. These features are defaulted to 40 seconds between retries.

Parameter: PPE3_param_incrThrottle_rqst_enable will enable the automatic throttle request. This will automatically ramp the engine to the value set in parameter 2344 when the PowerPack is requested on. This parameter is defaulted OFF for these features.

Parameter: PPE3_param_incrThrottle_startDelay is the amount of time that the PowerPack will wait to turn on.

This is to allow the engine to ramp to the operating RPM before the PowerPack is activated. This parameter is defaulted to 2 seconds for these features.

Parameter: PPE3_param_incrThrottle_targetRPMs is the target RPM for the engine to ramp to when the

PowerPack is activated. This parameter is defaulted to 935 RPM for these features.

Parameter: PPE3_param_incrThrottle_timeout is the amount of time that the inverter is inhibited from coming back on due to inadequate engine speed. This parameter is defaulted to 5 seconds for these features.


October 2012



MOUNT FEATURES

Table 176 – Programmable Parameters used with 595BAH

Parameter

PPE3_param_

Auto_or_

Manual_ON

PPE3_param_ mobile_or_ stationary

PPE3_param_

Auto_ReStart

PPE3_param_

ReStart_

Attempts

PPE3_param_

ReStart_Delay

PPE3_param_ incrThrottle_ rqst_enable

PPE3_param_ incrThrottle_sta rtDelay

PPE3_param_ incrThrottle_ targetRPMs

PPE3_param_ incrThrottle_ timeout

ID

2473

2487

2488

2490

2489

2357

2399

2344

2345

Description

If this is true, then the AC Power is automatically activated when the engine is started.

If this is true, then the AC Power is available any time the engine is running

If this is true, then the PowerPack 3 system will automatically attempt a re-start after an over load event.

This number indicates the number of re-start attempts after an overload event.



This parameter allows the throttle to ramp to the target RPM prior to enabling the PPE. The logic for this parameter is that a maximum load on the PPE would turn off the inverter if the alternator RPMs are not at target.

This is the target RPM rate for the throttle increase feature.

The amount of time until the inverter is inhibited because the engine speed is not at an adequate level

Default

1

1

1

3

40

0

2

935

5

Units

On/Off

On/Off

On/Off

Number

Seconds

On/Off

Seconds

RPM

Seconds

Min

0

0

0

0

0

0

0

900

0

Max

1

1

1

7

60

1

5

2000

30

Step

1

1

1

1

10

1

0.1

1

0.1

W

IRING

I

NFORMATION

WARNING: All electrical connections to the PowerPack 3 must be made by a qualified electrician. Failure to follow this warning could result in property damage, personal injury, or death.

A Hubbell Watertight Safety-Shroud male plug (Hubbell part number HBL2611SW) is needed to connect to the

AC output plug to mate with the PowerPack supplied Hubbell Watertight Safety-Shroud female socket (Hubbell part number HBL2613SW). These plugs are available at electrical and industrial supply houses.

Using this part combination will allow for a weather resistant connection to the PowerPack 3 unit. Alteration of the AC output plug, failure to use the correct male plug, or removal of the supplied socket will not guarantee a watertight connection.


October 2012



MOUNT FEATURES

The AC output from the PowerPack 3 is wired to a Ground Fault Circuit Interrupter (GFCI) to ensure protection against GND fault conditions. Be aware that standard duplex GFCI and non-GFCI receptacles need to be protected with a circuit breaker, usually rated for 15 or 20 AMPS. ..

PowerPack 3 Inverter/Regulator Component Detail

f_176

PowerPack 3 Kit, Left Side under Cab for vehicles built after March 2007.

PowerPack 3 Kit, Right Side under Cab for vehicles built after March 2007.

PowerPack 3 Kit, Remote Mount for vehicles built after March 2007.

Fuse, 58 volt, 10 amp: Alternator Field Wire fuse. International

®

Part Number: 2590768C1

T

ESTING

S

YSTEM

O

PERATION

1. Start the engine. Verify that the batteries are being charged. The voltmeter should be reading greater than

13.5 volts.

2. Verify green light in rocker switch is ON solid within five seconds.

3. Verify 120 volt AC output voltage. f_189

P

OWER

P

ACK

3 T

ROUBLESHOOTING

If the PowerPack 3 output does not power up or shuts down during vehicle operation, follow these steps to troubleshoot the system:

1. Set the 120VAC ON/OFF switch to OFF position, and ensure interlocks are satisfied, as described above, correcting as necessary.

2. Attempt to restart the PowerPack 3 by pressing the ON switch.


October 2012



MOUNT FEATURES

3. If the unit continues to shut-down, (blinking green light in the rocker switch and red warning light illuminated) disconnect any AC loads before restarting the PowerPack 3.

4. Check for green light on GFCI. If there is a red light press the reset button on GFCI.

5. Press the 120VAC switch to OFF, check the 30-Amp circuit breaker, and reset if necessary.

6. Wait several minutes to allow the system alternator and PowerPack 3 unit to cool, and then attempt to restart.

7. If the unit does not restart, then turn the vehicle’s ignition OFF, and then back ON again. This will restart the

PowerPack 3 output protection circuits.

8. If the above steps fail to restart the PowerPack 3 unit, then have the system serviced by a qualified technician.

NOTE: If the unit does not restart, the problem could be caused by overheating or other circuit protection devices. If the PowerPack 3 circuit breaker or the GFCI device is tripped, the green light in rocker switch will continue to show an indication that AC power is ON. Be advised to check these other elements of the system if

120 volt AC power is not present as expected.


®

(Pre-2007 Vehicles)

SPN

168

168

168

168

168

168

168

168

168

168

639

FMI

2

3

3

4

4

6

8

16

16

17

14

Byte 7

0

0

0

0

0

0

0

0

0

0

37


Blink Rate

0

0

0

0

0

0

0

0

0

0

255

Fast

Fast

Slow

Fast

Slow

Slow

Fast

Fast

Slow

Fast

Fast






PowerPack.










October 2012



MOUNT FEATURES


®

Builder (2007 Vehicles and post-2007)

SPN

0467

168

520664

168

520644

520771

115

520774

520773

520772

639

FMI

9

3

3

4

4

6

2

0

0

31

9

Byte 7

0

0

0

0

0

0

0

0

0

0

37


Blink Rate

0

0

0

0

0

0

0

0

0

0

255

Fast

Fast

Slow

Fast

Slow

Slow

Fast

Fast

Slow

Fast

Fast






PowerPack.








Communication fault between PowerPack and the ESC. Check for open circuit or short in J1939 datalink. Also, check the ignition circuit to the

NOTE: A complete aftermarket parts kit is under development. The PowerPack 3 kit part number is not available at this time.

H

OW

T

O

A

DD

T

HIS

F

EATURE

1. Remove power from batteries.

a. Remove the lid from the battery box.

b. Remove all battery cables from the batteries and battery box, starting with the negative terminals.

2. Replace the 3 battery box with a 4 battery box.

a. Remove cab steps from the battery box.

b. Remove the front side of the battery box.

c. Remove all batteries.

d. Remove old battery box from the frame rail.

e. Remove any options that may be on box, and transfer to new box.


October 2012



MOUNT FEATURES

f. Attach new 4 battery box to the frame rail. Some new mounting holes may need drilled in the frame rail.

Re-use existing holes as much as possible.

g. Add cover hold downs, and add new box to frame, 777937C1 retainers, 934871R1 nuts, 30278R1 screws, 30264R1 washers.

h. Put batteries in the two forward locations of the 4 battery box.

I. Install the PowerPack 3 Inverter Module in the most rearward location of the battery box. Align the PP3 module such that the mounting stud on the rear panel of the module projects through the rear of the battery box.

j. Ensure that the PP3 harnesses are carefully routed through the openings in the rear panel of the battery box without kinking or pinching.

k. Attach the battery box hold down bracket to secure the batteries and the PP3 Inverter Module.

l. Attach the retainer nut to the PP3 module stud on the back side of the battery box.

m. Attach vent tubes to each battery, and route out of battery box.

Sample Inverter on Installation on the Driver’s Side of the Vehicle

f_172

3. Add new alternator.

a. Remove air filter and cover turbo intake to prevent items from falling into intake.

b. Remove serpentine belt and old alternator.

c. Tie off old cables.

1. Seal terminal ends with heat shrink tube, fold back onto trunk of harness, and tape to trunk of harness.

d. Attach the Leece-Neville alternator (part number 3606039C91) to the engine. Transfer belt pulley from old alternator to the new alternator.

e. Check alternator mounting bolt torque. DO NOT OVER TORQUE.

1. Alternator to bracket mounting bolts 30 to 35 lb ft


October 2012



MOUNT FEATURES

f. Add new alternator harness overlay.

1. Route the PP3 harness next to existing engine harness to the starter; then follow battery cables to the battery box.

2. At base of battery box, route inverter cables to back of battery box by going under the frame rail.

g. Use tie wraps, every 12 inches, to attach the alternator harness to the battery cables.

A

LTERNATOR

H

ARNESS

The harness from the PowerPack 3 to the alternator must be properly routed and securely fastened to avoid any hot or sharp areas and to prevent cable movement. Failure to use the proper size wi

International 3200, DuraStar, WorkStar, 8000 truck Service Manual

Assistant Bot

Description SectionPage #

FORWARD

CONTENTS

SAFETY INFORMATION

INTRODUCTION

ELECTRICAL SYSTEM OVERVIEW

INTERNATIONAL

DIAMOND LOGIC

ELECTRICAL SYSTEM OVERVIEW

Multiplexing Architecture

Data Links

BODY CONTROLLER (BC)

REMOTE POWER MODULE (RPM)

GENERAL ELECTRICAL

J1939 HIGH SPEED DATA LINK CABLE (SAE J1939/15)

COLOR CODE SYSTEM FOR INTERNATIONAL

TRUCK

RECOMMENDED CIRCUIT PROTECTION

CIRCUIT PROTECTION DEVICES

ELECTRICAL COMPONENTS COMMONLY USED BY EQUIPMENT INSTALLERS

CONNECTORS 4450 AND 4460

STANDARD TERMINALS AND SPLICES

SPLICE CLIP INSTALLATION

SPLICE INSPECTION

CRIMP AND SEAL SPLICE SLEEVE INSTALLATION

DATA LINK REPAIR

J1708

J1939/11 Shielded Only

Wire Repair

WIRE SPLICING

J1939 HIGH SPEED DATA LINK CABLE (SAE J1939/15)

J1939

Adding Body Builder J1939, Power and Grounds

HIGH VOLTAGE CIRCUITS (GREATER THAN 50 VOLTS) ON INTERNATIONAL

AND BUSES

TRUCKS

UNDERSTANDING HIGH VOLTAGE EQUIPMENT AND CIRCUITS ON INTERNATIONAL

PRODUCTS

Auxiliary Power Units (APUs)

Shore Power

Inverters

Hybrid Electric Vehicles (HEVs)

HOW TO IDENTIFY HIGH VOLTAGE CIRCUITS

SERVICING NAVISTAR PRODUCTS

Best Work Practices

SUPPRESSION

WELDING INFORMATION

ROUTING GUIDELINES

Route and Clip Recommendations

Electrical Harness

ELECTRICAL DO’S AND DON'TS

HOW DO I - GENERAL INFORMATION

GENERAL

BODY CONTROLLER

3200, DURASTAR, WORKSTAR MODELS

BC CONNECTOR J3 (1600)

BC CONNECTOR J4 (1601)

BC CONNECTOR J5 (1602)

BC CONNECTOR J1 (1603)

BC CONNECTOR J2 (1604)

BATTERY, IGNITION & ACCESSORY TAPS

STANDARD BATTERY AND IGNITION TAPS

HEADLIGHTS ON W/WIPERS

BATTERY DISCONNECT SWITCH

BATTERY WARNING INDICATOR

CB & 2-WAY RADIO ACCOMMODATION PACKAGES

CB RADIOS

2-WAY RADIOS

POWER WINDOWS, LOCKS, REMOTE KEYLESS ENTRY

KEYLESS ENTRY SYSTEM REMOTE/WINDOW, POWER

PARTS INFORMATION

FUSED BATTERY CONNECTIONS INSIDE CAB

FUSED BATTERY CONNECTIONS INSIDE CAB

PRODUCTIVITY FEATURES

TEST EXTERIOR LAMPS EXCEPT BACK UPS

ALARM, PARKING BRAKE

WINDSHIELD WIPER SPEED CONTROL

HAZARD LIGHT OVERRIDE STOP LIGHTS