Navistar CV 2019 Series Quick setup guide

Navistar Electrical Systems CV
Integration Guide - Jay E.
Bissontz [Digital Watermark]
Page 1 of 84 Revision Date: 9/12/2019
Navistar Electrical Systems CV Vocational Series Integration Guide
Copyright Navistar Corporation 2019 All Rights Reserved

Navistar Electrical Systems CV
Integration Guide
Page 2 of 84 Revision Date: 9/12/2019
Table of Contents
1. Revision Summary Table....................................................................................................................................... 3
2. Forward: ................................................................................................................................................................. 3
3. Vehicle Architectures: ........................................................................................................................................... 5
3.1. Multiplexing Architecture:............................................................................................................................ 5
3.2. Power Take Off (PTO) & Engine Speed Controls (Sales Feature Code 12WGG)........................................ 6
3.3. Power Take-Off (PTO) - Quick Start Reference........................................................................................... 6
3.4. Factory PTO Settings.................................................................................................................................. 12
3.5. Primary PTO Operating Modes................................................................................................................... 15
3.6. Preset PTO Operating Modes and Programming........................................................................................ 16
3.6.1. Preset PTO - In-cab Operation: Enable Conditions [factory default programming]................................... 16
3.6.2. Preset PTO - Remote Operation: Enable Conditions [requires programming with Navistar CV
vehicle service tool and installation of an appropriate remote switch panel]........................................ 17
3.6.3. Preset PTO - Remote Operation with In-Cab Engage: Enable Conditions [requires programming
with Navistar CV vehicle service tool and installation of an appropriate remote switch panel]............. 18
3.6.4. Diesel Particulate Filter [DPF] Cleaning during Stationary PTO Operation................................................ 19
3.7. Variable PTO Operating Modes and Programming...................................................................................... 20
3.7.1. Variable PTO - In-cab operation: Enable Conditions - [requires programming with Navistar CV
vehicle Service tool]........................................................................................................................... 20
3.7.2. Variable PTO - Remote Operation: Enable Conditions - [requires programming with Navistar CV
vehicle service tool and appropriate remote switch panel provided by Truck Equipment
Manufacture (TEM)]........................................................................................................................... 20
3.7.3. Variable PTO - Remote Operation with In-Cab Engage: Enable conditions [requires programming
with Navistar CV vehicle service tool and appropriate remote switch panel provided by Truck
Equipment Manufacture (TEM)].......................................................................................................... 22
3.8. Diesel Particulate Filter [DPF] Cleaning during Stationary PTO Operation .................................................. 23
3.9. Mobile PTO Operating Modes and Programming........................................................................................ 24
3.9.1. Mobile PTO - in-cab operation only: Enable Conditions - [requires programming with Navistar CV
vehicle service tool]............................................................................................................................ 24
3.10. OSIM PTO (Operator Selectable In-Cab Mode) [New feature for 2017].................................................... 25
3.10.1. OSIM PTO - Preset [Stationary] Operation:Enable Conditions............................................................... 25
3.10.2. OSIM PTO - Variable[Stationary] Operation: Enable Conditions........................................................... 25
3.10.3. OSIM PTO - Mobile Operation: Enable Conditions................................................................................ 26
3.11. PTO System Disengage Conditions.......................................................................................................... 27
3.11.1. Stationary Modes [preset or variable] - in-cab control............................................................................. 27
3.11.2. Stationary Modes [preset or variable] - remote control [with or without in-cab engage]........................... 27
3.11.3. Mobile Mode .......................................................................................................................................... 29
3.12. Prolonged or Extended PTO Operation..................................................................................................... 30
3.12.1. Diesel Particulate Filter [DPF] Cleaning during Stationary PTO Operation.............................................. 30
3.13. PTO Operational Speed Control................................................................................................................ 31
3.13.1. [Variable] PTO operational speed control provides the following functions: ............................................ 31
3.13.2. In-cab Cruise Res + Switch (or Remote PTO Tap Up switch)................................................................. 31
3.14. Driver Information Center (DIC) Warnings Messages................................................................................ 36
3.15. Appendix: PTO, Remote Engine Speed Control, and General Safety Recommendations.......................... 36
4. Fast Idle Control –Engine Speed Control L/PTO................................................................................................. 42
4.1. To obtain Fast Idle capability you must order the following options:............................................................. 42
Required Initial Conditions................................................................................................................................. 42
4.2. Enable (Turn ON) Fast Idle......................................................................................................................... 43
4.3. Preset Fast Idle........................................................................................................................................... 43
4.4. Adding Fast Idle (UF3)................................................................................................................................ 43
5. Truck Equipment Manufacture (TEM) Auxiliary Switches................................................................................... 43
5.1. Switches/Relay outputs:.............................................................................................................................. 44
5.2. Wiring Schematic........................................................................................................................................ 51
6. Auxiliary Battery Connections.............................................................................................................................. 51
6.1. Repair/Recommendation:............................................................................................................................ 51
6.2. Additional Information:................................................................................................................................. 52
6.2.1. Positive Cable Recommendation.............................................................................................................. 52
7. Rearview Camera Installation ............................................................................................................................... 55
7.1. Mounting the Camera.................................................................................................................................. 55

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Integration Guide
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7.2. Camera Installation Guidelines.................................................................................................................... 55
8. Infor –Radio Telephone/Mobile radio (Transcever) Installation and trouble shooting Guidlines.................... 57
8.1. Transceiver Location................................................................................................................................... 58
8.2. Antenna Installation..................................................................................................................................... 58
8.3. Antenna Cable Routing............................................................................................................................... 59
8.4. Antenna Tuning........................................................................................................................................... 59
8.5. Radio Wiring and Connection Locations...................................................................................................... 60
8.6. Radio Wire Routing..................................................................................................................................... 61
8.7. Troubleshooting.......................................................................................................................................... 61
9. Relocation of electrical Coponents/Devices-Best Practices/Recommendations............................................... 66
9.1. Under-hood/Vehicle: ................................................................................................................................... 67
9.2. Under-dash:................................................................................................................................................ 67
9.3. Doors:......................................................................................................................................................... 67
9.4. Under Seats:............................................................................................................................................... 67
9.5. Rear Stowage Areas:.................................................................................................................................. 67
9.6. General Recommendation: ......................................................................................................................... 68
10. Appendix - General Electrical Section:............................................................................................................... 68
10.1. Color Code System for International® Truck Wiring: ................................................................................. 68
10.2. Recommended Circuit Protection:............................................................................................................. 69
10.3. Electrical Components Commonly Used by Equipment Installers:............................................................. 70
10.4. Wire Splicing and Termination - Standard Terminals and Splices:............................................................. 70
10.5. HIGH VOLTAGE CIRCUITS (GREATER THAN 50 VOLTS) ON INTERNATIONAL TRUCKS AND
BUSES:.............................................................................................................................................. 78
1. Revision Summary Table
REVISION
DATE
SECTION
CHANGE DESCRIPTION
REASON FOR CHANGE
REVISED BY
01
9
/
1
2
/201
9
ALL
INITIAL DRAFT
INITIATION OF
DOCUMENT
J. BISSONTZ
2. Forward:
Warning -In the pages of this document are a diverse set of truck chassis system and
subsystem integration features which contain the potential for both simple and complex
operational situations and interactions when integrated in combination with a truck
chassis and truck mounted equipment. It is the responsibility of persons performing
truck chassis and, or truck mounted equipment system integration and testing to fully
understand the plurality of operational outcomes and take the appropriate as well as
necessary precautions to avoid property damage, personal injury up to and including
death when performing system integration and, or test in association with the content of
this document.
Note - In this manual, International® Truck and Engine Corporation provides
information about its different products to assist those who wish to modify these
products for individual applications. International does not recommend or approve any
firm nor make any judgements 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.

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Integration Guide
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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.
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 procedures and instructions before you begin
work on the unit. 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.
DISCLAIMER: INTERNATIONAL 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.

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Integration Guide
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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.
3. Vehicle Architectures:
3.1. 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

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Integration Guide
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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.
3.2. Power Take Off (PTO) & Engine Speed Controls (Sales Feature Code 12WGG)
Feature Description: Engine speed control for electronicly controlled Power Take Off
(PTO) device, includes On/Off switch mounted on Dash, with steering wheel mounted
engine speed control button.
3.3. Power Take-Off (PTO) - Quick Start Reference
The PTO is an Truck Equipment Manufacture (TEM) integrated system that allows the
user to create an auxiliary power source for running add-on equipment, such as salt
spreaders, dump beds, lifts, winches, and lift buckets etc. The PTO system controls
engine speed to values higher than normal base idle, PTO load relay engagement, and
remote starting and shutdown of the engine.
PTO Components
The OEM PTO components consist of:
The transmission [internal] PTO gear –rotates with the torque converter
The in-cab PTO switch and cruise control SET and RES switches
The PTO telltale indicator
The Driver Information Center (DIC)
The Radio and Navigation Screen (HMI)
The Power Take Off Module (PTOM)
The remote PTO Truck Equipment Manufacture (TEM) connector [X191]

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Note: The interface connector [X191] is located at the rear of the cab near the RH
frame rail and comes with a cap which is the mating half to the truck harness
connector. This is the connector the Truck Equipment Manufacture (TEM) will use
to wire in external electrical components such as a control relay, oil solenoid [these
two are basic to all systems] and possibly external switches to control the PTO from
outside the cab.
Figures 4.1.1 & 4.1.2: Component Mounting Locations

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Integration Guide
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Figure 4.1.3: PTOM Mounting Location

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Integration Guide
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Figure 4.1.4: Instrument Panel Layout
Table 4.1.1: Instrument Panel Layout
Component Locations and Descriptions
(1) Trailer Brake Control Switch (9) Accessory Power Receptacle –110V AC
(KI4)
(2) Speaker –Left Instrument Panel (UQ3) (10) Accessory Power Receptacle –
Instrument Panel 2
(3) Instrument Cluster (11) Accessory Power Receptacle –
Instrument Panel 1
(4) Ambient Light/Sunload Sensor (12) USB Receptacle
(5) Info Display Module (13) Seat Heating and Cooling Switch –Driver
(6) Seat Heating and Cooling Switch –
Passenger
(14) Data Link Connector
(7) Speaker –Right Instrument Panel
(UQ3)
(15) Headlamp Switch
(8) Switches –PTO switch location (16) Transfer Case Shift Control Switch

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Integration Guide
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Figure 4.1.5: Steering Wheel Mounted Controls
Figure 4.1.6: X191 Engine Harness to Power Take-Off Jumper Harness
Connector Part Information [truck side]
Harness Type: Engine
OEM Connector: 15326863
Service Connector: 6040235C1
Description: 16-Way F 150 GT Series,
Sealed (BK)
Connector Part Information [Truck
Equipment Manufacture (TEM) Cap]
Harness Type: Power Take-Off
Jumper
OEM Connector: 15326868
Service Connector: 6040230C1
Description: 16-Way M 150 Series,
Sealed (BK)