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EPA 2010 Models
Electrical System Overview

EPA 2010 Electrical
Models - M2106, M2112, 108SD, 114SD

Body Builder Reference Guide
2010 Smart Plex Electrical Body Builder Reference Page 1 Rev A

EPA 2010 Models
Electrical System Overview

Index
Page 1
Page 2
Page 3
Page 4
Page 5
Page 6
Page 7
Page 8
Page 9
Page 10
Page 11
Page 12
Page 13
Page 14
Page 15
Page 16
Page 17
Page 18
Page 19
Page 20
Page 21

Index
Electrical Component Overview
Electrical Harness Overview
Electrical Power flow Overview
PNDB Power Net Distribution Box
Positive Disconnect Switch
Main Power Distribution Module (PDM)
PDM / VBAT Fuse Coverage
Bulk Head Module (BHM)
Bulk Head Module (BHM) Pin Detail
Chassis Module (CHM)
Chassis Module (CHM) Pin Detail
Multiplexing System Backbone
System Tap Points
J1708 Gateway
Low Current Smart Switches
High Current Switches (Battery Hot)
High Current Switch (BH) Schematics
High Current Switches (Ignition Interlocked)
High Current Switch (Ignition Interlocked) Schematics
High Current Switch Label Options

Page 22
Page 23
Page 24
Page 25
Page 26
Page 27
Page 28
Page 29
Page 30
Page 31
Page 32
Page 33
Page 34
Page 35
Page 36
Page 37
Page 38
Page 39
Page 40
Page 41
Page 42

Body Builder Lighting Interface
Body Builder PDM
Body Lighting Interface Schematics
Trailer PDM
Trailer Electrical Schematics (Seperate)
Trailer Electrical Schematics (Combination)
Wired Rite Prep
Wired Rite Schematic
Wired Rite Trailer and Floor connections
Tail Lights
Tail Light Schematics
Transmission Interface
Engine Interface
PTO Installation
PTO PTO Controls
PTO Air Schematics
PTO Electrical Schematics
Hybrid PTO Options
Remote Start Stop Schematics

VDR Prep Information (NFPA)
SmartPlex VDR Connections

2010 Smart Plex Electrical Body Builder Reference Page #2 Rev A

EPA 2010 Models
Electrical Component Overview
Body lighting
Interfaces
(Module 353, 296)

Tail Light
Configurations
(Module 294)

Trailer Interfaces
(Module 296, 297)

Accessory Air
Valve Assembly (AAVA)
(Multiple Modules )

Dash Switches
(Module 329)

Transmission Interfaces.
(Grey Plug)
(Plugs may also
be frame located
(Module , 34C)

Engine Interface
(Black Plug)
(Plugs may also
be frame located)
(Module 148, 163, 87L )

Chassis Module
(CHM Under Cab)
(Module 335, 32K)

Bulk Head Module
(BHM)
(Module 32A)

Power Distribution
(Module 285 PDM)

PNDB Power Net Distribution
Box (Module 33P/281/293)

2010 Smart Plex Electrical Body Builder Reference Page #3 Rev A

EPA 2010 Models
Electrical Harness Overview
ABS/AMU HARNESS Module 332
1) Connections to Forward chassis
harness and frame ground studs near
Chassis module
2) Connections to AMU (Mod 877 without ABS)
3) Connections to Wabco ABS ECU
4) Connections to rear combo valves
FORWARD CHASSIS HARNESS Module 288
1) Connections to Bulkhead module and Underhood PDM
2) Connections to headlamps
3) Connections to side marker/turn lamps
4) Connections to Chassis Module

POWERTRAIN HARNESS Module 286, 283
1) Connections to the Bulkhead
Module and Underhood PDM

FRONTWALL HARNESS Module 321
1) Connections to Bulkhead Module and Underhood PDM
2) Connection to Starter Mag Switch
3) Connection to Wiper Motor
4) Connection to the low coolant level sensor and horn (under surge tank)
5) Connection under cab to Washer pump and level switch
6) Pass-thru connector to Main Cab Harness and Powertrain Harness

AFT CHASSIS HARNESS Module 28A
1) Connections to Chassis Module
2) Connections to tail lamps

OVERHEAD CAB HARNESS Module 287
1) Inline connection to Main cab Harness
(at bottom of A pillar)
2) Connections to Marker Lamps
3) Connections to Dome Lamp

MAIN CAB HARNESS Module 320
1) Connections to bulkhead connector
2) Connections to diagnostic connector (behind ignition switch)
3) Connections to CPC
4) Pass-thru connector to engine compartment
5) Gauge Cluster
6) HVAC unit and controler
7) Steering wheel horn and windshield wiper

2010 Smart Plex Electrical Body Builder Reference Page #4 Rev A

Engine Connector

ICU

Bulkhead Module Outputs

EPA 2010 Models

Transmission Connector

B5.F - Cigar Lighter Output
B3.E - Horn
B5.E - SPARE (Utility Light/Spotlight)
B4.M - SPARE (Utility Light/Spotlight)
B5.G - SPARE (Ignition)
B5.H - Panel Lamps
B7.A1 - Panel Lamps (Smart Switch)
B4.F - SPARE (Left Heated Mirror)
B4.E - SPARE (Right Heated Mirror)
B6.A9 - Accessory (HVAC)
B6.A10 - Accessory (Radio)
B5.A - Battery (Dome Lamps)
B7.A12 - Battery (Smart Switch)
B6.A8 - Ignition (VCU)
B2.K - Ignition (Engine)

Electrical Power Flow Overview

ECM

Trailer Connector
Body Lighting Conn

TCM

Tail Lights

Main PNDB
Main PDM
BHM
Powertrain
PDM

B1.P - Ignition (ABS)
B2.L - Ignition (Trans)
B1.F - Fuel Water Sensor Power
B5.D - Instrument Cluster
B5.B - Dome Lamps Switched
B1.L - Left High Beam
B1.R - Left Low Beam
B5.C - Clearance Lamps
B1.K - Tail/License Plate
/Trailer Relay
B3.F - Wiper High
B3.H - Wiper Low
B3.G - Washer Pump
B2.M - AC Clutch
B4.B - Starter Relay (Crank)

BB PDM
BB PNDB

CHM

Chassis Module Outputs

Trailer PDM

Battery

J1939
Multiplexed
Network

Engine
Connector

ECM

Powertrain
PDM

TCM

Transmission
Connector

Main
PNDB

C4-D
C4-C
C3-N
C3-R
C3-L
C4-K
C3-K
C4-F
C3-C
C3-D
C5-H
C5-J
C5-L
C5-M
C3-A

Left Marker Lamp
Left Park Lamp
Turn Left Front/Side
Turn Right Front/Side
Right Low Beam
Right High Beam
Right DRL
Left DRL
Optional Fog/Road Lamps
Optional Fog/Road Lamps
AMU Solenoid #0
AMU Solenoid #1
AMU Solenoid #2
AMU Solenoid #3
Optional Fuel Water Separator Heater

C2-F
C2-H
C2-E
C2-A
C2-D

Trailer Marker Relay
Trailer Turn Left Relay
Trailer Turn Right Relay
Trailer Power Relay
Trailer Stop Lamp Relay

Trailer
PDM

BB
PDM

C4-M Right Marker Lamp
C4-L Right Park Lamp
C1-P Turn Right Rear
C1-G Turn Left Rear
C1-H Backup Alarm
C1-J Right Backup Lamp
C1-A Left Backup Lamp
C1-N Left Stop Lamp
C1-L Right Stop Lamp

BHM
Main
PDM
CHM

(296) Trailer
Connector

(353) Body
Lighting Conn

BB
PNDB

(294) Tail
Lights

ICU

Battery
2010 Smart Plex Electrical Body Builder Reference Page #5 Rev A

Fuse Cover
and label

EPA 2010 Models

Power Net Distribution Box (PNDB)

PNDB Power Net Distribution Box

The PNDB is a new power delivery designed for the
SmartPlex system to deliver more consistent and better
protected power from the battery to the other components
on the truck.

ATC Fuses

The PNDB also has protected keep alive circuits that
maintain power even with the cutoff switch is in the off position.
The primary reason for this change is to provide power to the
2010 DEF purge system which drains urea from the delivery
system and prevents the system from freezing during cold
conditions.

MIDI Fuse
Output
ATC Fuse
Output

Primary
Solenoid
for Cut off
Switch

The PNDB located at the front wall is equipped with three
MIDI fuses which supply power to the Main Power
Distribution Module. These fuse connections have been
relocated from the battery in 2010 to prevent corrosion
and improve the trucks reliability in severe conditions.

INSTALLATION WITH
DISCONNECT SWITCH

INSTALLATION WITHOUT
DISCONNECT SWITCH
Primary Solenoid
Cut Off Switch
Connection

A secondary PNDB is available as an option for the body builder and
will be located with the trailer and bodybuilder PDM located in the cab
behind the drivers seat on day cabs or under the rear bench seat for
crew cab units.

C

D

ATC -D
ATC -C
ATC -B
ATC -A

B

A
B
C
D
E
F

DESCRIPTION
AFTER TREATMENT ECU
EMERGENCY POWER
RADIO AND CLOCK
ALTERNATOR REMOTE SENSE
GROUND
SIGNAL OFF
LED INDICATOR
SIGNAL ON
SIGNAL RETURN
GROUND

A

X1 SOLENOID
CONTROL

1
2
3
4

3

X2 KEEP ALIVE
CIRCUIT

PIN

12

CONNECTOR

Battery
Input

Battery Input
300 AMPS Max

1 2 3 4

Fuse

Description

Function

Rating

Max. Fuse Allowed

ATC-A
ATC-B
ATC-C
ATC-D
MIDI-1 (Fuse 1)
MIDI-2 (Fuse 2)
MIDI-3 (Fuse 3)

Keep Alive Power
Keep Alive Power
Keep Alive Power
Keep Alive Power
High AMP Fuse
High AMP Fuse
High AMP Fuse

After Treatment ECU
Emergency Power
Radio and Clock
Alternator Remote Sense
Powertrain PDM
PDM #2
PDM #1

30 AMPS
20 AMPS
5 AMPS
5 AMPS
175 AMPS
125 AMPS
125 AMPS

30 AMPS
30 AMPS
30 AMPS
30 AMPS
200 AMPS
200 AMPS
200 AMPS

A B C D

A B C
D E F

Solenoid Control

ATC Fuse output
keeps power on after
disconnect
Mating connector
23-13153-410

2010 Smart Plex Electrical Body Builder Reference Page #6 Rev A

Positive Disconnect Switch
The disconnect switch system for 2010 has been reconfigured
to provide better application coverage and offer two levels
of power disconnect based on the options ordered with the truck.

EPA 2010 Models

Lockout Tab

Positive Cutoff Switch

Auxiliary Power
and Main Power
LED

Main Cab PNDB
Connector Plug
#23-13153-307

In cab disconnect switches will be offered in a locking or non locking
configuration.

1
2
3

Exterior battery mounted switches will be offered in the locking
configuration only.

1
2

3

Cutoff switches are equipped with red LED lights, which are
illuminated when power is on.

Body Builder PNDB
Connector Plug
#23-13662-401

4

Trucks equipped with the body builder auxiliary power system
will have an additional LED light on the switch.

Axillary Body Builder
Cutoff Switch

Standard
Cutoff Switch

X1, Main PNDB

Note: Both PNDB units will be deactivated when the switch is in
the off position.
293-058
293-060
293-061
293-057
293-063

Standard Power LED
X2, Aux PNDB

POSITIVE LOAD DISCONNECT W/CAB MTD CONTROL SWITCH MTD OB DR SEAT
POSITIVE LOAD DISCONNECT W/CAB MTD CTRL SW W/LOCKING PROV MTD OB DR DEAT
POSITIVE LOAD DISCONNECT W/BATTERY BOX CTRL SWITCH W/LOCKING PROVISION
NEGATIVE LOAD DISCONNECT W/CAB MTD DISCONNECT SWITCH
NEGATIVE LOAD DISCONNECT W/BATTERY BOX DISCONNECT SWITCH

In Cab Mounted Disconnect
Switch Mounting
293-058

Battery Box Disconnect Switch Mounting
with box mounted air tanks
(brackets will vary depending on application)
293-061

Battery Box Disconnect Switch Mounting
without box mounted air tanks
293-001, 293-061

2010 Smart Plex Electrical Body Builder Reference Page #7 Rev A

Power Distribution Module Fuse Specications*

EPA 2010 Models
Main Power Distribution Module (PDM)
Pin part number for harness connection
23-13213-120 TERM-FEMALE,(20-16) PAC12077411
23-13213-121 TERM-FEMALE,(14-12) PAC12129493
23-13213-122 TERM-FEMALE,(10)
PAC12077413

PDM Plugs
contain output
wires

Fuse
Location

MEGA
Fuse

Output
Connection

F1

1

Green A

F2

1

Green B

VBAT
Fuse

Primary Function

Fuse
Rating

Spare
Blower Motor

Secondary Function

Fuse
Rating

{

{

{

30A

{

{
30A
30A

F3

2

Green H

Spare

{

{

F4

2

Green G

Spare

{

{

F5

1

Black D

Ignition Switch

5A

{

F6

1

Black C

Spare

F7

1

Gray F

Bulkhead Module

F8

2

Green C

ICU3-M2

F9

2

Green D

F10

2

Blue G
Green F

{

Hydromax Relay

{
30A

30A

{

10A

{

{

Spare

{

{

30A†

Spare

{

{

{

VBAT 5 BHM

{

F11

2

Blue H

Spare

F12

1

Black H

Radio/Diagnostic

F13

1

Grey E

Chassis Module

F14

1

Black B

Spare

F15

2

Black A

Bulkhead Module

F16

2

Blue A

F17

2

Blue C

ABS ECU (pneumatic)
Chassis Module

VBAT 2 CHM

30A

F18

2

Blue B

Bulkhead Module

VBAT 3 BHM

30A

{

{

F19

2

Grey G

Chassis Module

VBAT 1 CHM

30A

{

{

F20

1

Black E

Bulkhead Module

VBAT 2 BHM

30A

{

{

F21

1

Black F

Spare

{

{

{

F22

1

Black G

Bulkhead Module

30A

{

{

Spare

{

{

{

Grey H

VBAT 3 CHM

VBAT 4 BHM

{

{

{

20A

{

{

30A

{

{

{

{

{

30A

{

15A

VBAT 1 BHM

F23

1

F24

1

Grey D

Spare

{

F25

2

Grey C

Spare

{

Spare

{

Blue E

ABS ECU (hydraulic)
{

Hydraulic Pump and
Motor (hydraulic ABS)
{

{
25A
{

25A
{

Grey A
F26

2

Grey B

{

{

Blue D

The main Power Distribution Module (PDM) distributes
battery power to the various control modules on the
vehicle.
The PDM contains mini fuses that protect
the power feed circuits to these modules.
For most trucks there will be spare fuse slots available
for customers to add additional wiring to the truck after
it is purchased.
There are four plugs attaching to the module that supply
output connections.

B

Single Wire Output
found on Green
Plug in Pin G

G
G

PDM #1
(MIDI-3)

Common spare fuse sockets are listed below but may
vary based on the options that have been requested.
Common Spare Fuse locations
F6, F10, F11, F14, F21, F23, F25, F26

Forward Chassis
Harness Plug (Blue)

Engine Harness
Plug (Green)

Multiple Wire output
Pin A & B on Grey
Plug and Pin D
on Blue Plug

H

H

G

F

B

D

C

C

C

A

D

F

A

B

PDM # 2
(MIDI-2)

A

D

E

AB

Forward
Chassis
Harness
Plug
(Grey)

H

B

G

C

E

F

D

H

E

Front
Wall
Harness
Plug
(Black)

2010 Smart Plex Electrical Body Builder Reference Page #8 Rev A

VBAT Fuse System
BHM and CHM output pins are powered by multiple VBAT fuses
through the main SmartPlex PDM unit. If one of these fuses is
tripped or blown then all pins in the circuit will be affected.
For this reason seemingly unrelated issues can occur at the same
time if a fuse is overloaded and trips.
The lists below show which pins are controlled with the VBAT fuses.

EPA 2010 Models
PDM VBAT Fuse Coverage

Bulkhead Module BHM
Power Supply Fuses and Associated Outputs for the Bulkhead Module
BHM Power Input

Chassis Module CHM

BHM Power
Input Pin

Fuse Supplying BHM
Power Input

Power In

CHM Power
Input Pin

Fuse Supplying CHM
Power Input

CHM Outputs Supplied

Power In

VBAT1

VBAT2

VBAT3

C4.P

Battery (dome lamps)

C3.J

C4.J

CHM
Output Pin

Power Out

Fuse 19 (30A)

Fuse 17 (30A)

Fuse 13 (30A)

BHM
Output Pin

Power Out

Power Supply Fuses and Associated Outputs for the Chassis Module
CHM Power
Input

BHM Outputs Supplied

B5.A

Battery (smart switches)

B7.A12

Ignition (VCU)

B6.A8

Ignition (engine)

B2.K

Ignition (ABS)

B1.P

Right Low Beam

C3.L

Turn Right Front/Side

C3.R

Turn Right Rear

C1.P

Right Stop Lamp

C1.L

Left Stop Lamp

C1.N

A/C Clutch

B2.M

Right DRL

C3.K

Smart Switch 1 Indicator

B7.B4

Fog/Road Lamps

C3.C/C3.D

Smart Switch 2 Indicator

B7.B8

Trailer Turn Right

C2.E

Smart Switch 3 Indicator

B7.A5

Smart Switch 4 Indicator

B7.A9

Smart Switch 5 Indicator

B7.B10

Battery (smart switch)

B7.A12

Left Park Lamp

C4.C

Right Park Lamp

C4.L

Left Marker Lamp

C4.D

Right Marker Lamp

C4.M

Trailer Marker Relay

C2.F

Right High Beam

C4.K

VBAT1

VBAT2

B3.D

B4.G

Fuse 22 (30A)

Fuse 20 (30A)

Ignition (trans)

B2.L

Fuel Water Sensor Power

B1.F

Dome Lamps Switched

B5.B

Left Low Beam

B1.R

Accessory (HVAC)

B6.A9

Accessory (radio)

B6.A10

Wake Up (instrument cluster)

B5.D

Left High Beam

B1.L
B3.F

Left Backup Lamp

C1.A

Wiper High

Right Backup Lamp

C1.J

Horn

B3.E

Backup Alarm

C1.H

Wiper Low

B3.H

Turn Left Front/Side

C3.N

Spare 8.0A HSD (ignition)

B5.G

Panel Lamps

B5.H

Turn Left Rear

C1.G

Panel Lamps (smart switch)

B7.A1

Left DRL

C4.F

Clearance Lamps

B5.C

Trailer Turn Left

C2.H

Tail Lamps/License Plate
Lamp/Trailer Tail Relay

B1.K*

Washer Pump

B3.G

12V Output (cigar lighter)

B5.F

Fuel Water Separator Heater

C3.A

AMU Solenoid 0

C5.H

AMU Solenoid 1

C5.J

AMU Solenoid 2

C5.L

AMU Solenoid 3

C5.M

VBAT3

VBAT4

B1.N

B4.K

Fuse 18 (30A)

Fuse 15 (30A)

Spare 8.5A (utility light/spotlight)

VBAT5

B1.J

Fuse 7 (30A)

B5.E / B4.M

Left Heated Mirror

B4.F

Right Heated Mirror

B4.E

2010 Smart Plex Electrical Body Builder Reference Page #9 Rev A

B3 Front
Wall Harness

EPA 2010 Models

B4 Front
Wall Harness

Bulk Head Module (BHM)
B5 Dash
Harness

Pin part numbers for harness connection
Outside Cab Connections:
23-13212-120 TERM-FEMALE,(18-16) PAC153047191
23-13212-121 TERM-FEMALE,(14-12) PAC15304720
23-13212-122 TERM-FEMALE,(10)
PAC15326004
Inside Cab Connections:
PAC12129494 TERM-FEMALE,(12-14)
PAC12034046 TERM-FEMALE,(16-18)

B6 Dash
Harness

B2 Engine
Harness

B7 Dash
Harness

B1 Forward Chassis
Harness

The Bulkhead Module (BHM)
The BHM is the primary command module for the SmartPlex electrical system.
The module controls the operation of the other component modules in
the system either directly or indirectly using messages sent over the J1939 network.

Key Bulkhead Module Outputs

The Bulkhead Module is mounted on the driver side of the front wall and connects
to the interior wiring through an opening in the front wall.

- Bulkhead Module outputs have defined amperage limits.
- If higher loads are required, bulkhead module outputs should be used as signal
power in conjunction with a relay.

The BHM has four harness connections on the engine side of the front wall and
three harness connections to the cab interior.
The BHM Unit contains all system parameters and the unit controls power flow
and circuit protection to the various components of the SmartPlex electrical system.
The BHM unit can also directly support up to 5 smart switches. The BHM is
programable and can be changed and updated by flashing the unit through
service link.
Power supply for the BHM is supplied using VBAT fuses, which reside in the
main PDM (see page 3)
The BHM is programmable and the feature screen in service link can be used to
change or add parameters to the BHM

20A

B5.F - Cigar Lighter Output

12A

B3.E - Horn

12A
Combined

B5.E - SPARE (Utility Light/Spotlight)
B4.M - SPARE (Utility Light/Spotlight)

6.7A
Combined

Combined

B5.H - Panel Lamps
B7.A1 - Panel Lamps (Smart Switch)

6.7A
6.7A
6.7A
6.7A

12A
Combined

B4.F - SPARE (Left Heated Mirror)
B4.E - SPARE (Right Heated Mirror)

6.7A
Combined

6.7A
Combined

B6.A9 - Accessory (HVAC)
B6.A10 - Accessory (Radio)

6.7A
Combined

B5.A - Battery (Dome Lamps)
B7.A12 - Battery (Smart Switch)

12A

B5.G - SPARE (Ignition)

6.7A
6.7A
6.7A
6.7A
6.7A

B6.A8 - Ignition (VCU)
B2.K - Ignition (Engine)
B1.P - Ignition (ABS)
B2.L - Ignition (Trans)
B1.F - Fuel Water Sensor Power
B5.D - Wake Up (Instrument Cluster)
B5.B - Dome Lamps Switched
B1.L - Left High Beam
B1.R - Left Low Beam
B5.C - Clearance Lamps
B1.K - Tail/License Plate/Trailer Relay
B3.F - Wiper High
B3.H - Wiper Low
B3.G - Washer Pump
B2.M - AC Clutch
B4.B - Starter Relay (Crank)

2010 Smart Plex Electrical Body Builder Reference Page #10 Rev A

Info

Published on : 2018-03-20 14:47:14
File Name : EPA2010ElectricalModels-M2106-M2112-108SD-114SD.pdf
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