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LETCO Enterprises Presents:
Freightliner P‐3 Cascadia Overview and HVAC System Design
Cascadia P‐3 2007‐2018
Cascadia Electronic Architecture
Cascadia Network Topology
1
New Green Diagnostic Connector
4
• The new connector is backwards compatible with vehicles built prior to model year 2016 that have a black pin receptacle.
• If the first generation USB-Link device is used a new adapter cable with the green 9-pin connector must be used, and the software driver must be version 9.3.1.0 or higher.
Entertainment
Exterior Brake
Driver Information
Vehicle Network Architecture Cascadia 2016 Telematics & 3rd parties
DriverAssistanceCabin Powertrain Hybrid
PT 3rd parties
Body & Trailer
Backbone
DIAGNOSTICS‐CAN
CABIN‐CAN J1939‐CAN
J1939 open
PT‐CAN
J1939‐CAN
SSL
SWB
switches
IPPC
CumminsECM
3rd PartyTCM
PLC4TrucksSAE J2497 ESP
XTrailerABS
7TrailerABS
TPMS
SRS
LDWS
VRDU2
Assistance‐CA
NSAM CAB
CPC4SSR
CGWCGW
SAS
ABS
ICU3/4MeGauges
UDSJ1939
MCM
ACM
TCM
VRDU
MPC
RDF
MQ‐Bus
ACC‐D
ACC-R
ECAS
HVACPCU
HVACACU
HVACFCU
SAM CHAS
MSF
FMS
J1939Radio
Tablet3rd Party Telematics
CTP ‐ FBPlus VT
Cabin CAN CGW03T
Department 6
500K CGW03
Department 7
250K CGW03
Department 8
Power Distribution 07‐early 10The Cascadia has two common
electrical blocks:MFJB (MEGA Fuse
Junction Block)
• Houses up to 5 fuses
• Provides cleaner power & higher voltage to cab and engine control systems than the old method of attaching them to starter stud.
• ECU’ s supplied dedicated power / grounds
MGJB (Main GroundJunction Block)
• A junction for connecting grounds to the battery.
Starter
Alternator
Load Cut-off Switch
MGJB
MFJB
SAM cabin
SAM chassis
Power Train PDM
Battery
+
+
+
+
+
+
+
+
-
-
-
-
-
-
-
+ -
+ -
Trailer PDM (opt)
Inverter (opt)
2
Power Distribution Components Emergency Power Feed
Cascadia Specific• Emergency power for
SAM Cab comes from the starter positive stud to the PTPDM fuse F7
• SAM Cab uses power from F7 for LVD function also
• Alternator sense • 2010 Fuse B in PNDB.• 2010 Fuse D Alt Sense.
Starter
Alternator
Load Cut-off Switch
MGJB
MFJB
SAM cabin
SAM chassis
Power Train PDM
Battery
+
+
+
+
+
+
+
+
-
-
-
-
-
-
-
+ -
+ -
Trailer PDM (opt)
Inverter (opt)
SAM cab EmergencyPower Feed/LVD sense F6
F7
IGNrelay
ALT sense
2
Power Distribution Mid 2010‐15
– Power Distribution Modules (PDM) contained in SAM’s
– Additional PowerTrain PDM 2007 and Up.
– Emergency power feed from starter stud to fuses F‐6 and F‐7 of PowerTrain PDM to feed SAM’s if Mega Fuse fails or open cut‐off switch.
– Auxiliary PDMs depending on options.
– (MFJB) MEGA Fuse Junction Block– (MGJB) Main Ground Junction
Block – Load Cut‐off Switch
Emergency Power Symptoms
Note:The lights that are activated during emergency power failure may not be the same for all trucks because of hard ware, soft ware, and programmable parameters.
If the Mega fuse that feeds power to the SAM Cab fails:
2
Load Disconnect Switch 07‐09
Load Disconnect Switch Update07‐09 MFJB andLoad Disconnect Switch
Power Net Distribution BoxCab Load Disconnect Switch
PNDB LED’s
Cab Load Disconnect Switch Power Net Distribution Box
PNDB TroubleshootingWhen the Cab Load Disconnect Switch (CLDS) is in the on position, an LED on the switch and another on the PNDB will be illuminated. If there is an error with the PNDB, the LED will flash at a ½ second rate. The PNDB will make a double flash if it was not able to switch on or off when commanded by the CLDS.If any of the fuses are open, conventional troubleshooting methods need to be used. The LED’s in the PNDB and switch are not affected by open fuses or load circuits.
LED on Cab Load Disconnect Switch (CLDS) is Flashing
Step Test Procedure Test Result Action
1Does the LED make a double flash for 5 seconds when the
switch is first turned on or off?
YesThe PNDB failed to switch itself on or off
when commanded by the switch. Replace a defective PNDB
No
Inspect the connectors in the interconnect harness between the PNDB and the cab load disconnect switch (CLDS). If either was not correctly seated or there is corrosion in the
connections, clean and reconnect. Otherwise, continue with step 2.
2
Measure continuity on the harness between the PNDB
and the CLDS. Are any of the circuits open or shorted to
ground?
Yes Repair the wiring fault as appropriate.
NoSubstitute a good CLDS to check if this
repair the problem. Otherwise replace the PNDB.
2
The Cascadia has Two SAM’s
SAM Cabin SAM Chassis
Cascadia is a Module Driven Truck Using SAM’s: (Signal detection & Activation Modules)
SAM’s are similar to the Main PDM used on the Century/Columbia they contain:
• Circuit protection and relays
• The SAM Cab and SAM Chassis control the basic electrical devices on the truck, like the BHM and CHM on an M2
• Both contain ECU’s that control vehicle electrical system
• ECU’s are connected by a data link
• Utilizes Inputs from Switches or Data
• Many Outputs are FET controlled
SAM Cabin
SAM Chassis
SAM Cab Module
• Signal Detection and Actuation Module
• SAM Cab Located under the Glove Box (similar to P‐2 Main PDM location)
• Houses fuses, relays and FETs• SAM Cab controls most cab
functions• Communicates with other modules
via CAN
SAM Chassis Module
• SAM Chassis Located under the hood on the front bulkhead on the drivers side of cab.
• Houses fuses, relays and FET’s
• SAM Chassis controls most chassis functions
• Communicates with other modules via CAN
• Is part of the Multiplexed electrical system
SAM Tips:Water or Corrosion in the Sam Cabin will
causes:
• Starter to engage when the unit is running down the road.
• The Engine Fan will come on without request.
• The A/C Clutch will engage without Request.
Water in the SAM Chassis or loose Ground:
• Bunk Lighting and Switches go Crazy
• Right rear Tail Lamp on all the time
• No Trailer Lights or Fuses for turn lights keep blowing.
SAM CABIN
SAM Chassis
Sam Chassis and PT PDM Issues: Missing Covers!
MSF (Modular Switch Field)
MSF Master (ECU) ‐ connected to the CAN Datalink through Starpoint connectorMSF Sub panels ‐ uses a proprietary sub‐bus DatalinkHard wire input to MSF Master: Stalk switch, Rotary switch Steering wheel switches
1
MSF Tips
• If Cruise Control Drops Out, Reflash• Dome Lights Stay On Unplug Connector D for two Minutes.• Headlamps on all the time, Check Connector E for proper
seating.• Four‐Way Flasher Flashes 2X Reboot Module.
E
D
Central Gateway Module (CGW)
• Located under Doghouse• Acts as a translator and router
between the Cabin CAN J1939 and J1708
• Is the Interface between Service Link and Cabin CAN ECU’s
• Available as a SGW (Simplified Gateway Module) 2010 forward.
SAE J1708(9.6kbs)
A B
C
D E
F
G H
J
SAE J1939-139-pin connector
Diagnostics CAN(500kbps)
Central Gateway
Cabin CAN(125kbps)
SAE J1939
CGW Tips
No CAN present:J1939 & J1708 present,Truck not in Emergency Power,Check Diagnostic Connector Pins H and J for 60 Ohms ResistanceCheck Pins 18 and 23 on CGWCheck Fuse F20 in SAM Cab (2 AMP)
Terminal Retention Issues At Central Gateway 2016
• Wire used for the data wiring is from supplier Champlin Cable, for both the 18 and 20 AWG.
• The insulation used on the wire is EXRAD 150 FX, 20 mill wall thickness with Outer Diameter between (1.88mm –2.08)
• The connector used at the Central Gateway is a 23-13151-011 Micro Quadlock.
• The connector was designed to be used with TXL style wire. The TXL has a max OD on the insulation of 1.90mm, which mates good with the connector.
• When DTNA changed over to OBD16 in January, it was discovered that the new wire has insulation that is at the max opening of the connector.
• The 500k wire for H1939 is running around 1.98 mm. which is slightly larger that of the TXL.
New Gateway Module A66-01045-002
No Programing required
New Gateway Modules have “1” resistor built inside for the
H1939 & J1939 Data links. Only one EOL resistor is
needed.
Terminal Retention Issues At Central Gateway 2016
• The larger insulation diameter is making it difficult for PKC to get the terminal's to seat and lock into the connector.
• Trucks have made it through the plants process and validation testing without seeing any issues or failures.
• Once trucks are in operation it is possible to have a terminal that isn’t locked into the connector shake loose and have a weak connection or….now you have it, but now you don’t connection. (or no connection at all)
• This is leading to communication errors and depending on vehicle configuration cause no start or a intermittent start issue.
• The SAM cabin wouldn’t get the message that its ok to start from the transmission because the Gateway isn’t properly connected.
Starpoint Connector
– Located under the dash on the dog house
– Connects the CAN ECU’s to the CAN Datalink
– Has a 60 Ohm resistor across data bus legs
Starpoint Tip:
If the Starpoint Connection Malfunctions, all the Panel lights and the Front HVAC Controller will be flashing!
• Check each Legs for 60 Ohms Resistance.
CPC (Common Powertrain Controller) Detroit and MB Power only
2010 Electronic Control Modules
1) Aftertreatment Control Module (ACM)
2) Motor Control Module 2 (MCM2)
3) Common Powertrain Controller 2+
1 2
3
ACM MCM2
CPC2+
1
Power Train Control ModulesPower Train Control Modules
EPA10 GHG14
CPC2+ CPC4
MCM2T MCM 2.1
ACM2T ACM 2.1
NA TCM01T
Close but not the Same!
StarPoint: Black Connector SharePoint: Yellow Connector
DT‐12 12 Speed Automated
Towing Precautions
•The ACM communicates with the MCM2 and CPC2+ via a dedicated CAN line
•Like DDEC VI modules it transmits data messages via the Unified Diagnostics Services protocol.
•Electronic diagnostics is done using the DDDL / DDRS / Drumroll family of tools/Diagnostic Link
•Programming the ACM follows procedures similar to MCM programming
Detroit Communications
P‐2 Wiring Harness
Multiplexed Electrical System
o Electrical devices, lamps, gauges, switch outputs – controlled by an ECU
o Use data links to send multiple signals to ECUs at tremendous speeds
o System can both– Perform tasks– Monitor components
o The communication by Datalinks:decreases total number of wires required.
o By connecting switches to ECUs. The ECUs can then share switch information on the Datalink with other ECUs.
Multiplexing Topology
A B
C
D E
F
G H
J
LOW AIRPRESSURE
SWITCH
AMBIENTTEMP
SENSOR
J15897/J1708JUNCTION BLOCK
TERMINATINGRESISTOR 1
TERMINATINGRESISTOR 2
Black = Hardwire
Green = J1939
Purple = Sub Bus
Orange = J1587
Blue = Cabin CAN
Brown Diag CAN
Red = DDC
How to Kill a Data Line!
Data Links – J1587/J1708
Data Links ‐ J1587/J1708• Low speed – 9600 bps• Twisted pair of wires• Orange/Dark Green• Connected to all ECUs that
require this link (some through CGW)
• ECUs share data• Engine transmits a good bit
of data• Typically runs dash gauges
J1939 Data Link• High speed – 250K bps• Twisted pair of wires• Dark Green/Yellow• Backbone architecture• Terminating resistors• Cab 33 Code !
Datalink J1939 4
ENGINECONTROLMODULE
PNEUMATIC
MODULEABS
TRANSMISSIONCONTROLMODULE
INSTRUMENTCLUSTER
HVAC CONTROL SWITCHES ·FRONT
HVAC CONTROL SWITCHES ·REAR
J193
9(2
50kb
ps)
A B
C
D E
F
G H
J
SAE J1939-139-pin connector
TerminatingResistor #1
TerminatingResistor #2
CAN (Controller Area Network)► High speed – 125K bps► Twisted pair of wires► Light Blue/White► Proprietary data link
connecting SAM Cab SAM Chassis MFS Master CGW
► Above ECUs are connected at Starpoint connector that has 60 ohms of resistance
► Can share information on both J1587/J1708 and J1939
► Connect to the CGW so the Cabin CAN ECUs can interface with ServiceLink
Datalink Cabin CAN
Starpo
int
Data Links Diagnostic CAN
Diagnostic CAN:• 512k bps • Twisted pair of wires • Brown with a blue stripe and
brown with a white strip • Connects to CGW and goes
to the Diagnostic connector • Note that this is a higher
speed than the cabin CAN• Point to Point Topology
Cascadia Clutch Request
29 HVAC DTC’s available through J1939 Data Link
Cascadia A/C System Components
• Sanden Compressor 2007‐09• Denso Compressor 2010‐current• Block TXV• Receiver/Drier • Condenser/Evaporator• Evaporator Temperature Sensor• Constant Output Temperature Sensor• Refrigerant Pressure Transducer• Low Air Pressure Switch• Ambient Air Temperature Sensor 2007 ‐09.
Sanden SHD Compressor 07‐09
• Shipped with 10 Ounces SP‐20 PAG Oil.
• Thermal fuse built into Field Coil for Belt Protection
Denso Compressor 2010 Forward
Shipped with 4.4 Ounces of ND‐8 PAG OilMini Stat‐O‐Seals: 14‐16 Ft Lbs.Red Label: DD enginesBlue Label: Cummins ISX
Thermal Sensor in Series with Clutch Power for Belt Protection.
Cascadia Component Details
Block TXV TXV and Evaporator
3 oz. Oil
Cascadia Component Details
Condenser Use Temperature Testing to Find Problems
1 oz. OilNormal Temperature Drop 20-50 Degrees F
Cascadia Component Details
Receiver DrierLines and Fittings
Torque to 14-16 Ft Lbs.
3 oz. Oil1 oz. Oil per line
Refrigerant Oil for Replacement Components Summary
Refrigerant Charge
Typical Charge:Cab Cab: 3.00 lbs.Sleeper: 4.12 lbs.Refer to Label on Unit or use ServicePro for exact amount.Confirm with Temperature Drop Test.
Cascadia HVAC Module Details
Valeo ‐ blend airDirect drive actuators (No external drive gears)Barrel doors instead of Flapper designSame blower motor used for the Front box and Bunk
Cascadia Temperature and Air Delivery Controls
• Control Head• 4 Electric Stepper Motors• 4 Doors: Defrost, Floor, Blend, and Recirculation• 2 Temperature Sensors: Evaporator and Duct • Recirculation Filter• Fresh Air Filter (outside of Front wall)• Brushless Blower Motor
Front Control Unit (FCU)
Front Control Unit (FCU) – ECU for front HVAC systemFCU communicates with other ECUs on J1939.FCU controls the four stepper motors.FCU determines when the A/C compressor should operate and sends request to SAM CABFCU can remotely control the bunk HVAC unit (bunk over‐ride).
Day Cab
SLEEPER CAB
Recirculation Mode
20 minute time out Must push to return to Recirculation
Front Control Panel Layout
Stepper MotorsSame Motor All Locations
Must Calibrate If Disconnected or Replaced
Actuator Motor DTC
Stepper Motor Recalibration
• Ignition On/ Engine Off• Blower mode to Off (CCW)• Temperature mode to Full Heat (CW)• Mode selector to Face (CCW)• Press A/C and Recirc together until LED’s begin to flash.• Recalibration complete when the LED’s stop flashing.
Temperature Sensors
COTC
Evaporator
Sensor Detail
COTC Sensor Evaporator Sensor
One Step Two Steps
Sensor Bench Test
Evaporator @ 32 F:8910‐9090 Ohms
COTC @ 32 F:31254‐34046 Ohms
Cabin Filters
Recirculation Filter Cabin Filter
Brushless Blower Motor Permanent Magnets (6)
Brushless Motor ‐ Coils
Cage
Same Motor in M2
Cascadia Compressor Clutch Operation
Air Pressure
Reads Off Primary Air TankN.O. Switch in Series with Secondary Tank SwitchChopped signal from SAM Cab Connector-Pin X13-10 to X13-11.
Ambient Temperature Sensor
Bumper Mounted Sensor Driver Side Mirror 2014 Up
Ambient Temperature DTC
ACP
Air Conditioning Pressure Transducer:Schrader Mounted.05 volts to 4.8 Volts normal operating range.Open circuit = No clutch and Full time engine fan.
Pressure Transducer DTC
HVAC ServiceLink Template
No Clutch Engagement Tips:
ACP Connection backed outConnecter C‐22, Pin 1 broken wire at terminalClutch Ground wire on mag switch connection at starter
Auxiliary Control Unit (ACU)
• ACU communicates over the J1939 with other ECUs.
• The auxiliary control unit (ACU) – ECU for bunk HVAC system.
• ACU controls the stepper motor in the bunk HVAC to operate a temperature mix door.
• ACU controls the bunk unit blower motor.
• ACU can remotely control the front HVAC when the parking brake is set.
J1939 Data Line Missing
Condensation from duct dripping into Sub Control Panel
HVAC Auxiliary Unit
Rear Control Panel Layout
Cascadia ParkSmart Auxiliary HVAC System Introduction
275 AMP Alternator
Battery Separator Switch
4 Additional Batteries
Pre-2011 Box
Heater
ParkSmart• The temperature control knob has 21
positions, each of which correspond to a desired cabin temperature between 60 and 85 degrees F.
• A sensor in the climate control panel monitors the cabin temperature.
• Dependent upon cabin temp and desired temp, the controller will either turn on the auxiliary A/C system or the fuel‐operated coolant heater.
• The fan speed is manually selected; 0 is off, and 8 is maximum.
• The blower must be on a position other than “off” for the system to operate.
Unit Location
Relay/Fuse Panel
(Relocated to side of unit mid-summer 2011)
Actuator
Heater Core Access
1
ParkSmart System Operation
• Important Note: The system is designed to maintain a desired cabin temperature for a given period of time which depends heavily on ambient outside temperature and solar load.
• The unit does not have the capacity to raise or lower the cabin temperature significantly.• The vehicle should be brought to desired temperature with the engine driven HVAC system prior to
shutting down and entering parked mode.To operate the ParkSmart unit in engine running mode simply select the desired temperature and blower
speed.For parked‐mode operation, set the desired temperature and a blower speed other than zero then push the
Park button. The LED on the Park button will then illuminate and the unit will start running.
External Components
Internal Components
ParkSmart Revision ‐ Rev5
Revision 5 July 2011
The condenser was relocated from under the cab to the back of the sleeper in order to improve airflow to the condenser and get it away from the radiant heat of the pavement.
This change required hoses and connections for manufacturing and has a single service port on the high side line.
R134a Charge: 2.00 LBS. POE Oil Required!
ParkSmart Revision ‐ Rev5
Electronics Moved in to Storage Bin
ParkSmart Revision ‐ Rev5
ESPAR heater fuel pump and filter relocated to fuel tank
Auxiliary PNDB with Optimized Idle System, No Battery Separator
Cascadia
Some Additional Tips
Wiring Diagram Notes 2
Wiring Diagram Types:A = AssemblyD = InstallationG = SubsystemL = Layout06 = Electrical12 = Air System
24 Volts vs AGM Batteries!
GHG2014 Change
DiagnosticLink is here
RUN SMART!
Thank You for Your Attention!
Larry can be reached at:[email protected]
P2 Century/Columbia Class
• HVAC Controls
Century Class Inputs, Outputs, and Control
Inputs
Duct Sensor
Blower MotorVariable voltagesignal
Bunkover ride
_ +Outputs
Aux HVAC Data LinkControl
EvaporatorSensor Thermistor
Blower Speed Mode Temp
RECRIC A/C
A/C Clutch
Binary Switch
Door Actuators
ModeRecirc/Fresh
Temp
Century Class Cab Blend Air Unit
Mode Actuator
Temperature Actuator
Heater Core Cover
Evaporator Core Cover
Recirc. Actuator
Recirc. Air Inlet (Filter not shown)
Century Class Cab Blend Air(front wall view)
Expansion Valve
Outside Air Inlet
Evaporator Tubes
Drain Tube
Heater hoseConnections
Floor Outlet
Defrost Outlet
SWD Outlet
Face Louver Outlet
Cabin Filter P‐2
Century Class Clutch Control
ECU monitored controls temp 37 – 44 degreesA/C clutch on @ 44 degree or higher
to get FCU to request A/C clutch on.
Evaporator Sensor
Century Class CDTC Sensor
ECU monitored to controltemperature by moving blend
air door
Constant Discharge Temperature Control Sensor
P‐2 Switches
P‐2 Blower Motor
Century Blower Motor runs, No A/C Clutch
P‐2 Template
P2 Recalibration
• Key On, Engine Off• Blower: Off• Mode: Defrost• Temp: Full Heat• Press: Recir and A/C together, hold until LED’s start to Blink• Blower runs on high speed, mode doors will cycle, Recir door opens and closes• Process complete when LED’s turn off.
Refrigerant and Oil Specs
No A/C Clutch
TSB
M‐2
DD‐5
DD‐5
DD‐5
M‐2
M‐2
M‐2
M‐2
M‐2