Professional Documents
Culture Documents
Enterprises Presents:
Freightliner P‐3 Cascadia Overview
and HVAC System Design
Cascadia P‐3 2007‐2018
1
Cascadia Electronic Architecture
Cascadia Network Topology
New Green Diagnostic Connector
4
Vehicle Network Architecture Cascadia 2016
Entertainment Driver Information Telematics & 3rd partiesFMS
J1939 CTP ‐ FB
Plus VT
Radio
Backbone
DIAGNOSTICS‐CAN J1939 open
UDS CGW
J1939 CABIN‐CAN CGW
J1939‐CAN J1939‐CAN
SSR
CPC4
SAM CHAS
VRDU
VRDU2
PT‐CAN
ECAS Cummins
MCM
ECM
Assistance‐CAN
SAM CAB
MPC
SRS 3rd Party
ACM
TCM
RDF
MSF TPMS
ACC‐D TCM ABS
SWB
HVAC
FCU ACC-R
SAS
MQ‐Bus
switches HVAC
ACU PLC4Trucks
SAE J2497 ESP
SSL
HVAC
PCU
IPPC
LDWS
X 7
Trailer Trailer
ABS ABS
Department 6
500K CGW03
Department 7
250K CGW03
Department 8
2
Power Distribution 07‐early 10
The Cascadia has two common Power Train PDM
electrical blocks:
- +
MFJB (MEGA Fuse + -
Starter
Junction Block)
Alternator
them to starter stud. +
MFJB
+ -
+
• ECU’ s supplied dedicated
Trailer PDM (opt)
power / grounds
MGJB (Main Ground + -
Inverter (opt)
Junction Block)
• A junction for connecting Battery + -
+ - -
grounds to the battery.
MGJB
2
Power Distribution Components
Emergency Power Feed Power Train PDM
Cascadia Specific Starter +
- IGN
relay
-
• Emergency power for + SAM cab Emergency F6
Power Feed/LVD sense
F7
SAM Cab comes from
the starter positive stud ALT sense
-
SAM cabin
to the PTPDM fuse F7 + +
-
• SAM Cab uses power Alternator
from F7 for LVD function
SAM chassis
also Load Cut-off Switch
+
MFJB
+ -
• Alternator sense +
• 2010 Fuse B in PNDB.
Trailer PDM (opt)
• 2010 Fuse D Alt Sense.
+ -
Inverter (opt)
Battery + -
+ - -
MGJB
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
2
Emergency Power Symptoms
If the Mega fuse that feeds power to the SAM Cab fails:
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.
Load Disconnect Switch 07‐09
Load Disconnect Switch Update
07‐09 MFJB and Power Net Distribution Box
Load Disconnect Switch Cab Load Disconnect Switch
PNDB LED’s
Cab Load Disconnect Switch Power Net Distribution Box
2
PNDB Troubleshooting
When 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
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
• ECU’s are connected by a data link
• Utilizes Inputs from Switches or Data
• Many Outputs are FET controlled
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 SAM CABIN
• Right rear Tail Lamp on all the time
• No Trailer Lights or Fuses for turn lights
keep blowing.
SAM Chassis
Sam Chassis and PT PDM Issues: Missing
Covers!
1
MSF (Modular Switch Field)
MSF Master (ECU) ‐ connected to the CAN Datalink through Starpoint connector
MSF Sub panels ‐ uses a proprietary sub‐bus Datalink
Hard wire input to MSF Master: Stalk switch, Rotary switch Steering wheel switches
MSF Tips D
• 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.
Central Gateway Module (CGW)
•
Central Gateway
Located under Doghouse
• Acts as a translator and router SAE J1708
(9.6kbs)
between the Cabin CAN J1939 and
J1708 Diagnostics CAN
(500kbps)
• Is the Interface between Service SAE J1939-13
9-pin connector
Link and Cabin CAN ECU’s E
D
C
•
F A B
Available as a SGW (Simplified G
H
J
(125kbps)
CGW Tips
No CAN present:
J1939 & J1708 present,
Truck not in Emergency Power,
Check Diagnostic Connector
Pins H and J for 60 Ohms
Resistance
Check Pins 18 and 23 on CGW
Check Fuse F20 in SAM Cab (2
AMP)
Terminal Retention Issues At Central
Gateway 2016
• Wire used for the data wiring is from New Gateway Modules have
supplier Champlin Cable, for both the 18 “1” resistor built inside for the
and 20 AWG. H1939 & J1939 Data links.
Only one EOL resistor is
• The insulation used on the wire is EXRAD needed.
150 FX, 20 mill wall thickness with Outer
Diameter between (1.88mm –2.08)
– 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
1
2010 Electronic Control Modules
ACM MCM2
1 2
CPC2+
1) Aftertreatment Control Module (ACM)
2) Motor Control Module 2 (MCM2)
3
3) Common Powertrain Controller 2+
Power Train Control Modules
EPA10 GHG14
CPC2+ CPC4
NA TCM01T
Close but not the Same!
StarPoint: Black Connector SharePoint: Yellow Connector
DT‐12 12 Speed Automated
Towing Precautions
Detroit Communications
•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
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
Black = Hardwire
Orange = J1587
J15897/J1708
JUNCTION BLOCK
Red = DDC
D
E
C
F A B
J
G
H
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
Datalink J1939 4
Terminating
Resistor #1
SAE J1939-13
9-pin connector
J1939 Data Link F
E
D
A
C
B
• High speed – 250K bps
J
G
H
• Twisted pair of wires
• Dark Green/Yellow
ENGINE
CONTROL
MODULE
(250kbps)
• Backbone architecture
J1939
PNEUMATIC
ABS
MODULE
• Terminating resistors
TRANSMISSION
• Cab 33 Code !
CONTROL
MODULE
INSTRUMENT
CLUSTER
HVAC CONTROL
SWITCHES · FRONT
HVAC CONTROL
SWITCHES · REAR
Terminating
Resistor #2
Datalink Cabin CAN
CAN (Controller Area Network)
► High speed – 125K bps
► Twisted pair of wires
Starpoint
► 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
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 Oil
Mini Stat‐O‐Seals: 14‐16 Ft Lbs.
Red Label: DD engines
Blue 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
1 oz. Oil
Normal Temperature Drop 20-50 Degrees F
Cascadia Component Details
Receiver Drier
Lines and Fittings
Valeo ‐ blend air
Direct drive actuators (No external drive gears)
Barrel doors instead of Flapper design
Same 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 system
FCU communicates with other
ECUs on J1939.
FCU controls the four stepper
motors.
Day Cab
FCU determines when the A/C
compressor should operate and
sends request to SAM CAB
FCU can remotely control the
bunk HVAC unit (bunk over‐
ride).
SLEEPER CAB
Recirculation Mode
• 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
Evaporator
COTC
Sensor Detail
COTC Sensor Evaporator Sensor
Evaporator @ 32 F: COTC @ 32 F:
8910‐9090 Ohms 31254‐34046 Ohms
Cabin Filters
Recirculation Filter Cabin Filter
Brushless Blower Motor
Same Motor in M2 Permanent Magnets (6)
Cage
Brushless Motor ‐ Coils
Cascadia Compressor Clutch Operation
Air Pressure
Reads Off Primary Air Tank
N.O. Switch in Series with
Secondary Tank Switch
Chopped 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 out
Connecter C‐22, Pin 1
broken wire at terminal
Clutch 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
Pre-2011 Box
Battery Separator Switch
Heater
4 Additional Batteries
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
1
Relay/Fuse Panel
(Relocated to side of
unit mid-summer
2011)
Actuator
• 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
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
2
Wiring Diagram Notes
Wiring Diagram Types:
A = Assembly
D = Installation
G = Subsystem
L = Layout
06 = Electrical
12 = Air System
24 Volts vs AGM Batteries!
GHG2014 Change
DiagnosticLink is here
RUN SMART!
Thank You for Your Attention!
Larry can be reached at:
LTURAY1974@aol.com
P2 Century/Columbia Class
• HVAC Controls
Century Class Inputs, Outputs, and Control
Inputs Control Outputs
_ Aux HVAC Data Link +
Duct Door
Sensor Actuators
Bunk
over ride
RECRIC A/C
Evaporator
Sensor Thermistor
Blower Motor
Variable voltage
A/C Clutch signal
Binary Switch
Century Class Cab Blend Air Unit
Recirc. Actuator
Mode Actuator
Temperature Actuator
SWD Outlet
Outside Air Inlet
Defrost Outlet
Floor Outlet
Heater hose
Connections
Drain Tube
Expansion Valve
Cabin Filter P‐2
Century Class Clutch Control
ECU monitored
controls temp 37 – 44 degrees
A/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 control
temperature by moving blend
air door
• 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