SERVICE BULLETIN (Also applies to Mack Trucks Australia) NUMBER: SB-724-006 DATE: 2/22/02 MODEL: All V-MAC III except LE, MR J1939 OVERLAY HARNESS FOR SERVICE USE A service replacement overlay harness for the J1939 CAN line is available through the MACK Parts System for V-MAC III CX, CV, CH, CL, DM, DMM, RD and RB model vehicles. This overlay harness eliminates the need to replace the complete main cab harness should a problem with the J1939 line be encountered. The harness includes all the necessary terminal ends, connector bodies and heat shrink tubing. Part numbers for the overlay harnesses are as follows: Part No. Description 1916-8000005 Harness, overlay, J1939 line, vehicles with ABS/ATC 1916-8000006 Harness, overlay, J1939 line, vehicles without ABS/ATC Procedures for installing the J1939 overlay harness are as follows: Installing Harness Part No. 1916-8000005 (Vehicles with ABS/ATC) 1 Figure 1 Overlay Harness Part No. 1916-8000005 (ABS/ATC-Equipped Vehicles) SB-724-006 Page 1 of 10 SERVICE PUBLICATIONS, ALLENTOWN, PA 18105 MACK TRUCKS, INC. 2002
2 1. Disconnect the batteries by disconnecting the negative battery cable first, then the positive cable. 2. Access the V-MAC III Vehicle Electronic Control Unit (VECU). (On all models excluding DM and DMM, the VECU is located below the dashboard, behind the rider's side kick panel. On DM and DMM models, the VECU is located on the left-hand side of the vehicle, mounted by the engine cover inside the cab.) 3. Remove the dashboard panels as required to access the main cab wiring harness. 4. Disconnect the J3 connector from the VECU. 5. Use the appropriate terminal end removal tool included in the V-MAC Terminal Removal/Installation Kit, tool No. J 44786, to remove the J1939 yellow wire (VJ3-1-0.8, or VJ3-1-0.5 if the original J1939 line is a three-wire harness) from cavity 1, green wire (VJ3-2-0.8, or VJ3-2-0.5 if the original J1939 line is a three-wire harness) from cavity 2 and the bare wire (VJ3-3-0.5 if utilized) from cavity 3 of the connector body. Figure 2 VECU Connector VJ3 6. Disconnect the power supply harness from the ABS ECU (18-pin on Meritor WABCO D-Full Versions and Eaton systems, and 15-pin on Meritor WABCO D-Basic and E versions). Use the appropriate terminal end removal tool included in the V-MAC Terminal Removal/Installation Kit, tool No. J 44786, to remove the J1939 green wire (VJ3-2A-0.8, or VJ3-2A-0.5 if the original J1939 line is a three-wire harness) from cavity 1, yellow wire (VJ3-1A-0.8, or VJ3-1A-0.5 if the original J1939 line is a three-wire harness) from cavity 3 and the bare wire (VJ3-3-0.5 if utilized) from cavity 2 of the connector body. SB-724-006 Page 2 of 10
If the J1939 harness is a two-wire harness (yellow and green wires) without the bare wire, cavity 2 of the 15-pin ABS ECU power supply harness is occupied by wire No. ABS-PS2-0.8. Do not remove this wire. 7. If the vehicle is equipped with an electronically controlled transmission, disconnect the J1939 connector from the transmission ECU pigtail harness. 8. Cut off the J1939 harness wires at convenient locations where the wires enter the main cab harness. 9. Open the hood and disconnect the J1939 harness connector from the engine harness connector. Cut the J1939 engine connector from the cab side of the harness and discard, then pull the J1939 harness wires through the bulkhead grommet and into the cab. Cut the wires at a convenient location where the J1939 harness wires enter the main cab harness. 10. Route the new J1939 overlay harness (part No. 1916-8000005) along the main cab harness. Use tie wraps (part No. 48RU2313P4) to secure the overlay harness to the main cab harness. When routing the overlay harness, use caution to avoid sharp edges and moving parts. 11. Route the engine leg of the overlay harness through the bulkhead grommet. 12. After the engine leg of the overlay harness has been routed through the bulkhead grommet, slide the heat shrink tubing (supplied with the overlay harness) over the wires. Install the connector body (supplied with the overlay harness) as follows: 3 Figure 3 J1939 Cab-Side Engine Harness Connector Installation Insert yellow wire (VJ3-1-0.8, or VJ3-1-0.5 if the original J1939 line was a threewire harness) into connector cavity A. Insert green wire (VJ3-2-0.8, or VJ3-2-0.5 if the original J1939 line was a threewire harness) into connector cavity B. Insert the bare wire (VJ3-3-0.5) into connector cavity C, only if a bare wire had been used with the original harness. SB-724-006 Page 3 of 10
If a bare wire was NOT USED with the original J1939 harness, DO NOT USE THE BARE WIRE of the overlay harness. Either fold the wire back and secure it to the harness with tie wraps, or cut it off. 13. Slide the heat shrink tubing over the connector body and use a suitable heat source to shrink the tube in place. 14. Install the blue wedge lock into the connector body, then connect the overlay harness connector to the engine harness connector. 15. Insert the wires into the VECU J3 connector body as follows: 4 Figure 4 J3 Connector Harness Wire Installation Insert the yellow wire (VJ3-1-0.8, or VJ3-1-0.5 if the original J1939 line was a three-wire harness) into J3 connector cavity 1. Insert the green wire (VJ3-2-0.8, or VJ3-1-0.5 if the original J1939 line was a three-wire harness) into J3 connector cavity 2. Insert the bare wire (VJ3-3-0.5) into J3 connector cavity 3, only if a bare wire had been used with the original J1939 harness. If a bare wire was NOT USED with the original J1939 harness, DO NOT USE THE BARE WIRE of the overlay harness. Either fold the wire back and secure it to the harness with a tie wrap, or cut it off. SB-724-006 Page 4 of 10
16. Insert the overlay harness terminal ends into the ABS ECU power supply harness connector as follows: Insert green wire (VJ3-2A-0.8, or VJ3-2A-0.5 if the original J1939 line was a threewire harness) into cavity 1 of the ABS power supply connector. Insert yellow wire (VJ3-1A-0.8, or VJ3-1A-0.5 if the original J1939 line was a three-wire harness) into cavity 3 of the ABS power supply connector. Insert bare wire (VJ3-3A-0.5) into cavity 2 of the ABS power supply connector only if a bare wire had been used with the original J1939 harness. If a bare wire was NOT USED with the original J1939 harness, DO NOT USE THE BARE WIRE of the overlay harness. Either fold the wire back and secure it to the harness with a tie wrap, or cut it off. 17. If equipped with an electronic transmission, connect the J1939 electronic transmission harness connector to the transmission ECU pigtail harness. If not equipped with an electronic transmission, insulate the harness connector with electrical tape and use a tie wrap to secure the connector to the main cab harness. The J1939 overlay harness is only available in one length to cover a variety of chassis models. On certain models (particularly DM and DMM models), there may be an excess length of wire after the installation is complete. In these cases, coil the extra length of wire together and use a tie wrap to secure the coil to the main harness. 18. Reinstall all dash panels that had been removed previously. 19. Reconnect the batteries by connecting the positive cable first, and then the negative cable. 20. Using the V-MAC III Service Support Software, reset the date and time. 21. Before placing the vehicle back into service, test the V-MAC system and ABS/ATC functions. Clear any codes in either system. SB-724-006 Page 5 of 10
Installing Harness Part No. 1916-8000006 (Vehicles without ABS/ATC) 5 Figure 5 Overlay Harness Part No. 1916-8000006 (Vehicles without ABS/ATC) 1. Disconnect the batteries by disconnecting the negative battery cable first, then the positive cable. 2. Access the V-MAC III Vehicle Electronic Control Unit (VECU). (On all models excluding DM and DMM, the VECU is located below the dashboard, behind the rider's side kick panel. On DM and DMM models, the VECU is located on the left-hand side of the vehicle, mounted by the engine cover inside the cab.) 3. Remove the dashboard panels as required to access the main cab wiring harness. SB-724-006 Page 6 of 10
6 4. Disconnect the J3 connector from the VECU. 5. Use the appropriate terminal end removal tool included in the V-MAC Terminal Removal/Installation Kit, tool No. J 44786, to remove the J1939 yellow wire (VJ3-1-0.8, or VJ3-1-0.5 if the original J1939 line is a three-wire harness) from cavity 1, green wire (VJ3-2-0.8, or VJ3-2-0.5 if the original J1939 line is a three-wire harness) from cavity 2 and the bare wire (VJ3-3-0.5 if utilized) from cavity 3 of the connector body. Figure 6 VECU Connector VJ3 6. If the vehicle is equipped with an electronically controlled transmission, disconnect the J1939 connector from the transmission ECU pigtail harness. 7. Cut off the J1939 harness wires at convenient locations where the wires enter the main cab harness. 8. Open the hood and disconnect the J1939 harness connector from the engine harness connector. Cut the J1939 engine connector from the cab side of the harness and discard, and then pull the J1939 harness wires through the bulkhead grommet and into the cab. Cut the wires at a convenient location where the J1939 harness wires enter the main cab harness 9. Route the new J1939 overlay harness (part No. 1916-8000006) along the main cab harness. Use tie wraps (part No. 48RU2313P4) to secure the overlay harness to the main cab harness. When routing the overlay harness, use caution to avoid sharp edges and moving parts. 10. Route the engine leg of the overlay harness through the bulkhead grommet. SB-724-006 Page 7 of 10
11. After the engine leg of the overlay harness has been routed through the bulkhead grommet, slide the heat shrink tubing (supplied with the overlay harness) over the wires. Install the connector body (supplied with the overlay harness) as follows: 7 Figure 7 J1939 Cab-Side Engine Harness Connector Installation Insert yellow wire (VJ3-1-0.8, or VJ3-1-0.5 if the original J1939 line was a threewire harness) into connector cavity A. Insert green wire (VJ3-2-0.8, or VJ3-2-0.5 if the original J1939 line was a threewire harness) into connector cavity B. Insert the bare wire (VJ3-3-0.5) into connector cavity C, only if a bare wire had been used with the original harness. If a bare wire was NOT USED with the original J1939 harness, DO NOT USE THE BARE WIRE of the overlay harness. Either fold the wire back and secure it to the harness with tie wraps, or cut it off. 12. Slide the heat shrink tubing over the connector body and use a suitable heat source to shrink the tube in place. 13. Install the blue wedge lock into the connector body, and then connect the overlay harness connector to the engine harness connector. SB-724-006 Page 8 of 10
14. Insert the wires into the VECU J3 connector body as follows: 8 Figure 8 J3 Connector Harness Wire Installation Insert the yellow wire (VJ3-1-0.8, or VJ3-1-0.5 if the original J1939 line was a three-wire harness) into J3 connector cavity 1. Insert the green wire (VJ3-2-0.8, or VJ3-1-0.5 if the original J1939 line was a three-wire harness) into J3 connector cavity 2. Insert the bare wire (VJ3-3-0.5) into J3 connector cavity 3, only if a bare wire had been used with the original J1939 harness. If a bare wire was NOT USED with the original J1939 harness, DO NOT USE THE BARE WIRE of the overlay harness. Either fold the wire back and secure it to the harness with a tie wrap, or cut it off. 15. If equipped with an electronic transmission, connect the J1939 electronic transmission harness connector to the transmission ECU pigtail harness. If not equipped with an electronic transmission, insulate the harness connector with electrical tape and use a tie wrap to secure the connector to the main cab harness. The J1939 overlay harness is only available in one length to cover a variety of chassis models. On certain models (particularly the DM and DMM models), there may be an excess length of wire after the installation is complete. In these cases, coil the extra length of wire together and use a tie wrap to secure the coil to the main harness. 16. Reinstall all dash panels that had been removed previously. 17. Reconnect the batteries by connecting the positive cable first, and then the negative cable. SB-724-006 Page 9 of 10
18. Using the V-MAC III Service Support Software, reset the date and time. 19. Before placing the vehicle back into service, test the V-MAC system and clear any codes in the system. The labor code and maximum labor allowance for installation of the J1939 overlay service harness are as follows: 724 2A 2T 80... 1.0 hr. Time to install J1939 overlay service harness SB-724-006 Page 10 of 10