NAYSTAR

FIELD SERVICE CAMPAIGN -— 22105
26 April 2022

SUBJECT:
12V System Battery Draw

MODELS INVOLVED:
International? eMV™ Series truck

DEFECT DESCRIPTION:

Certain International eMV™ Series trucks may experience a battery draw from the 12
volt battery system when vehicle is turned OFF. All other vehicles built during this period
have either been repaired prior to shipment or determined to not require this repair.

ELIGIBILITY:

This procedure applies ONLY to vehicles marked in the International® Service PortalS™
with FSC 22105. Also complete any other open campaigns listed on the Service Portal
at this time.

TOOLS REQUIRED:

Description Tool Number

9-inch Ratchet Crimper, 20 to 10 AWG

Crimping Tool Metri Pack 150 Push and Pull to Seat 16-22Ga
Wire Stripper, 22 to 10 AWG Locally Sourced
Diagonal Cutting Pliers

Pistol-Grip Heat Guns for Polyolefin & PVC Shrink Wrap
Modular Soldering Iron

Table 1 Tools Information

NOTE: Please submit Tool Case File to order 3549417C1 and / or call the Product
Support Center 1-800-336-4500.

PARTS REQUIRED:

Part Number Description Quantity

3549417C1 Terminal, Cable 1
Terminal, Elect, 76-Way Connector Wire, Female

3574285C1 16-Gauge 1

3574287C1 Terminal, Elect, Cable 1

3549415C1 Terminal, Elect, Cable 1

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3768013C1 Terminal, Cable, MTA F280, 16-14 Gauge 1
3727577C1 Type Ill” Cost Give Amp And Volt If AV 10 Amp, 4
2644000R1 Sleeve, Heat Shrink 1
3517502C1 Terminal, Elect, Butt SPLC 16 — 14 AWG 1
2644094R1 Split Loom Conduit 1/4-inch lenth Noe d)
Locally Sourced 16 AWG RED TXL wire 33-inch length (838 mm) 1
Locally Sourced 16 AWG RED TXL wire 60-inch length (1524 mm) 1
Locally Sourced 16 AWG RED TXL wire 74.8-inch length (1900 mm) 1
Locally Sourced Cable Tie Strap 25
Locally Sourced Solder (60/40 rosin core) 1

Table 2 Parts Information

WORK INSTRUCTIONS

WARNING! To prevent personal injury and / or death, or damage to property, park
vehicle on hard flat surface, turn the engine off, set the parking brake, and install
wheel chocks to prevent the vehicle from moving in both directions.

WARNING! To prevent personal injury and / or death, or damage to property,
always wear safe eye protection when performing vehicle maintenance.

WARNING! To prevent personal injury and / or death, or damage to property, keep
flames or sparks away from vehicle and do not smoke while servicing the
vehicle’s batteries. Batteries expel explosive gases.

WARNING! To prevent personal injury and / or death, or damage to property,
NEVER service a high-voltage vehicle without completing high-voltage safety
training. Before working on vehicle, read and obey all High-Voltage Safety and
Lock-Out Tag-Out procedures and information.

WARNING! To prevent personal injury and / or death, or damage to property, wear
and use approved high-voltage Personal Protective Equipment (PPE) when near a
high-voltage electric vehicle. Inspect PPE before use. Do not use gloves or other
PPE with expired dates, holes, cracks, or damage. NEVER touch energized
orange high-voltage cables or high-voltage components without wearing
approved high-voltage PPE.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 2

WARNING! To prevent personal injury and / or death, read all information in the
Safety Information and High-Voltage Safety sections of the service manual.

WARNING! To prevent property damage, personal injury and / or death, or
damage to property, remove, the ground cable from the negative terminal of the
battery box before disconnecting any electrical components. Always connect the
ground cable last.

WARNING! To prevent personal injury, and / or death, or damage to property, if
the vehicle must be raised, do not work under the vehicle supported only by
jacks. Jacks can slip or fall over.

1. Park vehicle on a level surface.

2. Shift transmission into Park or Neutral and set parking brake.
3. Turn ignition to Key OFF position.

4. Install wheel chocks.

5. Perform High-Voltage Isolation Level 1. Refer to eMV™ Technician Manual for
detailed instructions.

6. Turn 12 volt disconnect switch OFF.

7. Obtain and cut wire harnesses for this procedure:
e 16 AWG RED TXL wire cut to 33-inch length (838.20 mm)
e 16 AWG RED TXL wire cut to 60-inch length (1524 mm)
e 16 AWG RED TXL wire cut to 74.8-inch length (1900 mm)

8. Using wire stripper, remove approximately 1/4-inch (64 mm) of insulation at each
end of precut wire.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 3

nem 35=(- —

0000473994

Figure 1. Cable Terminal to 33-inch length wire
1. 3549417C1 cable terminal

9. Using recently cut AWG RED TXL 33-inch wire, insert end of wire into barrel of cable
terminal (Figure 1, Item 1).

NOTE: Ensure proper crimping is performed on all terminals.

10. Using crimping tool, crimp terminal to wire end.

ee \

0000473995

Figure 2. Butt Splice to 33-inch wire
1. 3517502C1 butt splice

11. At opposite end of 33-inch wire, insert end of wire into barrel of butt splice (Figure 2,
Item 1).

NOTE: Ensure proper crimping is performed on all terminals.

12. Using crimping tool, crimp butt splice to wire.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 4

0000473996

Figure 3. Cable Terminal to 74.8-inch wire
1. 3574285C1 cable terminal

13. Using recently cut AWG RED TXL 74.8-inch wire, insert end of wire into barrel of
cable terminal (Figure 3, Item 1).

NOTE: Ensure proper crimping is performed on all terminals.

14. Using crimping tool, crimp terminal to wire.

0000473997

Figure 4. Cable Terminal to 74.8-inch Wire
1. 3549415C1 Cable terminal

15. At opposite end of 74.8-inch wire, insert end of wire into barrel of terminal (Figure 4,
Item 1).

NOTE: Ensure proper crimping is performed on all terminals.

16. Using crimping tool, crimp terminal to wire.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 5

0000473998

Figure 5. Cable Terminal to 60-inch Wire
1. 3768013C1 Cable terminal

17. Using recently cut AWG RED TXL 60-inch wire, insert end of wire into barrel of
cable terminal (Figure 5, Item 1).

NOTE: Ensure proper crimping is performed on all terminals.

18. Using crimping tool, crimp terminal to wire.

0000473999

Figure 6. 16 AWG RED TXL 60-inch length wire
1. 3574287C1 Cable terminal

19. At opposite end of 60-inch wire, insert end of wire into barrel of terminal (Figure 6,
Item 1).

NOTE: Ensure proper crimping is performed on all terminals.

20. Using crimping tool, crimp terminal to wire.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 6
NOTE: The overlay harness that will pass through into the cab will only require
Split Loom Conduit for the underhood section of the harness.

21. After creating overlay harness, install each wire into separate Split Loom Conduit of
appropriate length.

22. Unlatch and open hood.

0000474000

Figure 7. Under Hood Power Distribution Module (PDM)
1. PDM

23. Access Under Hood PDM (Figure 7, Item 1).

24. Unlatch and remove PDM cover.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 7
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Figure 8. Under Hood PDM
1. Fuse location 3D

0000474002

25. Remove fuse from location 3D (Figure 8, Item 1). Discard fuse.

26. Remove PDM; refer to Technician Manual for detailed instructions.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 8

0000474003

Figure 9. PDM Connector

1. 1702M VCU interconnect
2. 6081 Under Hood PDM connector

27. Remove under hood PDM connector (Figure 9, Item 2) cover.

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0000474004

Figure 10. 6081 Under Hood PDM Connector
1. Cavity 7

NOTE: Identify correct wire at correct location before removing.

28. Remove terminal lock from connector and depopulate wire from Cavity 7 (Figure
10, Item 1).

29. Reinstall terminal lock to connector.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 10

0000474019

Figure 11. Butt Splice Connection
1. Cavity 7 wire to HVDU

30. Cut terminal from Cavity 7. Strip wire insulation approximately 1/4-inch (64 mm)
from Cavity 7 wire.

31. Insert heat shrink sleeve over recently-cut Cavity 7 wire from PDM connector.

32. Insert butt splice end of preassembled 33-inch wire (Figure 2, Item 1) into exposed
wire of cavity 7 near PDM (Figure 11, Item 1).

33. Using crimping tool, crimp butt splice.

NOTE: Make certain that solder and conductor are hot enough to allow solder to
flow into the individual conductors of the wire and inside of crimp splice.

34. Use a soldering iron, solder both conductors into crimped butt splice.

35. Slide heat shrink tube over the butt splice. Using a heat gun, apply sufficient heat to
shrink tubing over butt splice and wire.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 11
NOTE: When routing overlay harness, space cable tie straps every 12 to 14
inches apart.

36. Using cable tie straps, route and secure preassembled 33-inch harness from
connector 6081 under hood PDM connector to 1702M VCU/CAB interconnect.

37. Install PDM. Refer to Technician Manual for detailed instruction.
38. Disconnect 1702M Vehicle Control Unit (VCU) interconnect (Figure 9, Item 1).
39. Carefully remove 1702M VCU interconnect cover. Save cover for reuse.

40. Remove 1702M VCU interconnect terminal lock. Save lock for reuse.

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Figure 12. 1702M VCU/CAB Interconnect
1. Cavity 5

41. Populate opposite end of preassembled 33-inch length wire terminal into connector
Cavity 5 (Figure 12, Item 1) of 1702M VCU Interconnect.

42. Insert 1702M VCU interconnect terminal lock.

43. Install 1702M VCU interconnect cover and secure with a tie strap.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 12

0000474009

Figure 13. 1703F IP-Cowl Interconnect and 1702F IP-VCU
1. 1703F IP-Cowl Interconnect
2. 1702F IP-VCU Interconnect

44. Remove 1702F IP-VCU interconnect terminal lock (Figure 13, Item 1). Save lock for
reuse.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 13

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Figure 14. 1702F IP-VCU Interconnect
1. Cavity 5

NOTE: Ensure terminal is completely inserted into connector.

45. Using preassembeld 74.8-inch wire harness, populate terminal into Cavity 5 (Figure
14, Item 1) of 1702F IP-VCU Interconnect.

46. Insert 1702F IP-VCU interconnect terminal lock.

47. Reinstall 1702F IP-VCU interconnect to 1702M VCU Interconnect. Using torque
wrench, tighten bolt to 44 Ib-in. (5 N-m).

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 14

0000474011

Figure 15. Rework Wire