SERVICE MANAGERS / PARTS MANAGERS CUMMINS ISM ENGINE FAULT CODE WHEN FAN STARTS

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Delphia Gallagher
6 years ago
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July 2004 ATTENTION: SUBJECT: VEHICLES AFFECTED: SERVICE MANAGERS / PARTS MANAGERS CUMMINS ISM ENGINE FAULT CODE WHEN FAN STARTS CERTAIN AUTOCAR WX, WXR AND WXLL MODEL VEHICLES DELIVERED BETWEEN JULY

1 July 2004 ATTENTION: SUBJECT: VEHICLES AFFECTED: SERVICE MANAGERS / PARTS MANAGERS CUMMINS ISM ENGINE FAULT CODE WHEN FAN STARTS CERTAIN AUTOCAR WX, WXR AND WXLL MODEL VEHICLES DELIVERED BETWEEN JULY 2003 AND FEBRUARY 2004, VIN NUMBER RANGE TO SERVICE PROGRAM INFORMATION: Service Programs are product modifications that Autocar has determined should be performed on all vehicles affected, proactively. It is preferred that the modification takes place prior to a failure. The expense related to this Service Program will be eligible for warranty recovery based on the published program standard labor time and required parts. Service Programs do expire. Reimbursement will not be available for claims submitted after the expiration date published on the Service Program. It has come to our attention that certain WX, WXLL, WXR trucks with ISM engines log a fault code for an open circuit to fan solenoid when the A/C Pressure or Transmission Temperature Switches open to cause the fan to come on. Harness A changes the logic of the switches to request the engine ECU to turn the fan on without logging a fault code. NUMBER of VEHICLES AFFECTED: There are 99 vehicles with serial numbers in the range to Please see Page 8 for a listing of the trucks affected by this Service Program. NOTE: To verify or determine if a particular vehicle is affected by this Service Program, you should consult the Service/Warranty screen. By entering the Vehicle Identification Number into the VIN Profile, the screen will display any outstanding Service Program(s) and/or outstanding recall(s). If the Service Program number does not appear in the VIN Profile then it has been completed. Page 1 of 9

2 INSPECTION INSTRUCTIONS: There is no inspection for this Service Program. REPAIR: The recall repair consists of installing a wiring harness to tie into the existing engine chassis wiring to re-route where signals from the transmission temperature switch, PTO and AC high pressure switch are sent. The repair instructions are found starting on page 3 of this bulletin. TIME ALLOWANCE: Repair: hours per vehicle PARTS: 1 only A wiring harness CLAIMS FOR CREDIT: Expenses associated with the performance of this Service Program will be reimbursed based on the guidelines identified in this Bulletin, and by submitting a claim following published Instructions in the claim preparation section of the "Service Operations Manual". CLAIM CODING INFORMATION: Authorization Number: - Repair: hours per vehicle Expiration Date: - July 31, 2005 DEALER RESPONSIBILITY: Dealers are to perform the Service Program on all vehicles subject to the Service Program at no charge to the owner regardless of mileage, age of vehicle, or ownership as long as the repair is carried out before the expiration date of the program unless stated otherwise in this bulletin. Whenever a vehicle subject to this Service Program is taken into or is in your vehicle inventory or dealership for service, we strongly recommend you make every effort to perform the Service Program correction before the vehicle is sold or released to the owner. AUTOCAR LLC Page 2 of 9

3 REPAIR PROCEDURE WARNING To prevent eye injury, always wear eye protection when performing vehicle maintenance, service or inspection. DANGER Before working on a vehicle, set the parking brake, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. 1. Park the vehicle on a level surface. Turn off the engine, apply the parking brakes, and chock the rear tires to keep the vehicle from moving. 2. Tilt cab forward. See instructions on pages 6, 7 and 8 for proper sequence to tilt and lower cab. 3. With the cab tilted unplug the engine harness connection to the transmission oil temperature switch harness and install JUMPER 1 from harness A on the engine harness. Note: JUMPER1 is connected to PTOTSW2. See photo on Page Connect the PTOTSW2 harness oil temperature connector from harness A to the transmission oil temperature switch harness. 5. If the truck has a PTO installed remove the engine harness connector to the PTO and connect it to RRPT02 from harness A Then connect RRPT03 from harness A to the PTO connection. If the truck does not have a PTO installed, remove the weather plug from the engine harness PTO connector and connect it to RRPT02 from harness A Leave the weather connector on RRPT03 from harness A in place. 6. Remove 559PC wire from pin 6 of engine ECU connector and heat shrink end. If you are unable to remove the pin from the connector clip the 559PC wire two or more inches back from the connector and heat shrink the harness end of the wire with sealing heat shrink. Page 3 of 9

4 7. If you were able to remove the 559PC wire from pin 6 of ECU connector then install 682A2 wire from harness A into pin 6 of the ECU connector. If you were unable to remove the wire and cut it, then remove the pin on wire 682A2 and splice it to wire 559PC. Be sure to solder the splice connections and cover with sealing heat shrink. 8. If the truck is equipped with an AC pressure switch remove the engine harness from this switch and install JUMPER2 on this harness. Then connect PFSH2 from harness A to the AC pressure switch. If no AC pressure switch is in place leave weather cap on engine harness and JUMPER2 on PFSH2 connector. Installation of harness A is now complete. Note: JUMPER 2 is connected to PFSH2. See photo on Page Clip and bundle new harness and loose connectors from engine harness neatly. 10. To test the harness installation, lower the cab, connect your shop exhaust removal hose(s) to engine exhaust system and start engine. Raise the cab and disconnect the PTOTSW2 harness oil temperature connector from harness A to the transmission oil temperature switch harness. The engine fan should immediately startup. Reconnect the harness and the fan should stop after 3 minutes unless one of the other components is asking for cooling. If the truck has air conditioning carefully disconnect PFSH2 from harness A to the AC pressure switch (taking care not to get loose clothing or body parts caught in the spinning alternator drive belt and pulley) and the fan should start immediately, reconnecting the harness should stop the fan after 3 minutes unless one of the other components is asking for cooling. If disconnecting the connectors above does not start the fan immediately please shutoff the engine and connect your laptop to the engine and using Cummins Insite, check the Fan Control programming. If the truck has air conditioning or not the Air Conditioner Pressure Switch Input should be set to Enable and the Minimum Fan On Time for A/C Pressure Switch should be set for 180 seconds. If fan does still not operate with these settings please check the installation of the A harness. 11. Service Program is complete. Lower cab and lock in place as per the instructions shown on Page 8. Page 4 of 9

Harness A8720018-002 To Pin 6 on Engine ECU connector PFSH2 Connects to AC Pressure switch if available JUMPER 2 PTOTSW2 Connects to

5 Harness A To Pin 6 on Engine ECU connector PFSH2 Connects to AC Pressure switch if available JUMPER 2 PTOTSW2 Connects to Trans Oil Temp Switch JUMPER 1 RRPT02 Connects to Engine Harness PTO Connector RRPT03 To Customer PTO Connection if Available Page 5 of 9

Tilting Cab General NOTE! Remove or secure all loose articles and close all doors before tilting the cab. The area above and ahead of the cab must be clear.

6 Tilting Cab General NOTE! Remove or secure all loose articles and close all doors before tilting the cab. The area above and ahead of the cab must be clear. The front wheels should be pointed in the straight ahead position. Read the label affixed to the seat base for more cab tilting information. DANGER Apply the parking brakes and if the truck is equipped with a manual transmission, place the gear in neutral to prevent unwanted vehicle movement and possible injury or death. CAUT ION Due to the danger of sustaining personal injury and/or damage to the vehicle, never attempt to raise the cab outside under extremely windy conditions. The strong wind conditions could force the cab beyond the normal limits of its travel. Raising the Cab Release the cab latch by lifting the security lock (1) on the lever and then push lever (2) up until the cab latch hook (3) is free from its retainer. The cab lock is now in its open position (B). Release the cab latch on the other side of the cab. WARNING Disengage both cab DANGER latches before tilting the cab. Raising the cab with only one latch disengaged can result in vehicle damage. Page 6 of 9

SERVICE PROGRAM Remove the pump handle from its storage location on either the driver or passenger side rear cab corner. It is held in place with two clips to the cab wall.

Put one end of the pump handle into the pump and operate the pump in an up and down motion. As hydraulic pressure increases, the cab tilt cylinders will start to move the cab up.

7 SERVICE PROGRAM Remove the pump handle from its storage location on either the driver or passenger side rear cab corner. It is held in place with two clips to the cab wall. Place the flow valve selector on the cab tilt pump pointing rearward. The text on the selector handle that reads RAISE is now facing out. Put one end of the pump handle into the pump and operate the pump in an up and down motion. As hydraulic pressure increases, the cab tilt cylinders will start to move the cab up. When the cab goes over its balance point, it will fall at a controlled speed to its full tilt position and automatically relieves the hydraulic system pressure. W AR N I N G It is advisable to remove the pump handle when it is not in use as it sticks out past the cab and could cause injury to someone passing by. To stop the cab in a partially tilted position while raising it, stop pumping and place the flow valve selector in the hold position. Install the lock pin in the cab tilt lock tube wherever the holes line up. D AN G E R Do not rely on the hydraulic pressure to hold the cab in a partially open position. Always use the lock pin in the cab tilt lock tube to prevent personal injury or death. Page 7 of 9

Lowering the Cab Place the flow valve selector on the cab tilt pump pointing forward. The text on the selector handle that reads LOWER is now facing out.

8 Lowering the Cab Place the flow valve selector on the cab tilt pump pointing forward. The text on the selector handle that reads LOWER is now facing out. Remove the lock pin from the cab tilt lock tube. Put one end of the pump handle into the pump and operate the pump in an up and down motion. As hydraulic pressure increases, the cab tilt cylinders will start to move the cab. When the cab goes over its balance point, it will fall at a controlled speed until it settles over the rear mounts. Remove the pump handle from the pump and return it to its storage location inside the cab. Locking the Cab in Place The hold down latch hook (3) is placed into the retainer and then locked down by pulling the latch lever (2) down. Make sure the security lock (1) snaps into place to hold the latch lever in place. Lock the cab latch on the other side of the cab. Page 8 of 9

9 Trucks involved in this Service Program VIN No. VIN No. VIN No. 5VCHC6BEX4H VCDC6BEX4H VCDC6BE14H VCHC6BE14H VCDC6BE14H VCDC6BE34H VCHC6BE34H VCDC6BE34H VCDC6BE24H VCHC6BE54H VCHC6BE34H VCDC6BE44H VCHC6BE74H VCHC6BE54H VCDC6BE64H VCHC6BE94H VCHC6BE74H VCHC6BE74H VCHC6BE04H VCHC6BE94H VCHC6BE94H VCHC6BE94H VCHC6BE04H VCHC6BE04H VCDC6BE24H VCDC6BE64H VCEC6BE34H VCDC6BE44H VCDC6BE24H VCDC6BE24H VCDC6BE64H VCDC6BE44H VCDC6BE84H VCDC6BE84H VCDC6BE64H VCDC6BE14H VCDC6BEX4H VCDC6BE84H VCDC6BE74H VCDC6BE44H VCHC6BE84H VCDC6BE94H VCDC6BE64H VCDC6BE14H VCDC6BE94H VCHC6BE64H VCHC6BE54H VCDC6BE04H VCHC6BE84H VCHC6BE74H VCEC6BE44H VCHC6BEX4H VCDC6BE24H VCDC6BE54H VCDC6BE34H VCDC6BE44H VCDC6BEX4H VCDC6BE54H VCDC6BE64H VCEC6BE74H VCEC6BE14H VCDC6BE14H VCEC6BE94H VCDC6BE94H VCHC6BE14H VCEC6BE74H VCDC6BE04H VCDC6BE44H VCHC6BE14H VCDC6BE74H VCDC6BE04H VCHC6BE34H VCDC6BE94H VCDC6BE24H VCHC6BE54H VCDC6BE04H VCHC6BE44H VCDC6BE94H VCDC6BE24H VCHC6BE64H VCDC6BE54H VCDC6BE44H VCDC6BE14H VCDC6BE74H VCHC6BE44H VCHC6BE14H VCDC6BE94H VCHC6BE64H VCDC6BE44H VCDC6BE14H VCHC6BE84H VCDC6BE64H VCDC6BE34H VCHC6BEX4H VCDC6BE84H VCDC6BE54H VCDC6BE34H VCDC6BEX4H VCHC6BE54H Page 9 of 9

INTERMITTENT SHUTDOWN OF CUMMINS ENGINE AND VARIOUS FAULT CODES ON CERTAIN WX AND WXLL TRUCKS EQUIPPED WITH CUMMINS ENGINES

ATTENTION: SUBJECT: SERVICE MANAGERS / PARTS MANAGERS INTERMITTENT SHUTDOWN OF CUMMINS ENGINE AND VARIOUS FAULT CODES ON CERTAIN WX AND WXLL TRUCKS EQUIPPED WITH CUMMINS ENGINES Service Bulletin Information: