T2 Terminal Tractor Service Bulletin

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T2 Terminal Tractor Service Bulletin Subject: Updated HVAC Wiring Harness, T2's Terminal Tractors Product: Medium Terminal Tractor Bulletin # SB18TI0090 Date: Pages: 7-August-2018 Page 1 of 11 Units

1 T2 Terminal Tractor Service Bulletin Subject: Updated HVAC Wiring Harness, T2's Terminal Tractors Product: Medium Terminal Tractor Bulletin # SB18TI0090 Date: Pages: 7-August-2018 Page 1 of 11 Units Affected: T2 Tractors having experienced electrical connector failures on the backside of the blower motor due to over voltage and heat generated Possible Situation: HVAC electrical system redesign replaces the existing HVAC wiring harness. New updated harness incorporates the addition of relays and increased wire gauge. Solution: Service kit; SK8750 includes updated HVAC wiring harness on T2's equipped with air conditioning Solution: Service kit; SK8766 includes updated HVAC wiring harness on T2's equipped with heater only Pic of CTT harness Presentation pg 2/30 CAUTION: PROPER LOCKOUT / TAGOUT PROCEDURES AS WELL AS PERSONAL SAFTETY PROCEDURES AND DEVICES INCLUDING EYE PROTECTION ARE REQUIRED. THOROUGH REVIEW AND UNDERSTANDING OF T2 OPERATOR AND SERVICE MANAULS

o Park tractor on level surface o Set park brake o Chock wheels o Shut off engine

cables from batteries o Remove cab interior; terminal mounting plate, front

two electrical connectors * Remove nut from back of control panel SK8750 View C *

2 o Park tractor on level surface o Set park brake o Chock wheels o Shut off engine o Lockout / tagout Rewire disassembly procedure: o Disconnect battery electrical cables from batteries o Remove cab interior; terminal mounting plate, front console and right hand A-pillar cover o Remove HVAC control panel * Disconnect two electrical connectors * Remove nut from back of control panel SK8750 View C * Slide control panel mounting bracket off stud * Slide HVAC control module out Page 2 of 11

o Remove cab exterior front access panel SK8750 View D o Remove HVAC service panel

Condition units) * Single black wire does not need to be removed SK8750 Pic 7 o

3 o Remove cab exterior front access panel SK8750 View D o Remove HVAC service panel * Pull bottom of service panel out and slide down SK8750 Pic 2 * Cut wire ties holding harness. Harness routed thru bracket o Disconnect wire connector from resistor pack (Air Condition units) * Single black wire does not need to be removed SK8750 Pic 7 o Disconnect wire connector from thermostat (Air Condition units) o Pull entire thermostat assembly out, disconnect wires (Air Condition units) Page 3 of 11

o Push in on middle of blower motor to detach from clip holding

Disconnect ground wire o Slide harness grommet out of service

remove SK8750 Pic 10 o Disconnect existing harness connectors

Valve actuator (Red/Orange/Black wires) SK8750 Pic 14 SK8750 Pic

4 o Push in on middle of blower motor to detach from clip holding motor and roll motor down to gain access to ground wire. Disconnect ground wire o Slide harness grommet out of service panel slot o Slide loose harness through service panel bracket & remove SK8750 Pic 10 o Disconnect existing harness connectors from; * Fresh/Recirc actuator (Red/Green/Black wires) * Water Valve actuator (Red/Orange/Black wires) SK8750 Pic 14 SK8750 Pic 13 o Disconnect and remove remaining connections o Remove harness Page 4 of 11

Install new updated harness CTT00009100 o Route wiring harness through bracket on back side of HVAC service panel o Connect motor ground wire to blower motor o Push in on middle of blower motor and

slot on HVAC service panel o Wire tie harness to bracket o Reinstall HVAC service panel, secure with hardware o Route updated HVAC harness up into cab, underneath wiper motor o Reinstall cab front

5 Install new updated harness CTT o Route wiring harness through bracket on back side of HVAC service panel o Connect motor ground wire to blower motor o Push in on middle of blower motor and rotate up to lock motor in place o Reconnect wire connector to thermostat, slide thermostat in place and fasten with screw (AC units) o Reconnect wire connector to resister pack o Slide grommet into slot on HVAC service panel o Wire tie harness to bracket o Reinstall HVAC service panel, secure with hardware o Route updated HVAC harness up into cab, underneath wiper motor o Reinstall cab front access panel o Inside cab - continue removing old harness and route new harness along same route o Disconnect old harness connectors and reconnect new updated Panel/Defrost actuator connector (Red/Blue/Black) o Disconnect any remaining old harness connectors, remove and discard old harness Page 5 of 11

HVAC Supply Overlay Harness Installation Note: If main cab harness has been reworked under Service Kit: SK8649 CTT00009055 harness may not be required. Check service records!

6 HVAC Supply Overlay Harness Installation Note: If main cab harness has been reworked under Service Kit: SK8649 CTT harness may not be required. Check service records! SK8750 9/13 (in Color) o Lay out HVAC supply overlay harness in cab electrical center Cab fan connector (CFAN) will route up right hand A-pillar o Attach ground connector GD2000 to pass thru stud (PTSN) o Remove and replace two wire terminals of Red/White wires from cab power connector (CPJ2). Connector pin positions #4 and #7 Cab Power Distribution Connector CPJ2 - Unlocking HC1000 Wires and Pin Removal o Tools required: Tool p/n's: Ball point pen and J o Disconnect CPJ2 connector ends o Unlock the secondary locking devise by inserting ball point pen perpendicularly between connector housing's locking latch and secondary locking block. Page 6 of 11

o Carefully push pen inward until opening is felt (click noise) Presentation pg 22/30 o Pin removal -

unlocking red wire with white tracer pin.

Repeat for pin cavity position 7 Presentation pg 24/30 Top two pics o With wires/pins removed from

7 o Carefully push pen inward until opening is felt (click noise) Presentation pg 22/30 o Pin removal - Insert J tool in from the connection side of #4 connector housing cavity until it stops, unlocking red wire with white tracer pin. With tool in place the pin can be removed by pulling carefully on the red/white wire. Repeat for pin cavity position 7 Presentation pg 24/30 Top two pics o With wires/pins removed from connector, cut pins off and fold wire over and heat shrink wire ends. o Insert the new red/white wire/pin from overlay harness (CTT ) into connector cavities #4 and 7 Page 7 of 11

Chassis Power Crossover Connector - CHPC o Tool required: Tool p/n: J043203 or small flat screw driver o Disconnect CHPC connector ends from overlay harness Presentation pg 26/30 o With J043203 tool

o Insert the new yellow/black wire/pin from new overlay harness (CTT000009055) into connector cavity #2 o Dash panel lights - plug dimmer switch out (DSO) and dimmer switch in (DSI) overlay

8 Chassis Power Crossover Connector - CHPC o Tool required: Tool p/n: J or small flat screw driver o Disconnect CHPC connector ends from overlay harness Presentation pg 26/30 o With J tool remove the yellow/black wire (HC20003) from CHPC connector o With wire/pin removed from connector, cut pin off and fold wire over and heat shrink wire end. o Insert the new yellow/black wire/pin from new overlay harness (CTT ) into connector cavity #2 o Dash panel lights - plug dimmer switch out (DSO) and dimmer switch in (DSI) overlay connectors into existing matting connectors in cab o Route and connect Cab Fan Connector (CFAN) red wire with white tracer up to A-piller connector o Disconnect and replace existing connector if overhead cab fan is present. Cut old wire and cover with heat shrink over wire end and tie back New Heater - A/C Control Module CTT Page 8 of 11

o Install new HVCA control module into dash panel Slide control panel mounting

torque-tighten o Connect updated HVAC harness CTT00009100 connections to interior

pic 26 SK8750 pic 25 Relay Mounting Bracket - CTT00003799 SK8750 pic H page 12/13 o

updated HVAC harness (CTT00009100) over to right side of relay mounting bracket o Cut

9 o Install new HVCA control module into dash panel Slide control panel mounting bracket onto stud from inside of electrical center Install nut onto stud and torque-tighten o Connect updated HVAC harness CTT connections to interior connectors; HVAC Control Module, Vehicle Power and Fan Switch SK8750 pic 24 SK8750 pic 26 SK8750 pic 25 Relay Mounting Bracket - CTT SK8750 pic H page 12/13 o Remove existing relay mounting bracket if installed and any attached relays o Route updated HVAC harness (CTT ) over to right side of relay mounting bracket o Cut wire ties holding relays to new HVAC harness (CTT ) o Remove / separate relays from base Page 9 of 11

o Mount relay bases to relay mounting bracket with #10 torx screws Note: Relays must be mounted

in verticle position o Attach relay block decal (CTT00009105) above relays o Reinstall any

relay bracket CTT00003799 Final Installation o Route harness neatly and away from cab electrical

mounting plate o Reconnect batteries cables.

10 o Mount relay bases to relay mounting bracket with #10 torx screws Note: Relays must be mounted straight up and down SK8750 pic 29 SK8750 pic 28 SK8750 pic 30 o Reattach relays to relay base in verticle position o Attach relay block decal (CTT ) above relays o Reinstall any previously attached relays o Install relay mounting bracket with mounting hardware o Secure new relay bracket CTT Final Installation o Route harness neatly and away from cab electrical center SK8750 pic 31 o Reinstall plastic front console, right hand A-pillar cover and terminal mounting plate o Reconnect batteries cables. Apply thin film of dielectric grease to battery terminals o Test blower fan with fan switch at multiple speed settings o Return tractor to service Page 10 of 11

11 Special Tools: * 40 Torx Head Driver * 10mm Nut Driver * 1/4" Nut Driver * 1/2" Socket and 3/8" Ratchet * Drill and 1/8" Drill Bit * Flat and Phillips Screwdriver * AMP Pin Extractor Tool - Kalmar p/n: J * Delphi Pin Extractor Tool - Kalmar p/n: J * Ball point pen Warranty Coverage: The following expenses are covered using standard Kalmar warranty policy. * Travel - up to 3 hours round trip unless approved for additional time prior to repair * Labor hours * Parts kit - SK8750 Claim Submission: * To submit a claim in the C-Care warranty system select; o Location code: 26 - Recalls and Campaigns o Failure code: Campaign o Work code: SB18TI00xx o Hours claimed: 2.0 hours o Description: HVAC Wiring Harness - Field Rewire Modification Serial Numbers of Affected Tractors: * T2 Tractors produced prior to serial number xxxxxx Page 11 of 11

Terminal Tractor Service Bulletin Subject: Forward Facing Flood Lights w/ LED Light Bar Field Rewire Modification Product: Medium Terminal Tractor

Terminal Tractor Service Bulletin Subject: Forward Facing Flood Lights w/ LED Light Bar Field Rewire Modification Product: Medium Terminal Tractor Page 1 of 6 Units Affected: FedEx Ground Kalmar Ottawa T2 terminal tractors built between chassis serial numbers; 346358 and 346471. Possible Situation: The fuse holder is melting due to high current demand