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 200013 TO 200355. 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 A8720018-002 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 200013 to 200355. 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
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: - 1.5 hours per vehicle PARTS: 1 only A8720018-002 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: - 37110-2-02 1.5 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
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 A8720018-002 on the engine harness. Note: JUMPER1 is connected to PTOTSW2. See photo on Page 5. 4. Connect the PTOTSW2 harness oil temperature connector from harness A8720018-002 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 A8720018-002. Then connect RRPT03 from harness A8720018-002 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 A8720018-002. Leave the weather connector on RRPT03 from harness A8720018-002 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
7. If you were able to remove the 559PC wire from pin 6 of ECU connector then install 682A2 wire from harness A8720018-002 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 A8720018-002 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 A8720018-002 is now complete. Note: JUMPER 2 is connected to PFSH2. See photo on Page 5. 9. 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 A8720018-002 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 A8720018-002 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 A8720018-002 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 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. 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. 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. 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
Trucks involved in this Service Program VIN No. VIN No. VIN No. 5VCHC6BEX4H200013 5VCDC6BEX4H200060 5VCDC6BE14H200187 5VCHC6BE14H200014 5VCDC6BE14H200061 5VCDC6BE34H200188 5VCHC6BE34H200015 5VCDC6BE34H200062 5VCDC6BE24H200196 5VCHC6BE54H200016 5VCHC6BE34H200063 5VCDC6BE44H200197 5VCHC6BE74H200017 5VCHC6BE54H200064 5VCDC6BE64H200198 5VCHC6BE94H200018 5VCHC6BE74H200065 5VCHC6BE74H200230 5VCHC6BE04H200019 5VCHC6BE94H200066 5VCHC6BE94H200231 5VCHC6BE94H200021 5VCHC6BE04H200067 5VCHC6BE04H200232 5VCDC6BE24H200022 5VCDC6BE64H200069 5VCEC6BE34H200244 5VCDC6BE44H200023 5VCDC6BE24H200070 5VCDC6BE24H200246 5VCDC6BE64H200024 5VCDC6BE44H200071 5VCDC6BE84H200252 5VCDC6BE84H200025 5VCDC6BE64H200072 5VCDC6BE14H200254 5VCDC6BEX4H200026 5VCDC6BE84H200073 5VCDC6BE74H200257 5VCDC6BE44H200040 5VCHC6BE84H200074 5VCDC6BE94H200258 5VCDC6BE64H200041 5VCDC6BE14H200075 5VCDC6BE94H200261 5VCHC6BE64H200042 5VCHC6BE54H200081 5VCDC6BE04H200262 5VCHC6BE84H200043 5VCHC6BE74H200082 5VCEC6BE44H200270 5VCHC6BEX4H200044 5VCDC6BE24H200084 5VCDC6BE54H200273 5VCDC6BE34H200045 5VCDC6BE44H200085 5VCDC6BEX4H200298 5VCDC6BE54H200046 5VCDC6BE64H200086 5VCEC6BE74H200327 5VCEC6BE14H200047 5VCDC6BE14H200108 5VCEC6BE94H200328 5VCDC6BE94H200048 5VCHC6BE14H200109 5VCEC6BE74H200330 5VCDC6BE04H200049 5VCDC6BE44H200118 5VCHC6BE14H200336 5VCDC6BE74H200050 5VCDC6BE04H200150 5VCHC6BE34H200337 5VCDC6BE94H200051 5VCDC6BE24H200151 5VCHC6BE54H200338 5VCDC6BE04H200052 5VCHC6BE44H200153 5VCDC6BE94H200339 5VCDC6BE24H200053 5VCHC6BE64H200154 5VCDC6BE54H200340 5VCDC6BE44H200054 5VCDC6BE14H200173 5VCDC6BE74H200341 5VCHC6BE44H200055 5VCHC6BE14H200174 5VCDC6BE94H200342 5VCHC6BE64H200056 5VCDC6BE44H200183 5VCDC6BE14H200352 5VCHC6BE84H200057 5VCDC6BE64H200184 5VCDC6BE34H200353 5VCHC6BEX4H200058 5VCDC6BE84H200185 5VCDC6BE54H200354 5VCDC6BE34H200059 5VCDC6BEX4H200186 5VCHC6BE54H200355 Page 9 of 9