MODEL: SUBJECT: C2 BODY DEACTIVATION DOOR BUZZER, AIR DOOR W/ EXTERNAL KEY SWITCH DATE: DECEMBER 10, 2007 INDEX: C2 5 PAGE: 1 OF 6 DO NOT USE THIS PROCEDURE. INDEX C2 5, BULLETIN 5 IS NOW OBSOLETE AND IS REPLACED BY INDEX C2 2, BULLETIN 13. A request has been made for a procedure to deactivate the door buzzer when used with a external key switch. If you elect to rewire your unit, the instructions and parts required are provided below. 1. Installation of Solenoid: 1.1 Remove Door Access Cover, set aside. 1.2 Disconnect all wiring in the door control. Note: Tie and store out of the way. 1.3 Remove door control solenoid and discard. 1.4 Drill out existing solenoid mounting holes 7/16. Install the new parts, two (2) of each of the following required, Solenoids, #TBB 61170307, Bolts, #TBB 69001959 and Nuts, #TBB 69004261. Fig. 1 Product Support Bulletin Figure 1
PAGE: 2 of 6 INDEX: C2 5 1.5 Install fittings for new Solenoid and bolt. 1.6 Mount Solenoid Assemblies with fittings and check valves to door control bracket as shown in Fig. 1. 1.7 Relocate emergency dump valve. Fig. 1 1.8 Connect air lines from cylinder and solenoids. Fig. 1 & 2 1.9 Connect harness to entrance door switch. Connect solenoid and harness. Figure 2 2. Routing Harness: 2.1 Remove the following panels and trim: Panel over the driver's window, trim behind driver's window, metal panel beneath the switch cabinet, the switch panel, and the splash shield located under the switch panel to enable access to the Cab PDM and Switch Hub Module. 2.2 Route the harness and secure. Fig. 3 Figure 3
PAGE: 3 of 6 INDEX: C2 5 2.3 Insert ground circuit over driver's window. Fig. 4 Ground Circuit Figure 4 3. Wire Cab PDM: (Fig. 5) Note: You may need to remove a circuit from the Connector, if so secure and tie out of the way. 3.1 Connect the the circuits to the Cab PDM as shown. TBB 100306 TBB 100036 490XA to J11 (Orange) Position A 490XD to J11 (Orange) Position H 490YD to J11 (Orange) Position E 490YA to J15 (Grey) Position B Figure 5 - Cab PDM
PAGE: 4 of 6 INDEX: C2 5 4. Connect SHM (Fig. 6) 489N to J2 Position C 490Y to J1 Position E 490X to J1 Position A Figure 6 - Switch Hub Module 5. Access Connector P152: (Fig. 7) The Dash Body Interface Connector at the left kick panel. 489M to P152 Position D7 489L to P152 Position D8 Figure 7 - Access Connector P152
PAGE: 5 of 6 INDEX: C2 5 Optional External Door Control: 1. Locate the existing external door key or paddle switch and discard. Replace with appropriate Key Switch, #TBB 127580 or Paddle Switch, #TBB 116839. 2. Reconnect harness. 3. Open hood to access the chassis PDM and ground studs. Fig. 8 4. Remove the GND #1204. This may be located on top or bottom stud. It is a part of the Key Switch Harness. Remove wire from ground stud. May be located on either of these two studs. Figure 8 5. Disconnect the green connector on the PDM if cavity (B) is used go to Step 6, if not, go to Step 7. Fig. 9 6. Install an in-line fuse with 5-Amp Fuse, part #TBB 100032 to the PDM Power Stud. Note: Use the appropriate external sealed connectors for this application. Green Connector Fuse location Power Stud Figure 9
PAGE: 6 of 6 INDEX: C2 5 7. Remove the ring terminal from the GND #1204 ground circuit and replace with Electrical Terminal, part #PAC 12129493, Cable Seal, part #23-12494-000, and insert into Cavity B. Reconnect Connector. 8. Insert 5-Amp Fuse, part #TBB 100032 in the F2 position of the PDM. Downloading Updates: 1. Once in Service Link, choose "Bulkhead Module" category from the ECU list. 2. Choose "Features" tab. 3. If there are any RPNs displayed in the pop-up dialog box, you need to update. 4. At this point, the user will be prompted to download the updates. 5. If no updates, verify which RPN the unit has for the operation of the door. 6. See chart below for crossover for REFERENCE ONLY. 7. Enter the correct RPN to add to the unit. 8. On general information, synchronize with host. PARAMETER # REPLACED WITH DESCRIPTION 26-02045-000 NONE ENTRANCE DOOR CONTROL DISABLED 26-02045-001 26-02045-024 Air Dr, Bat, 2 Pos, w-buz, w-ext Dr Ctrl, w-o Pwr Dn, w-o Mot Int 26-02045-002 26-02045-024 Air or Electric Dr, Bat, 2 Pos, w-buz, w-o Ext Dr Ctrol, w-o Pwr Dn,w/o Mot Int 26-02045-003 26-02045-025 Air Dr, Bat, 3 Pos w-emg Ovr, w-buz, w-ext Dr Ctrl, w-o Pwr Dn, w-o Mot Int 26-02045-004 26-02045-025 Air Dr, Bat, 3 Pos w-emg Ovr, w- Buz, w-o Ext Dr Ctrl, w-o Pwr Dn, w-o Mot Int 26-02045-008 26-02045-025 Air Dr, Bat, 3 Pos w-emg Ovr, w-buz, w-ext Dr Ctrl, w-o Pwr Dn, w-o Mot Int 26-02045-009 26-02045-028 Air Dr, Bat, 3 Pos w-emg Ovr, w- Buz, w-o Ext Dr Ctrl, w-o Pwr Dn, w-o Mot Int MATERIALS REQUIRED: PART NUMBER QTY. DESCRIPTION TBB 124072 2 SOLENOID MUFFLER, 18" NPT MALE TBB 67000698 2 MALE CONNECTOR QUICK CONNECT AIR FITTING, 1/8 NPT, 1/4 TUBE OD TBB 67000706 2 FEMALE CONNECTOR QUICK CONNECT AIR FITTING, 1/8 NPT, 1/4 TUBE OD TBB 61170307 2 SOLENOID AIR VALVE PARKING BRAKE, NORMALLY OPEN TBB 25068375 AR 1/4 OD, NYLON AIR LINE TBB 69008058 1 TEE - FEMALE RUN, PUSH TO FIT TBB 69001959 2 BOLT 3/8-16 X.750, HEX FLANGE, STEEL, NON-SERRATED FLANGE TBB 69004261 2 FLANGE NUT, 3/8-16, SERRATED TBB 100306 2 RELAY, MICRO 280 SPDT 5 PIN TBB 67000769 2 CHECK VALVE, 1/8 NPT TBB 67000697 2 FITTING, CLOSE NIPPLE, 1/8 NPT TBB 100036 1 MINI FUSE, BLADE STYLE, 20 AMP, FAST ACTING PAC12129493 1 TERM - FEM, MP280S, 12-14AWG 23-12497-000 1 SEAL - CABLE, MP280S, MP280ST, WP TBB 100032 1 5-AMP FUSE TBB 125811 1 HARNESS OVERLAY, AG2 AIR-OPERATED ENTRANCE DOOR PLEASE CHECK FOR CURRENT PART NUMBER SUPERSESSIONS BEFORE ORDERING. WARRANTY STATUS: INFORMATION ONLY