T2 Terminal Tractor Service Bulletin

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 harness part number; CTT00009100 incorporates the addition of relays and increased wire gauge

Solution: Service kit; SK8766 includes updated HVAC wiring harness on T2's equipped with heater only.

Pic of CTT00009100 harness Presentation pg 2/30

CAUTION: PROPER LOCKOUT / TAGOUT PROCEDURES AS WELL AS PERSONALSAFTETY PROCEDURES AND DEVICES INCLUDING EYE PROTECTION ARE REQUIRED.THOROUGH REVIEW AND UNDERSTANDING OF T2 OPERATOR AND SERVICE MANAULS

Date: Pages: Subject: HVAC Wiring Harness, T2's equipped with Heater Only

7-August-2018 Page 1 of 11 Product: Medium Terminal Tractor

Bulletin # SB18TI0089

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

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 * Single black wire does not need to be removed SK8750 Pic 7

o Disconnect wire connector from thermostat o Pull entire thermostat assembly out, disconnect wires

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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

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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 rotate up to lock motor in place o Reconnect wire connector to thermostat, slide thermostat in place and fasten with screw 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

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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.

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 J043200 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.

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o Carefully push pen inward until opening is felt (click noise)

Presentation pg 22/30

o Pin removal - Insert J043200 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 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 (CTT000009055) into connector cavities #4 and 7

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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 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 (CTT000009055) 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 Control Module CTT00009074

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 CTT00009100 connections to interior connectors; HVAC Control Module, Vehicle Power and Fan Switch

SK8750 pic 24 SK8750 pic 26 SK8750 pic 25

Relay Mounting Bracket - CTT00003799

SK8750 pic H page 12/13

o Remove existing relay mounting bracket if installed and any attached relays o Route updated HVAC harness (CTT00009100) over to right side of relay mounting bracket o Cut wire ties holding relays to new HVAC harness (CTT00009100) 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 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 (CTT00009105) above relays o Reinstall any previously attached relays o Install relay mounting bracket with mounting hardware o Secure new relay bracket CTT00003799

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

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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: J043200 * Delphi Pin Extractor Tool - Kalmar p/n: J043203 * 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 - 2.0 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: 26.1 - 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

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