19 August 2009

National Service Teleconference

IC Products – Jim Clark
I know in the past that your technicians may have been instructed to remove the cover
on the electronic throttle control. We have been notified by our supplier that
removing the covers on the throttle voids the warranty. Instead of removing the cover
there are two ways to check the throttle to see if the gear has a broken tooth. If you
have a laptop you can go into the tester screen for the throttle. When you turn the key
on the throttle goes into a spring test. You should be able to see the throttle cycle
from 20% to approx. 75%. If the throttle completes this test the gear should be intact.

The way to check this throttle without a laptop is to remove the mixer from the top of
the throttle so that you can see into the bore of the throttle. When you cycle the key
switch ON and then OFF, the butterfly in the throttle will cycle along the same
percentages that I had mentioned above. If it does not, it probably has a broken tooth.
The codes that you should be seeing with a broken or struck throttle are 461, 471, and
481. If your techs are getting these codes, they should also check to see what software
in loaded in the SECM. If the truck does not have the latest software, V09 or later, you
need to run the update. If not, it will probably fail another throttle in the future.

I cannot stress enough about the wealth of information that is available to you and
your technicians through PartsPRO. In the PDF files, truck service and service manuals,
EPA 2004 and 2007; 2004 is the Tier II and 2007 is Tier III. In these files there are PDF
files that are downloadable and printable. There are troubleshooting manuals and
updates to get the latest software.

Electric Truck Products – Russ Davies

TMX & ECX Fault Code 79 when the Accelerator is depressed:

The problem we are seeing is the enable switch not turning off when the accelerator is
released slowly. You can check this looking at the enable switch in the tester menu.
The enable switch should turn off every time you release the accelerator slowly.
 The correct accelerator for the TMX and ECX is Part Number 2792134 accelerator (silver
box). This is the same accelerator that was used on the TMG & ECG trucks. When you
use 2792134 you will need some hardware (bolt & nut) that will go through the
mounting holes to mount this accelerator to the bracket. Once new accelerator in
installed the accelerator will need to be re-learned using the ZAPI handset and the
program VACC menu.

Contact Russ Davies at 1-859-422-6421 if you require additional assistance.

TMX, ECX, P232, C232, P152, and C152 Intermittent Horn:

We are seeing some warranty claims for failed horns on the above listed truck models.
We have been testing the returned horns and cannot get them to fail. We believe that
some of these horns are being replaced when the technician is being told the truck
has intermittent horn operation. When the truck is tested the tech can find nothing
wrong so the horn is replaced.

We may have found one item that may lead to some of the issues with the intermittent
horn operation. In testing some older trucks, we found that some of the horn buttons
had been installed improperly in the steering wheel and the wire terminal was
contacting the inner area of the hand wheel causing a dead spot in the outer area of
the button.

There is a vertical terminal on the back of the horn button must be in installed in the
area that shown below. If the horn button is NOT installed with the vertical terminal in
this area the vertical terminal will hit the inside steering wheel causing the horn not to
work intermittently, especially when you press on the button in the area above the
vertical terminal. If you are having an intermittent horn, check to insure that the horn
button is installed properly before changing the horn. See new SI Bulletin!

The vertical terminal on the back of the horn button must be in installed in the area
that shown below. If the horn button is NOT installed with this vertical terminal in this
area, the vertical terminal will hit the inside steering wheel causing the horn to work
intermittently, especially when you press on the button in the area above this
terminal. If you are having an intermittent horn operation, check to insure that the
horn button is installed properly.

Training and Administrative – Glen Wood

1. Technician Mechanical Aptitude Test and Answer Sheet is available on PartsPRO

a. What’s New on PDF page
b. Send completed answer sheets to Dave Nicolette or Becky Smith for scoring
c. Results will be returned within 24 hours
2. Service Videos
a. 3-10 minute videos on different service items
b. Available through PartsPRO
c. First is retrieving fault codes from Tier trucks using accelerator pedal
d. Also adding one on lift chains identification and measuring

3. New SI bulletin released on PartsPRO update 298

a. ECX Drive Motor bearing and seal replacement
b. SI on horns and horn buttons will be released Aug 24th with PartsPRO Update
299
c. Please distribute to all listed on bulletin

4. Tier II & Tier III training manuals are available from CCI
a. 36520 Tier III Mitzi
b. 36516C Tier III GM 4.3
c. 91505B Tier II Mitzi
d. 91507B Tier II GM 4.3

5. AFA Return Material Tags

a. Tags will be sent out to all dealers – packs of 50
b. Tags will be available from Danny Clark, Return Material Manager
c. Truck Warranty part returns only, NOT OS&D part returns

6. Next Service Teleconference is tentatively set for October 21st.