Auxiliary Heater Harness – 2015 Aeromaster Ford F-59 Chassis

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Auxiliary Heater Harness
Campaign Directive
ATTENTION: THIS IS NOT A RELEASED DOCUMENT.
2016 Utilimaster® 3/7/2016 Page 1 of 8
Aux_Heater_Wiring_CD-A.docx PSR-100173
Customer: Cintas
Situation: Auxiliary heater may blow fuse on main dash harness
Corrective Action Summary: Replace heater switch and route new power harness with inline fuse from battery
Range of Units Affected: 2015 Aeromaster on the Ford F59 chassis equipped with auxiliary cab heaters manufactured after January 1, 2016. Contact Utilimaster Warranty Department to verify chassis VIN.
Authorized to Perform the Work:
√ Customer or customer contractor
√ Utilimaster or Utilimaster contractor
Auxiliary Heater Harness
Campaign Directive
ATTENTION: THIS IS NOT A RELEASED DOCUMENT.
2016 Utilimaster® 3/7/2016 Page 2 of 8
Aux_Heater_Wiring_CD-A.docx PSR-100173
Parts Required:
KIT 23003824SK-Auxiliary Heater Harness Kit
Part Number
Description
Qty
16303502
WIRE SXL CRS/LNK POLY WHT 16GA
2 ft
16511375-20000
CONN BUTT H/S
2
16511367-20250
TERMINAL FEMALE SPADE
1
16511367-64250
TERMINAL FEMALE SPADE .
3
16511375-64000
CONN BUTT H/S 16-14
2
16511375-28000
CONN BUTT H/S 22-18
2
11300177
SCREW STP PNH TX 1/4-20 x .75 ZN
2
16514677
RELAY 12V 60A
1
16516418-1D1G66
SW BODY CARLING 0N/OFF
1
16516417-G2008
ACTR SW CARLING GRN “AUX HTR”
1
16512443-64312
TERMINL RING H/S INSULATE
2
16516872-00750
BUSHING SNAP .750
1
16303200
RED 10 GA WIRE
19 ft
16510019
3/8” SPLIT LOOM
19 ft
16605701
STRAP WIRE TIE BLK 15.35”
10
16514575-00150
15A FUSE
1
16512651
FUSE HOLDER
1
03104479
DECAL SERVICED JOB CODE
1
03103213-D002EN
AUX HEATER HARNESS BULLETIN
1
Tools Required:
• Standard combination and ratchet wrench sets
• Phillips and standard screw driver sets
• Drill with F-bit (or1/4″), 7/32″, and 3/4″ bits
• Sta-Kon terminal crimping tool or equivalent
• Deburring tool or file
• Heat gun
Auxiliary Heater Harness
Campaign Directive
ATTENTION: THIS IS NOT A RELEASED DOCUMENT.
2016 Utilimaster® 3/7/2016 Page 3 of 8
Aux_Heater_Wiring_CD-A.docx PSR-100173
Wiring Overview
Heater harness wiring overview
Auxiliary Heater Harness
Campaign Directive
ATTENTION: THIS IS NOT A RELEASED DOCUMENT.
2016 Utilimaster® 3/7/2016 Page 4 of 8
Aux_Heater_Wiring_CD-A.docx PSR-100173
Procedure
1. Disconnect the Negative (-) battery cable(s).
2. Use an F-bit to drill a pilot hole in the LH cowl.
3. Use a 3/4″ bit to enlarge hole.
Hole for battery power harness
4. Feed the heater power supply harness through cowl riser, apply sealant to harness bushing and secure.
5. Route power harness along the cowl harness, RH chassis harness and frame rail to the battery box.
Power harness secured to cowl harness to frame rail
Auxiliary Heater Harness
Campaign Directive
ATTENTION: THIS IS NOT A RELEASED DOCUMENT.
2016 Utilimaster® 3/7/2016 Page 5 of 8
Aux_Heater_Wiring_CD-A.docx PSR-100173
Keep all fasteners for installation.
6. Remove (6) screws from the dash hood and set aside.
Dash hood
7. Disconnect the auxiliary heater control switch and discard.
Auxiliary heater switch
Auxiliary Heater Harness
Campaign Directive
ATTENTION: THIS IS NOT A RELEASED DOCUMENT.
2016 Utilimaster® 3/7/2016 Page 6 of 8
Aux_Heater_Wiring_CD-A.docx PSR-100173
8. Drill a 7/32″ hole in the dash bracket.
9. Cut and strip Ground wire and crimp a ring terminal and terminal connector to each end.
10. Secure the WHITE Ground wire ring terminal to the cowl with a 1/4-20 fastener.
Relay Ground wire
11. Cut, strip and crimp a terminal connector to the RED battery harness.
12. Cut the DARK BLUE switch wire. Strip wires and crimp terminal connectors to both ends.
13. Connect RED Battery harness, both DARK BLUE heater power switch and Ground terminals to relay.
Switch wiring
Auxiliary Heater Harness
Campaign Directive
ATTENTION: THIS IS NOT A RELEASED DOCUMENT.
2016 Utilimaster® 3/7/2016 Page 7 of 8
Aux_Heater_Wiring_CD-A.docx PSR-100173
14. Insert replacement switch in dash and connect harness.
Switch (top shown) and dash opening
15. Install inline fuse at battery box.
16. Connect to Positive (+) battery terminal.
17. Connect the Negative (-) battery cable(s).
Inline fuse on heater power harness
Secure wire harnesses a maximum of every 18″.
All wire harnesses need to be free and clear from the range of motion of any moving part and MUST be prevented from falling into the range of motion of a moving part.
18. Test system operation.
19. Secure all harnesses with wire ties to the LH chassis harness, cross member and frame rails.
20. Install dash.
Auxiliary Heater Harness
Campaign Directive
ATTENTION: THIS IS NOT A RELEASED DOCUMENT.
2016 Utilimaster® 3/7/2016 Page 8 of 8
Aux_Heater_Wiring_CD-A.docx PSR-100173
21. Use Job Code 13-N3-91-Z4 from this document to complete the SERVICED decal.
22. Adhere the decal to the upper right-hand corner of the driver’s door pocket panel next to the bulkhead wall. Do NOT cover any previously applied decals.
Service decal on driver’s door pocket (cargo side)
NOTE: In order to be reimbursed for labor, the repair MUST be completed and warranty claim filed within 1 year from the initial date of this publication.
File Warranty By: April 11, 2017
Contact Utilimaster to Order Parts and File Warranty.
Email: [email protected] Phone: 574-848-2000
Mail or Express Service: Fax: 574-848-2809
Utilimaster
Attn: Warranty Dept.
603 Earthway Blvd.
Bristol, IN 46507-9182, USA
Labor Allowance: Up to 0.75 hours Job Op Code: 13-N3-91-Z4
Document Part Number: 03103213-D002EN Revision: A
This material is confidential and the property of Utilimaster. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Utilimaster. Utilimaster® is a registered trademark of Spartan Motors USA, Inc. Utilimaster attempts to provide information that is accurate, complete, and useful. All information contained in this document is based on the latest product information available at the time of publication. However, because of the Utilimaster policy of continual product improvement, Utilimaster reserves the right to amend the information in this document at any time without prior notice.

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