Service Bulletin No.2793

Size: px

Start display at page:

Download "Service Bulletin No.2793"

Lucas Johns
5 years ago
Views:

1 Service Bulletin No.2793 MODEL TYPE SECTION/GROUP DATE 102 E / ELS Series Coaches Product Improvement 7--Electrical July 11, 2001 SUBJECT CONDITIONS HORTON FAN CLUTCH Parts may be purchased from MCI Service Parts, Louisville, Kentucky or from MCI Service Parts, Newcastle, Ontario. Description: Effective with unit number on 102 E model coaches and unit number on 102 ELS modelcoaches, MCI has made design changes to the engine fan clutch installation which will extend the service life of the clutch. 102 E SERIES PARTS LIST Qty. Old P/N Description Solenoid, fan controls, Humphrey Qty. New P/N Description Valve assembly, fan controls, S60 only Valve assembly, fan controls, S60 / CAT / CUMMINS Filter, fan controls Harness, fan controls Seal, rear junction box Nut, hex, lock, flanged, 1/ Capscrew, 1/ x Fitting, 45 degree elbow, 1/4 NPT to JIC Fitting, nipple, 1/4 NPT hex, steel Grommet, 3/8 inch I.D., 1/16 groove, rubber 10 inch Tube, airline, 3/8 inch O.D., black a/r Thread sealant Junction box, rear ( OPTIONAL ) The customer can purchase the optional, new rear junction box instead of reworking the existing junction box. Service Information: 1. Old and new parts are not interchangeable. 2. Old and new parts will be available for service replacement. 102 ELS SERIES PARTS LIST Qty. New P/N Description Fitting, cap nut, JIC # 6 Service Information: 1. Old and new parts are not interchangeable. 2. Old and new parts will be available for service replacement. Service Procedure: General notes Read this entire procedure before beginning work. Use Safe Shop Practices At All Times.

DATE PAGE 2 102 E SERIES RETROFIT PROCEDURE 1. Turn the main battery disconnect switch to the OFF position. 2. Exhaustthecoachairbypullingthedraincock onthesuspensiontank locatedinthefrontwheelhousing.

2 DATE PAGE E SERIES RETROFIT PROCEDURE 1. Turn the main battery disconnect switch to the OFF position. 2. Exhaustthecoachairbypullingthedraincock onthesuspensiontank locatedinthefrontwheelhousing. 3. Open the side service door and push the engine door release lever. 4. Open the engine door and locate the rear junction box--- remote control. Position the ENGINE RUN and REMOTE START switches to the OFF position. 5. Remove the four screws from the cover plate. Pull the cover plate down to access the valve assembly ( Figure 1 ). 6. Locate the valve assembly 4 pin Deutch harness ( Figure 1 ). Disconnect the harness. 7. Disconnect the main harness from the junction box, by turning the metal collar counter-clockwise ( Figure 1 ). 8. Disconnect the two stainless steel air lines from the female cross ( Figure 1 ). Crack the fittings loose, to allow any trapped air to bleed off. 9. Locate the three bolts that mount the junction box to the bracket ( Figure 1 ). Remove the three mounting bolts. 10. Remove the junction box from the engine compartment, and place on a workbench. 11. Remove the existing valve assembly, the female cross, the 1/8 NPT to JIC 4 elbow, and the airlines from the junction box ( Figure 1 ). 12. Remove and retain the two mounting bolts and nuts from the pressure protection valve ( Figure 1 ). Remove the pressure protection valve. female cross pressure protection valve disconnect 4 pin deutch harness disconnect main harness Figure 1. Existing valve assembly.

DATE PAGE 3 If the customer has purchased the optional, new rear junction box, then the steps in this procedure referring to drilling holes in the junction box can be omitted. 13.

3 DATE PAGE 3 If the customer has purchased the optional, new rear junction box, then the steps in this procedure referring to drilling holes in the junction box can be omitted. 13. Using a 1 1/4 inch hole saw, drill two holes at the dimensions outlined in Figure Using a knife, cut the airline tube ( part number ) in half. Using a 5/8 inch drill bit, drill a hole for the airline tubes, in line with the two fittings, through each side of the junction box ( Figures 2 and 8 ). Install the grommets ( part number ) into the holes. 15. Install the two seals ( part number ), over the 1 1/4 inch holes, on the inside of the box ( Figure 2 ). 16. Install the pressure protection valve to the valve assembly. Install the valve assembly, with the pressure protection valve connected, tothe junction box using the twomountingbolts andnuts removedin Step12 ( Figure 2 ). 17. Using a 9/32 inch drillbit, match drillfour holes, used tomountthe valveassembly, throughthe junctionbox ( Figure 2 ). 18. Install the valve assembly to the junction box, using the two outside holes only, using two capscrews ( part number ) and two nuts ( part number ) ( Figure 2 ). 19. Install the 1/4 NPT to JIC 6 elbow ( part number ) and the existing 1/8 NPT tojic 4 elbow intothe valve assembly ( part number ) ( Figure 8 ). female cross filter pressure protection valve airline tube outside hole (Step 18) inside hole seal ( 2 ) airline tube Figure 2. Fan controls valve assembly.

DATE PAGE 4 7.64 9.01 4.03 5.40 TOP 1.25 DIA 2.20 4.31 4.42 6.53 7.22 7.48 Figure 3. 20.

Align the bottom hole on the junction box to the hole on the bracket ( Figure 4 ).

4 DATE PAGE TOP 1.25 DIA Figure Using a pencil grinder, ream out a section of the bracket allowing clearance for the hex nut ( Figures 4 and 5 ). 21. Align the bottom hole on the junction box to the hole on the bracket ( Figure 4 ). Install the junction box to the bracket using one of the existing mounting screws removed in Step 9. Ensure that the junction box is square to the bracket. junction box mounting bracket Figure 4.

DATE PAGE 5 22. Using a 9/32 inch drill bit, match drill the two inside valve assembly mounting holes in the bracket, from the junction box.

). Figure 5. Rear view of junction box mounted to bracket. 23. Apply thread sealant to the threads on the nipple ( part number 19---10---489 ).

5 DATE PAGE Using a 9/32 inch drill bit, match drill the two inside valve assembly mounting holes in the bracket, from the junction box. Install the junction box to the bracket, using the two inside holes, using two capscrews ( part number ) and two nuts ( part number ) ( Figure 5 ). Figure 5. Rear view of junction box mounted to bracket. 23. Apply thread sealant to the threads on the nipple ( part number ). Installthe nipple to the outlet fitting on the fan control filter ( part number ). Install the fan control filter, with the nipple connected, to the pressure protection valve ( Figure 6 ). 24. Using two wrenches, install the female cross to the IN port of the fan control filter ( Figures 6 and 7 ). IN port of fan control filter Figure 6.

6 DATE PAGE Connect the fan control harness ( part number ) to the fan control valve assembly. 26. Connect the fan control harness to the main 4 pin deutsch harness. 27. Connect the main harness to the junction box, by turning the harness head clockwise. 28. Re---connect the two stainless steel airlines to the female cross, removed in Step Re---install the four screws to the cover plate. 30. Position the ENGINE RUN and REMOTE START switches to the ON position. 31. Close the engine door. To ensure proper installation, perform a fan test following the steps outlined below. 1. Using a piece of cardboard, block the radiator and half of the charge air cooler. 2. Start up the coach, and raise to 2100 r.p.m. Watch and monitor the coolant temperature gauge on the instrument panel. Temperatures will vary, depending upon engine manufacturer. 3. At approximately 196 degrees ( on the coolant temperature gauge ), the fan should go from OFF to LOW speed. 4. At approximately 205 degrees, the fan should go from LOW speed to HIGH speed. Remove the cardboard. 5. At approximately 190 degrees, the fan should return to LOW speed. 6. At approximately 176 degrees, the fan should turn OFF. Procedure complete.

7 DATE PAGE 7 female cross Figure 7. Side view existing elbow Figure 8. Rear view.

DATE PAGE 8 102 ELS SERIES RETROFIT PROCEDURE 1. Turn the main battery disconnect switch to the OFF position. 2. Open the side service door and push the engine door release lever. 3.

8 DATE PAGE ELS SERIES RETROFIT PROCEDURE 1. Turn the main battery disconnect switch to the OFF position. 2. Open the side service door and push the engine door release lever. 3. Open the engine door and locate the rear junction box--- remote control. Position the ENGINE RUN and REMOTE START switches to the OFF position. 4. Locate the #6 fan brake hose ( larger hose ), on the back of the junction box. 5. Disconnect the #6 fan brake hose from the #6 JIC fitting on the back of the remote control. 6. Install the cap ( part number ) on the #6 JIC fitting. hose assemblies Figure Disconnect the end of the #6 fan brake hose from the fitting ( Figure 10 ). 8. Remove applicable p---clips, and discard the #6 fan brake hose. 9. Install the cap ( part number ) on the fitting ( Figure 10 ). 10. Position the ENGINE RUN and REMOTE START switches to the ON position. 11. Close the engine door. Replacing the #6 fan brake hose with a cap changes the operation of the fan. The fan will always be turning at LOW or HIGH speed, there will be no OFF condition.

9 DATE PAGE 9 female cross Figure 10. Procedure complete.

Service Bulletin No. 2994

Service Bulletin No. 2994 MODEL TYPE SECTION/GROUP DATE E / J Series Coaches equipped with Linnig Fan Clutch Service Information 6--Cooling July 30, 2008 SUBJECT CONDITIONS LINNIG FAN CLUTCH MOUNTING NUTS Parts may be purchased