Service Bulletin No. 359C

Transcription

1 MODEL TYPE SECTION/GROUP DATE D / E / J Series Coaches Field Change Program 7-- Electrical Feb. 21, 2012 SUBJECT LINNIG CLUTCH COIL LOW RESISTANCE CONDITIONS THIS BULLETIN SUPERCEDES FIELD SERVICE BULLETINS 359 AND 359B IN THEIR ENTIRETY. FIELD SERVICE BULLETIN 359 WAS REVISED TO REVISION B TO OUTLINE THE LABOR ALLOWANCES FOR TESTING THE RESISTANCE LEVEL IN ADDITION TO REPLACEMENT OF THE CLUTCH COIL. FIELD SERVICE BULLETIN 359B WAS REVISED TO REVISION C TO INFORM CUSTOMERS THAT THE EXISTING CLUTCH COIL MUST BE RETURNED TO MCI TO RECEIVE THE LABOR CREDIT ALLOWANCE. Customer Complaint: Driver s air conditioning display indicates a trouble code A22. Cause: Resistance level in the clutch coils is below 9 ohms. This low resistance is due to production issues during the manufacturing process of the clutch coil at our Vendors facility. Corrective Action: MCI strongly encourages owners of the D, E4500 and J4500 model coaches listed in the table below to determine the resistance level of the compressor clutch coil by implementing the steps in this procedure as soon as possible to to to to to to to Qty. New P/N Description a/r Coil Service Procedure: Read this entire procedure before beginning work. UseSafeShopPracticesAtAllTimes. To avoid personal injury, never enter or perform work in the engine compartment prior to positioning the ENGINE RUN and ENGINE START switches on the engine compartment remote control box to the OFF position. Allow enough time for components to cool down prior to working in the engine compartment. 1. For E / J model coaches, activate the disconnect feature of the main battery disconnect ( MDS ) system by pressing ( for one second only ) the momentary toggle switch on the MDS module to OFF. An audible click can be heard from the main solenoids in the MDS module. Position the rotary switch to the DOWN ( OFF ) position. For D model coaches, turn the main battery disconnect switch to the OFF position. 2. Chock both sides of the tires.

2 DATE FEB. 21, 2012 PAGE 2 3. Open the curbside, rear service compartment door. Locate the compressor ( Figure 1 ). 4. Disconnect the harness shown in Figure 1. Figure Insert the Ohmmeter red probe in position A of the harness plug. Insert the Ohmmeter black probe in position C of the harness plug ( Figure 2 ). Figure 2.

3 NOTICE DATE FEB. 21, 2012 PAGE 3 If the Ohmmeter displays a resistance across the two wire leads lower than 9.0 ohms, proceed to Step 6. to install a new clutch coil. If the Ohmmeter displays a resistance across the two wire leads of 9.0 ohms or higher, re-connect the harness. No further action required. Procedure complete. Figure 3.

4 DATE FEB. 21, 2012 PAGE 4 CAUTION DO NOT use impact tools when working on the compressor. Use caution when compressing the shock to avoid personal injury. 6. Using a ratchet strap, carefully compress the shock to achieve enough slack for belt removal from the compressor clutch pulley ( refer to Figure 5 ). Figure 4. Reference photo of belt tension shock assembly. Figure 5. Reference photo of ratchet strap compressing the shock. 7. Remove the belt from the compressor clutch pulley. 8. Follow the steps and instructions in the attached LINNIG Assembly Instruction for Electromatic Clutch shown in Figure 6, including observing all warnings and cautions contained therein. NOTICE Ensure to retain the existing clutch coil to receive the labor allowance credited to your MCI Fleet Support Parts Account. 9. Remove and retain the existing clutch coil to be returned to MCI. 10. Install a new clutch coil, p/n

5 DATE FEB. 21, 2012 PAGE 5 DISASSEMBLY INSTRUCTION For disassembly grease circlip ( do NOT remove circlip ) and turn the holding--down bolt left to loosen. Hold down the rotor with an open-- ended spanner or ring spanner WAF41. In this way the clutch will be disconnected from the cone-- shaft. WITH ANY OTHER METHOD OF DISASSEMBLY ( PRESS OR HAMMER ) YOU RISK A DAMAGE OF THE CLUTCH. CLUTCH DAMAGES IN THIS MODE ARE OUTSIDE ANY WARRANTY. ASSEMBLY INSTRUCTION 1. Attach coil according to instruction manual of the compressor manufacturer. Connect cable in a way that avoids contact with hot components. 2. Remove circlip and holding--down bolt from clutch assembly. Slide clutch-- assembly onto compressor shaft. Look through the center-- hole for a correct position of the compressor shaft key in the rotor--keyway. Rotor should turn freely without touching the coil. Consider the control mark. Insert and tighten holding-- down bolt M12. Torque to 63 ft--lbs. Holding down the rotor with an open-- ended spanner or ring spanner WAF41. Insert circlip. 3. Slide pulley over the stud screws and bolt on with nuts Figure 6. ITEM DESCRIPTION 1 Compressor 6 Bolt ( holding-- down ) 2 Coil 7 Circlip 3 Capscrews 8 Pulley 4 Clutch Assembly 9 Nuts 5 Stud Screw

6 DATE FEB. 21, 2012 PAGE Upon completion of all steps and instructions in the LINNIG Assembly Instruction for Electromatic Clutch shown in Figure 6, orient the belt on the compressor clutch pulley. 12. Carefully release the tension from the ratchet strap compressing the shock. 13. Position the ENGINE RUN and ENGINE START switches on the engine compartment remote control box to the ON position. 14. Start up the engine and visually check for proper installation. 15. Shut down the engine and close the engine compartment door(s). Mail or fax the completed limited warranty claim form and verification form to MCI s warranty department, or photocopy and mail to: MCI Fleet Support Attn: Warranty Department 7001 Universal Coach Drive Louisville, KY Fax Number to receive credit for the hours used to complete this task for any further information. Contact the MCI Fleet Support Technical Center at Field Change Program Conditions: The parts required for this change will be supplied without charge. A labor allowance of 0.1 hour will be granted against claim SB359C.1, for testing the resistance level in the clutch coil. A labor allowance of 1.50 hour will be granted against claim SB359C.2, for testing the resistance level in the clutch coil as well as removal and installation of a new clutch coil. NO PAYMENT WILL BE ISSUED BY MOTOR COACH INDUSTRIES UNTIL THE COMPLETED LIMITED WARRANTY CLAIM FORM, VERIFICATION FORM AND THE EXISTING CLUTCH COIL HAVE BEEN RECEIVED BY MCI. ONLY ONE ( 1 ) CLAIM CAN BE FILED ( EITHER SB 359, SB 359B OR SB 359C ). This labor allowance will be credited to your MCI Fleet Support Parts Account on receipt of the attached MCI Field Change Program Verification Form and a Warranty Claim Form as detailed in your Owner Warranty manual to MCI s Warranty department. A MCI Field Change Program Verification Form needs to be submitted for each VIN affected. Photocopy the attached MCI Field Change Program Verification Form as required for the number of affected coaches in your fleet. This program will end on June 15, Motor Coach apologizes for any inconvenience resulting from this campaign, but urges you to implement this change as soon as possible. Sincerely, Motor Coach Industries

7 MCI FIELD CHANGE PROGRAM (FCP) VERIFICATION CUSTOMER NAME: CONTACT INFORMATION (PLEASE PRINT FCP INFORMATION ONE FORM PER UNIT FCP#: Coach Model Model Year COACH SERIAL #: (At least the last 5 digits) MILEAGE: DATE COMPLETED / / IMPORTANT: TO RECEIVE CREDIT FOR ANY ALLOWABLE LABOR CHARGES, THIS VERIFICATION FORM MUST BE RETURNED TO MCI UPON COMPLETION OF THE FCP. SUBMITTED BY: (Please Print) DATE / / TITLE: (Please Print) SIGNATURE: COMMENTS: FAX T O: MAIL ING ADDRESS: MOTOR CO ACH INDUSTRI ES A TTN: WARRANT Y DE PT UNI VE RS AL COACH DRIVE LOUISVILLE, KY MCI part # C