Electric Fan Drive Cooling System Conversion With Bosch Alternator – H3 Series US10 Cooling System – 2009-2018 Prevost

SEOCONTENT-START

Writer: <QF7720959 rev 5>
EL
Instruction Sheet IS-19900D
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH BOSCH
ALTERNATOR – H3 SERIES US10 COOLING SYSTEM
REVISION : D THIS DOCUMENT SUPERSEDES PREVIOUS VERSION.
June 27, 2019 Images added step 32
MATERIAL
Kit IS19900 “H3 US10 electric fan drive retrofit with Bosch alternator” contains the following
parts:
Part No. DESCRIPTION Qty
050195 FAN SUPPORT PANEL A1 1
050200 UPPER SHROUD TRANSITION A6 1
050201 LEFT SHROUD TRANSITION A7 1
050202 RIGHT SHROUD TRANSITION A8 1
050203 LOWER SHROUD TRANSITION A9 1
050204 UPPER LEFT SHROUD PANEL H3 US10+ A11 1
050229 ELECTRICAL CONNECTOR COVER A15 1
050206 UPPER RIGHT SHROUD PANEL H3 US10+ A12 1
050213 LOWER SHROUD PANEL H3 US10+ A14 1
050208 LH SIDE SHROUD PANEL H3 US10+ A10 1
050255 RH SIDE SHROUD PANEL & WURTH BOX SUPPORT
H3 US10+
A13 1
IS‐19900D
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012349 IDLER PULLEY
Mechanical
1
012941 PULLEY, DRIVE Mechanical
1
012942 L.H. ENGINE MOUNT Mechanical
1
011213 SUPPORT, IDLER + TENSIONER
Mechanical
1
453076 CAP, DUST Mechanical
1
506026 1x BELT, DRIVE POLY V 10PK1695
1x BELT, DRIVE POLY V 10PK1695 (for your spare kit)
Mechanical
2
510991 TENSIONER, BELT Mechanical
1
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564593 BOSCH HD10PLBH ALTERNATOR 28V-150AMP J180 Mechanical
1
0600265 PULLEY, ALTERNATOR 10PK, 73 DOB Mechanical
1
050286 CAC INLET PIPE H3 US10+ Pipe
1
050406 CAC OUTLET PIPE H3 US10+ Pipe
1
050414 RADIATOR INLET COOLANT PIPE H3 US10+ Pipe
1
050288 RADIATOR OUTLET PIPE H3 US10+ Pipe
1
501027 FITTING, SAE 45º #4FL-Mx1/4NPT-M BR Fitting
1
501308 ADAPTER / PIPE FITTING / 1/4NPT-Fx1/4NPT-M BR Fitting
1
501329 ELBOW 45º / PIPE FITTING / 1/4NPT-Mx1/4NPT-F BR Fitting
1
501332 ELBOW 90º / PIPE FITTING / 1/4NPT-Mx1/4NPT-F BR Fitting
1
052366 HOSE 3/8 ID X 61 in LONG hose 1
20550690 HOSE, FLEXIBLE – CHARGE AIR
Location: turbo outlet & engine intake
Hose 2
531469 HOSE, FLEXIBLE – CHARGE AIR
Location: CAC outlet
Hose 1
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531471 HOSE, FLEXIBLE – CHARGE AIR
Location: CAC inlet
Hose
1
052889 HOSE, SILICONE 2 1/2″ ID
Location : coolant pipes
Hose
1
053617 HOSE, SILICONE
Location : coolant pipes
Hose
3
21490616 CLAMPS, SPRING LOAD – CHARGE AIR
Location: CAC outlet & inlet
Clamps 8
21490630 CLAMP, SPRING LOAD – CHARGE AIR
Location: turbo outlet & engine intake
Clamps 4
992089 HOSE CLAMP CT CAILLAU 60mm-80mm
Location : coolant pipes
Clamps
16
992081 HOSE CLAMP CT CAILLAU 12-22
Location : coolant filter
Clamps
4
21185073 MOUNT, ANTI-VIBRATION Support
/bracket
1
050305 BRACKET, RADIATOR INLET PIPE Support
/bracket
1
050265 COOLANT FILTER SUPPORT H3 Support
/bracket
1
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050266 ALTERNATOR BATTERY CABLE SUPPORT Support
/bracket
1
050303 ALTERNATOR TELLTALE BRACKET Support
/bracket
1
050214 UPPER RADIATOR SUPPORT H3 Support
/bracket
1
060102 ALTERNATOR BRACKET, LOWER Support
/bracket
1
010060 DECAL, BELT ROUTING Misc.
1
069205 DECAL, WARNING Misc.
2
391028 INSERT, ALTERNATOR TELLTALE Misc. 1
506025 RUBBER EXTRUSION, BLACK Misc.
8 ft
060297 STUD ADAPTER, ALTERNATOR M/F-M8 Misc.
1
380360 GROUND STUD
Misc.
1
506040 TAPE, ADHESIVE AD1 EPDM CC GY 5/16″X3/4″X25′ Misc. 1
562113 TELLTALE LIGHT MODULE Misc. 1
21937327 FILTER, COOLANT Misc.
1
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012921 GROUND STUD
Electrical
1
561610 CONNECTOR HOUSING, PED WEATHER-PACK 4
WIRES
Electrical
1
561783 CAVITY PLUG, CONNECTOR Electrical
4
22722850 I/O-B MULTIPLEX MODULE Electrical
1
23499009-EFD MCM, PROGRAMMED Electrical 1
563593 CONNECTOR, WITH END-OF-LINE 120 OHMS
RESISTOR
Electrical
2
563750 FUSE HOLDER, AMG TYPE Electrical
1
564520 FUSE, AMG 300A Electrical
1
564612 CIRCUIT BREAKER BOX Electrical
1
565191 FAN, ELECTRIC Electrical
8
563533 HAND GUARD, FAN Electrical
8
068820 HARNESS, FAN DRIVE Harness
1
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069246 GROUND CABLE, FAN DRIVE Harness
1
069504 GROUND CABLE, LEFT ALTERNATOR Harness
1
069511 CONTROL HARNESS, LEFT ALTERNATOR Harness
1
23445869 MCM TO I/O-B INTERFACE HARNESS Harness 1
23488790 FAN TO RJB INTERFACE HARNESS H3 Harness 1
23490553 VEHICLE INTERFACE HARNESS Harness 1
23498450 MASTER RELAY TO 300A FUSE CABLE, 300mm Harness 1
23498721 FAN DRIVE POWER CABLE, 4600mm Harness 1
23498785 L.H. ALTERNATOR POWER CABLE, 4450mm Harness 1
N37749 TIE, NYLON DOUBLE hardware
15
504016 TIE, NYLON BLACK (LARGE) hardware
58
504013 MOUNT, TIE HOLE 1/4″ hardware
25
504751 MOUNT, TIE SWIVEL hardware
4
504750 MOUNT, TIE TREE hardware
1
509490 MOUNT, TIE DOUBLE GRAY hardware
15
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509491 TIE, NYLON LARGE EXTRA STRONG 250 LBS hardware
38
562679 MOUNT, SQUARE SELF-ADHESIVE BLACK hardware
4
500449 WASHER, FLAT SS .687X1.5X0.078 (M16,5/8) hardware 1
500482 WASHER, SPLIT LOCK Z050 .506X.873X.125
(M12,1/2)
hardware 1
500942 WASHER, SPLIT LOCK N500 8.1X14.8X2
(M8,5/16,#18)
hardware 4
502570 WASHER, SPLIT LOCK SS 6.1X11.8X1.6 (M6,#12) hardware 62
502573 WASHER FL SS 6.4 X 12.0 X 1.6 (M6,1/4) hardware 1
507657 WASHER, BANJO FITTING M14 hardware 8
5001341 WASHER, FLAT SS 8.4X17X1.6 (M8,5/16) hardware 6
5001737 WASHER, SPLIT LOCK N500 10.2X18.1X2.2
(M10,3/8)
hardware 4
5001751 WASHER, FLAT N500 10.5X26X2 (M10,3/8) hardware 10
5001833 WASHER, BELLEVILLE SPR SS 301
6.65X17.4X1.27(M6,1/4
hardware 32
5001868 WASHER, BELLEVILLE SS 8.4X18X2 (M8,5/16) hardware 4
5001935 WASHER, FLAT SS 10.5X18X1.6 (M10,3/8) hardware 1
5002008 WASHER, FLAT HARD N500 13X35X5 (M12,1/2) hardware 1
500998 NUT HEX BR 1/2-13 hardware 1
502837 NUT HEXF STO N500 M8-1.25 hardware 2
502859 NUT HEX NYRT NX500 M10-1.5 G10 hardware 4
5001182 NUT HEX NYRT SS M6-1 hardware 1
5001665 NUT HEX NYRT NX500 M22-2.5 hardware 1
5001728 NUT HEXF STO N500 M12 CL10 hardware 1
5001761 NUT HEXF NYRT NX500 M12-1.75 G8 hardware 2
5001930 NUT HEXF NYRT NX500 M10-1.50 PC 10 hardware 2
5001983 NUT HEX NYRT NSS M8-1.25X9.5 hardware 3
21429955 NUT, FLANGED hardware 1
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500119 SCREW, CAP HEX SS NSS M8X1.25X20 hardware 4
500658 SCREW TC PAN PH Z050 10-24X3/4 hardware 11
502719 SCREW, CAP HEX SS NSS M10X20 G8.8 hardware 1
502686 SCREW, CAP HEX SS NSS M6X30 hardware 33
502804 SCREW, CAP HEX N500 M10-1.5X25 G8.8 hardware 8
502848 SCREW TC HEX F N500 1/4-20X3/ hardware 22
502950 SCREW SHR HEXF N500 12.9X160LG CL10.9 hardware 1
5001296 SCREW, CAP HEXFN500 M12-1.75 X 80 CL10.9 PT hardware 6
5001643 SCREW, CAP HEXF G500 M8-1.25X25 G8.8 PT hardware 3
5001697 SCREW, CAP HEX SS NSS M6X16 hardware 62
5001738 SCREW, CAP HEX N500 M8X30 G8.8 FT hardware 4
5001745 SCREW, CAP HEX N500 M8-1.25X25 G8.8 hardware 2
5001786 SCREW, CAP HEXF AD N500 M12-1.75X30 G8.8 hardware 1
5001799 SCREW, CAP HEXF N500 M10-1.5 X 70 G10.9 hardware 4
5001800 SCREW, CAP HEXF N500 M10X45 G10.9 hardware 1
5001940 SCREW CAP HEX N500 M12X1.75X140 hardware 2
504379 RIVET, POP DOME SS OE 3/16X1/4 hardware
41
504610 RIVET MGL PRDG SS 1/4X5/8 hardware
14
IS-19900 INSTRUCTION SHEET 1
FI-19900 FEUILLE D’INSTRUCTION 1
IS‐19900D
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Other parts or products that may be required:
Part No. DESCRIPTION
680459 LOCTITE 404, INSTANT ADHESIVE 9.3gr
680098 LOCTITE 567 THREAD SEALANT 250ML
680038 LOCTITE 243, BLUE THREADLOCKER 50ML
684013 LOCTITE COLOR GUARD RUBBER COATING
Writer: <QF7720959 rev 5>
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PROCEDURE
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the
ignition switch to the OFF position and trip the main circuit breakers equipped with a trip
button.
DIAGRAM OF ELECTRICAL CONNECTIONS
Writer: <QF7720959 rev 5>
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HOSE CLAMP TORQUE (coolant lines and charge air cooler)
HOSE CLAMPS
No DESCRIPTION TORQUE
1
(Ø 2 ½ ” or
less)
Constant-Torque hose clamps – coolant lines
Oetiker hose clamps – Green spring – coolant lines
Oetiker hose clamps – unpainted spring – coolant lines
Caillau hose clamps – coolant lines
90-100 lbf-in
12-18 lbf-in
8-9 lbf-in
30 lbf-in
2
(Ø 4 ¼ ”)
Constant-Torque hose clamps 4.25in – charge air cooler
(CAC)
4.5-5.5 lbf-ft
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Writer: <QF7720959 rev 5>
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1. In the main power compartment, place the
battery master switch to the OFF position. Trip
all the main breakers that have a manual trip
feature (CB2, CB4, CB6, etc…depending on
the year model).
2. Remove L.H. side rear fender.
FIGURE 1
Drain the cooling system
3. Connect the coolant extractor. Use the coolant
extractor to drain the coolant from the engine.
An alternate method is to drain the coolant into
a suitable container using the drain hose.
FIGURE 2
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4. Unfasten cap screws and remove access
panel located behind tag axle L.H. side wheel.
FIGURE 3
5. Open radiator door to access radiator
assembly. Unfasten upper arm assembly.
FIGURE 4
6. Remove radiator sealing frame.
FIGURE 5
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7. Remove clamps and then break hoses from
the front coolant and charge air pipes.
FIGURE 6
8. Remove rear coolant and charge air hose
clamps then break hoses loose.
FIGURE 7
9. Remove the upper radiator assembly support
bracket.
FIGURE 8
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10. Remove the lower radiator assembly protector
tube.
FIGURE 9
11. Disconnect the radiator vent hose on top of
the radiator.
12. Cut the cable tie and disconnect electrical
connector from the fan clutch. The remaining
connector on the chassis cable will be capped
and left in place.
13. Remove fan drive shaft fasteners at the fan
clutch.
FIGURE 10
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14. Open the secondary lock of connector
#561610. Insert a cavity plug #561783 in each
of the four (4) cavities with the smallest end
protruding as shown on the example at right.
Close the secondary lock.
15. Cap the chassis fan clutch cable with this
connector. Secure the connector on the inner
wall above the radiator using:
 1x tree mount #504750
 1x nylon tie #504016
FIGURE 11
FIGURE 12
FIGURE 13
16. Remove the fan drive casting.
FIGURE 14
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17. Unscrew all lower radiator assembly mounting
fasteners (2 bolts on R.H. side, 2 bolts on L.H.
side).
FIGURE 15
18. Position a forklift under the radiator assembly
that is capable of safely lifting the radiator. With
assistance, slide radiator assembly out and
onto the forklift. Transfer radiator assembly to a
secure location.
FIGURE 16
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19. Remove the tripod from the radiator/CAC
assembly.
FIGURE 17
FIGURE 18
20. Remove the fan shroud.
FIGURE 19
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21. The new cooling pack arrangement requires
being located four inches closer to the engine
to give the needed clearance for the electric
fans. For this reason, rotate both the
radiator/CAC assembly mounting support
180° and reinstall.
BEFORE
FIGURE 20: MOUNTING SUPPORT IN INITIAL POSITION
AFTER
FIGURE 21: MOUNTING SUPPORT AFTER 180° ROTATION
22. Remove the rear bumper (undo three nuts and
one attachment plate each side).
FIGURE 22
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23. On the engine hot side, remove the following
pipes:
 radiator inlet & outlet pipes
 CAC inlet and outlet pipes
Keep the fittings found on the radiator outlet
pipe for reuse
FIGURE 23
FIGURE 24
24. Remove all the drive belts mounted on the
crank pulley.
FIGURE 25
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25. Remove the drive pulley. Discard the 6 bolts.
FIGURE 26
26. Remove the rust, clean and prepare the
surface on the vibration damper as shown.
Work the surface to achieve a smooth finish.
FIGURE 27
FIGURE 28
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27. Properly support the engine as one of the
engine support will be interchanged in the
upcoming steps.
FIGURE 29
28. Remove the two (2) coolant hoses shown on
the image. Keep the two (2) banjo fittings for
later use.
BANJO FITTING
FIGURE 30
29. Remove the L.H. rear engine support (10
bolts). Keep the hardware for reinstallation.
Take note that the water pump belt
idler/tensioner assembly will be reused as
is. Do not take apart tensioner or idler.
FIGURE 31: L.H. REAR ENGINE SUPPORT
IS‐19900D
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30. Remove the water pump idler/tensioner
assembly from the former engine mount. To do
so, unscrew three (3) bolts from the back of the
engine mount.
FIGURE 32
31. Reinstall idler/tensioner assembly as a unit on
the new L.H. engine mount #012942.
Mount the idler/tensioner assembly using
three (3) cap screws #5001643
Tighten to 14‐17 lb‐ft
FIGURE 33
32. Install the new engine mount #012942 using
seven (7) M14 screws saved from the former
engine support with this exception of:
 Ground stud #012921 (1x) and nylon
insert NYRT nut #5001665 (1X)
 Isolator cap screw #5001940 (2X)
 Nut #5001761 (2X)
FIGURE 34
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FIGURE 35: FOUR (4) SCREWS UNDER THE
REINFORCEMENT CHANNEL
FIGURE 36: REAR VIEW – GROUND STUD
FIGURE 37
FIGURE 38
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33. Install the new crank pulley using six new bolts
#5001296. Use blue Loctite on the bolt threads.
Torque to 26 lb-ft in the numerical order 1,
2, 3, 4, 5, 6, 1
Once done perform a final tightening to the
value of 66 lbf-ft.
FIGURE 39
34. Reinstall the water pump drive belt.
FIGURE 40: WATER PUMP DRIVEBELT
35. Reinstall the AC compressor drive belts.
36. Install the idler support #011213 using three (3)
screws #5001799. At the same time, install the
alternator lower bracket #060102.
screws #5001799 prescribed torque:48 lbf-ft
FIGURE 41: BRACKET #060102
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37. Make a smooth round clearance in the engine
cradle to allow required space for the alternator
lower bracket #060102 installed at the previous
step. Carefully work the edge to achieve a
smooth finish and contour.
Measurements: ↔ 2″, ↕¾″
Apply paint to protect the metal against
corrosion
FIGURE 42
38. Install the new idler #012349 with screw
#5001786 and washer #5002008.
Tighten to 59 lb-ft
FIGURE 43
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39. Install the dust cap #453076.
FIGURE 44
FIGURE 45
40. Install the new alternator belt tensioner
#510991. Secure with one screw #5001799 on
which blue Loctite is applied on the threads.
FIGURE 46: TENSIONER MOUNTING SCREW TORQUE : 48
lb-ft
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41. Apply anti-seize compound (Prevost p/n:
680335) inside the alternator mounting ears
and inside the sleeves found on the support
attached to the engine.
FIGURE 47
FIGURE 48
42. Install the alternator.
A: screw #502950 & nut #5001728 (torque: 82
lbf-ft)
B: screw #5001800 & nut #5001930 (torque:
48lbf-ft)
C: apply blue Loctite and then torque to 48 lbf-ft
FIGURE 49
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Simultaneously, install the alternator
“power cable” support #050266 to the
alternator as shown on the picture.
FIGURE 50
43. Install the alternator pulley #0600265 (for
further details, refer to Maintenance
Information IM16-17).
Use washer #500449 and flanged nut #21429955
torque: 75 lbf-ft
FIGURE 51
44. Install the alternator drive belt #506026.
FIGURE 52
45. On the alternator, install the stud adapter
#060297 at B1+ stud terminal.
torque: 11 lbf-ft
FIGURE 53
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46. Perform the “Multiplex Modules Disconnection
Procedure Prior to Welding” found in your
vehicle Maintenance Manual, Section 00:
General.
47. Weld the new coolant filter support #050265 on
the engine cradle.
23 ½ inches from the end of the cradle
FIGURE 54
FIGURE 55
FIGURE 56
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FIGURE 57
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48. As a preparation to welding, use a grinder with
abrasive disc to remove some paint to reach
bare metal. Weld the ground stud #380360
centered in the beam and at 14 inches from the
beam end.
49. Apply black paint to the area surrounding the
ground stud and the ground stud circular base.
DO NOT apply paint on the electrical contact
surfaces.
FIGURE 58
FIGURE 59: GROUND STUD #380360
FIGURE 60: GROUND STUD #380360
50. Install a tie mount #509490 with one screw
#502686 at the back of the L.H. engine mount.
FIGURE 61
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51. Install the alternator ground cable #069504.
Secure to the ground stud on the alternator
using washer #502573 and nut #5001182.
torque: 6 lbf-ft
FIGURE 62
52. Secure the alternator ground cable to the
previously installed tie mount using one nylon
tie #509491.
53. Secure the alternator ground cable #069504 to
the previously installed ground stud on the L.H.
engine mount.
Use screw #502719 & washer #5001935
torque: 20 lbf-ft
Protection against corrosion. Apply Color
Guard rubber coating on the ground stud once
the ground cable is hooked up.
FIGURE 63
54. To the previously installed coolant filter
support, install the filter holder recovered from
the former installation.
FIGURE 64
55. Install a new coolant filter onto the filter holder.
Check the clearance between the filter and the
near hose clamps of the coolant pipe leading to
the transmission oil cooler.
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56. Transfer the drain plug and the coolant
extractor quick connect fitting saved from the
old radiator outlet pipe.
Apply Loctite 567 Thread Sealant prior
installation of the fittings
57. Install the new radiator outlet pipe #050288.
Reinstall with the flexible hose #053617 and
four (4) hose clamps #992089. Use steel wire
to hold the end of the pipe until the radiator is
installed if required.
A: # 992089 hose clamp (4x); torque: 30 lbf-in
B: drain plug
C: coolant extractor quick connect valve
D: # 053617 silicone hose
FIGURE 65
58. Reinstall the elbow between the copper heater
line and the new radiator outlet pipe.
For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 12.
FIGURE 66
59. Using blue flexible hose #052366, prepare two
new short hoses for the coolant filter.
a) Cut two sections of blue flexible hose, one 22
inches long and a second one, 38 inches
long.
A : hose clamp #992081 (4x)
B: banjo fitting copper washer #507657 (6x)
b) Use the banjo fittings recovered from the
previous installation.
hose clamp torque: 30 lbf-in
FIGURE 67
FIGURE 68
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60. Install the 22″ long and 38″ long hoses
prepared at the previous step as shown on the
images.
FIGURE 69
FIGURE 70
61. Connect the DEF injector coolant line return
hose to the radiator outlet pipe.
Use two (2) new banjo fitting copper washer
#507657
FIGURE 71: DEF INJECTOR COOLANT LINE RETURN HOSE
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62. Connect the coolant line that comes from the
surge tank to the radiator outlet pipe.
TORQUES:
Constant-Torque with spring washers clamps :
90-100 lbf-in
Oetiker clamps – green spring : 12-18 lbf-in
Oetiker clamps – unpainted spring : 8-9 lbf-in
Caillau clamps : 30 lbf-in
FIGURE 72
63. Secure the coolant hoses together using nylon
ties.
A : nylon tie (handcuff type) #N37749 (about 3
to 6, as required)
FIGURE 73
FIGURE 74
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64. Secure the coolant hose near the engine block
«push-lok» fitting as shown.
B : nylon tie #504016 (1x)
FIGURE 75
65. Hook up the “L.H. alternator power cable”
#23498785 to the alternator (+) terminal which
is the stud adapter.
A: nut M8 #5001983 torque: 11 lbf-ft
B: flat washer #5001341
C: nylon tie #504016 (2x)
D: tie mount #504013 (2x)
E: rivet #504379 (2x)(hole diameter: Ø 13/64)
FIGURE 76
FIGURE 77
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66. Connect the “fan drive ground cable” #069246
to the ground stud previously welded to the
chassis.
A: split lock washer #500482
B: brass nut #500998
C: fan drive ground cable #069246
FIGURE 78
FIGURE 79
67. Apply Color Guard rubber coating on the
ground stud connection.
FIGURE 80: GROUND STUD WITH RUBBER COATING
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68. Apply Color Guard rubber coating at the
alternator ground ( ) and positive (+)
connections.
FIGURE 81: GROUND CONNECTION ON THE ALTERNATOR
FIGURE 82: POSITIVE (+) CONNECTION ON THE
ALTERNATOR
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69. Install a tie mount #509490 at the location
shown on the picture. Secure the tie mount
with a rivet.
A: tie mount #509490
B: rivet #504610 (hole diameter: Ø 17/64)
C: nylon tie #509491
D: fan drive power cable #23498721
70. Secure the “fan drive power cable” #23498721
onto the tie mount using a nylon tie. Make sure
to leave 26 inches long from the tie mount up
to the end of the “fan drive power cable” red
connector.
FIGURE 83
FIGURE 84
FIGURE 85
FIGURE 86
71. Install six (6) tie mounts to secure the “fan
drive power cable” and the “L.H. alternator
power cable” as shown on the picture.
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FIGURE 87
A: tie mount #509490
B: rivet #504610 (hole diameter: Ø 17/64)
C: nylon tie #509491
FIGURE 88
72. Route the “fan drive power cable” and the
“L.H. alternator power cable” up to the main
power compartment. Refer to the pictures at
right as a guide for the installation.
73. Secure both cables using five (5) tie mounts
#509490 fixed with five (5) rivets #504610
(hole diameter: Ø 17/64). Secure the cables
on the tie mounts as previously done with ten
(10) nylon ties # 509491.
A: tie mount #509490
B: rivet #504610 (hole diameter: Ø 17/64)
C: nylon tie #509491
FIGURE 89
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FIGURE 90
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74. INSTALLATION OF THE “FAN TO RJB
INTERFACE” HARNESS #23488790
a) Route the “fan to RJB interface” harness
#23488790 up to the main power
compartment. Secure this harness to the
fan drive power cable using nylon ties
#504016.
b) This harness will be connected close to the
fan drive power cable, thus it also requires
26 inches of free length.
FIGURE 91
A: FAN TO RJB INTERFACE” HARNESS #23488790
B: FAN DRIVE POWER CABLE
C: NYLON TIES #504016 (23x approx.)
FIGURE 92
FIGURE 93
FIGURE 94
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75. INSTALLATION OF THE ALTERNATOR
CONTROL HARNESS #069511
a) Connect the harness #069511 to the
alternator.
b) Secure the harness with nylon ties as
shown on the pictures.
FIGURE 95: C: NYLON TIES #504016 (2x)
FIGURE 96: C: NYLON TIES #504016 (2x)
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76. Connect the new CAC outlet pipe #050406 to
the engine intake elbow. NOTE: in case of
interference between this pipe and the ping
tank, rotate the ping tank.
A: #20550690 hose (1x)
B: #21490630 spring loaded clamp (2X)
Constant Torque hose clamps 4.25in – charge
air cooler (CAC) 4.5-5.5 lbf-ft
FIGURE 97
FIGURE 98: CONNECTION AT THE ENGINE INTAKE ELBOW
FIGURE 99
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77. If your vehicle is equipped with AFSS
(Automatic Fire Suppression System), the new
CAC outlet pipe #050406 is likely to come into
interference with a AFSS extinguishing agent
hose (see image) near the end of the pipe that
connects with the Charge Air Cooler.
If this is the case, move the hose the other side
of the bracket shown, to prevent rubbing
between the hose and the CAC outlet pipe.
FIGURE 100
78. On the diagonal member, change the existing
radiator inlet pipe bracket for the new bracket
#050305. Use the existing hardware.
FIGURE 101
79. Install the new radiator inlet pipe #050414.
A: #052889 silicone hose
B: # 992089 hose clamp (4x); torque: 30 lbf-in
FIGURE 102
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80. Install the new CAC inlet pipe #050286. Use
one new #20550690 CAC flexible hose.
Secure the hose using two (2) spring loaded
clamps #21490630.
A: #20550690 hose
B: #21490630 spring loaded clamp (2X), torque:
5 lbf-ft
FIGURE 103: CONNECTION AT THE TURBO OUTLET
ELBOW
81. Reinstall the cooling pack.
FIGURE 104
82. Secure the cooling pack base with the following
parts:
A: 4x screw #502804
B: 8x washer #5001751
C: 4x nut #502859
FIGURE 105
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83. In case of interference between the charge air
cooler and the DPF intake pipe, loosen the
pipe’s V-band clamps. Move the pipe in order
to increase the clearance, then hold the pipe in
place and tighten the V-band clamps.
FIGURE 106
FIGURE 107
84. Using parts #501332, #501308, #501329,
#501027, mount the brass fitting assembly
shown on the image at right.
Apply Loctite 567 Thread Sealant on the
threads
A: #501027
B: #501329
C: #501308
D: #501332
FIGURE 108: BRASS FITTING ASSEMBLY
85. Remove the vent hose fitting found on the
radiator.
FIGURE 109
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86. Install the brass fitting assembly in place of
the former vent hose fitting and then connect
the radiator vent hose.
87. Prepare the cooling pack upper attachment
with the three (3) rectangular plates (see
image) recovered from the former installation
and the following parts:
A: anti-vibration mount #21185073
B: upper radiator support #050214
C: 2x screw #5001738 , 2x nut #502837
D: 2x screw #5001738 , 2x washer #500942
E: 2x screw #5001745 , 2x washer #500942
FIGURE 110
One end of the upper attachment is
mounted on the radiator frame (image at
right)
FIGURE 111
Bolt the anti-vibration mount onto the
vehicle chassis
FIGURE 112
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88. Reinstall all the blue flexible hoses at the CAC
and radiator (at the lower connections of the
cooling pack). Install with the following parts:
A: #21490616 clamp (4x)
B: #531471 flexible hose
C: #053617 silicone hose
D: #992089 (4x)
FIGURE 113
89. Reinstall all the blue flexible hoses at the CAC
and radiator (at the upper connections of the
cooling pack). Use the following parts::
A: 1x flex hose #531469
B: 1x silicone hose #053617
C: 4x clamp #21490616
D: 4x clamp #992089
For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 12
FIGURE 114
90. Reinstall the lower cooling pack protector
tube with the following hardware:
4x Screw #502804
4x split lock washer #5001737
FIGURE 115
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91. Install the sealing element #050200. Screw it
on the existing threaded holes on the upper
part of the radiator. Secure with the following
hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 116
FIGURE 117
92. Install the sealing element #050203. Screw it
on the existing threaded holes on the bottom
of the radiator. Secure with the following
hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 118
93. Prepare the sealing elements #050201 and
#050202. On both parts, apply foam tape
#506040 on the edges as shown on the
image.
FIGURE 119
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94. Install the sealing elements #050201 and
#050202. Screw them onto the upper and
lower sealing elements installed at the
previous steps. Secure with the following
hardware:
8x bolt #5001697
8x lock washer #502570
A: #050201
B: #050202
FIGURE 120
95. Cut two pieces of 39 inches (990 mm) long
of rubber extrusion #506025.
96. Using good industrial glue (Loctite 404 or
similar product), glue the two pieces of
rubber extrusion centered on the
reinforcement angles of fan support panel
#050195.
FIGURE 121
FIGURE 122
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97. Install panel #050195. Secure with the
following hardware:
19x bolt #5001697
19x lock washer #502570
FIGURE 123
98. Install the upper left #050204 and upper right
#050206 sealing elements.
Secure with the following hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 124
99. Install the lower sealing element #050213.
Secure with the following hardware:
5x bolt #5001697
5x lock washer #502570
FIGURE 125
100. Install the L.H. side sealing element
#050208.
Secure with the following hardware:
4 bolts #5001697
4 lock washers #502570
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FIGURE 126
101. Install the R.H. side sealing element
#050255.
Secure with the following hardware:
4x bolt #5001697
4x lock washer #502570
FIGURE 127
102. Install the fans and fan hand guards on the
panel in the same arrangement shown on
the image. Be sure to place the fan so that
the cable is at the proper location, 3
O’clock, 6 O’clock or 12 O’clock. Refer to the
image at right.
FAN HAND GUARD
Install with the following hardware:
32x bolts #502686
32x lock washers #5001833
Prescribed torque:30 lbf-in
FIGURE 128
103. Take note that each harness is labeled with
a number corresponding to an appropriate
fan location.
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104. Snap the fan blue connector in the holes
punched on the panel for that matter.
FIGURE 129
105. Route and secure the fan cables as shown
on the images.
Secure with the following parts:
A= nylon tie mount #504013 + rivet
#504379 + nylon tie #504016
B= nylon tie #504016
Do not tighten the nylon ties at this moment
FIGURE 130
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FIGURE 131
106. Install the circuit breaker box #564512.
Install with the following hardware:
4x bolt #500119
4x lock washer #5001868
FIGURE 132
A: 2x bolt #500119 + 2x lock washer
#5001868
FIGURE 133
A: 2x bolt #500119 + 2x lock washer
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#5001868
107. Connect each fan to the corresponding
connection port on the circuit breaker box.
FIGURE 134
108. Tighten the nylon ties previously installed
while routing the fan cables.
109. Use two (2) additional nylon ties #504016 to
secure the extra-length of cables together
close to the circuit breaker box as shown on
the image at right.
FIGURE 135
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110. Install the electrical connector cover #
050229.
Fasten with the following hardware:
4x bolt #5001697
4x lock washer #502570
111. Using good industrial glue (Loctite 404 or
similar product), glue three (3) pieces of
rubber extrusion #506025 as shown on the
connector cover.
FIGURE 136
FIGURE 137
112. Complete the installation of the sealing
elements. Screw the panels to the chassis
threaded holes where shown on the image.
Use the following hardware:
22x bolt #502848
FIGURE 138
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113. Complete the connection to the fan circuit
breaker box (three connectors: gray, black
and red).
A: fan drive ground cable (black connector)
B: fan drive power cable (red connector)
C: “fan to RJB interface” harness (gray
connector)
FIGURE 139
114. Secure the fan drive ground cable and the
fan drive power cable connected to the fan
drive circuit breakers box as shown on the
pictures.
A: rivet #504379 (6x) (hole diameter: Ø 13/64)
B: tie mount #504013 (6x)
C: nylon tie #504016 (6x)
D: handcuff nylon tie #N37749 (1x)
FIGURE 140
FIGURE 141
115. Connect the alternator control harness
connector C-ALT3 to connector C-ALT3 of
the “fan to RJB interface” harness. Secure
the extra length of harness as shown with
nylon ties.
A: handcuff nylon tie #N37749 (3x)
B:nylon tie #504016 (4x)
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FIGURE 142
FIGURE 143
INSTALLATION OF ELECTRIC COMPONENTS AND HARNESS
CONNECTIONS IN THE MAIN POWER COMPARTMENT
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DIAGRAM OF ELECTRICAL CONNECTIONS
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116. In the battery compartment, disconnect the
battery ground cable from the chassis
ground stud.
FIGURE 144
117. Most of the electric components will be
installed on the bulkhead at the right of
master relay R1 (when facing it). Locate the
master relay R1 (refer to the image at right).
FIGURE 145
118. If the situation applies to the vehicle on
which you are working on, remove the two
(2) useless studs found on the bulkhead and
then smooth the surface.
FIGURE 146
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FIGURE 147
119. Make sure this is no voltage applied to the
master relay R1 posts and then, remove the
master relay R1 cover.
FIGURE 148
120. Disconnect the four (4) cable lugs connected
to the master relay R1 upper post.
121. Momentarily, connect the angled lug of the
“master relay R1 to 300A fuse” cable
#23498450.
FIGURE 149
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122. Find the best location where to install the
fuse holder #563750 on the bulkhead. Take
note that the fuse holder must be installed at
a distance that allows cable #23498450 to
reach it.
123. Drill two 11/64 pilot holes for the installation
of the fuse holder on the main power
compartment bulkhead. Secure with the
following hardware:
A: tapping screw #500658 (2x) + flat
washer #5001341 (2x)
FIGURE 150
124. Reinstall the four (4) other cable lugs to the
master relay R1 upper post.
Being the largest lug at R1, the cable #23498450
lug should be placed first on the post (behind
all the other lugs) (or second if rubbing is likely
to happen).
Master relay R1- Port 30 – M10-1.5 stud nut
torque: 160-195 lb-in (18-22 Nm)
FIGURE 151: ON THIS PICTURE, CABLE #23498450 LUG IS
IN SECOND (2ND) POSITION BECAUSE IT WAS LIKELY TO
RUB ON THE HEAD OF ONE OF THE FOUR SCREWS.
125. Reinstall the master relay R1 cover.
FIGURE 152
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126. Place the 300A fuse #564520 in the fuse
holder underneath the cable lugs.
127. Connect to the free post of the fuse holder
the two (2) following cables that are routed
from the alternator and the fan drive circuit
breakers box:
 Fan drive power cable #23498721
 L.H. alternator power cable #23498785
A: nut #5001983 (2x)
B: washer #5001341 (2x)
Thread the nuts and tighten to a torque of 96
lbf-in (11Nm).
FIGURE 153: TAKE NOTE THAT THE 300A FUSE IS NOT
SEEN ON THE PICTURE ABOVE BUT IT SHOULD BE
INSTALLED AT THIS STEP
128. Secure the “fan drive power” cable and the
“L.H. alternator power” cable as shown on
the pictures at right using the following parts:
A: tie mount #509490 (2x)
B: rivet #504610 (2x) (hole diameter: Ø 17/64)
C:nylon tie #509491 (3x)
FIGURE 154
FIGURE 155
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129. Install the MCM #23499009-EFD and the
I/O-B module #22722850 on the bulkhead.
 Spacing between the I/O-B and the MCM=1
inch
 Pilot holes diameter: 11/64”
Install with the following hardware:
Tapping screws #500658,
3x for the MCM
4x for the I/O-B module
FIGURE 156: MAIN POWER COMPARTMENT
130. Depending on the coach configuration, an
existing mounting plate may extend where
the MCM should be installed and cause
interference. If this mounting plate useless,
cut it off along the red line shown on the
image.
IMPORTANT: Do not leave a sharp edge.
Smooth down the edge.
FIGURE 157
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131. In the main power compartment, connect the
“fan to RJB interface harness” to the “MCM
to I/O-B interface harness” #23445869 by
means of connector C-EFD1.
132. Connect the MCM and the I/O-B module
together using the “MCM to I/O-B interface
harness” #23445869.
133. Connect the OEL resistors connector RES1F
and RES2F (part #563593) to the “MCM to
I/O-B interface harness”. See the image at
right and the following pictures for reference.
FIGURE 158
FIGURE 159
A:nylon tie #504016 (3x)
FIGURE 160
A:nylon tie #504016 (2x)
FIGURE 161
A:nylon tie #504016 (3x)
B:nylon tie #509491 (2x)
C:swivel mount #504751 (1x)
FIGURE 162
B:nylon tie #509491 (2x)
C:swivel mount #504751 (1x)
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134. In the main power compartment, connect the
“vehicle interface harness” #23490553 to
the “MCM to I/O-B interface harness” by
means of connector C-EFD2.
FIGURE 163
135. Connect circuit 24VI, 24VD & GND2 to post
1, 2 & 5 respectively of the junction block.
FIGURE 164
136. Get the J1939 signal. To do so, locate
connector C193 among the existing
harnesses of the main power compartment.
137. Disconnect connector C193 and connect
with C193FS and C193FP of the “vehicle
interface harness” #23490553.
FIGURE 165
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138. In the main power compartment, locate I/O-B
module A52 (alternately named AE52).
139. At A52 (or AE52), remove existing circuit 291
and 292 from connector J1:1 (pin 1) and J1:2
(pin 2).
140. For each circuit, cut the terminal and put a
heat shrinking sleeve at the end of the wire.
Those circuits won’t be used anymore.
141. Insert circuit 291 and 292 of the “vehicle
interface harness” #23490553 into
connector J1 pin 1 and J1 pin 2 respectively.
FIGURE 166
142. On the bulkhead, install the alternator
telltale bracket #050303. Fasten to the
bulkhead using two (2) rivets #504379 (hole
diameter: Ø 13/64).
143. Place the alternator telltale insert #391028
in the telltale light module #562113.
144. Connect the appropriate branch of the “fan to
RJB interface harness” to the telltale light
module.
FIGURE 167
FIGURE 168
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FIGURE 169
145. There are remaining nylon ties and tie
mounts in the kit. Use them to secure the
harnesses and cables that may seem loose.
The goal is to prevent rubbing of the cables
and harnesses.
FIGURE 170
146. Place one (1) warning decal #069205 as
shown on the image.
FIGURE 171
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147. Install a second warning decal #069205 as
shown on the radiator door.
FIGURE 172
148. Fasten the radiator door upper arm
assembly.
FIGURE 173
149. Refill the cooling system. Connect coolant
extractor. Use coolant extractor to refill the
coolant from the engine.
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FIGURE 174
150. Reinstall the bumper.
FIGURE 175
151. Reinstall the access panel located behind
tag axle L.H. side wheel.
FIGURE 176
152. Reinstall the L.H. side rear fender.
FIGURE 177
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153. In the battery compartment, connect the
battery ground cable to the chassis ground
stud.
FIGURE 178
154. In the main power compartment, set the battery master switch to the ON position.
155. Set the ignition switch to the ON position.
156. In the main power compartment, reset the circuit breakers and wait two (2) minutes for the new
installer I/O-B module to be programed.
SYSTEM TEST
157. Start the engine to idle.
158. With the engine in idle (600 rpm), use the
Diagnostics menu of the Driver Information Display
to engage the fans in speed 1.
Diagnostics > Vehicle Tests > Activate Radiator FAN Speed 1
The height (8) fans should run at 50% of the maximum
speed. You need to evaluate the sound level and the
power of the air stream to determine the speed.
159. Engage the fans in speed 2.
Diagnostics > Vehicle Tests > Activate Radiator FAN Speed 2
The eight (8) fans should run at 75% of the maximum
speed.
160. Set the engine to the fast idle, the fans should then
engage at 100% of the maximum speed.
161. If the fans behave in accordance with the criterions
of the previous steps, then they operate normally.
FIGURE 179
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/
Federal)