SMB-177 – HVAC Coolant Hose Inspection – New Flyer Xcelsior

SEOCONTENT-START

SMB-177 1 of 5
SERVICE MANUAL BULLETIN
This Service Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. Refer to details below.
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2017 New Flyer Industries Canada ULC
ISSUE DATE: Dec 06 2017
SMB-177
APPLICABILITY
VEHICLE LENGTH  30ft.  35ft.  40ft.  60ft.  ALL
VEHICLE TYPE
 Xcelsior®  MiDi®  Invero®
 ALL
 Low Floor  High Floor
FUEL TYPE
 Diesel  Diesel/Electric  CNG  LNG
 ALL
 Fuel Cell  Trolley/Electric  Battery/Electric
SUBJECT HVAC Coolant Hose Inspection
SECTION TITLE PM – PREVENTIVE MAINTENANCE
DETAILS This bulletin provides new inspection and replacement requirements for
the coolant hoses located above the SDS enclosure installed on your
New Flyer vehicle.
This bulletin applies to all Xcelsior® models fitted with a front rooftop
HVAC unit manufactured by Thermo King or MCC.
Make this Service Bulletin available to service personnel to inform them
of changed information.
2 of 5 SMB-177
SERVICE MANUAL BULLETIN
SMB-177
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2017 New Flyer Industries Canada ULC
1. Quarterly Preventive
Maintenance
1.1. HVAC Coolant Hose Inspection
Inspect the overhead HVAC coolant hoses
on a quarterly basis as follows:
1. Open the SDS enclosure and locate the
two coolant hoses above the SDS upper
shelf. See “Fig. 1: HVAC Coolant Hoses”
on page 2.
Fig. 1: HVAC Coolant Hoses
2. Open the center aisle HVAC access door
and locate the opposite ends of the two
coolant hoses. See “Fig. 2: Coolant Hoses
Access” on page 2.
3. Inspect hoses for any evidence of leakage
or weeping at the end fittings. Replace
both hoses if leakage or weeping is evident.
Refer to 2.1. “HVAC Coolant Hose
Replacement” on page 3 in this bulletin for
replacement procedure.
Fig. 2: Coolant Hoses Access
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SMB-177 3 of 5
SERVICE MANUAL BULLETIN
SMB-177
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2017 New Flyer Industries Canada ULC
2. Four Year Preventive
Maintenance
Open the SDS access door and confirm
whether a spill tank assembly is installed
above the SDS enclosure.
❒ Refer to 2.1. “HVAC Coolant Hose
Replacement” on page 3 of this bulletin if a
spill tank assembly is not installed.
❒ Refer to 2.2. “HVAC Coolant Hose
Replacement with Spill Tank Assembly” on
page 4 of this bulletin if a spill tank assembly
is installed.
2.1. HVAC Coolant Hose Replacement
Allow heating system to cool and
relieve system pressure. Keep away
from hot coolant and surfaces to avoid
injury.
Replace the HVAC coolant hoses, located
above the SDS enclosure, every four
years.
1. Set the Battery Disconnect switch to the
OFF position.
2. Close the coolant supply and return
valves, located under the driver’s platform
and at the booster pump location in the
engine compartment.
3. Drain the coolant from the rooftop HVAC
unit by disconnecting the coolant hoses
under the driver’s platform and drain into a
suitable container.
DO NOT allow coolant to drip onto electronic
equipment in the SDS enclosure
when removing the HVAC coolant
hoses. Use plastic sheets or similar
means to protect any electronic equipment
located beneath the HVAC coolant
hoses.
4. Open the SDS enclosure and locate the
two coolant hoses above the SDS upper
shelf. See “Fig. 1: HVAC Coolant Hoses”
on page 2.
5. Loosen the coolant hoses at the connection
to the copper lines and drain into a
suitable container. Disconnect the hoses
from copper line once coolant has completely
drained.
6. Open the center aisle HVAC access door
and locate the opposite ends of the two
coolant hoses.
7. Use a backup wrench and loosen each
coolant hose fitting from the HVAC unit and
allow any coolant to drain into a suitable
container.
8. Disconnect and remove both hoses from
the SDS enclosure. Discard hoses.
9. Install new hoses, ensuring threads on
mating fittings are dry. Torque hoses, using
a backup wrench, to 108 to 113 ft-lb. (146
to 153 Nm).
10.Reinstall the coolant hoses under the
driver’s platform. Torque hose clamps to 80
in-lb. and torque again to 80 in-lb. after 30
minutes.
☞NOTE:
If using power torque driver, ensure tool
RPM does not exceed 75 RPM.
11.Open the coolant supply and return shutoff
valves located below the driver’s platform
and at the booster pump location in the
engine compartment.
12.Set the Battery Disconnect switch to the
ON position.
13.Fill and deaerate the cooling/heating system.
Refer to Section 6 & 10 of your New
Flyer Service Manual for fill and deaeration
procedure.
14.Check for leaks and repair as required.
4 of 5 SMB-177
SERVICE MANUAL BULLETIN
SMB-177
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2017 New Flyer Industries Canada ULC
2.2. HVAC Coolant Hose Replacement
with Spill Tank Assembly
Allow heating system to cool and
relieve system pressure. Keep away
from hot coolant and surfaces to avoid
injury.
Replace the HVAC coolant hoses, located
above the SDS enclosure, every four
years.
1. Set the Battery Disconnect switch to the
OFF position.
2. Close the coolant supply and return
valves, located under the driver’s platform
and at the booster pump location in the
engine compartment.
3. Drain the coolant from the rooftop HVAC
unit by disconnecting the coolant hoses
under the driver’s platform and drain into a
suitable container.
DO NOT allow coolant to drip onto electronic
equipment in the SDS enclosure
when removing the HVAC coolant
hoses. Use plastic sheets or similar
means to protect any electronic equipment
located beneath the HVAC coolant
hoses.
4. Locate the drain hose and shutoff valve at
the lower front section of the SDS enclosure.
See “Fig. 3: HVAC Coolant Hoses”
on page 5.
5. Open the shutoff valve at the end of the
hose and drain any coolant from the primary
collection tank. Close the shutoff
valve once all coolant has been drained.
6. Open the SDS enclosure and locate the
two coolant hoses above the SDS upper
shelf.
7. Loosen the hose clamps and disconnect
the two coolant hoses connected to the
90° fittings on the spill tank assembly.
8. Remove the fasteners that attach the spill
tank assembly to the SDS rack structure
and remove the spill tank assembly.
9. Locate the two coolant hoses that pass
through the funnel and skirt assembly.
10.Loosen the coolant hoses at the connection
to the copper lines and drain into a
suitable container. Disconnect the hoses
from copper line once coolant has completely
drained.
11.Open the center aisle HVAC access door
and locate the opposite ends of the two
coolant hoses.
12.Use a backup wrench and loosen each
coolant hose fitting from the HVAC unit and
allow any coolant to drain into a suitable
container.
13.Disconnect and pull both hoses out
through the rubber skirt on the funnel
assembly. Discard hoses.
SMB-177 5 of 5
SERVICE MANUAL BULLETIN
SMB-177
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2017 New Flyer Industries Canada ULC
14.Install new hoses, ensuring threads on
mating fittings are dry. Torque hoses, using
a backup wrench, to 108 to 113 ft-lb. (146
to 153 Nm).
15.Replace the spill tank assembly, using
original fasteners.
16.Reinstall coolant hoses on the 90° fittings
on the spill tank assembly. Torque hose
clamps to 80 in-lb. wait 30 minutes, then
torque again to 80 in-lb.
☞NOTE:
If using power torque driver, ensure tool
RPM does not exceed 75 RPM.
17.Reinstall the coolant hoses under the
driver’s platform. Torque hose clamps to 80
in-lb. and torque again to 80 in-lb. after 30
minutes.
☞NOTE:
If using power torque driver, ensure tool
RPM does not exceed 75 RPM.
18.Open the coolant supply and return shutoff
valves located below the driver’s platform
and at the booster pump location in the
engine compartment.
19.Set the Battery Disconnect switch to the
ON position.
20.Fill and deaerate the cooling/heating system.
Refer to Section 6 & 10 of your New
Flyer Service Manual for fill and deaeration
procedure.
21.Check for leaks and repair as required.
Fig. 3: HVAC Coolant Hoses
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