FCP 480

Subject: Modine e-fan Harness Rework
Field Change Program:
Field Campaign
Coach Section:
06-Cooling
FCP Number:
Revision:
480
A
P/N:
06-01-1648, 06-01-1655
Date:
07/21/2020
Type:
Product Integrity
Application:
Coach Model
Model Year
VIN
J4500
2019 - 2020
68536, 68801, 68849, 68855, 68953 - 68955, 68983 68987, 68989 - 69008, 69010, 69013, 69031 - 69124,
69126 - 69516, 69519 - 69705, 69707 - 69754, 69756 69758, 69760 - 69779, 69781 - 69826, 69828 - 69838,
69842, 69847 - 69857, 69863
D45CRT-LE
2019
81000 - 81043, 81045 - 81057, 81059, 81061, 81062,
81064, 81074
This field campaign does not necessarily apply to all the above-mentioned coaches.
The owners of the coaches affected by this field campaign will be advised by a letter
indicating the Vehicle Identification Number (VIN) of each applicable coach.
Read this entire procedure before beginning work.
Use Safe Shop Practices at All Times.
To avoid personal injury:
a. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses and
protective gloves are required for working with DEF Fluid.
b. Turn the main battery disconnect switch to the OFF position.
c. Ensure that both the front and the rear wheels are chocked.
d. Position the ENGINE RUN and ENGINE START switches on the engine
compartment remote control box to the OFF position.
e. Allow enough time for components to cool down prior to working in the engine
compartment.
FCP 480
Modine e-fan Harness Rework
1.0 Description
Customer complaint:
Modine Manufacturing Co. (“Modine”) has notified Motor Coach Industries (“MCI”) that
some of the e-fan engine cooling modules may have their harness rubbing on an
uncovered metal edge, which could lead to harness damage and cooling module failure.
Cause:
The e-fan engine cooling module harness was routed too tightly during the module
assembly in the fuse compartment.
Corrective action:
MCI and Modine urge owners of the affected coaches to have the following procedure
performed as soon as possible.
2.0 Material requirements
Refer to section 5.1.
3.0 Special tools
Inspection Mirror
CRC SP400 corrosion inhibitor, MCI P/N: 23-02-0119, or equivalent.
Sikaflex-221 black adhesive, MCI P/N: 21-7112-32.
4.0 Inspection
Open the e-fan swingout door on the driver's side.
Open the swingout door
Motor Coach Industries Ltd.
Page 2 of 16
FCP 480
Modine e-fan Harness Rework
Insert inspection mirror through the fan, as shown below, and look for harness in the fuse
compartment.
Insert mirror and look for
harness in fuse compartment
Fuse compartment
Inspection mirror
If there is any visible red wire resting on the fuse compartment edge as shown below,
continue to Section 5.0. Otherwise, continue to Section 6.0.
Good
If no red wire is visible, continue to
Section 6.0
Bad
If red wire is visible, continue to
Section 5.0
Notice:
Take a picture of the inspection similar to the picture shown above to submit with
the warranty claim.
Motor Coach Industries Ltd.
Page 3 of 16
FCP 480
Modine e-fan Harness Rework
5.0 Harness rework
5.1
Material requirements
Service kit 6483783 contains the following parts:
ITEM
1
2
3
PART NO
6483650
06-01-1975
19-11-259
QTY
1
10
2
U/M
EA
EA
EA
DESCRIPTION
Kit- Modine
Nut Cap
Tyrap- 13.38” LG
Modine kit 6483650 contains the following parts:
ITEM
1
2
3
4
5.2
PART NO
6482599
6482600
6482601
6482602
QTY
1
1
1
10
U/M
EA
EA
EA
EA
DESCRIPTION
Bracket- E-fan Power Stud
Trim Lock- 22”
Trim Lock- 1”
Tie Base W/ Mount
Adding trim lock in the fuse compartment
Remove and save the four nut covers and nuts securing the fan shown below. Cut and
discard tie bases required to move the fan.
Remove and save the
nut covers and nuts
Remove and save the four nuts securing the fuse access cover.
Remove and save the nuts
Motor Coach Industries Ltd.
Page 4 of 16
FCP 480
Modine e-fan Harness Rework
Pull the fuse access cover out of the module without disconnecting the fuses. Cut and
discard tie bases required to move the cover out.
Inspect the red wire for abrasion or exposed conductors. If no damage is found, continue
to the next steps. Otherwise, refer to the maintenance manual to replace the harness.
Good
Bad
Notice:
Take a picture of the inspection similar to the picture shown above to submit with
the warranty claim
Remove and discard the edge grip in the fuse compartment.
Remove and discard
the edge grip
Motor Coach Industries Ltd.
Page 5 of 16
FCP 480
Modine e-fan Harness Rework
Install the 22” long trim lock, MCI P/N: 6482600, along the inside edge of the fuse
compartment shown below.
Install 22’’ long trim lock
Install the 1” long trim lock, MCI P/N: 6482601, along the RH shorter edge of the fuse
compartment, as sown below.
Install 1” long trim lock
Insert the curved edge of the fuse access cover into the grommet and install the access
cover using existing nuts. Torque the nuts to 7 Ft-Lbs.
Insert the cover into
the grommet and
install the cover
Motor Coach Industries Ltd.
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FCP 480
Modine e-fan Harness Rework
Re-install the fan using existing hardware. Torque the nuts to 7 Ft-Lbs.
Re-install the fan using
existing nuts
Install existing nut covers to the fan mounting nuts.
Install the tie bases, MCI P/N: 6482602, at the location shown below and secure the
harness.
Install the tie bases and
secure the harness
Motor Coach Industries Ltd.
Page 7 of 16
FCP 480
Modine e-fan Harness Rework
Install nut covers to the fan mounting nuts at the locations shown below, if absent.
Install nut covers
5.3
Replacing the power stud bracket
Pull back the rubber boots on both the harnesses installed to the power stud.
Pull back the rubber boots
Remove and save the washer and nut securing the power cable going into the e-fan.
Remove and save
the nut and washer
Motor Coach Industries Ltd.
Page 8 of 16
FCP 480
Modine e-fan Harness Rework
Remove and save the washer and nut securing the power cable coming from inside the
coach.
Remove and save
the nut and washer
Remove and save the two nuts securing the power stud bracket. Remove the power stud.
Remove and save the
nuts. Discard the bracket
Remove and save the components secured to the power stud bracket. Discard the
bracket.
Install the components saved in the previous step to the new power stud bracket, MCI
P/N: 6482599, in the order shown below. Torque the jam nut to 18.5 Ft-Lbs.
Motor Coach Industries Ltd.
Page 9 of 16
FCP 480
Modine e-fan Harness Rework
Install the assembled power stud bracket using existing hardware. Torque the nuts to 7
Ft-Lbs.
Install the
assembled bracket
Re-install the power cable coming from inside the coach to the power stud, as shown
below, using existing washer and nut. Torque the nut to 14.75 Ft-Lbs.
Install the cable using
existing hardware
Re-install the power cable going into the e-fan to the power stud, as shown below, using
existing washer and nut. Torque the nut to 14.75 Ft-Lbs.
Install the cable using
existing hardware
Motor Coach Industries Ltd.
Page 10 of 16
FCP 480
Modine e-fan Harness Rework
Apply corrosion inhibitor, MCI P/N: 23-02-0119, on both sides of the stud and re-place
boots over the power stud.
Apply corrosion inhibitor, 23-020119, and re-place the rubber boots
Secure the two rubber boots on the power stud with a zip tie, MCI P/N: 19-11-259.
Secure the rubber boots with zip
tie, 19-11-259
Pull back the rubber boots on the ground stud and apply corrosion inhibitor, MCI P/N: 2302-0119.
Pull back the rubber boots and apply
corrosion inhibitor, 23-02-0119
Motor Coach Industries Ltd.
Page 11 of 16
FCP 480
Modine e-fan Harness Rework
Re-place the rubber boots on the ground stud and secure them with zip ties, MCI P/N:
19-11-259.
Secure the rubber boots with zip
tie, 19-11-259
Motor Coach Industries Ltd.
Page 12 of 16
FCP 480
Modine e-fan Harness Rework
6.0 Bulb seal inspection
6.1
Inspection
Inspect the radiator for loose bulb seal.
Inspect the radiator for
loose bulb seal
If bulb seal is found loose, continue to Section 6.2. Otherwise, procedure is complete.
6.2
Securing the loose bulb seal
Pull back the section of loose bulb seal and clean the bulb seal and radiator surfaces with
isopropyl alcohol.
Pull back the section of
loose bulb seal
Apply 1/4” thick bead of Sikaflex 221 black, MCI P/N: 21-7112-32, on the inside surface
of bulb seal and secure it back to the radiator.
Apply 1/4” thick bead of Sikaflex 221
black, 21-7112-32, on the inside
surface of bulb seal and secure it to
the radiator
Motor Coach Industries Ltd.
Page 13 of 16
FCP 480
Modine e-fan Harness Rework
7.0 Field Change Program Conditions:
The parts required for this change will be supplied without charge.
A labor allowance of 1 hour will be granted if the harness is found to need rework.
A labor allowance of 4 hours will be granted if the harness is found to need replacement.
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 along with a
picture, as mentioned in Section 4.0 and Section 5.2 of this document 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 Month DD, YYYY.
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.
Motor Coach Industries Ltd.
Page 14 of 16
FCP 480
Modine e-fan Harness Rework
7.1
MCI FIELD CHANGE PROGRAM (FCP) VERIFICATION
CONTACT INFORMATION
CUSTOMER NAME:
____________________________________________________
(PLEASE PRINT)
FCP INFORMATION – ONE FORM PER UNIT
FCP#: 480
Coach Model ___________
COACH SERIAL #:
Model Year _______________
DATE COMPLETED __ / __ /____
(At least the last 5 digits)
MILEAGE:
IMPORTANT: TO RECEIVE CREDIT FOR ANY ALLOWABLE LABOR CHARGES, THIS
VERIFICATION FORM MUST BE RETURNED TO MCI UPON COMPLETION OF THE
FCP (ALONG WITH A PICTURE OF INSPECTION AS MENTIONED IN SECTIONS 4.0
AND 5.2 IN THIS DOCUMENT).
SUBMITTED BY: (Please Print)
______________________________________________________
DATE
__ / __ /____
TITLE: (Please Print) _____________________________________________
SIGNATURE:
________________________________________________________________
COMMENTS:
Motor Coach Industries Ltd.
Page 15 of 16
FCP 480
Modine e-fan Harness Rework
FAX TO: 800-360-8886
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 40258
Fax Number 1-800-360-8886
To receive credit for the hours used to complete this task. Contact the MCI Fleet Support
Technical Center at 1-800-241-2947 for any further information.
Motor Coach Industries Ltd.
Page 16 of 16