FCP 483

Subject: MCC Evaporator Motor Replacement
Field Change Program:
Field Campaign
Coach Section:
16- Heating & A/C
FCP Number:
Revision:
483
A
P/N:
16-06-1622
Date:
08/05/2020
Type:
Product Integrity
Application:
Coach Model
Model Year
VIN
J4500
2019 - 2020
68983 - 68987, 68989 - 68999, 69001 - 69007, 69010,
69031 - 69036, 69038 - 69050, 69052 - 69058, 69061 69068, 69073, 69076 - 69080, 69082 - 69087, 69089,
69091 - 69093, 69095, 69097, 69098, 69100 - 69105,
69110 - 69113, 69115 - 69127, 69129, 69130, 69132 69134, 69136, 69138 - 69143, 69146 - 69168, 69170 69174, 69189 - 69193, 69195 - 69197, 69199 - 69214,
69217, 69218, 69220 - 69222, 69224 - 69227, 69229 69231, 69233, 69235 - 69238, 69240 - 69245, 69247 69249, 69251, 69254 - 69257, 69259 - 69262, 69264 69273, 69275 - 69278, 69280 - 69287, 69289, 69290,
69292, 69294 - 69302, 69304 - 69323, 69325 - 69331,
69333, 69335 - 69337, 69340 - 69342, 69344 - 69350,
69358, 69360 - 69363, 69365 - 69374, 69376, 69379 69384, 69386, 69388 - 69398, 69400 - 69408, 69412 69421, 69423 - 69431, 69433 - 69445, 69447, 69449,
69450, 69452, 69453, 69455 - 69471, 69473 - 69487,
69489 - 69518, 69531, 69532, 69535 - 69580, 69585 69668, 69670 - 69677, 69679, 69680, 69682 - 69685,
69687, 69688, 69692, 69701, 69706, 69708, 69714, 69715,
69723, 69733, 69735, 69738, 69739, 69748.
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 coach concerned.
FCP 483
MCC Evaporator Motor Replacement
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.
1.0 Description
Customer complaint:
Mobile Climate Controls (“MCC”) has informed Motor Coach Industries (“MCI”) that
certain new style evaporator motors supplied by MCC for MCI J4500 coaches may have
inadequate electrical contacts at the main circuit board, which could result in premature
failure of the motor.
Cause:
MCC advises that certain motors have been found to have inadequate electrical contacts
at the main circuit board that may degrade rapidly once the motor is put in service.
Corrective action:
MCI recommends that owners of the affected coaches contact MCC for a replacement
motor and to have the following procedure performed as soon as possible.
Motor Coach Industries Ltd.
Page 2 of 19
FCP 483
MCC Evaporator Motor Replacement
2.0 Material requirements
ITEM
1
MCC PART No
25-3237
MCI PART NO
16-06-1546
QTY U/M DESCRIPTION
1
EA
Evaporator Motor - 24V
1
To obtain a replacement motor, please contact MCC by sending an email to Willie
Aningalan at [email protected] and request shipment of a replacement
motor to your address.
3.0 Special tools
Thread locker (Vendor: Loctite, VPN: 243)
Flexible foil tape (Vendor: 3M, VPN: 3350)
Anti-seize lubricant (Vendor: Permatex, VPN: 80078)
Hub Puller (Vendor: Supco, VPN: FBP100)
Corrosion inhibitor, MCI P/N: 23-02-0119 (Vendor: CRC VPN: SP 400)
4.0 Removing the existing motor
Remove the evaporator door in the Baggage Bay #3 compartment.
Remove and save
the evaporator door
Remove and discard the flexible foil tape on the blower housings.
Remove and discard the
flexible foil tape
Motor Coach Industries Ltd.
Page 3 of 19
FCP 483
MCC Evaporator Motor Replacement
Remove and save the five screws securing the left-hand and right-hand transition ducts.
Remove and save
the screws
Open the battery compartment door.
Open the battery
compartment door
Remove and save the bolt securing the LH transition duct mounting plates (one in the
battery compartment and the other in evap compartment). Save the mounting plates.
Remove and save the
bolt and mounting plates
Motor Coach Industries Ltd.
Page 4 of 19
FCP 483
MCC Evaporator Motor Replacement
Remove and save the eight screws securing the condenser compartment access panel
located in the street-side of Baggage Bay 3. Save the access panel.
Remove and save the eight
screws and access panel
Remove and save the bolt securing the RH transition duct mounting plates (one in the
condenser compartment and the other in evap compartment. Save the mounting plates.
Remove and save the
bolt and mounting plates
Remove and save the four bolts securing the blower assembly to the mounting base.
Remove and save the
bolts
Motor Coach Industries Ltd.
Page 5 of 19
FCP 483
MCC Evaporator Motor Replacement
Remove and save the four bolts securing the LH and RH blower to the blower assembly
base.
Remove and save the
bolts
Remove and save the four bolts securing the blower housing supports to the blowers.
Save the blower housing supports.
Remove and save the
bolt and mounting plate
Separate the blower housings from the transition ducts.
Separate the blower
housings
Motor Coach Industries Ltd.
Page 6 of 19
FCP 483
MCC Evaporator Motor Replacement
Disconnect the power, ground, and speed control wires on the evaporator motor. Save
the nuts. Ensure to hold the nut below the ring terminal with a wrench.
Disconnect the power,
ground, and speed
control wires
Remove and save the four bolts securing the relay base plate.
Remove and save the
bolts
Carefully remove the motor assembly from Baggage Bay 3 and place the assembly on a
workbench.
Carefully move the
motor assembly on to a
workbench
Motor Coach Industries Ltd.
Page 7 of 19
FCP 483
MCC Evaporator Motor Replacement
Remove and save the set screws on both blowers. Ensure to mark the left-hand and righthand blower before removing the set screws.
Remove and save the
set screws on both
blowers
Secure the hub puller to the LH blower shaft using the three set screws as shown below.
Secure the hub puller to
the blower
Remove the LH blower by slowly tightening the bolt on the hub puller.
Tighten the bolt on hub
puller
Motor Coach Industries Ltd.
Page 8 of 19
FCP 483
MCC Evaporator Motor Replacement
Repeat the steps on the RH blower assembly.
Remove and save the four bolts securing the motor to the mounting bracket and set the
motor aside.
Remove and save the
four bolts
5.0 Installing new evaporator motor
Remove and save the two bolts securing the new motor in shipping box.
Remove and save the
two bolts
Place the new motor on the workbench. Apply Permatex anti-seize lubricant on the motor
shafts.
Apply anti-seize lubricant
on the motor shafts
Motor Coach Industries Ltd.
Page 9 of 19
FCP 483
MCC Evaporator Motor Replacement
Apply two drops of Loctite 243 thread locker to the existing set screws and re-install the
RH blower assembly to the shaft away from the ground and power studs. Repeat the
steps to secure the LH blower to the motor shaft. Torque the set screws to 150 In-Lb.
Apply two drops of Loctite 243
thread locker and re-install the
RH blower assembly to the shaft
Place the motor assembly in the evaporator compartment.
Place the motor assembly
in the evaporator
compartment
Apply two drops of Loctite 243 to the existing bolts and re-install mounting base assembly
to the coach. Torque the bolts to 75 In-Lb.
Re-install mounting base
assembly to the coach
Motor Coach Industries Ltd.
Page 10 of 19
FCP 483
MCC Evaporator Motor Replacement
Connect the left-hand and right-hand blower housing to the transition ducts. Secure the
transition ducts to the blower housing using ten existing screws (5 on each side).
Secure the transition
ducts using existing
screws
Re-install the RH transition duct mounting plate using existing bolt. Ensure the flange of
both mounting plates is at the bottom.
Re-install mounting
plates using existing bolt
Re-install the LH transition duct mounting plates using existing bolt. Ensure the flange of
both mounting plates is at the bottom.
Re-install mounting plates
using existing bolt
Motor Coach Industries Ltd.
Page 11 of 19
FCP 483
MCC Evaporator Motor Replacement
Apply two drops of Loctite 243 to the existing bolts and secure the blower housings to the
mounting base assembly (2 on each side). Torque the bolts to 75 In-Lb.
Secure the blower housings
to mounting base assembly
using existing bolts
Apply two drops of Loctite 243 to the existing bolts and re-install the two blower housing
support mounts to the mounting base assembly. Torque the bolts to 75 In-Lb.
Re-install the blower housing
supports to mounting base
assembly using existing bolts
Apply two drops of Loctite 243 to the existing bolts and re-install the relay base plate to
the coach. Torque the bolts to 75 In-Lb.
Re-install the relay
base plate using
existing bolts
Motor Coach Industries Ltd.
Page 12 of 19
FCP 483
MCC Evaporator Motor Replacement
Clean the mounting nuts, ring terminals on all the wires and cables with isopropyl alcohol
to get rid of the hi tack adhesive.
Connect the speed control cable, labeled: POS-EFRL2, to the outboard stud using
existing nut and torque the nut to 50 In-Lb. Hold the bottom nut with a wrench while
tightening the top nut.
Connect the cable POSEFRL2 to the outboard stud
CAUTION
Failure to hold the bottom nut with a wrench while tightening the top nut may result
in loose connection.
Connect the black power wire to the middle stud using existing nut and torque the nut to
50 In-Lb. Hold the bottom nut with a wrench while tightening the top nut.
Connect the black power wire
to the middle stud
CAUTION
Failure to hold the bottom nut with a wrench while tightening the top nut may result
in loose connection.
Motor Coach Industries Ltd.
Page 13 of 19
FCP 483
MCC Evaporator Motor Replacement
Connect the white ground wires and cable to the inboard stud using existing nut and
torque the nut to 50 In-Lb. Hold the bottom nut with a wrench while tightening the top nut.
Connect the ground wires and
cable to the inboard stud
CAUTION
Failure to hold the bottom nut with a wrench while tightening the top nut may result
in loose connection.
Spray corrosion inhibitor, MCI P/N: 23-02-0119, on all the studs.
Spray corrosion inhibitor, 2302-0119, on all the studs
Place 3M 3350 flexible foil tape to connect the blower housings and transition ducts.
Install flexible foil tape
Motor Coach Industries Ltd.
Page 14 of 19
FCP 483
MCC Evaporator Motor Replacement
Re-install the condenser compartment access panel using existing screws.
Re-install the condenser
compartment access panel
Re-install the evaporator door.
Re-install the
evaporator door
6.0 Testing
Turn on the main disconnect switch in the battery compartment.
Turn on engine and set HVAC to 60° F. Run the HVAC for 5 minutes and ensure the
HVAC system runs without any issues.
7.0 Shipping the old evaporator motor
Secure the old evaporator motor in the shipping box using existing four bolts.
Secure the old motor
using existing four bolts
Motor Coach Industries Ltd.
Page 15 of 19
FCP 483
MCC Evaporator Motor Replacement
Place the packaging inside the shipping box as it was received.
CAUTION
Failure to ship the motor as shown above may result in warranty claim denial.
Ship the box to the following address:
Ametek Dynamic Fluid Solutions
Attention: Laura Davis
Dept: Engineering
100 E. Erie St, Suite 200,
Kent, OH-44240
Phone number: (330) 877-3851
Motor Coach Industries Ltd.
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FCP 483
MCC Evaporator Motor Replacement
8.0 Field Change Program Conditions:
The replacement motor required for this change will be supplied without charge.
A labor allowance of 2.5 hours will be granted for the rework.
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 08/04/2021.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 17 of 19
FCP 483
MCC Evaporator Motor Replacement
8.1 MCI FIELD CHANGE PROGRAM (FCP) VERIFICATION
CONTACT INFORMATION
CUSTOMER NAME:
____________________________________________________
(PLEASE PRINT)
FCP INFORMATION – ONE FORM PER UNIT
FCP#: _________
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.
SUBMITTED BY: (Please Print)
______________________________________________________
DATE
__ / __ /____
TITLE: (Please Print) _____________________________________________
SIGNATURE:
________________________________________________________________
COMMENTS:
Motor Coach Industries Ltd.
Page 18 of 19
FCP 483
MCC Evaporator Motor Replacement
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.
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