SB1334

SERVICE BULLETIN
SB1334
ADDRESSEES
: ABC Customer Care and Parts Source
Owners and operators of coaches listed under “Application”
VEHICLE MODEL
: TD925US
MANUAL SECTION
: 5.10 Brakes – Front axle brakes
BULLETIN TYPE
: Field Change Program
DATE
: March 17th, 2016
SUBJECT
: To change “Quick release valve” of front axle brakes
TERMS & CONDITIONS
: Refer to the warranty section further in this Bulletin.
APPLICATION:
Model
TD925US
VIN
42814 Î 42820
42877 Î 42879
42881
42892
DESCRIPTION:
• On the above mentioned units it is necessary to change the pre-assembled quick release valve
VH11173539 (together with two-way valve VH637209080) of the front axle brakes by preassembled relay valve VH11480342.
• To address this change, Van Hool is conducting a Field Change Program, to install the parts
provided in kit # VH11493383. Terms and conditions of which are explained further on under
“Warranty”.
• Owners and operators of the affected units should follow the procedure below to change the
quick release valve of the front axle brakes.
PARTS:
Conversion kit VH11493383 - Figure 1
VH reference
11480342
660229805
660209930
660636402
660625907
Description
Pre-assembled relay valve
Screw M8x1.25x25mm
Self-locking nut M8x1.25mm
Coil spring lock washer
Washer
Qty.
1
2
2
2
4
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Figure 1: Van Hool conversion kit 11493383
PROCEDURE:
If you do not have the expertise to perform this procedure, do not hesitate to go to your nearest
ABC Customer Care & parts Source dealership.
1. General:
This job should be executed by a technician experienced in air systems.
2. Special tools, equipment or services:
No special tools, equipment or services are required.
3. Preparations:
• Park the vehicle on a level-surfaced inspection pit with the front wheels straight. When using
portable post lifts (always use 6 post lifts) instead of an inspection pit, always lower the
suspension first.
• Apply the parking brake and stop the engine.
• Switch off all systems and turn off the battery master switch on the dashboard.
• Open the mechanical battery switch.
• Put a “DO NOT OPERATE” tag on the instrument panel before beginning any inspection or
performing any repair.
• Open the rear engine compartment door and push on the red button of the safety switch and
equip it with a key lock.
• Depressurize the compressed-air tank of the front-axle brakes by means of the tank drain
valve. For the location of the air tanks, refer to chapter 13.17 of the maintenance manual.
• Read the entire procedure before beginning to work.
WARNING!
Observe safe shop practices at all times.
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4. Pneumatics - safety rules and installation recommendations:
To avoid personal injury when working on or around the air system and its components, the
following precautions should be taken:
• When lines are being disconnected, make sure to completely de-pressurize the system
affected.
• Unless you are certain that all system air pressure has been vented, never connect or
disconnect a pressurized line. It may whip, as air escapes. Also, never remove a component
or open a line unless you are certain that all system air pressure has been vented.
• Keep hands away from the brake caliper; they may apply as the system pressure drops. Stay
away from deflating air bellows.
• Never exceed the recommended air pressure and always wear safety glasses, when working
on air systems.
Before installing a line, be sure to blow it out with compressed air to remove any dirt, which may
have been allowed to enter while the tubing was in storage. Cap the line while routing it during
installation.
• Tubing should be installed free of strain, twist or torsion. Avoid acute bending and stretching.
• When installed, check all tubing connections for tightness.
• Make sure there is adequate clearance between the tubing and anything it might be able to
contact.
• Install tubing away from heat sources.
5. Raufoss fittings:
Most of the air lines are connected with Raufoss fittings. Please find some extra information
about these fittings.
a. To separate fitting housing from nipple
Step
1
Action
Open the snap arms on the fitting housing by using an ordinary snap ring
pliers.
Figure 2
2
Pull the housing from the nipple.
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b. To separate air line from fitting housing
Step
1
Action
Push the air line to the bottom of the fitting housing.
Figure 3
2
Apply the release tool to the air line by opening the slit.
Figure 4
3
Close the slit when applied on the air line and press the release tool into the
housing. Use silicone spray to ease the insert of the tool.
Figure 5
4
Pull the air line out while pushing the tool. Turning the air line can easy the
action.
Figure 6
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c. To connect air line
Step
Action
1
CAUTION!
Never insert a damaged or dirty tube end into the fitting!
Cut the air line at 90°. A maximum deviation of 10° is allowed. Secure the air
line cutting process to avoid scratches, burrs, damage, or dirt.
Figure 7
2
Insert the air line into the fitting housing by pushing and turning it
simultaneously.
Figure 8
3
Push the air line far enough until it has passed the main seal O-ring into the
housing to avoid slipping out. The connection is sealed now.
Figure 9
If the air line is not fully assembled, a local slot in the blue cone element will
give space for a displacement of the environmental seal O-ring. When
pressurized this will give a clear whistle sound. The air line can be re-pushed
under pressure. When the whistle sound is gone, the air line is fully assembled.
Figure 10: Local slot
in the blue cone element
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d. To connect fitting housing to nipple
Step
Action
1
Never force the nipple into the housing with an obviously angled
position.
Enter the nipple in a straight position in the housing during press-in operation.
Push the nipple far enough into the housing until you hear 2 ‘clicks’.
Figure 11: Push the nipple far enough into the
housing
6.
To change quick release valve by relay valve from kit:
Step
6.1
Action
Remove underneath the vehicle the protection panel located below the driver seat
to get access to the pneumatic components.
Figure 12
6.2
Remove quick release valve 11173539 (together with the two-way valve
11480411) from the front axle brakes.
Figure 13: Quick release
valve + two-way valve
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6.3
6.4
Locate the already installed 5/8” air line marked with a red/green ring. Remove the
plug of this line.
Install pre-assembled relay valve 11480342 from the kit. Secure the valve to the
bracket with screws 660229805 (2x), washers 660625907 (4x) coil spring lock
washers 660636402 (2x) and nuts 660209930 (2x) from the kit.
Figure 14: Fixation of preassembled relay valve
6.5
Connect the air lines to the pre-assembled relay valve 11480342 as follows:
At the relay valve:
1. Red-green 5/8” sup
2. Green 1/2”
3. Green 1/2”
At the two-way valve:
4. Green 5/8”
5. Green 1/4”
6. Green 3/8”
7. Green 1, 3/8”
6.6
Figure 15
Check the air system for air leaks.
End of procedure.
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WARRANTY:
1. Terms and conditions:
Van Hool will accept warranty claims for this repair as follows:
Parts: parts will be supplied through regular channels, free of charge.
Labor allowance: 13/4 hour for labor will be awarded per coach repaired.
Campaign expiration date: Service Bulletin issue date + 1 year.
2. Claim references:
•
•
Causal part: quick release valve 11173539 (together with two-way valve 11480411)
Job code: O05021N
Claim submission: Contact ABC Customer Care Warranty Department for guidance.
INFORMATION HANDLING:
Important supplements and modifications of technical information not yet included
in the manual are communicated by means of Service Bulletins.
VAN HOOL CUSTOMER PORTAL:
Consult the Van Hool customer portal for the latest service documentation. Beside the
maintenance manual, you will also find the operating manual and the spare parts
catalogue of your vehicle on the customer portal. The customer portal is accessible
through www.vanhool.be, and only with a code (password)
from Van Hool. If you do not have a password yet, request it by using
the link on the Van Hool website.
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