IS-19900J

Instruction Sheet
IS-19900J
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH BOSCH
ALTERNATOR
H3 coaches (2PCH…) US10 to GHG17 incl. (B-1721 to J-0184)
REVISION : J
Jan 17-23
THIS DOCUMENT SUPERSEDES PREVIOUS VERSION.
Note added regarding power cable connection (step 115)
REVISION : i
THIS DOCUMENT SUPERSEDES PREVIOUS VERSION.
Parts obsolete: 050303, 391028, 562112
Replaced by:
830165
24V RED TELLTALE LIGHT MODULE
381594
BRACKET, TELLTALE
561540
TAB TERMINAL, ST,16-14,1/4 INS
New holes drilled for cooling pack relocation
June 17-20
QTY: 1x
QTY:1x
QTY: 2x
IMPORTANT NOTE
VEHICLES EQUIPPED WITH OPTIONAL PRIME ENERGY MANAGEMENT SYSTEM
TO PREVENT OVERLOADING THE L.H. SIDE ALTERNATOR, IT IS VERY IMPORTANT TO
DISABLE « PRIME » SYSTEM ON VEHICLES RECEIVING THIS CONVERSION. PLEASE
CONTACT YOUR NEAREST PREVOST SERVICE CENTER TO HAVE THE PRIME
SYSTEM DISABLED. A SOFTWARE TOOL IS NEEDED TO DO SO.
MATERIAL
Kit IS19900 contains the following parts:
Qty
Part No.
DESCRIPTION
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
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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
MECHANICAL
012349
IDLER PULLEY
Mechanical
1
012941
PULLEY, DRIVE
Mechanical
1
012942
L.H. ENGINE MOUNT
Mechanical
1
011213
SUPPORT, IDLER + TENSIONER
Mechanical
1
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453076
CAP, DUST
Mechanical
1
506026
1x BELT, DRIVE POLY V 10PK1695
Mechanical
2
1x BELT, DRIVE POLY V 10PK1695 (for your spare
kit)
510991
TENSIONER, BELT
Mechanical
1
560748
BOSCH HD10PLBH ALTERNATOR 28V-150AMP
J180
Mechanical
1
0600265
PULLEY, ALTERNATOR 10PK, 73 DOB
Mechanical
1
Pipe
1
Pipe
1
Pipe
1
Pipe
1
Fitting
1
Fitting
1
Fitting
1
Fitting
1
PIPES
050286
CAC INLET PIPE H3 US10+
050406
CAC OUTLET PIPE H3 US10+
050414
RADIATOR INLET COOLANT PIPE H3 US10+
050288
RADIATOR OUTLET PIPE H3 US10+
501027
FITTING, SAE 45º #4FL-Mx1/4NPT-M BR
501308
ADAPTER / PIPE FITTING / 1/4NPT-Fx1/4NPT-M
BR
501329
ELBOW 45º / PIPE FITTING / 1/4NPT-Mx1/4NPT-F
BR
501332
ELBOW 90º / PIPE FITTING / 1/4NPT-Mx1/4NPT-F
BR
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HOSES
052366
HOSE 3/8 ID X 61 in LONG
hose
1
030096
HOSE, FLEXIBLE - CHARGE AIR
Hose
2
Hose
1
Hose
1
Hose
1
Hose
3
Clamps
8
Clamps
4
Clamps
16
Location: turbo outlet & engine intake
531469
HOSE, FLEXIBLE - CHARGE AIR
Location: CAC outlet
531471
HOSE, FLEXIBLE - CHARGE AIR
Location: CAC inlet
052889
HOSE, SILICONE 2 1/2" ID
Location : coolant pipes
053617
HOSE, SILICONE
Location : coolant pipes
CLAMPS+ SEALS
21490616
CLAMPS, SPRING LOAD - CHARGE AIR
Location: CAC outlet & inlet
21490630
CLAMP, SPRING LOAD - CHARGE AIR
Location: turbo outlet & engine intake
992089
HOSE CLAMP CT CAILLAU 60mm-80mm
Location : coolant pipes
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992081
HOSE CLAMP CT CAILLAU 12-22
Clamps
4
Location : coolant filter
SUPPORTS/BRACKETS
21185073
MOUNT, ANTI-VIBRATION
Support
/bracket
1
050305
BRACKET, RADIATOR INLET PIPE
Support
/bracket
1
050265
COOLANT FILTER SUPPORT H3
Support
/bracket
1
050266
ALTERNATOR BATTERY CABLE SUPPORT
Support
/bracket
1
050214
UPPER RADIATOR SUPPORT H3
Support
/bracket
1
060102
ALTERNATOR BRACKET, LOWER
Support
/bracket
1
381594
U-SHAPED BRACKET, ALTERNATOR TELLTALE
1
MISC.
010060
DECAL, BELT ROUTING
Misc.
1
069205
DECAL, WARNING
Misc.
2
506025
RUBBER EXTRUSION, BLACK
Misc.
8 ft
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Misc.
1
Misc.
1
TAPE, ADHESIVE AD1 EPDM CC GY
5/16"X3/4"X25'
Misc.
1
FILTER, COOLANT
Misc.
1
Electrical
1
060297
STUD ADAPTER, ALTERNATOR M/F-M8
380360
GROUND STUD
506040
21937327
ELECTRICAL
012921
GROUND STUD
561540
TERMINAL, TAB
561610
CONNECTOR HOUSING, PED WEATHER-PACK 4
WIRES
Electrical
1
561783
CAVITY PLUG, CONNECTOR
Electrical
4
563593
CONNECTOR, WITH END-OF-LINE 120 OHMS
RESISTOR
Electrical
2
563750
FUSE HOLDER, AMG TYPE
Electrical
1
564520
FUSE, AMG 300A
Electrical
1
EL
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564612
CIRCUIT BREAKER BOX
Electrical
1
565191
FAN, ELECTRIC
Electrical
8
563533
HAND GUARD, FAN
Electrical
8
830165
24V RED TELLTALE LIGHT MODULE
22722850
I/O-B MULTIPLEX MODULE
Electrical
1
23499009-EFD
MCM, PROGRAMMED
Electrical
1
1
HARNESSES
068820
HARNESS, FAN DRIVE
Harness
1
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
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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
HARDWARE MISC
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
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
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507657
WASHER, BANJO FITTING M14
5001341
WASHER, FLAT SS 8.4X17X1.6 (M8,5/16)
5001737
WASHER, SPLIT LOCK N500 10.2X18.1X2.2
(M10,3/8)
5001751
WASHER, FLAT N500 10.5X26X2 (M10,3/8)
5001833
WASHER, BELLEVILLE SPR SS 301
6.65X17.4X1.27(M6,1/4
5001868
WASHER, BELLEVILLE SS 8.4X18X2 (M8,5/16)
5001935
WASHER, FLAT SS 10.5X18X1.6 (M10,3/8)
5002008
WASHER, FLAT HARD N500 13X35X5 (M12,1/2)
500998
NUT HEX BR 1/2-13
502837
NUT HEXF STO N500 M8-1.25
502859
NUT HEX NYRT NX500 M10-1.5 G10
5001182
NUT HEX NYRT SS M6-1
5001665
NUT HEX NYRT NX500 M22-2.5
5001728
NUT HEXF STO N500 M12 CL10
5001761
NUT HEXF NYRT NX500 M12-1.75 G8
5001930
NUT HEXF NYRT NX500 M10-1.50 PC 10
5001983
NUT HEX NYRT NSS M8-1.25X9.5
21429955
NUT, FLANGED
500119
SCREW, CAP HEX SS NSS M8X1.25X20
500658
SCREW TC PAN PH Z050 10-24X3/4
502719
SCREW, CAP HEX SS NSS M10X20 G8.8
502686
SCREW, CAP HEX SS NSS M6X30
502804
SCREW, CAP HEX N500 M10-1.5X25 G8.8
502848
SCREW TC HEX F N500 1/4-20X3/
502950
SCREW SHR HEXF N500 12.9X160LG CL10.9
5001296
SCREW, CAP HEXFN500 M12-1.75 X 80 CL10.9 PT
5001643
SCREW, CAP HEXF G500 M8-1.25X25 G8.8 PT
5001697
SCREW, CAP HEX SS NSS M6X16
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hardware
8
hardware
6
hardware
4
hardware
10
hardware
32
hardware
4
hardware
1
hardware
1
hardware
1
hardware
2
hardware
4
hardware
1
hardware
1
hardware
1
hardware
2
hardware
2
hardware
3
hardware
1
hardware
4
hardware
11
hardware
1
hardware
33
hardware
8
hardware
22
hardware
1
hardware
6
hardware
3
hardware
62

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5001738
SCREW, CAP HEX N500 M8X30 G8.8 FT
5001745
SCREW, CAP HEX N500 M8-1.25X25 G8.8
5001786
SCREW, CAP HEXF AD N500 M12-1.75X30 G8.8
5001799
SCREW, CAP HEXF N500 M10-1.5 X 70 G10.9
5001800
SCREW, CAP HEXF N500 M10X45 G10.9
5001940
SCREW CAP HEX N500 M12X1.75X140
hardware
4
hardware
2
hardware
1
hardware
4
hardware
1
hardware
2
RIVETS
504379
RIVET, POP DOME SS OE 3/16X1/4
504610
RIVET MGL PRDG SS 1/4X5/8
IS-19900
INSTRUCTION SHEET
FI-19900
FEUILLE D’INSTRUCTION
41
14
1
1
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
EL
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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
EL
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HOSE CLAMP TORQUE (coolant lines and charge air cooler)
HOSE CLAMPS
No
DESCRIPTION
1
(Ø 2 ½ ” or
less)
2
(Ø 4 ¼ ”)
EL
TORQUE
Constant-Torque hose clamps - coolant lines
90-100 lbf-in
Oetiker hose clamps – Green spring - coolant lines
12-18 lbf-in
Oetiker hose clamps – unpainted spring - coolant lines
8-9 lbf-in
Caillau hose clamps - coolant lines
30 lbf-in
Constant-Torque hose clamps 4.25in - charge air cooler
(CAC)
Writer:
4.5-5.5 lbf-ft

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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.
FIGURE 10
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 11
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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 12
FIGURE 13
FIGURE 14
16. Remove the fan drive casting.
FIGURE 15
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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 16
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 17
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19. Remove the tripod from the radiator/CAC
assembly.
FIGURE 18
FIGURE 19
20. Remove the fan shroud.
FIGURE 20
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21. The new cooling pack arrangement requires
being located closer to the engine to give the
needed clearance for the electric fans. For this
reason, rotate both the cooling pack mounting
support 180° and reinstall.
BEFORE
FIGURE 21: MOUNTING SUPPORT IN INITIAL POSITION
AFTER
FIGURE 22: MOUNTING SUPPORT AFTER 180° ROTATION
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22. Drill two (2) new holes for both cooling pack
mounting supports at ¾ inch (19 mm) from the
previous holes, towards the engine.
FIGURE 23: NEW HOLES FOR THE COOLING PACK MOUNTING SUPPORTS
FIGURE 24: NEW HOLE FOR THE COOLING PACK MOUNTING SUPPORTS (DETAIL VIEW)
23. Remove the rear bumper (undo three nuts and
one attachment plate each side).
FIGURE 25
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24. 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 26
FIGURE 27
25. Remove all the drive belts mounted on the crank
pulley.
FIGURE 28
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26. Remove the drive pulley. Discard the 6 bolts.
FIGURE 29
27. Remove the rust, clean and prepare the surface
on the vibration damper as shown. Work the
surface to achieve a smooth finish.
FIGURE 30
FIGURE 31
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28. Properly support the engine as one of the
engine support will be interchanged in the
upcoming steps.
FIGURE 32
29. Remove the two (2) coolant hoses shown on the
image. Keep the two (2) banjo fittings for later
use.
BANJO FITTING
FIGURE 33
30. 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 34: L.H. REAR ENGINE SUPPORT
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31. 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 35
32. 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 36
33. 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 37
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FIGURE 38: FOUR (4) SCREWS UNDER THE
REINFORCEMENT CHANNEL
FIGURE 39: REAR VIEW – GROUND STUD
FIGURE 40
FIGURE 41
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34. 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 42
35. Reinstall the water pump drive belt.
FIGURE 43: WATER PUMP DRIVEBELT
36. Reinstall the AC compressor drive belts.
37. 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 44: BRACKET #060102
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38. 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 45
39. Install the new idler #012349 with screw
#5001786 and washer #5002008.
Tighten to 59 lb-ft
FIGURE 46
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40. Install the dust cap #453076.
FIGURE 47
FIGURE 48
41. Install the new alternator belt tensioner
#510991. Secure with one screw #5001799 on
which blue Loctite is applied on the threads.
FIGURE 49: TENSIONER MOUNTING SCREW TORQUE : 48
lb-ft
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42. 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 50
FIGURE 51
43. Install the alternator.
A: screw #502950 & nut #5001728 (torque: 82 lbfft)
B: screw #5001800 & nut #5001930 (torque:
48lbf-ft)
C: apply blue Loctite and then torque to 48 lbf-ft
FIGURE 52
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Simultaneously, install the alternator “power
cable” support #050266 to the alternator as
shown on the picture.
FIGURE 53
44. Install the alternator pulley #0600265 (for further
details, refer to Maintenance Information IM1617).
Use washer #500449 and flanged nut #21429955
torque: 75 lbf-ft
FIGURE 54
45. Install the alternator drive belt #506026.
FIGURE 55
46. On the alternator, install the stud adapter
#060297 at B1+ stud terminal.
torque: 11 lbf-ft
FIGURE 56
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47. Perform the “Multiplex Modules Disconnection
Procedure Prior to Welding” found in your
vehicle Maintenance Manual, Section 00:
General.
48. Weld the new coolant filter support #050265 on
the engine cradle.
23 ½ inches from the end of the cradle
FIGURE 57
FIGURE 58
FIGURE 59
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FIGURE 60
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49. 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.
FIGURE 61
50. 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 62: GROUND STUD #380360
FIGURE 63: GROUND STUD #380360
51. Install a tie mount #509490 with one screw
#502686 at the back of the L.H. engine mount.
FIGURE 64
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52. Install the alternator ground cable #069504.
Secure to the ground stud on the alternator
using washer #502573 and nut #5001182.
torque: 6 lbf-ft
53. Secure the alternator ground cable to the
previously installed tie mount using one nylon tie
#509491.
FIGURE 65
54. 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 66
55. To the previously installed coolant filter support,
install the filter holder recovered from the former
installation.
FIGURE 67
56. 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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57. Transfer the drain plug and the coolant extractor
quick connect fitting saved from the old radiator
outlet pipe.
Apply Loctite 567 Thread
installation of the fittings
Sealant
prior
58. 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
FIGURE 68
B: drain plug
C: coolant extractor quick connect valve
D: # 053617 silicone hose
59. 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 69
60. 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)
FIGURE 70
b) Use the banjo fittings recovered from the
previous installation.
hose clamp torque: 30 lbf-in
FIGURE 71
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61. Install the 22″ long and 38″ long hoses prepared
at the previous step as shown on the images.
FIGURE 72
FIGURE 73
62. Connect the DEF injector coolant line return
hose to the radiator outlet pipe.
Use two (2) new banjo fitting copper washer
#507657
FIGURE 74: DEF INJECTOR COOLANT LINE RETURN HOSE
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63. 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
FIGURE 75
Oetiker clamps – unpainted spring : 8-9 lbf-in
Caillau clamps : 30 lbf-in
64. Secure the coolant hoses together using nylon
ties.
A : nylon tie (handcuff type) #N37749 (about 3 to
6, as required)
FIGURE 76
FIGURE 77
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65. Secure the coolant hose near the engine block
«push-lok» fitting as shown.
B : nylon tie #504016 (1x)
FIGURE 78
66. 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 79
FIGURE 80
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67. 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 81
FIGURE 82
68. Apply Color Guard rubber coating on the ground
stud connection.
FIGURE 83: GROUND STUD WITH RUBBER COATING
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69. Apply Color Guard rubber coating at the
alternator ground
connections.
(
)
and
positive
(+)
FIGURE 84: GROUND CONNECTION ON THE ALTERNATOR
FIGURE 85: POSITIVE (+) CONNECTION ON THE
ALTERNATOR
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70. 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
71. 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 86
FIGURE 87
FIGURE 88
FIGURE 89
72. 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 90
A: tie mount #509490
B: rivet #504610 (hole diameter: Ø 17/64)
C: nylon tie #509491
FIGURE 91
73. 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.
74. 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
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FIGURE 93
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75. 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 94
A: FAN TO RJB INTERFACE” HARNESS #23488790
B: FAN DRIVE POWER CABLE
C: NYLON TIES #504016 (23x approx.)
FIGURE 95
FIGURE 96
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FIGURE 97
76. 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 98: C: NYLON TIES #504016 (2x)
FIGURE 99: C: NYLON TIES #504016 (2x)
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77. 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: #030096 hose (1x)
B: #21490630 spring loaded clamp (2X)
FIGURE 100
Constant Torque hose clamps 4.25in - charge air
cooler (CAC)
4.5-5.5 lbf-ft
FIGURE 101: CONNECTION AT THE ENGINE INTAKE
ELBOW
FIGURE 102
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78. 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 103
79. On the diagonal member, change the existing
radiator inlet pipe bracket for the new bracket
#050305. Use the existing hardware.
FIGURE 104
80. Install the new radiator inlet pipe #050414.
A: #052889 silicone hose
B: # 992089 hose clamp (4x); torque: 30 lbf-in
FIGURE 105
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81. Install the new CAC inlet pipe #050286. Use
one new #030096 CAC flexible hose. Secure
the hose using two (2) spring loaded clamps
#21490630.
A: #030096 hose
B: #21490630 spring loaded clamp (2X), torque:
5 lbf-ft
FIGURE 106: CONNECTION AT THE TURBO OUTLET
ELBOW
82. Reinstall the cooling pack.
FIGURE 107
83. Place the cooling pack supports over the new
holes that were previously made.
FIGURE 108
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84. Secure the cooling pack base with the following
parts:
A: 4x screw #502804
B: 8x washer #5001751
C: 4x nut #502859
FIGURE 109
85. 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 110
FIGURE 111
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86. 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 112: BRASS FITTING ASSEMBLY
87. Remove the vent hose fitting found on the
radiator.
FIGURE 113
88.
Install the brass fitting assembly in place of
the former vent hose fitting and then connect
the radiator vent hose.
89. 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 114
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One end of the upper attachment is mounted
on the radiator frame (image at right)
FIGURE 115
Bolt the anti-vibration mount onto the
vehicle chassis
FIGURE 116
90. 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 117
91. 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
FIGURE 118
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For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 12
92.
Reinstall the lower cooling pack protector
tube with the following hardware:
4x Screw #502804
4x split lock washer #5001737
FIGURE 119
93.
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 120
FIGURE 121
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94.
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 122
95.
Prepare the sealing elements #050201 and
#050202. On both parts, apply foam tape
#506040 on the edges as shown on the
image.
FIGURE 123
96.
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 124
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97.
Cut two pieces of 39 inches (990 mm) long of
rubber extrusion #506025.
98.
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 125
FIGURE 126
99.
Install panel #050195. Secure with the
following hardware:
19x bolt #5001697
19x lock washer #502570
FIGURE 127
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100. Install the upper left #050204 and upper right
#050206 sealing elements.
Secure with the following hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 128
101. Install the lower sealing element #050213.
Secure with the following hardware:
5x bolt #5001697
5x lock washer #502570
FIGURE 129
102. Install the L.H. side sealing element #050208.
Secure with the following hardware:
4 bolts #5001697
4 lock washers #502570
FIGURE 130
103. Install the R.H. side sealing element #050255.
Secure with the following hardware:
4x bolt #5001697
4x lock washer #502570
FIGURE 131
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104. 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
FIGURE 132
Install with the following hardware:
32x bolts #502686
32x lock washers #5001833
Prescribed torque:30 lbf-in
105. Take note that each harness is labeled with a
number corresponding to an appropriate fan
location.
106. Snap the fan blue connector in the holes
punched on the panel for that matter.
FIGURE 133
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107. 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 134
FIGURE 135
108. Install the circuit breaker box #564512.
Install with the following hardware:
4x bolt #500119
4x lock washer #5001868
FIGURE 136
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A: 2x bolt #500119 + 2x lock washer
#5001868
FIGURE 137
A: 2x bolt #500119 + 2x lock washer
#5001868
109. Connect each fan to the corresponding
connection port on the circuit breaker box.
FIGURE 138
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110. Tighten the nylon ties previously installed
while routing the fan cables.
111. 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 139
112. Install the electrical connector cover #
050229.
Fasten with the following hardware:
4x bolt #5001697
4x lock washer #502570
113. Using good industrial glue (Loctite 404 or
similar product), glue three (3) pieces of
rubber extrusion #506025 as shown on the
connector cover.
FIGURE 140
FIGURE 141
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114. 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 142
115. 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)
NOTE
TRICK: Pre-twist the red and black cables counter-clockwise then insert the cables in their connector and lock. This will ensure that there’s
some pre-tension in the locking (clockwise) direction. This pre-tension will help the cables to
stays in place(locked position).
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116. 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 144
FIGURE 145
117. 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)
FIGURE 146
FIGURE 147
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INSTALLATION OF ELECTRIC COMPONENTS AND HARNESS
CONNECTIONS IN THE MAIN POWER COMPARTMENT
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DIAGRAM OF ELECTRICAL CONNECTIONS
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118. In the battery compartment, disconnect the
battery ground cable from the chassis ground
stud.
FIGURE 148
119. 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 149
120. 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 150
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FIGURE 151
121. Make sure this is no voltage applied to the
master relay R1 posts and then, remove the
master relay R1 cover.
FIGURE 152
122. Disconnect the four (4) cable lugs connected
to the master relay R1 upper post.
123. Momentarily, connect the angled lug of the
“master relay R1 to 300A fuse” cable
#23498450.
FIGURE 153
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124. 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.
125. 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 154
126. 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 155: 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.
127. Reinstall the master relay R1 cover.
FIGURE 156
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128. Place the 300A fuse #564520 in the fuse
holder underneath the cable lugs.
129. 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 157: TAKE NOTE THAT THE 300A FUSE IS NOT
SEEN ON THE PICTURE ABOVE BUT IT SHOULD BE
INSTALLED AT THIS STEP
130. 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 158
FIGURE 159
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131. Install the MCM #23499009-EFD and the I/OB 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 160: MAIN POWER COMPARTMENT
132. 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 161
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133. 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.
134. Connect the MCM and the I/O-B module
together using the “MCM to I/O-B interface
harness” #23445869.
135. 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 162
FIGURE 163
A:nylon tie #504016 (3x)
FIGURE 164
A:nylon tie #504016 (2x)
FIGURE 165
A:nylon tie #504016 (3x)
B:nylon tie #509491 (2x)
C:swivel mount #504751 (1x)
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FIGURE 166
B:nylon tie #509491 (2x)
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136. 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 167
137. Connect circuit 24VI, 24VD & GND2 to post
1, 2 & 5 respectively of the junction block.
FIGURE 168
138. Get the J1939 signal. To do so, locate
connector C193 among the existing
harnesses of the main power compartment.
139. Disconnect connector C193 and connect with
C193FS and C193FP of the “vehicle
interface harness” #23490553.
FIGURE 169
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140. In the main power compartment, locate I/O-B
module A52 (alternately named AE52).
141. At A52 (or AE52), remove existing circuit 291
and 292 from connector J1:1 (pin 1) and J1:2
(pin 2).
142. 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.
143. Insert circuit 291 and 292 of the “vehicle
interface
harness”
#23490553
into
connector J1 pin 1 and J1 pin 2 respectively.
FIGURE 170
144. Install the U-shaped telltale light module
bracket #381594 at an appropriate place in
the electrical compartment where it can be
reached by the “fan to RJB interface”
harness. Fasten to the bulkhead using two (2)
rivets #504379 (hole diameter: Ø 13/64).
145. Install two tab terminals #561540 on the 24V
red telltale light module (#830165) wires.
146. Install the telltale light module in the telltale
module bracket #381594. Using a P-Touch,
make a label indicating “LH ALT”.
147. Connect the appropriate branch of the “fan to
RJB interface harness” to the telltale light
module.
FIGURE 171
FIGURE 172
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148. 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 173
149. Place one (1) warning decal #069205 as
shown on the image.
FIGURE 174
150. Install a second warning decal #069205 as
shown on the radiator door.
FIGURE 175
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151. Fasten the
assembly.
radiator
door
upper
arm
FIGURE 176
152. Refill the cooling system. Connect coolant
extractor. Use coolant extractor to refill the
coolant from the engine.
FIGURE 177
153. Reinstall the bumper.
FIGURE 178
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154. Reinstall the access panel located behind
tag axle L.H. side wheel.
FIGURE 179
155. Reinstall the L.H. side rear fender.
FIGURE 180
156. In the battery compartment, connect the
battery ground cable to the chassis ground
stud.
FIGURE 181
157. In the main power compartment, set the battery master switch to the ON position.
158. Set the ignition switch to the ON position.
159. 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.
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IMPORTANT NOTE
VEHICLES EQUIPPED WITH OPTIONAL PRIME ENERGY MANAGEMENT SYSTEM
TO PREVENT OVERLOADING THE L.H. SIDE ALTERNATOR, IT IS VERY IMPORTANT TO
DISABLE « PRIME » SYSTEM ON VEHICLES RECEIVING THIS CONVERSION. PLEASE
CONTACT YOUR NEAREST PREVOST SERVICE CENTER TO HAVE THE PRIME SYSTEM
DISABLED. A SOFTWARE TOOL IS NEEDED TO DO SO.
SYSTEM TEST
160. Start the engine to idle.
161. 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.
162. 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.
163. Set the engine to the fast idle, the fans should then
engage at 100% of the maximum speed.
164. If the fans behave in accordance with the criterions
of the previous steps, then they operate normally.
FIGURE 182
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/
Federal)
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