IS-19910i

Instruction Sheet
IS-19910i
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH
DELCO REMY ALTERNATOR
H3 coaches (2PCH…) US10 to GHG17 incl. (B-1721 to J-0184)
REVISION : i
THIS DOCUMENT SUPERSEDES PREVIOUS VERSION.
Jan 17-23
Note added regarding power cable connection (step 114)
REVISION : H
THIS DOCUMENT SUPERSEDES PREVIOUS VERSION.
June 17-20
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
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.
Recommended Alternator Conversion Kits
Take note that you can install a Delco Remy 55SI 24V-250A alternator on the engine curbside using one
of the following recommended installation kit:
Kit:
IS19913
Applicable to: H3 Series, US10
Kit:
IS19908
Applicable to: H3 Series, from D-2364 up to J-0184
Writer:
EL

MATERIAL
Kit IS19910 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
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
012349
IDLER PULLEY
Mechanical
1
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012941
PULLEY, DRIVE
Mechanical
1
010090
L.H. ENGINE MOUNT
Mechanical
1
011213
SUPPORT, IDLER + TENSIONER
069893
PULLEY, DELCO REMY ALTERNATOR 10PK 69
DOB
Mechanical
1
453076
CAP, DUST
Mechanical
1
506067
1x BELT 10PK1703 ARAMIDE
1x BELT 10PK1703 ARAMIDE (for your spare kit)
Mechanical
2
510991
TENSIONER, BELT
Mechanical
1
560720
DELCO REMY ALTERNATOR 55SI 24V-250A
Mechanical
1
050286
CAC INLET PIPE H3 US10+
Pipe
1
050406
CAC OUTLET PIPE H3 US10+
Pipe
1
050414
RADIATOR INLET COOLANT PIPE H3 US10+
Pipe
1
050288
RADIATOR OUTLET PIPE H3 US10+
Pipe
1
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Mechanical
1

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Fitting
1
Fitting
1
Fitting
1
Fitting
1
HOSE 3/8 ID X 61'' LONG
hose
1
HOSE, FLEXIBLE - CHARGE AIR
Hose
1
Hose
1
Hose
1
Hose
1
Hose
1
Hose
3
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
052366
030096
Location: engine intake
550095
HOSE, FLEXIBLE - CHARGE AIR
Location: turbo outlet
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
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21490616
CLAMPS, SPRING LOAD - CHARGE AIR
Clamps
8
Clamps
4
Clamps
16
Clamps
4
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
992081
HOSE CLAMP CT CAILLAU 12-22
Location : coolant filter
21185073
MOUNT, ANTI-VIBRATION
Support
/bracket
1
050305
BRACKET, RADIATOR INLET PIPE
Support
/bracket
1
050265
COOLANT FILTER SUPPORT H3
Support
/bracket
1
050214
UPPER RADIATOR SUPPORT H3
Support
/bracket
1
069890
LH LOWER ALTERNATEUR SUPPORT
Support
/bracket
1
069891
LH UPPER ALTERNATEUR SUPPORT
Support
/bracket
1
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381594
U-SHAPED BRACKET, ALTERNATOR TELLTALE
Support
/bracket
1
069205
DECAL, WARNING
Misc.
2
010111
DECAL, BELT
Misc.
1
506025
RUBBER EXTRUSION, BLACK
Misc.
8 ft
380360
GROUND STUD
Misc.
1
506040
TAPE, ADHESIVE AD1 EPDM CC GY 5/16"X3/4"X25'
Misc.
1
21937327
FILTER, COOLANT
Misc.
1
012921
GROUND STUD
Electrical
1
56561540
TERMINAL, TAB
561610
CONNECTOR HOUSING, PED WEATHER-PACK 4
WIRES
Electrical
1
561783
CAVITY PLUG, CONNECTOR
Electrical
4
22722850
I/O-B MULTIPLEX MODULE
Electrical
1
23499009-EFD
MCM, PROGRAMMED
Electrical
1
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563593
CONNECTOR, WITH END-OF-LINE 120 OHMS
RESISTOR
Electrical
2
563750
FUSE HOLDER, AMG TYPE
Electrical
1
564520
FUSE, AMG 300A
Electrical
1
564612
CIRCUIT BREAKER BOX, WURTH
Electrical
1
565191
FAN, ELECTRIC
Electrical
8
563533
HAND GUARD, FAN
Electrical
8
830165
24V RED TELLTALE LIGHT MODULE
Electrical
23498721
FAN DRIVE POWER CABLE, 4600mm
Harness
1
23524934
L.H. ALTERNATOR POWER CABLE – DELCO
REMY
Harness
1
23498450
MASTER RELAY TO 300A FUSE CABLE, 300mm
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
068820
HARNESS, FAN DRIVE
Harness
1
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069246
GROUND CABLE, FAN DRIVE
Harness
1
0610037
CONTROL HARNESS, LEFT ALTERNATOR
Harness
1
0610035
GROUND CABLE, LEFT ALTERNATOR
Harness
1
N37749
TIE, NYLON, DOUBLE
hardware
15
509491
TIE, NYLON LARGE EXTRA STRONG 250 LBS
hardware
38
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
562679
MOUNT, SQUARE SELF-ADHESIVE BLACK
hardware
4
500411
WSH FL SS .260X.697X.05 (M6,1/4)
hardware
500449
WASHER, FLAT SS .687X1.5X0.078 (M16,5/8)
1
1
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500482
WASHER, SPLIT LOCK Z050 .506X.873X.125
(M12,1/2)
500942
WASHER, SPLIT LOCK N500 8.1X14.8X2
(M8,5/16,#18)
502570
WASHER, SPLIT LOCK SS 6.1X11.8X1.6 (M6,#12)
502573
WASHER FL SS 6.4 X 12.0 X 1.6 (M6,1/4)
507657
5001137
WASHER, BANJO FITTING M14
WSH FL SS .203X.438X.06 (M5,#10)
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
5001180
NUT HEX NYRT SS 10-24
5001182
NUT HEX NYRT SS M6-1
5001665
NUT HEX NYRT NX500 M22-2.5
5001761
NUT HEXF NYRT NX500 M12-1.75 G8
5001930
NUT HEXF NYRT NX500 M10-1.50 PC 10
5001983
500685
NUT HEX NYRT NSS M8-1.25
NUT HEX NYRT SS 5/16-18
500119
500658
SCREW, CAP HEX SS NSS M8X1.25X20
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
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8
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7
hardware
4
hardware
10
hardware
32
hardware
4
hardware
1
hardware
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hardware
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hardware
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hardware
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hardware
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1
hardware
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hardware
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11
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502848
SCREW TC HEX F N500 1/4-20X3/
5001296
5001308
SCREW, CAP HEXFN500 M12-1.75 X 80 CL10.9 PT
SCR CAP HEXF N500 M10-1.5X40 G10.9
hardware
22
hardware
6
hardware
hardware
4
3
hardware
62
hardware
4
hardware
2
hardware
1
hardware
4
hardware
2
5001643
SCREW, CAP HEXF G500 M8-1.25X25 G8.8 PT
5001697
SCREW, CAP HEX SS NSS M6X16
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
5001940
SCREW CAP HEX N500 M12X1.75X140
5002091
SCR CAP HEXF N500 M10-1.5X120 G10.9
hardware
504379
RIVET, POP DOME SS OE 3/16X1/4
hardware
4
41
504610
RIVET MGL PRDG SS 1/4X5/8
hardware
14
IS-19910
INSTRUCTION SHEET
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
NOTE
Material can be obtained through regular channels.
PROCEDURE
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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.
ELECTRICAL CABLES & HARNESSES DIAGRAM
HOSE CLAMP TORQUE (coolant lines and charge air cooler)
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HOSE CLAMPS
No
DESCRIPTION
1
(Ø 2 ½ ” or
lower)
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)
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EL
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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
(CB2,
CB4,
CB6,
lever
or
button
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.
Keep the three small (3) rectangular plates for
reuse
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.
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 10
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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 11
FIGURE 12
FIGURE 13
16. Remove the fan drive casting.
FIGURE 14
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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 15
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 16
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19. Remove the tripod from the radiator/CAC
assembly.
FIGURE 17
FIGURE 18
20. Remove the fan shroud.
FIGURE 19
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21. The new cooling pack arrangement requires
being located four inches closer to the engine
to give the needed clearance for the electric
fans. For this reason, rotate both the cooling
pack assembly mounting supports 180° and
reinstall.
BEFORE
FIGURE 20: MOUNTING SUPPORT IN INITIAL POSITION
AFTER
FIGURE 21: 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 22: NEW HOLES FOR THE COOLING PACK MOUNTING SUPPORTS
FIGURE 23: 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 24
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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 hose clamps, the flexible hoses for
later reuse
Keep the fittings found on the pump inlet pipe
for later reuse
FIGURE 25
FIGURE 26
25. Remove all the drive belts mounted on the crank
pulley.
FIGURE 27
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26. Remove the drive pulley. Discard the 6 bolts.
FIGURE 28
27. Remove the rust, clean and prepare the surface
on the vibration damper as shown. Make a
smooth surface for the pulley that will be
reinstalled later on.
FIGURE 29
FIGURE 30
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28. Properly support the engine as one of the
engine support will be interchanged.
FIGURE 31
29. Remove the two (2) coolant hoses shown on the
image. Keep the two (2) banjo fittings for later
use.
BANJO FITTING
FIGURE 32
30. Remove the L.H. rear engine support on which
the coolant filter is installed (10 bolts). Keep the
hardware for reuse.
Take note that the water pump belt
idler/tensioner assemble will be reused as is.
Do not take apart tensioner or idler.
FIGURE 33: L.H. REAR ENGINE SUPPORT
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31. Cut the engine cradle rail as shown to increase
the clearance between the cradle and the
alternator. Carefully work the edge to achieve a
smooth finish and contour.
Wear
appropriate
equipment.
personal
protection
Protect engine and area with blankets.
Blow area clean when completed.
Apply paint to protect the bare metal
FIGURE 34
32. Remove the water pump idler/tensioner
assembly from the former engine mount. To do
so, unscrew three (3) bolts at the back of the
engine mount.
FIGURE 35
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33. Reinstall the idler/tensioner assembly as a unit
on the new L.H. engine mount #010090.
Mount the idler/tensioner assembly using
three (3) cap screws #5001643
Tighten to 14-17 lb-ft
FIGURE 36
FIGURE 37
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34. Install the new engine mount #10090 using
seven (7) M14 screws saved from the former
engine support with the exception of:
•
Ground stud #012921 (1x) and nylon
insert NYRT nut #5001665 (1X)
•
•
Isolator cap screw #5001940 (2X)
Nut #5001761 (2X)
FIGURE 38
Seven (7) mounting screws torque : 90-94 lb-ft
(128 Nm)
FIGURE 39
Tighten ground stud to 94 lb-ft
Tighten stud nut to 94 lb-ft
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FIGURE 40
Tighten isolator screws to 60 lb-ft
35. 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 41
36. Reinstall the water pump drive belt.
FIGURE 42: WATER PUMP DRIVEBELT
37. Reinstall the AC compressor drive belts.
38. Install alternator
#069891.
brackets
#069890
and
Note: Install the upper bracket #069891 with
short end towards bumper and long end towards turbo.
Use:
4x cap screws #5001308
Apply blue Loctite
Tighten to 48 lb-ft
FIGURE 43
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39. Installing the LH alternator pulley. Place
#560720 alternator flat on a bench with the shaft
horizontal.
Required tools:
•
•
15-16” crowfoot adapter
8mm hex bit
Clean shaft and pulley with brake cleaner.
Slide pulley #069893 on shaft by hand.
Hand thread nut on shaft until snug.
Using thin wall15/16”adapter and 8mm hex bit to
block shaft rotation, tighten to 70-80 lbf-ft.
Never use power tools to install pulley and nut.
FIGURE 44
Note: Do not apply any pressure to end of the
shaft. Internal damage may occur if the shaft is
pushed back and turned.
40. Install alternator on support with four (4)
#5002091 M10x120 screws.
Apply blue Loctite
Tighten to 48 lb-ft
FIGURE 45
41. Install the idler support #011213 using:
3x screws #5001799
Tighten to 48 lb-ft
FIGURE 46
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42. Install the new idler #012349 with screw
#5001786 and washer #5002008.
Tighten to 59 lb-ft
FIGURE 47
43. Install the dust cap #453076.
FIGURE 48
FIGURE 49
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44. Install the new alternator tensioner #510991.
Secure with one screw #5001799 on which
blue Loctite is applied.
FIGURE 50: Tensioner mounting screw torque : 48 lb-ft
45. Install belt #506067. To do so, rotate the
automatic belt tensioner using a ½ square drive
breaker bar.
FIGURE 51
46. Remove former belt routing decal and replace
with decal #010111.
FIGURE 52
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47. Install control harness #0610037 on alternator.
Connect circuit I to Indicator (I) post.
Connect circuit S to Sense (S) post.
Use the following hardware:
•
•
2x nylon lock nut #5001180
2x washer #5001137
Tighten to the following torque values:
Sense (S): 25-45 lb-in
Indicator (I): 25-45 lb-in
Apply Color Guard Rubber Coating on the
connections.
FIGURE 53
FIGURE 54
48. Perform the “Multiplex Modules Disconnection
Procedure Prior to Welding” found in your
vehicle Maintenance Manual, Section 00:
General.
49. Weld the new coolant filter support #050265 on
the engine cradle.
23 ½ inches from the end of the cradle
FIGURE 55
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FIGURE 56
FIGURE 57
FIGURE 58
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50. As a preparation to welding, buff the paint to
reach bare metal. Weld the ground stud
#380360 centered in the beam and at 14 inches
from the beam end.
FIGURE 59
FIGURE 60: GROUND STUD #380360
51. Apply black paint to the area surrounding the
ground stud and also on the ground stud circular
base. DO NOT apply paint on the electrical
contact surfaces.
FIGURE 61: GROUND STUD #380360
52. Install a tie mount #504013 with one screw
#502686 at the back of the L.H. engine mount.
FIGURE 62
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53. Install the alternator ground cable #0610035.
Use the ground screw and lock washer supplied
with alternator with the addition of a flat
washer #500411.
torque: 50-60 lbf-in
54. Secure the alternator ground cable to the
previously installed tie mount using one (1)
nylon tie #509491.
FIGURE 63
FIGURE 64
55. Secure the alternator ground cable to the
previously installed ground stud on the L.H.
engine mount.
Use screw #502719 & washer #5001935
Tighten to 20 lbf-ft
Protection against corrosion. Apply Color
Guard rubber coating on the ground stud
once the ground cable is hooked up.
FIGURE 65
56. To the previously installed coolant filter support,
install the filter holder recovered from the former
installation.
FIGURE 66
57. Install the new coolant filter onto the filter holder.
Check the clearance between the filter and the
close hose clamps of the coolant pipe leading to
the transmission oil cooler.
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58. Transfer the drain plug and the coolant extractor
quick connect fitting saved from the old pump
inlet pipe.
Apply Loctite 567 Thread
installation of the fittings
Sealant
prior
59. Install the new radiator outlet pipe #050288.
Reinstall with the flexible hose #053617 and the
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 67
B: drain plug
C: coolant extractor quick connect valve
D: # 053617 silicone hose
60. 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 68
61. 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 38 inches long.
A : hose clamp #992081 (4x)
B: banjo fitting copper washer #507657 (6x)
FIGURE 69
b) Use the banjo fittings recovered from the
previous installation.
hose clamp torque: 30 lbf-in
FIGURE 70
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62. Install the 22” long and 38” long hoses prepared
at the previous step as shown on the images.
FIGURE 71
FIGURE 72
63. Connect the DEF injector coolant line return
hose to the radiator outlet pipe.
Use two (2) new banjo fitting copper washer
#507657
FIGURE 73: DEF INJECTOR COOLANT LINE RETURN HOSE
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64. Connect the coolant line coming 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 74
Oetiker clamps – unpainted spring : 8-9 lbf-in
Caillau clamps : 30 lbf-in
65. Secure the coolant hoses together using nylon
ties.
A : handcuff nylon tie #N37749 (3x)
FIGURE 75
FIGURE 76
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66. Secure the coolant hose near the engine block
«push-lok» fitting as shown.
B : nylon tie #504016 (1x)
FIGURE 77
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67. Hook up the “L.H. alternator power cable”
#234524934 to the alternator positive (+) post.
Place the flash washer between the cable lug
and the nut.
1x nut #500685
torque: 80-125 lbf-in
1x flat washer #5001341
Apply Color Guard rubber coating at the alternator
ground (
) and positive (+) connections.
IMPORTANT NOTE
FIGURE 78
Early alternators are provided with a shorter positive
stud.
With the short stud, nut #500685 does not thread
fully to allow the locking nylon insert to grip on the
threads.
In this case, DO NOT use nut #500685. Use the nut
and lock washer provided with the alternator instead. Tighten to: 80-125 lb-po (9.0-14.0 N-m).
FIGURE 79:
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NUT #500685 DOES NOT THREAD FULLY TO ALLOW
THE LOCKING NYLON INSERT TO GRIP ON THE
THREADS (UPPER IMAGE)
-
HARDWARE TO USE WITH SHORT STUD (LOWER
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68. 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 80
FIGURE 81
69. Apply Color Guard rubber coating on the ground
stud connection.
FIGURE 82: GROUND STUD WITH RUBBER COATING
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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
FIGURE 83
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 84
FIGURE 85
FIGURE 86
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 87
A: tie mount #509490
B: rivet #504610
C: nylon tie #509491
FIGURE 88
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 seven (5) tie mounts
#509490 fixed with seven (5) rivets #504610
(hole diameter: Ø 17/64). Secure the cables on
the tie mounts as previously done with fourteen
(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 90
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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 91
A: FAN TO RJB INTERFACE” HARNESS #23488790
B: FAN DRIVE POWER CABLE
C: NYLON TIES #504016 (23x approx.)
FIGURE 92
FIGURE 93
FIGURE 94
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76. 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) (torque:
5 lbf-ft)
FIGURE 95
FIGURE 96: CONNECTION AT THE ENGINE INTAKE ELBOW
FIGURE 97
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77. 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 98
78. On the diagonal member, change the existing
radiator inlet pipe bracket for the new one
#050305. Use the existing hardware.
FIGURE 99
79. Install the new radiator inlet pipe #050414.
A: #052889 silicone hose
B: # 992089 hose clamp (4x), torque: 30 lbf-in
FIGURE 100
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80. Install the new CAC inlet pipe #050286. Use
one new #550095 CAC flexible hose. Secure
the hose using two (2) spring loaded clamps
#21490630.
A: #550095 hose
B: #21490630 spring loaded clamp (2X), torque:
5 lbf-ft
FIGURE 101: CONNECTION AT THE TURBO OUTLET
ELBOW
81. Reinstall the cooling pack.
FIGURE 102
82. Place the cooling pack supports over the new
holes that were previously made.
FIGURE 103
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83. Secure the cooling pack base with the following
parts:
A: 4x screw #502804
B: 8x washer #5001751
C: 4x nut #502859
FIGURE 104
84. In case of interference between the charge air
cooler and the DPF inlet 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 105
FIGURE 106
85. 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
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D: #501332
FIGURE 107: BRASS FITTING ASSEMBLY
86. Remove the vent hose fitting found on the
radiator.
FIGURE 108
87.
Install the brass fitting assembly in place of
the former vent hose fitting and then connect
the radiator vent hose to the radiator.
88. 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 109
One end of the upper attachment is mounted
on the radiator frame (image at right)
FIGURE 110
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Bolt the anti-vibration mount onto the
vehicle chassis
FIGURE 111
89. 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) (torque: 5 lbf-ft)
B: #531471 flexible hose
C: #053617 silicone hose
D: #992089 (4x)
FIGURE 112
90. 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 (torque: 5 lbf-ft)
D: 4x clamp #992089
FIGURE 113
For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 12
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91.
Reinstall the lower cooling pack protector
tube with the following hardware:
4x Screw #502804
4x split lock washer #5001737
FIGURE 114
92.
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 115
FIGURE 116
93.
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
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FIGURE 117
94.
Prepare the sealing elements #050201 and
#050202. On both parts, apply foam tape
#506040 on the edges as shown on the
image.
FIGURE 118
95.
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 119
96.
Cut two pieces of 39 inches (990 mm) long of
rubber extrusion #506025.
97.
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 120
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FIGURE 121
98.
Install the fan support panel #050195. Secure
with the following hardware:
19x bolt #5001697
19x lock washer #502570
FIGURE 122
99.
Install the upper left #050204 and upper right
#050206 sealing elements.
Secure with the following hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 123
100. Install the lower sealing element #050213.
Secure with the following hardware:
5x bolt #5001697
5x lock washer #502570
FIGURE 124
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101. Install the L.H. side sealing element #050208.
Secure with the following hardware:
4 bolts #5001697
4 lock washers #502570
FIGURE 125
102. Install the R.H. side sealing element #050255.
Secure with the following hardware:
4x bolt #5001697
4x lock washer #502570
FIGURE 126
103. With a paint marker, identify the fans from 1
to 8 with the corresponding number found on
a label on their respective blue connector.
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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 127
Install with the following hardware:
32x bolts #502686
32x lock washers #5001833
Prescribed torque:30 lbf-in
105. Snap the fan blue connector in the holes
punches on the panel for that matter.
FIGURE 128
106. 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 129
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FIGURE 130
107. Install the circuit breaker box #564512.
Install with the following hardware:
4x bolt #500119
4x lock washer #5001868
FIGURE 131
A: 2x bolt #500119 + 2x lock washer #5001868
FIGURE 132
A: 2x bolt #500119 + 2x lock washer #5001868
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108. Connect each fan to the corresponding
connection port on the circuit breaker box.
FIGURE 133
109. Tighten the nylon ties previously installed
while routing the fan cables.
110. 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 134
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111. Install the electrical connector cover #
050229.
Fasten with the following hardware:
4x bolt #5001697
4x lock washer #502570
112. Using good industrial glue (Loctite 404 or
similar product), glue three (3) pieces of
rubber extrusion #506025 as shown on the
connector cover.
FIGURE 135
FIGURE 136
113. 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 137
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114. Complete the connection of the cables and
harness to the fan circuit breakers box (three
connectors: gray, black, 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).
FIGURE 138
115. 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 139
FIGURE 140
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116. 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 141
FIGURE 142
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INSTALLATION OF ELECTRIC COMPONENTS AND HARNESS
CONNECTIONS IN THE MAIN POWER COMPARTMENT
SCHEMATIC DIAGRAM OF ELECTRICAL CABLES & HARNESSES
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117. In the battery compartment, disconnect the
battery ground cable from the chassis ground
stud.
118. Most of the electric components will be
installed on the bulkhead at the right of
master relay R1 (when facing it). Identify the
master relay R1 on the image at right.
FIGURE 143
119. 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
sand to leave a smooth surface.
FIGURE 144
FIGURE 145
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120. Make sure this is no voltage at the master
relay R1 posts and then, remove the master
relay R1 cover.
FIGURE 146
121. Disconnect the four (4) cable lugs connected
to the master relay R1 upper post.
122. Momentarily, connect the elbowed lug of the
“master relay R1 to 300A fuse” cable
#23498450.
FIGURE 147
123. Find the best location where to install the fuse
holder #563750 on the bulkhead. Take note
that the fuse holder must be installed at the
distance that allows cable #23498450 to
reach it.
124. 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 screws #500658 (2x) + flat
washer #5001341 (2x)
FIGURE 148
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125. 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 149: 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.
126. Reinstall the master relay R1 cover.
FIGURE 150
127. Place the 300A fuse #564520 in the fuse
holder underneath the cable lugs.
128. 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 #23524934
A: nut #5001983 (2x)
B: washer #5001341 (2x)
Thread the nuts and tighten to a torque of 96
lbf-in (11Nm).
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FIGURE 151: TAKE NOTE THAT THE 300A FUSE IS NOT
PRESENT ON THE PICTURE ABOVE BUT IT SHOULD BE
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129. 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 152
FIGURE 153
130. 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 154: MAIN POWER COMPARTMENT
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131. 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 155
132. 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.
133. Connect the MCM and the I/O-B module
together using the “MCM to I/O-B interface
harness” #23445869.
134. 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 156
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FIGURE 157
A:nylon tie #504016 (3x)
FIGURE 158
A:nylon tie #504016 (2x)
FIGURE 159
A:nylon tie #504016 (3x)
B:nylon tie #509491 (2x)
C:swivel mount #504751 (1x)
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FIGURE 160
B:nylon tie #509491 (2x)
C:swivel mount #504751 (1x)

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135. 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 161
136. Connect circuit 24VI, 24VD & GND2 to post
1, 2 & 5 respectively of the junction block.
FIGURE 162
137. Get the J1939 signal. To do so, locate
connector C193 among the existing
harnesses in the main power compartment.
138. Disconnect connector C193 and connect with
C193FS and C193FP of the “vehicle
interface harness” #23490553.
FIGURE 163
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139. In the main power compartment, locate I/O-B
module A52 (alternately named AE52).
140. At A52 (or AE52), remove existing circuit 291
and 292 from connector J1:1 (pin 1) and J1:2
(pin 2).
141. 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.
142. Insert circuit 291 and 292 of the “vehicle
interface
harness”
#23490553
into
connector J1 pin 1 and J1 pin 2 respectively.
FIGURE 164
143. 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).
144. Install two tab terminals #561540 on the 24V
red telltale light module (#830165) wires.
145. Install the telltale light module in the telltale
module bracket #381594. Using a P-Touch,
make a label indicating “LH ALT”.
146. Connect the appropriate branch of the “fan to
RJB interface harness” to the telltale light
module.
FIGURE 165
FIGURE 166
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147. 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 167
148. Install one (1) warning decal #069205 as
shown on the image.
FIGURE 168
149. Install a second warning decal #069205 as
shown on the radiator door.
FIGURE 169
150. Fasten the
assembly.
radiator
door
upper
arm
FIGURE 170
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151. Refill the cooling system. Connect coolant
extractor. Use coolant extractor to refill the
coolant from the engine.
FIGURE 171
152. Reinstall the rear bumper.
FIGURE 172
153. Reinstall the access panel located behind
tag axle L.H. side wheel.
FIGURE 173
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154. Reinstall L.H. side rear fender.
FIGURE 174
155. In the battery compartment, connect the
battery ground cable to the chassis ground
stud.
FIGURE 175
156. In the main power compartment, set the
battery master switch to the ON position.
157. Set the ignition switch to the ON position.
158. 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.
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.
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SYSTEM TEST
159. Start the engine to idle.
160. 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.
161. 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.
162. Set the engine to the fast idle, the fans should then
engage at 100% of the maximum speed.
163. If the fans behave in accordance with the criterions
of the previous steps, then they operate normally.
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/
Federal)
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