Service Bulletin No. 1015 - ABC Companies · Figure 11: Surge tank filler tube bracket Figure 12: Radiator outlet tube 12.Remove the wire straps securing fan clutch electric lead

PAGE 1/16 DATE : FEB 9th, 1998SERVICE BULLETIN No. 1015

QUALITIES THAT MAKE THE DIFFERENCE

MODEL : T2140 & T2145

TYPE : Product improvement

MANUAL &

SECTION : Maintenance Manual: Chapter 2- Cooling System

DATE : February 9 th, 1998

SUBJECT : Intercooler and radiator removaland reinstallation

CONDITIONS : Parts may be obtained from International Coach PartsInc., 17469 West Colonial Drive, Building A, Wintergarden,FL 34787

DESCRIPTION : The removal and reinstallation of the T-2100 Seriesintercooler and radiator are fairly straightforward. On some vehicles however,difficulties may arise when trying to take the intercooler out of the radiatorcompartment. This is partly due to the lack of elasticity of the intercooler outletclosing rubber fitted to the engine flitch panel. Therefore this Service Bulletindescribes two methods of removal. The "Standard Procedure" details theremoval of intercooler and radiator on coaches that already have the modifiedsofter closing rubber fitted. The "Alternative Procedure" offers a solution forintercooler removal on vehicles equipped with the harder intercooler closingrubber. Finally a separate procedure explains how the engine flitch panel canbe modified to accept the softer closing rubber.

NOTE: Van Hool will cover the intercooler outlet closing rubber modification(parts according to list below and an additional labor cost of one and a halfhours to the flat rate of a radiator removal/installation) if the radiator orintercooler must be changed due to a warrantable failure.

Service Bulletin No. 1015

PARTSAlways use genuine maintenance products and parts. Do not accept imitations!

Part No.

VH 10632040VH 10632044VH 10632046

Service Bulletins are issued to supplement or supersede information in the Van Hool manuals. NoteService Bulletin number, date and subject on the register at the end of the relevant chapter(s). FileService Bulletin separately for future reference.

Description

Intercooler closing rubber, completeMounting bracket, shortMounting bracket, long

Qty.

111

PAGE 2/16SERVICE BULLETIN No. 1015DATE : FEB 9th, 1998

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SERVICE PROCEDURE:SERVICE PROCEDURE:SERVICE PROCEDURE:SERVICE PROCEDURE:SERVICE PROCEDURE:

!!! CAUTION !!!

USE SAFE SHOP PRACTICES AT ALL TIMESREAD ENTIRE PROCEDURE BEFORE BEGINNING WORK

1.1.1.1.1. PreparationsPreparationsPreparationsPreparationsPreparations

1. Put coach on level ground.

2. Apply parking brake.

3. Turn ignition off.

4. Place battery master switch in the “off” position.

5. Put “DO NOT OPERATE” tag on instrument panel to prevent inadvertentstarting.

6. Close gate valves (heating system shut-off valves).

• T2140:the gate valve in the heating system supply line is located behindthe right hand engine compartment door; the one in the heating returnline is accessible via the interior access trap above the transmission.

• T2145:both gate valves are located in the combustion heatercompartment on the left hand side of the coach (see figure 1).

7. Chock up wheels.

2.2.2.2.2. Intercooler and radiator removal: standard procedureIntercooler and radiator removal: standard procedureIntercooler and radiator removal: standard procedureIntercooler and radiator removal: standard procedureIntercooler and radiator removal: standard procedure

1. Open radiator compartment door.

2. Open engine compartment door.

Figure 1: Location of gate valves in T2145combustion heater compartment


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3. Allow engine to cool down.

4. Place a suitable container beneaththe radiator compartment to collectcoolant while draining the system.

5. Remove radiator filler cap (seeFigure 2) by slowly turning anti-clockwise.

!!! CAUTION !!!

WAIT UNTIL THE TEMPERATURE ISBELOW 50°C (120°F) BEFORE REMOVINGTHE COOLING SYSTEM PRESSURE CAP.

FAILURE TO DO SO CAN CAUSEPERSONAL INJURY FROM HEATED

COOLANT SPRAY.Figure 2: Radiator filler cap (1) andsurge tank (2)

Figure 3: Location of radiator draincock

Figure 4: Transmission oil cooler feed line(B500-transmission)

6. Open radiator draincock (seeFigure 3).

7. Working beneath the radiatorcompartment, loosen the hoseclamps of the transmission oilcooler feedline indicated in Figure 4.Detach the hose to drain thecoolant.

!!! CAUTION !!!

COOLANT CONTAINS TOXICSUBSTANCES. THEY MAY IRRITATE THEEYES. DO NOT SWALLOW OR INHALE.

AVOID PROLONGED OR REPEATEDCONTACT WITH THE SKIN.

NOTE

If the coolant is not going to bereused, dispose of used coolant andantifreeze in accordance with federal,

state and local regulations.


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8. Undo and remove the two M6angle gusset retaining boltsclamping the bottom door seal ofthe radiator compartment (seeFigures 5 and 6). Remove anglegusset and fold back the seal.

Figure 5: Location of angle gusset

Figure 6: Radiator compartment bottom doorseal

Figure 7: Radiator compartment bottomclosing plate

9. Undo and remove the three cap-screws securing the radiatorcompartment bottom closing plate(see Figure 7). Remove closingplate.

10.In the engine compartment,slacken the fan drive belts byloosening the idler pulley hub nut(2, Figure 8) first, then by turningthe hexagon head (1, Figure 8) ofthe threaded adjusting rod counter-clockwise to reduce tension.Remove the fan belts.

Figure 8: Engine to fan drive belt tensioner


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11.With diagonal cutter pliers, cutloose the surge tank and filler neckoverflow tubes (see Figure 9).Stow away tubes.

Figure 9: Surge tank and filler neck overflowtubes

Figure 10: Fan clutch electric connector

Figure 11: Surge tank filler tube bracket

Figure 12: Radiator outlet tube

12.Remove the wire straps securingfan clutch electric lead to engineflitch panel. Disconnect connectornear upper right hand fan supportbracket (see Figure 10).

13.On coaches equipped withCummins engine, undo andremove capscrew and nut securingsurge tank filler tube to fan clutchsupport bracket (see Figure 11).

14.Loosen hose clamps securing theradiator outlet tube (see Figure 12)and disconnect the tube.


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15.Disconnect and remove fanassembly steady bar on the lefthand side of the enginecompartment (see Figure 13).

Figure 13: Fan assembly steady bar

Figure 14: Radiator steady bar and surge tankbreather hose

Figure 15: Lower left hand fan and clutchcarrier retaining screws

Figure 16: Upper left hand fan and clutchcarrier retaining screws

16.Disconnect and remove radiator tochassis steady bar (1, Figure 14).Slacken hose clamp and detachsurge tank breather hose fromradiator (2, Figure 14).

17.Starting at the bottom, undo andremove three of the four capscrewsand locknuts securing the fan andclutch carrier to the left hand radia-tor support brackets (see Figures15 and 16). Slacken the toplocknut so that it can be undone byhand but leave the capscrew inplace.


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Figure 17: Fan and clutch carrier retainingbolts (right hand)

Figure 18: Engine cooling fan assembly

Figure 19: Lower hose clamps of surge tankfiller tube (1) and radiator inlet tube (2)

Figure 20: Upper hose clamps of surge tankfiller tube (1) and radiator inlet tube (2)

18.Withdraw three of the four boltssecuring the fan and clutch carrierto the right hand side of the radia-tor (see Figure 17). Loosen the topbolt so that it can be removed byhand.

19.With the aid of an assistant,withdraw the upper carrier retainingscrews and lift out the enginecooling fan assembly from theradiator cowling (see Figure 18).

!!! CAUTION !!!

THIS COMPONENT WEIGHS 23 KG(50 LB) OR MORE. TO AVOID PERSONAL

INJURY AND/OR DAMAGE TO THEVEHICLE, GET ASSISTANCE TO HANDLE

THE COMPONENT.

20.On coaches equipped withCummins engine, sloosen lowerhose clamps of surge tank fillertube (1, Figure 19) and radiatorinlet tube (2, Figure 19).

21.On coaches equipped withCummins engine, loosen upperhose clamps of surge tank fillertube (1, figure 20) and radiator inlettube (2, Figure 20). Detach andremove both tubes.


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22.On coaches equipped with DetroitDiesel engine, undo and removethe support bracket retainingscrews of the surge tank filler tube(1, Figure 21) and radiator inlettube (2, Figure 21).

Figure 21: Support bracket retaining screwsof the surge tank filler tube (1) and radiatorinlet tube (2)

Figure 22: Upper and lower hose clamps ofsurge tank filler tube and radiator inlet tube

Figure 23: Cummins intercooler outlet hose

Figure 24: DD intercooler outlet bellows (viewfrom passenger compartment)

23.On coaches equipped with DetroitDiesel engine, loosen upper andlower hose clamps of surge tankfiller tube and radiator inlet tube.Detach and remove both tubes.

24.On coaches equipped withCummins engine, loosen upperconstant-torque hose clamp ofintercooler outlet hose (see Figure23). Detach hose.

25.On coaches equipped with DetroitDiesel engine, loosen both con-stant-torque hose clamps retainingintercooler outlet bellows (seeFigure 24). Slide bellows over airintake duct.

26.Remove coolant receptacle fromunder coach.


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27.Undo and remove the rubber bufferretaining nut (1,Figure 25) and thethree capscrews securing the leftintercooler support bracket to theradiator (2, Figure 25). Removesupport bracket.

Figure 25: Left intercooler support bracketand mounting hardware

Figure 26: Right intercooler support bracket

Figure 27: Intercooler bottom plate

Figure 28: Intercooler inlet hose

28.Undo and remove the rubber bufferretaining nut and the three cap-screws securing the rightintercooler support bracket to theradiator (see Figure 26). Removesupport bracket.

29.Remove intercooler bottom plate(see Figure 27).

30.Using a hydraulic transmission jackand a wooden block, support theintercooler at the base and raise itslightly. Loosen the two constanttorque hose clamps securing theintercooler inlet hose and removethe hose (see Figure 28).


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Figure 29: Radiator buffer: left

Figure 30: Radiator buffer: right

Figure 31: Fan and clutch carrier supportbrackets

31.With the aid of an assistant, lowerthe intercooler, tilt it and carefullyease it out of the radiator compartment.

!!! CAUTION !!!

THIS COMPONENT WEIGHS 30 KG(66 LB). TO AVOID PERSONAL INJURYAND/OR DAMAGE TO THE VEHICLE OR

COMPONENT, GET ASSISTANCE TOHANDLE IT.

NOTE

If the intercooler cannot be removedfrom the radiator compartment, referto the alternative service procedure

further in this bulletin.

32.Using a hydraulic transmission jackand a wooden block, support theradiator at the base and raise itslightly.

33.Unscrew and remove the radiatorbuffer retaining nuts (see Figures29 and 30). Withdraw the largeplain washers and rubber bufferhalves.

34.With the aid of an assistant, turnthe radiator around its vertical axisuntil the fan and clutch carriersupport brackets (see Figure 31)show up in the radiatorcompartment. Taking care to keepthe brackets in the right order andthe correct way round, unscrew theretaining bolts and withdraw thebrackets.

35.With the aid of an assistant, lowerthe radiator, tilt it and carefullyease it out of the radiatorcompartment.

!!! CAUTION !!!

THIS COMPONENT WEIGHS 60 KG(132 LB). TO AVOID PERSONAL INJURYAND/OR DAMAGE TO THE VEHICLE OR

COMPONENT, GET ASSISTANCE TOHANDLE IT.


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Figure 32: Cummins intercooler outlet hose,lower clamp (view from passenger compart-ment)

3.3.3.3.3. Intercooler removal: alternativeIntercooler removal: alternativeIntercooler removal: alternativeIntercooler removal: alternativeIntercooler removal: alternativeservice procedureservice procedureservice procedureservice procedureservice procedure

If the intercooler cannot be removedfrom the radiator compartment, somemodifications of the engine/radiatorflitch panel are necessary. Proceed asfollows:

1. On coaches equipped withCummins engine, loosen lowerconstant-torque hose clamp ofintercooler outlet hose (see Figure32) inside engine compartment.Detach and remove hose.

2. On coaches equipped with DetroitDiesel engine:

a. Inside engine compartment,undo and remove the bolts,nuts and springwasherssecuring the power steering oiltank to the chassis (see Figure33). Lift away the unit and tie ittemporarily to the HVACcompressor with wire straps.

b. Unscrew the air duct clampassembly retaining nuts (seeFigure 34). Remove clampassembly.

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Figure 33: Power steering oil tank retainingscrews

Figure 34: Air duct clamp assembly


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c. Loosen intake manifold con-stant-torque hose clampindicated in Figure 35. Removeair duct with intercooler bellowsand intake hose.

3. Below the surge tank, an optionalcoolant temperature gauge may beinstalled (see Figure 36). Usediogonal cutter pliers to remove thewire straps securing thetemperature gauge lead.

4. Next to the surge tank is amounting plate with two solenoidair valves, a control valve, apressure regulator and a distributorblock (see Figure 37). Undo andremove the two M8 retainingscrews left and right of themounting plate and lift the com-plete assembly out of the way. Theintercooler closing rubber can nowbe reached (see Figures 38 and39).

Figure 35: Intake manifold hose clamp

Figure 36: Optional coolant temperature gauge

Figure 37: Air valve mounting plate

Figure 38: Intercooler closing rubber, Cummins(view fom passenger compartment)

Figure 39: Intercooler closing rubber, DetroitDiesel (view from passenger compartment)


5. a. With a steel ruler, measure theheight of the flitch panelmounted rubber. It should be232 mm (9 1/8 inch) high (seeFigure 40). Remove the lowerpart of the rubber by cuttingalong the edges of the mountingframe with a utility-knife asindicated by dotted line.

b. If the height of the rubbermeasures 172 mm (6 3/4 inch),first remove the rubber asexplained in item 5a (see alsoA - Figure 41).Next, cut through the lower partof the mounting frame andthrough the flitch panel steelwith a reciprocating saw tomodify the flitch panel openingas shown by B - Figure 41.

!!! CAUTION !!!

WHEN MODIFYING THE FLITCH PANELOPENING, TAKE GREAT CARE NOT TO

DAMAGE THE INTERCOOLER WEB.MAKE THE TWO VERTICAL CUTS FIRSTAND FOLD THE LIP BACK 90° TOWARDSTHE ENGINE. FINISH THE MODIFICATION

BY MAKING THE HORIZONTAL CUTWITH THE INTERCOOLER REMOVED.

6. The intercooler can now beremoved from the radiatorcompartment as explained in“Intercooler and Radiator Removal:Standard Procedure” item 31.

Figure 40: Intercooler closing rubber, heightand cutting line

Figure 41: Intercooler closing rubber, removaland flitch panel modification

9 1/8 inch

T04493

6 3/4 inch

2 3/8 inch

A

BT04496


Figure 43: Mounting frame, 9/32 inch cornerholes

4.4.4.4.4. Flitch panel modificationFlitch panel modificationFlitch panel modificationFlitch panel modificationFlitch panel modification

With the intercooler and radiatorremoved from the radiatorcompartment, the flitch panel openingcan easily be modified to accept adetachable intercooler closing rubber.Proceed as follows:

1. From inside the radiatorcompartment, using a pneumatichand drill and a 5/32 inch drill bit,remove the rivets securing theclosing rubber mounting frame tothe flitch panel. Remove theremains of frame and rubber.

2. Cut flitch panel opening to size asshown in Figure 42. Deburr cuttingedges with multi-cut file.

3. Using intercooler outlet closingassembly (VH 10632040) as atemplate, drill mounting framecorner holes in flitch panel out to9/32 inch diameter (see Figure 43).

4. From inside the radiatorcompartment, have an assistantpush the mounting bracket studs ofthe long bracket (VH 10632046)through the bottom corner holes,and the studs of the shortmounting bracket (VH 10632044)through the upper corner holes.

Figure 42: Flitch panel opening dimensions

4 39/64 inch

5 1/8 inch6

31/3

2 in

ch

9 1/

8 in

ch

T04494


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5. Slide the intercooler outlet closingassembly over the studs protrudinginto the engine compartment andsecure with M6 self-locking nuts .See figure 44 for completedinstallation.

Figure 44: Intercooler outlet closing assembly,completed installation

5.5.5.5.5. Radiator and intercooler installation.Radiator and intercooler installation.Radiator and intercooler installation.Radiator and intercooler installation.Radiator and intercooler installation.

1. Reinstallation of radiator and intercooler is the reverse sequence to removal.

2. Once the installation completed, seal off the bottom closing plate in theradiator compartment with black neutral silicone sealer.

3. To tighten fan belts, refer to Chapter 3 of the Maintenance Manual.

4. To fill the cooling system, refer to Chapter 2 of the Maintenance Manual.

5. Open the gate valves.

6. Start engine and allow to run for 20 minutes. Check cooling system plumbingfor leaks. Check induction system hose clamps for tightness. Rectify ifnecessary.

7. Check “all systems go” on multifunction display (indicated by an asterisk onthe bottom middle of multifunction display).

8. Remove wheel chocks and warning label on instrument panel.

9. Shut down engine.

Procedure complete.

SERVICE INFORMATION:SERVICE INFORMATION:SERVICE INFORMATION:SERVICE INFORMATION:SERVICE INFORMATION:

1. Parts

Parts will be made available for service purposes only.


2. Tools

Following tools and products will be needed to execute the proceduredescribed in this Bulletin.

• 3/8" drive metric socket & ratchet set

• 1/2' drive ratchet

• 17,19 and 22 mm 1/2' drive sockets

• 1/2' drive breaker bar

• 10, 13, 17, 19 and 22 mm box wrenches

• 1/4' drive 9/32 inch socket

• 1/4' flexible driver

• utility knife

• reciprocating saw

• multi-cut flat file

• pneumatic hand drill

• 4 and 7 mm drill bits

• diagonal cutter pliers

Service Bulletin No. 1015 - ABC Companies · Figure 11: Surge tank filler tube bracket Figure 12: Radiator outlet tube 12.Remove the wire straps securing fan clutch electric lead

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