Printed in Canada

Service Bulletin No.2793MODEL TYPE SECTION/GROUP DATE

SUBJECT

CONDITIONS

102 E / ELS Series Coaches Product Improvement

HORTON FAN CLUTCH

Parts may be purchased from MCI Service Parts, Louisville, Kentucky or from MCIService Parts, Newcastle, Ontario.

7--Electrical July 11, 2001

Description:Effective with unit number 61572 on 102 E model coaches and unit number 61609 on 102 ELS model coaches, MCI hasmade design changes to the engine fan clutch installation which will extend the service life of the clutch.

102 E SERIES PARTS LISTQty. Old P/N Description1 07-06-1001 Solenoid, fan controls, HumphreyQty. New P/N Description1 07-13-1097 Valve assembly, fan controls, S60 only1 07-13-1118 Valve assembly, fan controls, S60 / CAT / CUMMINS1 07-13-1098 Filter, fan controls1 07-13-1099 Harness, fan controls2 07-13-1101 Seal, rear junction box4 19-03-0519 Nut, hex, lock, flanged, 1/4---204 19-1-11 Capscrew, 1/4---20 x 0.751 19-10-2381 Fitting, 45 degree elbow, 1/4 NPT to JIC 61 19-10-489 Fitting, nipple, 1/4 NPT hex, steel2 19-12-4 Grommet, 3/8 inch I.D., 1/16 groove, rubber10 inch 07-13-1125 Tube, airline, 3/8 inch O.D., blacka/r Thread sealant

1 07-13-1103 Junction box, rear ( OPTIONAL )

NOTEThe customer can purchase the optional, new rear junction box instead of reworking the existing junctionbox.

Service Information:1. Old and new parts are not interchangeable.2. Old and new parts will be available for service replacement.

102 ELS SERIES PARTS LISTQty. New P/N Description2 19-10-2424 Fitting, cap nut, JIC # 6

Service Information:1. Old and new parts are not interchangeable.2. Old and new parts will be available for service replacement.

Service Procedure:General notesRead this entire procedure before beginning work.Use Safe Shop Practices At All Times.

Printed in Canada

PAGEDATE 2Service Bulletin No. 2793

102 E SERIES RETROFIT PROCEDURE1. Turn the main battery disconnect switch to the OFF position.2. Exhaust the coach air by pulling the drain cock on the suspension tank located in the front wheel housing.3. Open the side service door and push the engine door release lever.4. Open the engine door and locate the rear junction box---remote control. Position the ENGINE RUN and

REMOTE START switches to the OFF position.5. Remove the four screws from the cover plate. Pull the cover plate down to access the valve assembly

( Figure 1 ).6. Locate the valve assembly 4 pin Deutch harness ( Figure 1 ). Disconnect the harness.7. Disconnect the main harness from the junction box, by turning the metal collar counter-clockwise

( Figure 1 ).8. Disconnect the two stainless steel air lines from the female cross ( Figure 1 ).

NOTECrack the fittings loose, to allow any trapped air to bleed off.

9. Locate the three bolts that mount the junction box to the bracket ( Figure 1 ). Remove the three mountingbolts.

10. Remove the junction box from the engine compartment, and place on a workbench.11. Remove the existing valve assembly, the female cross, the 1/8 NPT to JIC 4 elbow, and the airlines from the

junction box ( Figure 1 ).12. Remove and retain the two mounting bolts and nuts from the pressure protection valve ( Figure 1 ).

Remove the pressure protection valve.

disconnect4 pin deutchharness

disconnectmain harness

femalecross

pressure protectionvalve

Figure 1. Existing valve assembly.

Printed in Canada

PAGEDATE 3Service Bulletin No. 2793

NOTEIf the customer has purchased the optional, new rear junction box, then the steps in this procedure referringto drilling holes in the junction box can be omitted.

13. Using a 1 1/4 inch hole saw, drill two holes at the dimensions outlined in Figure 3.14. Using a knife, cut the airline tube ( part number 21---7408---156 ) in half. Using a 5/8 inch drill bit, drill a hole

for the airline tubes, in line with the two fittings, through each side of the junction box ( Figures 2 and 8 ).Install the grommets ( part number 19---12---4 ) into the holes.

15. Install the two seals ( part number 07-13-1101 ), over the 1 1/4 inch holes, on the inside of the box( Figure 2 ).

16. Install the pressure protection valve to the valve assembly. Install the valve assembly, with the pressureprotection valve connected, to the junction box using the two mounting bolts and nuts removed in Step 12( Figure 2 ).

17. Using a 9/32 inch drill bit, match drill four holes, used to mount the valve assembly, through the junction box( Figure 2 ).

18. Install the valve assembly to the junction box, using the two outside holes only, using two capscrews ( partnumber 19-1-11 ) and two nuts ( part number 19-03-0519 ) ( Figure 2 ).

19. Install the 1/4 NPT to JIC 6 elbow ( part number 19-10-2381 ) and the existing 1/8 NPT toJIC 4 elbow into thevalve assembly ( part number 07-13-1097 ) ( Figure 8 ).

filter

pressureprotectionvalve

female crossairline tube

outside hole (Step 18)

seal ( 2 )insidehole

airlinetube

Figure 2. Fan controls valve assembly.

Printed in Canada

PAGEDATE 4Service Bulletin No. 2793

2.204.314.42

6.537.227.48

4.035.40

7.649.01

1.25DIA

TOP

Figure 3.20. Using a pencil grinder, ream out a section of the bracket allowing clearance for the hex nut ( Figures 4 and

5 ).21. Align the bottom hole on the junction box to the hole on the bracket ( Figure 4 ). Install the junction box to

the bracket using one of the existing mounting screws removed in Step 9.

NOTEEnsure that the junction box is square to the bracket.

junction boxmounting bracket

Figure 4.

Printed in Canada

PAGEDATE 5Service Bulletin No. 279322. Using a 9/32 inch drill bit, match drill the two inside valve assembly mounting holes in the bracket, from the

junction box. Install the junction box to the bracket, using the two inside holes, using two capscrews ( partnumber 19-1-11 ) and two nuts ( part number 19-03-0519 ) ( Figure 5 ).

Figure 5. Rear view of junction box mounted to bracket.23. Apply thread sealant to the threads on the nipple ( part number 19---10---489 ). Install the nipple to the outlet

fitting on the fan control filter ( part number 07---13---1098 ). Install the fan control filter, with the nippleconnected, to the pressure protection valve ( Figure 6 ).

24. Using two wrenches, install the female cross to the “ IN ” port of the fan control filter ( Figures 6 and 7 ).

“ IN “ port offan control filter

Figure 6.

Printed in Canada

PAGEDATE 6Service Bulletin No. 279325. Connect the fan control harness ( part number 07---13---1099 ) to the fan control valve assembly.26. Connect the fan control harness to the main 4 pin deutsch harness.27. Connect the main harness to the junction box, by turning the harness head clockwise.28. Re---connect the two stainless steel airlines to the female cross, removed in Step 8.29. Re--- install the four screws to the cover plate.30. Position the ENGINE RUN and REMOTE START switches to the ON position.31. Close the engine door.

To ensure proper installation, perform a fan test following the steps outlined below.1. Using a piece of cardboard, block the radiator and half of the charge air cooler.2. Start up the coach, and raise to 2100 r.p.m. Watch and monitor the coolant temperature gauge on the

instrument panel.

NOTETemperatures will vary, depending upon engine manufacturer.

3. At approximately 196 degrees ( on the coolant temperature gauge ), the fan should go from OFF to LOWspeed.

4. At approximately 205 degrees, the fan should go from LOW speed to HIGH speed.

NOTERemove the cardboard.

5. At approximately 190 degrees, the fan should return to LOW speed.6. At approximately 176 degrees, the fan should turn OFF.

Procedure complete.

Printed in Canada

PAGEDATE 7Service Bulletin No. 2793

female cross

Figure 7. Side view.

19--10--2381

existing elbow

Figure 8. Rear view.

Printed in Canada

PAGEDATE 8Service Bulletin No. 2793

102 ELS SERIES RETROFIT PROCEDURE

1. Turn the main battery disconnect switch to the OFF position.2. Open the side service door and push the engine door release lever.3. Open the engine door and locate the rear junction box---remote control. Position the ENGINE RUN and

REMOTE START switches to the OFF position.4. Locate the #6 fan brake hose ( larger hose ), on the back of the junction box.5. Disconnect the #6 fan brake hose from the #6 JIC fitting on the back of the remote control.6. Install the cap ( part number 19---10---2424 ) on the #6 JIC fitting.

hoseassemblies

Figure 9.

7. Disconnect the end of the #6 fan brake hose from the fitting ( Figure 10 ).8. Remove applicable p---clips, and discard the #6 fan brake hose.9. Install the cap ( part number 19---10---2424 ) on the fitting ( Figure 10 ).

10. Position the ENGINE RUN and REMOTE START switches to the ON position.11. Close the engine door.

NOTEReplacing the #6 fan brake hose with a cap changes the operation of the fan. The fan will always be turning atLOW or HIGH speed, there will be no OFF condition.

Printed in Canada

PAGEDATE 9Service Bulletin No. 2793

female cross

Figure 10.

Procedure complete.