Service Bulletin No. 241 MODEL TYPE SECTION/GROUP DATE E4500 / J4500 Series Coaches Field Change Program 16-- HVAC Apr. 27, 2005 SUBJECT SPORLAN WATER VALVE FLOW WASHER CONDITIONS Description: MCI is informing our customers that CARRIER TRANSICOLD A/C INDUSTRIES is instituting a Field Change Program to improve the reliability of the of the Sporlan water valve installation. As a result, MCI advises that owners of E4500 / J4500 model coaches in the range of, and including, unit numbers 62341 to 63090 implement the specified steps in this procedure. Parts Qty. New P/N Description 1 16-08-6190 Flow Washer a/r 16-08-6191 Installation Tool a/r 16-08-6192 Diaphragm ( if required upon inspection ) Service Procedure: General notes Read this entire procedure before beginning work. UseSafeShopPracticesAtAllTimes. 1. Turn the main battery disconnect switch to the OFF position. 2. Open the # 3 baggage bay compartment door. Locate and open the main evaporator access door. 3. Locate the water valve in the main evaporator compartment ( Figure 1 ). water valve location Figure 1. Water valve location in main evaporator compartment.
Service Bulletin No. 241 DATE APR. 27, 2005 PAGE 4. Visually inspect and verify which type of water valve is installed on the coach ( Figure 2 ). Parker water valve Sporlan water valve Figure 2. Water valve identification. If a Parker water valve is installed on the coach, close the main evaporator access and # 3 baggage bay compartment doors. NO further action is required. If a Sporlan water valve is installed on the coach, proceed to Step 5. 5. Place a blanket or tarp over the motor and relays to protect them from any coolant that may spill. 6. Using hose clamps, clamp off the inlet and outlet hoses ( Figure 3 ). Figure 3. 7. Position a clean container under the water valve, to collect any coolant. 2
Service Bulletin No. 241 DATE APR. 27, 2005 PAGE 8. Remove and retain the four bolts that secure the stem assembly to the water valve body. 9. Note the orientation of the diaphragm, to ensure it is properly re-installed. Position your hand under the water valve. Carefully remove the stem assembly, ensuring that the spring, o-ring and diaphragm are retained. If the diaphragm does not fall out when the stem assembly is removed, carefully remove it. Coolant may be trapped behind the diaphragm. 10. Using a hook tool, remove the flow washer ( Figure 4 ). Discard the flow washer. To avoid damaging the seal, DO NOT pry out the flow washer. Sporlan water valve flow washer Figure 4. 11. Using a clean rag, clean the valve of any debris. 12. Orientate and place the new flow washer ( part number 16-08-6190 ) in the water valve, with the outer edge ( concave ) facing outwards towards the baggage bay compartment. 13. Re-position any obstructions that prevent the rubber mallet from squarely hitting the entire face of the installation tool on the flow washer. 14. Seat the flow washer using the installation tool ( part number 16-08-6191 ) and a rubber mallet, ensuring that force is applied squarely around the entire face of the installation tool. 15. Using a clean cloth, carefully remove any debris from the diaphragm ( clean the small hole ). Inspect the diaphragm for any signs of damage. If damaged, replace diaphragm ( part number 16-08-6192 ). 16. Re-install the cleaned diaphragm and then the spring. 17. Using the four screws removed in Step 8., secure the stem assembly to the water valve body. Torque to 6 ft-lbs. 18. Carefully remove the hose clamps, ensuring no damage to the inlet and outlet hoses. 19. Turn the main battery disconnect switch to the ON position. Start up the engine. 20. Check for leaks. Check the coolant level. Add coolant as required. 21. Close the main evaporator access and the # 3 baggage bay compartment doors. Procedure complete. 3
Service Bulletin No. 241 DATE APR. 27, 2005 PAGE 4 Mail or fax the completed warranty claim form to MCI s warranty department, or photocopy and mail it to: MCI Fleet Support Attn: Warranty Department 7001 Universal Coach Drive Louisville, KY 40258 Fax Number 1-800--- 360--- 8886 to receive credit for the hours used to complete this task. 1-800-241-2947 for any further information. Contact the MCI Fleet Support Technical Center at Field Change Program Conditions: The parts required for this change will be supplied without charge. A labor allowance of 0.5 hours will be granted, for the procedure of installing the specified part(s) in this bulletin on E4500 and J4500 model coaches. This labor allowance will be credited to your MCI Fleet Support Parts Account on receipt of a Warranty Claim Form as detailed in your Owner Warranty manual. This program will end on October 27, 2005. Motor Coach apologizes for any inconvenience resulting from this campaign, but urges you to implement this change as soon as possible. Sincerely, Motor Coach Industries U.S. and Canadian Service Departments.
In an effort to better serve our customers, MCI is requesting that you complete this form in conjunction with Field Campaign 241. Until October 27, 2005 fax this completed form to: To: Motor Coach Industries HVAC Survey Fax: (502) 318-3199 Date: VIN: Main water valve manufacturer: Sporlan Parker Main water valve tested: No Yes, Passed Yes, Failed Sporlan valve diaphragm inspected for tears and abrasion: No Yes, Passed Yes, Failed Sporlan diaphragm replaced: No Yes Completed by: (Please Print) Thank you! Motor Coach Industries