NHTSA ID Number: 10167371
Manufacturer Communication Number: SB 3121
TSB/Document Date: 2019-11-08
Summary
The Service Bulletin informs owners of model year 2019 J4500 model coaches equipped with an ISX, X12, or DD13 engine with E-fan to replace the existing T bolt charge air cooler ("CAC") clamps, MCI
P/N: 19-04-0482, with a new clamp, MCI P/N: 19-04-0539, and to torque all CAC clamps on the coach to 70-80 In-lbs. instead of 90-110 In-lbs.
Service Bulletin No. 3121
MODEL:
TYPE:
J4500
SECTION/GROUP:
Service Information
DATE:
10/07/2019
06- Cooling
SUBJECT:
J coach CAC clamps replacement
CONDITIONS:
Service Information Only
Description:
Motor Coach Industries (“MCI”) is instructing customers operating MY19 J-4500 coaches equipped with an
ISX, X12, or DD13 engine with E-fan to replace the existing T bolt charge air cooler (“CAC”) clamps, MCI P/N:
19-04-0482, with a new, more reliable clamp, MCI P/N: 19-04-0539, and to torque all CAC clamps on the
coach (old and new) to 70-80 In-Lbs instead of 90-110 In-Lbs.
This service bulletin applies to MY19 J4500 coaches in the VIN range 68983-69554.
Read this entire procedure before beginning work.
Use Safe Shop Practices At All Times.
To avoid personal injury:
a. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses and
protective gloves are required for working with DEF Fluid.
b. Turn the main battery disconnect switch to the OFF position.
c. Ensure that both the front and the rear wheels are chocked.
d. Position the ENGINE RUN and ENGINE START switches on the engine
compartment remote control box to the OFF position.
e. Allow enough time for components to cool down prior to working in the engine
compartment
Motor Coach Industries Ltd.
Page 1 of 14
Service Bulletin No. 3121
1.0
Special Tools
10-150 Lb torque wrench with 1/2” socket.
2.0
Rework instruction
Open the engine door using the latch behind the curb side service door.
Rotate the lever counter
clockwise
To replace the clamps, follow the rework instructions listed below based on the engine type.
2.1
Units equipped with an ISX engine
2.1.1
Material requirement
ITEM
PART NO.
QTY
U/M
DESCRIPTION
1
19-04-0539
6
EA
Clamp-CAC, T-Bolt, 91-94 MM, COIL SPRING
Page 2 of 14
Service Bulletin No. 3121
2.1.2
Replace the clamps and correct the torque
Remove and discard both of the CAC clamps on the outlet hose.
Remove and discard
the old clamps
Install two new CAC clamps, MCI P/N: 19-04-0539, and torque them to 70-80 In-Lbs.
Install new clamps and
torque them to 70-80 In-Lbs
Remove and discard the clamp in front of the air filter towards the driver side.
Remove and discard
the clamp
Page 3 of 14
Service Bulletin No. 3121
Install a new CAC clamp, MCI P/N: 19-04-0539, and torque it to 70-80 In-Lbs.
Install new clamp and
torque it to 70-80 In-Lbs
Loosen the CAC clamp next to the newly installed clamp and retorque it to 70-80 In-Lbs.
Loosen it and retorque
to 70-80 In-Lbs
Remove and discard both of the CAC clamps close to the CAC unit on inlet hose.
Remove and discard
the clamps
Motor Coach Industries Ltd.
Page 4 of 14
Service Bulletin No. 3121
Install two new CAC clamps, MCI P/N: 19-04-0539, and torque them to 70-80 In-Lbs.
Install new clamps and torque
them to 70-80 In-Lbs
Remove and discard the first CAC clamp on the far side of the inlet hose, behind the air filter.
Remove and discard
the clamp
Install a new CAC clamp, MCI P/N: 19-04-0539, and torque it to 70-80 In-Lbs.
Install new clamp and
torque it to 70-80 In-Lbs
Page 5 of 14
Service Bulletin No. 3121
Loosen the CAC clamp next to the newly installed clamp and retorque it to 70-80 In-Lbs.
Loosen it and retorque
to 70-80 In-Lbs
Loosen the CAC clamps on the intake manifold and retorque them to 70-80 In-Lbs.
Loosen them and
retorque to 70-80 In-Lbs
Page 6 of 14
Service Bulletin No. 3121
2.2
Units equipped with an X12 Engine
2.2.1
Material requirement
ITEM
PART NO.
QTY
U/M
DESCRIPTION
1
19-04-0539
8
EA
Clamp-CAC, T-Bolt, 91-94 MM, COIL SPRING
2.2.2
Replace the clamps and correct the torque
Remove and discard both of the CAC clamps on the outlet hose.
Remove and discard
the clamps
Install two new CAC clamp, MCI P/N: 19-04-0539, and torque them to 70-80 In-Lbs.
Install new clamps and
torque them to 70-80 In-Lbs
Page 7 of 14
Service Bulletin No. 3121
Remove and discard both of the clamps in front of the air filter.
Remove and discard
the clamps
Install new CAC clamps, MCI P/N: 19-04-0539, and torque them to 70-80 In-Lbs.
Install new clamps and
torque them to 70-80 In-Lbs
Remove and discard both of the CAC clamps close to the CAC unit on the inlet hose.
Remove and discard
the clamps
Page 8 of 14
Service Bulletin No. 3121
Install two new CAC clamps, MCI P/N: 19-04-0539, and torque them to 70-80 In-Lbs.
Install new clamps and
torque them to 70-80 In-Lbs
Remove and discard the first CAC clamp on the far side of the inlet hose, behind the air filter.
Remove and discard
the clamp
Install new CAC clamp, MCI P/N: 19-04-0539, and torque it to 70-80 In-Lbs.
Install new clamp and
torque to 70-80 In-Lbs
Page 9 of 14
Service Bulletin No. 3121
Loosen the CAC clamp next to the newly installed clamp and retorque it to 70-80 In-Lbs.
Loosen the clamp and
retorque to 70-80 In-Lbs
Remove and discard the first CAC clamp on the intake manifold towards the engine door.
Remove and discard
the clamp
Install new CAC clamp, MCI P/N: 19-04-0539, and torque it to 70-80 In-Lbs.
Install new clamp and
torque to 70-80 In-Lbs
Page 10 of 14
Service Bulletin No. 3121
Loosen the CAC clamps on the intake manifold next to the newly replaced clamp and retorque it to 70-80
In-Lbs.
Loosen it and retorque
to 70-80 In-Lbs
2.3
Units equipped with a DD13 Engine
2.3.1
Material requirement
ITEM
PART NO.
QTY
U/M
DESCRIPTION
1
19-04-0539
7
EA
Clamp-CAC, T-Bolt, 91-94 MM, COIL SPRING
2.3.2
Replace the clamps and correct the torque
Remove and discard both of the CAC clamps on the outlet hose.
Remove and discard
the clamps
Page 11 of 14
Service Bulletin No. 3121
Install two new CAC clamps, MCI P/N: 19-04-0539, and torque them to 70-80 In-Lbs.
Install new clamps and
torque them to 70-80 In-Lbs
Remove and discard the clamp in front of the air filter towards the driver side.
Remove and discard
the clamp
Install new CAC clamp, MCI P/N: 19-04-0539, and torque it to 70-80 In-Lbs.
Install new clamp and
torque it to 70-80 In-Lbs
Page 12 of 14
Service Bulletin No. 3121
Loosen the CAC clamp next to the newly installed clamp and retorque it to 70-80 In-Lbs.
Loosen it and retorque
to 70-80 In-Lbs
Remove and discard both of the CAC clamps close to the CAC unit on the inlet hose.
Remove and discard
the clamps
Install two new CAC clamps, MCI P/N: 19-04-0539, and torque them to 70-80 In-Lbs.
Install new clamps and
torque to 70-80 In-Lbs
Page 13 of 14
Service Bulletin No. 3121
Remove and discard both of the CAC clamps on the far side of the inlet hose, behind the air filter.
Remove and discard
the clamps
Install two new CAC clamps, MCI P/N: 19-04-0539 and torque them to 70-80 In-Lbs.
Install new clamps and
torque them to 70-80 In-Lbs
Loosen the CAC clamps on the intake manifold and retorque them to 70-80 In-Lbs.
Loosen them and
retorque to 70-80 In-Lbs
End of the procedure
Motor Coach Industries Ltd.
Page 14 of 14
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TSB/Document ID: SB 3121
Replacement Service Bulletin Number:
MFR Communication Date: 2019-10-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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