NHTSA ID Number: 10168841
Manufacturer Communication Number: 1M8-11619-11
TSB/Document Date: 2019-12-07
Summary
"Summary of MCI
Maintenance Council issues regarding: Council Item - ZF Hub Bolts, Council Item - Aluminum Rad Cleaning, Council Item - APU HVAC, Council Item - Molded Coolant Hoses, Council Item - Coolant Isolation Valves, Council Item - Braided Brake Hose Failing, Council Item - Mud Flap Mounting, Council Item - Cold Weather Starting, Council Item - Sensata Ivnerter Failures, Council Item - Engine Compartment Heat, Council Item - Front Fender Tire Clearance, Council Item - ECAS Module Failures, 12-06-1124, Council Item - Auto Chain Regulator, Council Item - Tag Steer Solenoids, Council Item - Brushless Motor - Parcel Rack, Council Item - Low Coolant Sensor Failures, Council Item - Coolant Rapid Fill Fittings, Council Item - WCL Weight Capacity, Council Item - Amaya WC Pedestals Breaking, Council Item - Kiel WC Sliders, Council Item - Auto-Chain Disengagement, Council Item - DD Idler Pulley, Council Item - Condenser Assembly Drain/Driver's HVAC Unit, Council Item - Doser Coolant Lines, Council Item - Third Brake Lamp Failures, Council Item - NDA Shipping Costs, Council Item - Transmission Breather, Council Item - Fuel Tank Drain Procedure, Council Item - Water Leaks, Council Item - Fogged Glass, Council Item - Engine Door Hinge Seizing, Council Item - Radiator Leaks, Council Item - Radiator Bracket Corrosion, Council Item - Belt Tension, Council Item - EFan Testing, Council Item - eCoach Batteries, Council Item - J3500 Suspension, Council Item - Publications, Council Item - Kiel Seat Belts Mechanisms, Council Item - DD13 Engine Speed Sensor"
From:
Sent:
To:
Subject:
Attachments:
Steve Batho
Wednesday, November 6, 2019 12:18 PM
Max Cook; [email protected]; [email protected]; [email protected];
[email protected]; [email protected]; [email protected];
[email protected]; [email protected]; [email protected];
[email protected]; [email protected]; [email protected];
[email protected]; [email protected]; [email protected];
[email protected]; [email protected]; Ibrahem Abdalla; Paul Fazio; Sean Greene;
Kevin Keith; Steve Kiner; David Mailhot; Brent Maitland; Bruce Malcolm; Tim Nash;
[email protected]; Anthony Amaducci; Jim Stibgen; Dan Crespo
MCI Maintenance Council - Items Discussed Slides
Maintenance Council - Resolution Presentation, Final Modified, 2019-Nov.pdf
Expires:
Wednesday, November 4, 2020 11:00 PM
Attached are the updated slides from Maintenance Council on legacy items.
We do ask that you us discretion in forwarding these documents. By nature many of them are still an ongoing
investigation and may be subject to change.
Thank you, I am glad we can assist in a better understanding of the topics for all involved.
Steve
Steve Batho
Director, Customer Service
MCI Coach Business
Cell:
Office: 905‐655‐2415
[email protected]
1
Maintenance Council Follow Up Item
Council Item – ZF Hub Bolts
Issue – Difficult to remove
Background – Vendor made a change to many of the wheel end
bolts, from Allen type to Torx
Remedy –
• Torx hardware is more corrosion resistant than the previous
Allen bolts but corrosion damage can still occur.
• Hardware testing involved exposure to 720 hours of salt spray
• Part # for Torx Screw Kit: 02-01-1365 (1 kit per hub)
• Torx socket size: E24
• Used on rotor/hub bolts, spindle/axle bolts, and
drive axle flange bolts
1
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Aluminum Rad Cleaning
Issue – Need recommended cleaning solution for Aluminum Radiator
Background – Have Modine recommend best process including how to clean
an E-coat rad
Remedy –
• Maintenance Manuals have
been updated with Modine
radiator core cleaning
recommendations.
• Service Parts Kit Info
2
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – APU HVAC
Issue – Need coach HVAC while engine is not running
Background – Industry demanding APU HVAC due to increasingly strict idle
requirements
Remedy – Bergstrom HVAC system currently being tested at Arrow Stage and
Genetec
•
3
Future Design Change Suggestion: :Lithium-Ion Batteries relocated to Condenser Compt
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Braided Brake Hose Failing
Issue – Routing/mounting/clamping needs to be more like
Setra 417
Background – During research into routing changes,
discovered many failures due to metal braiding inside hose
corroding/failing
Remedy – Routing being modified
• New hose vendor – Parker, Cutin: week of Sep 6
• Looking at a 3rd type of hose, but still in field testing
6
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Sensata Inverter Failures
Issue – Sensata inverter GFCI outlets not serviceable
Background – Replacement is very expensive, and manufacturer wouldn’t
authorize servicing
Remedy – Vendor authorized repair of GFCI outlets. MCI SI Bulletin 3108
NFIPart Retrofit Kit #’s:
9
07-08-5135
07-08-9634
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
3600W
4000W
Maintenance Council Follow Up Item
Council Item – Engine Compartment Heat
Issue – Can EFans be programmed to reduce engine compartment heat?
Background – With EFans potentially running less than mechanical driven fan,
concern was voiced about hotter engine compartment temps.
Remedy – Engine compartment temperature testing underway.
Field testing conducted. Lab/ Hot Room testing underway
On-going, not completed yet
10
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Front Fender Tire Clearance
Issue – Wider profile tires are scrubbing on fender
Background - More customers are using 365 tires. This tire will scrub front fender
and frame member behind fender
Remedy – Modification to suspension calibrations, reducing low ride setting.
Instead of 3+”, reduced to 1-1.5”
11
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – ECAS Module Failures,
12-06-1124
Issue – Not much detail, but suspect
failure due to excessive corrosion
Background - Coach operated in
extreme conditions
Remedy – Minimal component failure, but
will continue to monitor
15 Failures in the past 2 years/ .6%
2300 coaches equipped with this valve during
this time period
12
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Auto Chain Regulator
Issue – Regulator Valves failing prematurely were reported
Background – Vendor reported a manufacturing process issue
Remedy – Vendor has replaced original valve with new Haldex Pressure Protection
Valve
• Part #: 90555397/ 03-33-2946
• All coaches with this valve have been reworked
• Factory installation modified to include this valve
13
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Brushless motor - Parcel Rack
Issue – Request for parcel rack retrofit kit
Background – Brush equipped motors are “wear items”. Brushless motors
available in other applications on the coach
Brushless parcel rack blower motors are in production now
Remedy – Retrofit kits available
15
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Coolant rapid fill fittings
Issue – Customer requesting fittings available on coach, instead of having to
retrofit themselves
Background – Sales working to create an option available during coach
ordering process
Remedy –
• Part # of fitting: 19-10-2018
• Available as a Special
17
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – WCL weight capacity
Issue – WCL needs to handle more weight due to new mobility products introduced
into market
Background – Lifts having difficulty lifting passengers on motorized scooters/
mobility devices
Remedy –
• Ricon has released 880# cassette lift
• Braun options: J/ Baylift – 660#, D/Cassette – 750#, CRT-LE Ramp – 1000#
18
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Kiel WC sliders
Issue – need to get part #s for customer on updated part
Background – Kiel recently updated to a new pedestal, more robust
Remedy –
• Service Parts kit being developed
• VPN: 146488
• Slider Foot Bar Kit: T03-3071
20
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Auto-Chain Disengagement
Issue – Chains not disengaging at 30 mph+
Background – Aftermarket kit purchased from MCI. T/T light and sonalert active
when road speed reaches 30 mph. Programming issue.
Remedy –
• Working with Engineering to resolve
• Part #: 07-10-0611
21
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – DD idler pulley
Issue – Idler used on alternator belt
Background – idler pulley has been improved.
Remedy –
•
Original Configuration
Supersession by DDC
• Part # A4712002470
• DDC Bulletin 18SP738
• Available by December
22
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
New Configuration
Maintenance Council Follow Up Item
Council Item – Condenser Assembly drain/ Driver’s HVAC Unit
Issue – Drain is mounted too high
Background – Suspect issue is related to driver’s HVAC unit,
dripping condensation into the stepwell.
Remedy –
• Designing louvered closing panel
• Part #: 16-14-1643
23
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Doser coolant lines
Issue – Hoses failing from high heat
Background – Doser coolant lines need heat shield
Remedy –
• FPR & CIF is not showing any data, issue not being reported
• Sourced heat shield material.
• Service parts researching the value of a kit offering higher temp
hose and heat sleeve.
24
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – NDA Shipping Costs
Issue – UPS NDA charges much higher than FedEx
Background – Information request only
VS
Remedy –
• Shipping costs are more comparable with the combining of MCI Service Parts and
New Flyer Service Parts (NFIParts)
26
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Water leaks
Issue – Getting into coach from various locations
Background – Discovered not a single location:
Windshields
Marker Lights
Roof Seams/Drip Rail
Remedy –
• Windshield fencing redesign, part # T03-3046
• Cutting in Sep/2019, Unit # TBD
• Marker light gasket
• Unit cutin: 69187
• Roof seam/ drip rail sealing modifications
• Unit cutin: 69323
• PUP Initiative repairs
29
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Fogged Glass
Issue – Entrance doors and drivers windows
Background – Over the years there have been numerous
issues with the windows fogging.
Vendor process changed March/2013
Remedy –
• Vendor procedure changed
approximately @ 66500
• significantly reduced issue, but still an
item MCI is monitoring.
30
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Radiator Leaks
Issue – Leaks seemed caused by excessive corrosion, punctures/leaks
Background – Corrosion has been a major contributor to leaks
Also a large number of punctures/leaks
• Stones/ road debris picked up by fan blades and thrown into core
Remedy –
• Updated cleaning procedure in the Maintenance Manuals
• Discussed on slide 2
• Efan design: “push” air through core, and also have a slower air velocity,
32
• Less incidence of stone damage from the giant single fan constantly running
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Radiator Bracket Corrosion
Issue – Radiator shroud needs better drainage
Background – Issue observed that dirt/debris building up in the shroud
between the Efans and the radiator.
Remedy – Production design incorporates drain holes. Suspect concern was
raised on prototype system without drain holes
33
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Belt Tension
Issue – Alt belts and AC belt wear/slapping
Background – Projects under way now to address issue
Original Configuration
Remedy –
• Idler configuration redesign for X12 installation
• Dual V with 2 idlers, basic with X12, new version with 4 idlers
34
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
New Configuration
Maintenance Council Follow Up Item
Council Item – EFan testing
Issue – need info on harsh environment testing, clean mode at start-up, manual
override to reverse
Background – New technology for customers, concerned about longevity
Remedy – Multiple coaches retrofitted with Efans have been running for an
extended period with virtually no issues.
Regular maintenance is still required, same as earlier configuration
Added bonus of engine accessibility with swing out rad design
35
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – eCoach batteries
Issue – How to dispose of old batteries
Background – New technology, need engineering team to answer
Remedy –
• Did you know:
• When batteries are changed out from an eCoach,
they still have usable life in another application…
• Discussion topic for facility tour at Anniston
36
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Publications
Issue – Need more Spanish material
Background – Some manuals have been done in the past for specific
coach orders. Requesting basic manuals available in Spanish
Remedy –
• Working on J4500 Maintenance Manual in Spanish for MY2021
38
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – Kiel seat belts mechanisms
Issue – shoulder belt mechanisms failing
Background - Issues reported concerning retractors not functioning correctly.
Catches while pulling out the belt to attach, won’t retract, etc
Remedy – Kiel has updated to a new retractor
• Change due to a supplier issue
• This retractor is backwards compatible
Part #:
39
03-11-3307
Rear Cross Seat
03-11-3094
Belt Asm – Seat, 3 Point, Avance
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
Maintenance Council Follow Up Item
Council Item – DD13 Engine Speed Sensor
Issue – Engine speed sensor being damaged
Background – Location of sensor makes it susceptible to damage, no
shielding
Remedy – Researched the
number of failed parts/field
issues
No documented failures of this
sensor due to external damage.
Will continue to monitor
As a customer request/special,
a shield can be created.
40
© Motor Coach Industries Int’l, Inc. and its subsidiaries. All Rights Reserved.
- Mixes well with conventional fluids
- Low-moisture formula provides excellent vapor lock...
- Ideal for hydraulic and disc brakes
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TSB/Document ID: 1M8-11619-11
Replacement Service Bulletin Number:
MFR Communication Date: 2019-11-06
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Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT ADAPTIVE/MOBILITY
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