TSB‐09242021

Technical Service Bulletin
***Attention this is not a recall***
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A TSB may or may not be covered as a warranty repair. Contact Rosenbauer America Warranty department for details.

Please read the entire Bulletin before proceeding with any work. Contact Rosenbauer
America if there are any concerns with information contained in this document.
Subject: Charged Air Cooler (CAC) cold air intake pipe (Drivers Side) clearances.
Applies To: 2012‐2021 Rosenbauer Commander Chassis with Cummins ISL‐9L Engines.
Condition: Charged Air Cooler (CAC) cold side pipe may make contact with the adjacent steel
coolant pipe wearing a hole in it causing a loss in engine performance and/or check engine light
related to engine boost pressure.

Correction: Follow Inspection Instructions below and proceed with the appropriate steps
listed (Adjustment or Replacement). Order replacement parts as necessary.

Tools Needed:
Item.

Tool

1.

.250” CLEARANCE TOOL

2.

INCH POUND TORQUE WRENCH

3.

3/8” SOCKET

4

7/16” SOCKET DEEPWELL

5.

1‐1/16” OPEN END WRENCH

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TSB‐09242021

Work Instructions:
Included below are detailed instructions for Inspection (all cases), Adjustment (if
necessary) or Replacement (if necessary, and only if pipe damage is reported).
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Time Allowed: 0.2 hours for inspection; 0.5 hours for adjustment; 1.0 hours for replacement.
Inspection Instruction: Locate CAC Pipe in the driver’s side of the engine coming out of the
fan shroud (Fig. 2).
1. Insert .250” clearance tool between CAC and steel coolant pipe and check clearances
(See. Fig. 1).
2. Clearances should be 0.250” or more.
3. If there is acceptable clearance no further action is necessary, please complete the TSB
decal instructions (Fig. 3).
4. If there is not acceptable clearance, proceed to Adjustment Instruction immediately
below.
Adjustment Instruction: Upon completion of inspection instructions and if it is discovered that
there are not acceptable clearances (no damage beyond minor witness marks),
1. Loosen the 7/16” band‐clamp nuts on both ends of CAC pipe and loosen the rubber
hoses.
2. Rotate CAC pipe until clearances are with‐in tolerance.
3. Reposition the clamps and hand‐tighten 7/16” band‐clamp nuts to a torque of 50 in‐lbs.
(6.79 N‐m), confirming that required clearances are maintained after torquing.
4. Complete the TSB decal instructions (Fig. 3).

If Replacement is needed (CAC Pipe is damaged), please see below.
Replacement Instructions: If there is significant wear (e.g., visible divot or hole in the CAC
pipe), please contact your Rosenbauer America Dealer to order replacement parts. They will
want photos of the damage for their documentation.
Before beginning, we recommend taking photos of the worksite to create a reference for
completion. Note orientation of clamp bolts, etc. for reassembly.
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TSB‐09242021

Important Note: Use no power tools for re‐assembly.
Parts needed: All from Rosenbauer America. Warranty coverage will apply if in‐force.
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Qty.

Part#

Description

1

8625121‐001

DECAL, RECALL/TSB LABEL

1

8603655‐001 Rev. B.

PIPE‐CAC COLD REV B

1

P5269354

HOSE, AIR COMPRESSOR INTAKE, 24”

2

T50L Black

ZIP TIES, .16” MIN. WIDE X 7” MINIMUM LENGTH

1

0150215

LocTite 567™ OR EQUIVALENT THREAD ADHESIVE

1. Loosen the clamp screw (3/8” bolt head) on CAC end of the black reinforced rubber air
compressor intake line (at brass 90‐degree fitting).
2. Pull hose off the brass fitting and secure out of the way for reassembly. If replacement
hose is needed for Rev. B. of CAC pipe replacement, remove this hose completely.
3. Use 1‐1/16” open‐end wrench to remove brass elbow from old CAC pipe. Keep this
fitting for reuse.
4. Loosen the 7/16” nuts on the band‐clamps at each end of the pipe
5. Pull damaged CAC pipe out of the silicone adapters and discard.
6. Install new CAC pipe, clocking it to meet clearance requirements detailed in Fig. 1.
7. Reposition and hand‐torque the 7/16” nuts on the band‐clamps to 50 in‐lbs. (67.79 N‐
m), confirming that required clearances are maintained during torquing.
8. Apply pipe thread sealant to the brass fitting threads before screwing it into the new
CAC pipe. Note: Because we are threading brass into aluminum with thread sealant, use
the 1‐1/16”” open end wrench to tighten only one (1) full revolution beyond hand‐tight,
then only enough to align to air compressor intake hose.
9. Attach the air compressor intake hose to brass fitting(s) (Continued next page).
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TSB‐09242021

10. (Continued from previous page) Position and hand‐torque 3/8” hose clamps screws to
75 in‐lbs. (8.5 N‐m.
11. Apply zip ties to secure to engine bracket as‐before.
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12. Confirm clearances again.
13. Install TSB decal per below (Fig. 3).

Fig. 1

ISL‐9L

Inset Detail

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TSB‐09242021

Fig. 2 CAC Cold Pipe and Aire Compressor Intake Hose.

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Fig. 3

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