NHTSA ID Number: 10231097
Manufacturer Communication Number: IS-19912E
TSB/Document Date: 2023-02-04
Summary
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH DELCO REMY ALTERNATOR. REVISION: E Note added regarding power cable connection
IS-19912E
Page 76 / 92
137. Using the blue hose previously saved, make a
protective sheath. Cut to an appropriate size
and secure around the cables using nylon ties.
FIGURE 171
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IS-19912E
Page 77 / 92
138. Complete the connection to the fan circuit
breaker box (three connectors: gray, black
and red).
A: fan drive ground cable (black connector)
B: fan drive power cable (red connector)
C: “fan to RJB interface” harness (gray
connector)
NOTE
TRICK: Pre-twist the red and black cables counter-clockwise then insert the cables in their connector and lock. This will ensure that there’s
some pre-tension in the locking (clockwise) direction. This pre-tension will help the cables to
stays in place(locked position).
FIGURE 172
Secure the cables appropriately using nylon ties
and/or « handcuff » type nylon tie #N37749 as
required
FIGURE 173
139. Install the sealing element #050415.
Secure with the following hardware:
•
•
bolts #5001697 (1x)
lock washers #502570 (1x)
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IS-19912E
Page 78 / 92
FIGURE 174
140. Install the sealing element #050364.
Secure with the following hardware:
•
screw #502848 (1x)
FIGURE 175
141. Install the sealing element #050363.
Secure with the following hardware:
•
•
bolts #5001697 (4x)
lock washers #502570 (4x)
FIGURE 176
142. Complete the installation of the sealing
elements. Screw the panels to the chassis
threaded holes where shown on the image.
Use the following hardware:
•
screw #502848 (19x)
FIGURE 177
INSTALLATION OF ELECTRIC COMPONENTS AND HARNESS CONNECTIONS IN
THE MAIN POWER COMPARTMENT
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DIAGRAM OF ELECTRICAL CONNECTIONS
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IS-19912E
Page 80 / 92
143. In the battery compartment, disconnect the
battery ground cable from the chassis
ground stud.
FIGURE 178
144. Make sure there is no voltage applied to
the master relay R1 posts and then,
remove the master relay R1 cover if
applicable.
FIGURE 179
145. Complete the routing of the “fan drive
power cable” and the “alternator power
cable” inside the electrical compartment
through the upper cable boot.
FIGURE 180
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IS-19912E
Page 81 / 92
146. Install the fuse holder #563750 at the location
shown on the image. To do so, drill two 11/64
pilot holes for the installation of the fuse holder
Secure with the following hardware:
A: tapping screw #500658 + flat washer
#5001341
FIGURE 181
FIGURE 182
147. Prepare to the installation of the MCM module
#23499009_EFD.
First, use the MCM as a template to mark the drilling
position. Drill three holes of Ø1/4″.
FIGURE 183
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IS-19912E
Page 82 / 92
148.Prepare the mounting screws as shown on the
image using the following hardware.
A: Screw #502888 (3x)
B: Flat washer #502709 (9x)
C: Nut #502854 (3x)
Note: At each of the three mounting points, there is
a flat washer on the other side of the bulkhead.
149.Install the MCM module 23499009_EFD.
FIGURE 184
D: Flanged nut #5001932 (3x)
FIGURE 185
150. Cut one pieces of 4 ″ (100 mm) long of rubber
extrusion #506025.
151. Using good industrial glue (Loctite 404 or
similar product), glue the piece of rubber
extrusion on the I/O module support #053043
as shown on the image.
FIGURE 186
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IS-19912E
Page 83 / 92
152. Use the I/O module support #053043 as a
template to mark the drilling position. Drill four
(4) holes as shown on the image.
Diameters:
2 holes for the rods: 13/64″
2 holes for the screws: 1/8″
FIGURE 187
FIGURE 188
153. Install the U-shaped telltale light module
bracket #381594 at an appropriate place in
the electrical compartment where it can be
reached by the “fan to RJB interface”
harness #23488790. Fasten using two (2)
rivets #504379.
154. Fix the I/O module on the support #053043.
Secure the module using the following
hardware:
•
•
screw 10-24x 5/8 #5001447 (4x)
nut with nylon insert #5001180 (4x)
FIGURE 189
155. Install the I/O module. Secure with the
following hardware:
A: screw #500623 (2x)
FIGURE 190
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IS-19912E
Page 84 / 92
156. Place the 300A fuse #564520 (item A) in the
fuse holder previously installed.
157. Connect to the lowest post of the fuse holder
the two (2) following cables that are routed
from the alternator and the fan drive circuit
breakers box:
•
•
Alternator power cable (item B)
Fan drive power cable (item C)
•
item D: flat washer #5001341 (1x) & nut
#5001983 (1x)
158. Thread the nuts and tighten to a torque of 96
lbf-in (11 Nm)
FIGURE 191
159. Connect the elbow lug of the “master relay R1
to 300A fuse” cable #23498450 to the R1 stud
identified on the image and the upper stud on
the fuse holder.
item A: flat washer #5001341 (1x) & nut
#5001983 (1x)
Master relay R1- Port 30 – M10-1.5 stud nut
torque: 160-195 lb-in (18-22 Nm)
Fuse holder: tighten to a torque of 96 lbf-in
(11 Nm).
FIGURE 192
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IS-19912E
Page 85 / 92
160. In the upper part of the electrical
compartment, attach the cables and
harnesses as shown. Use the following
hardware
nylon tie #504016 (3x)
•
FIGURE 193
161. On harness #23490553, cut the three ring
terminals and replace by three (3) terminals
#561608.
162. In the main power compartment, locate
connector CCUST.
163. Unplug the socket terminal connector of
CCUST. Insert the three (3) terminals in the
connector.
circuit 24VI in cavity #1
circuit 24 VD in cavity #3
ground circuit in cavity #4
FIGURE 194
A: terminal #561608 (3x)
B: socket terminal connector of CCUST
FIGURE 195
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IS-19912E
Page 86 / 92
164. In the main power compartment, connect the
“fan to RJB interface harness” to the “MCM to
I/O-B interface harness” #23445869 by means
of connector C-EFD1.
165. Connect the MCM and the I/O-B module
together using the “MCM to I/O-B interface
harness” #23445869.
166. Connect the OEL resistors connector RES1F
and RES2F (part #563593) to the “MCM to
I/O-B interface harness”. See the image at
right and the following pictures for reference.
Use nylon ties as required, ideally one nylon tie
every 6 ″.
FIGURE 196
FIGURE 197
FIGURE 198
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IS-19912E
Page 87 / 92
167. In the main power compartment, connect the
“vehicle interface harness” #23490553 to
the “MCM to I/O-B interface harness” by
means of connector C-EFD2.
FIGURE 199
168. Plug the socket terminal connector previously
installed to the CCUST existing in the main
power compartment.
FIGURE 200
169. Get the J1939 signal. To do so, locate
connector C193 among the existing
harnesses of the main power compartment.
170. Disconnect connector C193 and connect with
C193FS and C193FP of the “vehicle
interface harness” #23490553.
FIGURE 201
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IS-19912E
Page 88 / 92
171. In the main power compartment, locate I/O-B
module A52 (alternately named AE52).
172. At A52 (or AE52), remove existing circuit 291
and 292 from connector J1:1 (pin 1) and J1:2
(pin 2).
173. For each circuit, cut the terminal and put a
heat shrinking sleeve at the end of the wire.
Those circuits won’t be used anymore.
174. Insert circuit 291 and 292 of the “vehicle
interface
harness”
#23490553
into
connector J1 pin 1 and J1 pin 2 respectively.
Use nylon ties as required to secure harness
#23490553
FIGURE 202
175. Install two tab terminals #561540 on the 24V
red telltale light module (#830165) wires.
176. Install the telltale light module in the telltale
module bracket #381594. Using a P-Touch,
make a label indicating “LH ALT”.
177. Connect the branch of FAN TO RJB
INTERFACE HARNESS identified ALT-L to
the telltale light module.
FIGURE 203
FIGURE 204
178. There are remaining nylon ties and tie mounts
in the kit. Use them to secure the harnesses
and cables that may seem loose. The goal is
to prevent rubbing of the cables and
harnesses.
179. Tighten all the nylon ties that were left loose,
for example, the one between the fan circuit
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FIGURE 205
IS-19912E
Page 89 / 92
breakers box
compartment.
and
the
main
power
180. Place one (1) warning decal #069205 as
shown on the image.
FIGURE 206
181. Install a second warning decal #069205 as
shown on the radiator door.
FIGURE 207
182. Fasten the
assembly.
door
upper
arm
FIGURE 208
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IS-19912E
Page 90 / 92
183. Refill the cooling system. Connect coolant
extractor. Use coolant extractor to refill the
coolant from the engine.
FIGURE 209
184. Reinstall the bumper.
FIGURE 210
185. Reinstall the access panel located behind tag
axle L.H. side wheel.
FIGURE 211
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IS-19912E
Page 91 / 92
186. In the battery compartment, connect the
battery ground cable to the chassis ground
stud.
FIGURE 212
187. Set the battery master switch to the ON position.
188. Set the ignition switch to the ON position.
189. In the main power compartment, reset the circuit breakers and wait two (2) minutes for the new
installer I/O-B module to be programed.
IMPORTANT NOTE
VEHICLES EQUIPPED WITH OPTIONAL PRIME ENERGY MANAGEMENT SYSTEM
TO PREVENT OVERLOADING THE L.H. SIDE ALTERNATOR, IT IS VERY IMPORTANT TO
DISABLE « PRIME » SYSTEM ON VEHICLES RECEIVING THIS CONVERSION. PLEASE
CONTACT YOUR NEAREST PREVOST
SERVICE CENTER TO HAVE THE PRIME SYSTEM
DISABLED.
SYSTEM TEST
190. Start the engine to idle.
191. With the engine in idle (600 rpm), use the
Diagnostics menu of the Driver Information
Display to engage the fans in speed 1.
Diagnostics > Vehicle Tests > Activate Radiator FAN
Speed 1
The height (8) fans should run at 50% of the
maximum speed. You need to evaluate the sound
level and the power of the air stream to determine
the speed.
192. Engage the fans in speed 2.
Diagnostics > Vehicle Tests > Activate Radiator FAN
Speed 2
The eight (8) fans should run at 75% of the maximum
speed.
193. Set the engine to the fast idle, the fans should
then engage at 100% of the maximum speed.
194. If the fans behave in accordance with the
criteria of the previous steps, then they
operate normally.
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FIGURE 213
IS-19912E
Page 92 / 92
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/
Federal)
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TSB/Document ID: IS-19912E
Replacement Service Bulletin Number:
MFR Communication Date: 2023-01-17
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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