co

INS

BUS CORPORATION

Service Bulletin
Dear Collins Bus Corporation Customer,
Issue Date: April 17, 2014

Subject: Lighted Sign
Models Affected: Light for End Cap Signage on SW - OPTION 540-11-12

Notes: This service bulletin is intended to assist Collins Bus distributors, their
customers and or service shops in the proper techniques for repair and maintenance.
Issues described in this bulletin may not apply to all Collins Bus units. Authorized
technicians will be able to decide whether or not a unit with similar issues will benefit
from the provided information.
Details: Information contained in this bulletin will help you better find and replace
Lighted Sign LED Strips or potential issues with Lighted Sign LED Strips. Please
follow instructions provided with each picture for details on problems and suggested
repair.

Issue: Lighted LED Strip may experience corrosion at the wire connection which
may cause failure.
Location: Top Front center and Top Rear center of end cap.
See Figure 1-A

Figure 1-A Front

Figure 1-A Rear

Corrective Action: Replace Lighted LED Strips with the new Lighted
Sign Retro-Kit

Parts Needed:
(6) 210210 LED tag lights
Two 210209 Harnesses
Six¾ inch plastic grommets 210723
Four blue butt connectors 403169
One blue ring terminal 403150
Twelve 412287 #8x1 Stainless Steel screws
Two 210723 ¾" grommet one sided
Electrical tape

Note: Buses without A/C Please Order
Optional parts
1 - 442104 Maintenance access plate
4 - 10-24 x 5/8 white torx screws 429125
T-25 torx plus stick fit driver

Tools needed:
Drill
1/8" drill bit
¾" universal bit
Wire crimpers
Wire strippers
5' piece of fish wire
Phillips driver

Step1: Drill a 1/8" weep hole in the lights approx. ¼'' from edge that is to be installed
to allow water to drain. Weep hole may be drilled in lights after installed as well.
NOTE: This step was added to document.

Step2: Start at the front of the bus.

Step3: Use Template to mark 9 holes - center the template on the sign depression
bottom edge. Mark the holes labeled FRONT.
See Figure 1-B

Step4: Drill all the holes with 1/8" bit.
Step5: Drill center hole for all three lights with 3/4" bit.
Step6: Slip gasket over wires on light and push circuit module through gasket.
See Fiqure 2-A
Fiqure 2-A

Step 7: If grommet is not slit, cut it with a pair of wire strippers.
See Figure 2-B

Figure 2-B

Step8: Install grommet on light between circuit.
See Figure 2-C

Figure 2-C

Step9: Push light wires, circuit module and grommet into¾'' hole on front of bus.
Step10: Install light facing up with a gasket between the light and the bus using
Self - tapping screws. Be careful not to strip screws in fiberglass.

Use clutch on drill to protect it.
Step11: Repeat steps 5 thru 9 for other two lights.

Step12: cut wires going to old strip light at grommet
Step13: Pull old rubber grommet out of hole and pull wires out of grommet.
Step14: Use butt connectors to cap off old lighted sign wires.
Step15: Push wires into bus.
Step16: Plug old lighted sign wire hole with new grommet.
Step17: Return to inside of bus.
Step18: Remove dimmer behind electrical panel. (Located on the right side behind
the electrical panel opening).
Step19: Cut yellow and blue wires from dimmer back to green lighted sign wires.
Step20: Using 210209 harness supplied in kit with two blue butt connectors.
Step21: Use butt connector on harness to connect three white wires from harness to
white ground on dimmer. See Fiqure 3-A

Fiqure 3-A

Step22: Connect green wire bullet connectors to black wires on all three lights.

See fiqure 3-B
Fiqure 3-B

Step23: Connect green wire bullet connectors to black wires on all three lights.

See fiqure 4-A
Fiqure 4-A

..

INSTALLATION REAR OF BUS WITH A/C

SCHOOL BUS
Step 1:

Inside the rear of the bus take off the A/C evaporator cover.

Step 2:

Go to outside rear of bus.

Step 3:

Cut wires going to old strip light at grommet.

Step 4:

Pull old rubber grommet out of hole and pull wires out of grommet.

Step 5:

Use butt connectors to cap off old lighted sign wires.

Step 6:

Push wires into bus.

Step 7:

Plug old lighted sign wire hole with new grommet.

Step 8:

Use Template to mark 9 holes, center the template on the sign
depression bottom edge. Mark the holes labeled REAR.
See Fiqure 4-B
Fiqure 4-B

Step 9:

Drill with 1/8 bit.

Step 10:

Drill center hole for all three lights with ¾ bit.

Step 11: Push Fish wire thru the ¾ hole on the passenger side that was
drilled to mount the light
Step 12: Push the wire toward the driver side of the unit until you get to the
ale access hole or cutout.
Step 13:

Use supplied 210209 harness with one blue butt and one blue ring
terminal. The ring terminal is only used if the bus has an AIC
Evaporator. If neither one has a ring terminal, cut the butt off of the
white wire and replace it with a ring terminal.

Step 14:

Tape fish wire to longest wires with blue bullets on harness 210209
inside the bus.

Step 15:

Pull wires from inside to outside the bus until they are sticking out
the wire hole drilled for the light.

Step 16:

Repeat for all three lights make sure to use the shortest harness on
the closest hole to the ale access hole and the next shortest on the
middle hole.

Step 17:

Locate existing harness behind driver's side flashing warning lights
through ale access hole.

Step 18:

Locate existing green wire labeled LTD SGN 56 in the harness.

Step 19:

Cut wire and butt off end going toward the Evaporator.

Step 20: Use the butt connector on the new harness to attach three green
wires to the other end of LTD SGN 56 wire.
Step 21:

Use ring terminal on white wire to ground to the nearest chassis
ground location. See Fiqure 5-A
Fiqure 5-A

Step 22:

Proceed outside to rear of bus.

Step 23:
Slip gasket over wires on light and push circuit module through
gasket
Step 24:

If¾ inch grommets are not slit - cut three of them with wire cutters.

Step 25:
Install grommets on lights between light housing and circuit board
bulge on wire.
Step 26:

Connect green wire bullet connectors to black wires on three lights.

Step 27:

Connect white wire bullet connectors to white wires on three lights.

Step 28:
Install lights facing up with a gasket between the light and the bus
using self-tapping screws. Be careful not to strip out screws by over
tightening. Use clutch on drill to prevent over tightening.

TIME ALLOWANCE: 1 ½ HOURS TOTAL PER BUS (FRONT AND REAR)

INSTALLATION REAR OF BUS WITHOUT A/C

-.,~
.

'

.

~,

~

•
SCHOOL BUS

. •·.
·- ~

l

_;·'

Step 1:
If the bus does not have an evaporator a 6 inch access hole will
need to be drilled in the inside rear end cap. Drill with a hole saw at the
location from the table below.
An 8x8 maintenance panel can be
ordered to cover the hole. The part number is 442104.
REAR
WHEELS

HEAD
HEIGHT

Single

Low

Single

High

Dual

High

Step 2:

VERTICAL
LOCATION

6" from the
bottom of the
end cap
12" from the
bottom of the
end cap
14" from the
bottom of the

Proceed outside to rear of bus.

HORIZONTAL
LOCATION

6" from drivers side
of rear door
6" from drivers side
of rear door
6" from drivers side
of rear door

Step 3:

Cut wires going to old strip light at grommet.

Step 4:

Pull old rubber grommet out of hole and pull wires out of grommet.

Step 5:

Push wires into bus.

Step 6:

Plug old lighted sign wire hole with new grommet.

Step 7:

Use Template to mark 9 holes, center the template on the sign
depression bottom edge. Mark the holes labeled REAR. See
Fiqure 5-B
Fiqure 5-B

Step 8:

Drill marked holes with 1/8 bit.

Step 9:

Drill center hole for all three lights with ¾ bit.

Step 10: Push Fish wire thru the ¾ hole on the passenger side that was
drilled to mount the light
Step 11: Push the wire toward the driver side of the unit until you get to the
ale access hole or cutout.
Step 12:

Use supplied 210209 harness with one blue butt and one blue ring
terminal. The ring terminal is only used if the bus has an A/C
Evaporator. Cut off the ring terminal and replace with a blue butt
connector.

Step 13:

Tape fish wire to longest wires with blue bullets on harness 210209
inside the bus

Step 14:

Pull wires from inside to outside the bus until they are sticking out
the wire hole drilled for the light.

Step 15:

Repeat for all three lights make sure to use the shortest harness on
the closest hole to the ale access hole and the next shortest on the
middle hole.

Step 16:

Locate old lighted sign wires through new 6 inch drilled hole.

Step 17:

Locate existing green wire labeled LTD SGN 56 in the harness.

Step 18:
Use the butt connector on the new harness to attach three green
wires to the other end of LTD SGN 56 wire
Step 19:

Connect white wire from new harness to white wire in old harness.

Step 20:
Mount 442104 access plate over 6 inch hole with four 10-24 x 5/8
white torx screws.
Step 21:

Go back outside bus to rear

Step 22:
Slip gasket over wires on light and push circuit module through
gasket
Step 23:

If¾ inch grommets are not slit cut three of them with wire cutters.

Step 24:
Install grommets on lights between light housing and circuit board
bulge on wire.
Step 25:

Connect green wire bullet connectors to black wires on three lights.

Step 26:

Connect white wire bullet connectors to white wires on three lights.

Step 27:
Install lights facing up with a gasket between the light and the bus
using self-tapping screws. Be careful not to strip out screws by over
tightening. Use clutch on drill to prevent over tightening.

TIME ALLOWANCE: 1 ½ HOURS TOTAL PER BUS (FRONT AND REAR)

We regret the inconvenience this service may cause you. Please be assured
that Collins Bus Corporation is striving to build our buses with the best value and
safety available. Thank you for your cooperation in this matter. If you have questions
about anything contained in this bulletin please contact
Ginger Markus,
(Customer Service Coordinator for Collins Bus)
1-800-533-1850 ext 424
Randy Keesling,
(Customer Service Coordinator for Collins Bus)
1-800-533-1850 ext 414

Sincerely,
COLLINS BUS CORPORATION

Kelli Petz,
Customer Service Manager