NHTSA ID Number: 10120420
Manufacturer Communication Number: Sp16-01
TSB/Document Date: 2017-10-21
Summary
On the vehicles affected by this bulletin, it is necessary to perform a Multiplex software update plus other corrective measures to improve the charging system. The corrective measures of this bulletin are very important and must all be carried out on the involved vehicles.
Special Bulletin
Revision_:
SP16-01
Date
Expiration
Release
Page
05.2016
05.2018
1
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This document supersedes previous revisions.
CHARGING SYSTEM IMPROVEMENT
Prevost
vehicles
APPLICATION
NOTICE TO SERVICE CENTERS
Verify vehicle eligibility by checking warranty bulletin status with SAP or via ONLINE WARRANTY SYSTEM
available on Service / Warranty tab of Prevost website.
Model
VIN
Vehicles
2PCCS349XGC735962
2PCCS3494GC735973
2PCCS3493GC735981
2PCCS3492GC735986
2PCCS3498GC735989
X3-45 VIP Commercial use
Model Year : 2016
2PCCS3493GC736001
2PCCS3492GC736006
2PCCS3497GC736020
2PCCS3497GC736048
2PCCS349XGC736061
2PCCS3493GC736063
2PCCS3495GC736064
This bulletin does not necessarily apply to all the above-mentioned vehicles, some vehicles may have been modified
before delivery. The owners of the vehicles affected by this bulletin will be advised by a letter indicating the Vehicle
Identification Number (VIN) of each vehicle concerned.
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DESCRIPTION
On the vehicles affected by this bulletin, it is necessary to perform a Multiplex software update plus other
corrective measures to improve the charging system. The corrective measures of this bulletin are very
important and must all be carried out on the involved vehicles.
MATERIAL NEEDED
Order Electrical Improvement kit #7770176 that includes the following parts:
Part No.
Description
Qty
062490
SLEEVE, HEAT SHRINKING 6‐IN LONG
1
067835
CABLE, JUMPER Rev.C
1
564055
TERMINAL, SOCKET (BUSSMAN CONNECTOR)
1
564590
ADAPTER, STUD
1
5001341
WASHER, FLAT M8 STAINLESS STEEL
3
5001787
NUT, M8 STAINLESS STEEL
2
12089679
SEAL, CABLE (BUSSMAN CONNECTOR)
1
NOTE
Material can be obtained through regular channels.
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The bulletin structure is as follows (the corrective measures can be performed in any order):
DONE
1.
MULTIPLEX SOFTWARE UPDATE
2.
ELECTRICAL COMPONENTS – CORRECTIVE MEASURES
DONE
2.1
ALTERNATOR JUMPER CABLE INSPECTION & REPLACEMENT
DONE
2.2
ALTERNATOR 24VD (direct) ON PIN #4 CHANGED FOR 24VI (indirect)
PROCEDURE
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.
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MULTIPLEX SOFTWARE UPDATE
1. A Multiplex software update should be performed on the vehicle.
2. You must make an appointment at your nearest Prevost Service Center in order to receive the
software update. You can also contact your Prevost Service Representative for help.
2.
ELECTRICAL COMPONENTS – CORRECTIVE MEASURES
2.1
ALTERNATOR JUMPER CABLE INSPECTION / REPLACEMENT
RISK OF ELECTRICAL SHOCK
The alternator is connected to the batteries through master relay R1. If the ignition switch is in the OFF
position and the battery master switch (master cut-out) is set to the OFF position, there should not be
electrical power to the alternator terminals. However, a faulty master relay R1 could eventually leave the
battery power circuit closed, thus electrical power would be present at the alternator terminals.
Using a multimeter, probe the alternator B1+ terminal and the ground terminal. Make sure that the
voltage reading is 0 volt prior disconnecting the alternator cables.
1. Disconnect power cable A from the
upper alternator B1+ stud terminal.
FIGURE 1
A : (+) POWER CABLE
B : (+) JUMPER CABLE
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2. Disconnect jumper cable B from the
upper alternator B1+ stud terminal.
To do so, unscrew and remove stud
adapter C and flat washer.
3. Disconnect jumper cable B from the
lower alternator B1+ stud terminal.
To do so, remove hex nut and
washer.
FIGURE 2
B : (+) JUMPER CABLE
C : (+) STUD ADAPTER
CHECKING YOUR VEHICLE STUD
ADAPTER
4. Inspect the stud adapter that you
have just removed from the upper
alternator. The hex part of the stud
adapter must measure 1 inch long.
5. If the stud adapter hex part is too
short (about 13/16"), install stud
adapter #564590 included in kit
#7770176.
Using improper stud adapter leaves
jumper
cable
lug
improperly
tightened and does not provide
good
electrical
conductivity
between the lug and the alternator
stud.
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FIGURE 3
CORRECT
(part #564590)
FIGURE 4
INCORRECT
(part #564159)
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6. Reinstall the jumper cable #067835 revision C included
in kit #7770176 (FIGURE 5, FIGURE 6).
Rev.C lug terminal through hole diameter= 5/16" CORRECT
Rev.B lug terminal through hole diameter= 13/32" INCORRECT
FIGURE 5
Rev.B diameter of the through hole is too large, reducing
contact surface with the stud and the nut thus reducing
electrical conductivity between the lug and the alternator
stud (FIGURE 7).
FIGURE 6
FIGURE 7
7. Reinstall appropriate jumper cable B
(i.e. rev.C) with appropriate stud
adapter. Refer to FIGURE 8.
FIGURE 8
B : JUMPER CABLE #067835 revision C
C : STUD ADAPTER #564590 torque: 10 lbf-ft
D: FLAT WASHER #5001341
E: NUT M8 #5001787 torque: 10 lbf-ft
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8. Reinstall power cable A. To do so,
connect power cable A to the upper
alternator B1+ stud terminal. Refer
to FIGURE 9.
FIGURE 9
A : POWER CABLE
D: FLAT WASHER #5001341
E: NUT M8 #5001787 torque: 10 lbf-ft
9. Protect the alternator studs
against corrosion. Apply anticorrosion compound or Color Guard
Rubber Coating on alternator
terminals, cable lugs and nuts.
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ALTERNATOR 24VD (DIRECT) ON PIN #4 CHANGED FOR 24VI (INDIRECT)
1. Inside rear electrical compartment (rear
junction box), locate VECR module (FIGURE 10).
FIGURE 10 : VECR
2. Unplug connector no. 11 (green).
FIGURE 11
3. Using an extractor tool or a small flat blade
screwdriver, remove wire 24VDALT from cavity
H of connector no.11 (FIGURE 11 to FIGURE 14).
FIGURE- 12 : EXTRACTOR DELPHI 12094430
Remove the terminal by disengaging the flexible lock tab on the
terminal. Gently remove the terminal from the connector by
pulling on the wire.
FIGURE 13
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4. Relocate wire 24VDALT to cavity C of
connector no.2 (red) on the harness.
Cavity C of connector no.2 should be available.
This branch of the circuit will be protected by 10A
fuse F64 (see FIGURE 16 below).
Should cavity C not be available, refer to your
vehicle wiring diagram page 5.1 to select
another free cavity protected by a 10A or 15A
fuse (see FIGURE 16 for reference).
IMPORTANT NOTE: If required, extend wire
24VDALT using 16 AWG red electrical wire in order
to reach connector no.2.
Cut and discard existing terminal. Extend wire
24VDALT by doing one soldered joint. Use the
included piece of heat shrinking sleeve to protect
the soldered joint. Place seal #12089679 at the end
of wire and crimp terminal #564055 (see FIGURE
15).
FIGURE 14
FIGURE 15
FIGURE 16 : WIRING DIAGRAM PAGE 5.1
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PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)
ESTIMATED TIME
The software update time is not included in the labor reimbursed by this Special Bulletin. The Multiplex
software update is covered under “Red Carpet Policy”.
The time required to perform this special bulletin is approximately 1hour 30 minutes (1.5 h).
OTHER
VBC Bulletin
N/A
Fail Code
06.15
Defect Code
09
System Condition
B
Causal Part
067835
Prevost engages in a continuous program of testing and evaluating to provide the best possible product. Prevost, however, is not
committed to, or liable for updating existing products.
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TSB/Document ID: Sp16-01
Replacement Service Bulletin Number:
MFR Communication Date: 2016-05-26
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:SOFTWARE
MFR Component System:
MFR Component Subsystem:
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