WARRANTY
BULLETIN
DATE :
EXPIRATION:
SUBJECT :

MAY 2016
MAY 2018

WB16-02B
SECTION :

06 - Electrical

CHARGING SYSTEM IMPROVEMENT

REVISION B: THIS WARRANTY BULLETIN SUPERSEDES PREVIOUS VERSION.
1. Page 18, step 9: 7/64" measurement increased to ¼"
2. Page 19, step 10: drill bit diameter 9/64" changed for 7/64"
3. Page 19, step 11: note added Use a 1/8 drill bit for the installation of the rivets
4. Page 19, steps 13 & 14: improper drip edge number in text and in figures 51, 52. Text #470278
changed for #420152

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
X3-45 coaches
Model Year : 2015 - 2016
H3-41, H3-45 coaches
Model Year : 2015 - 2016

VIN
From 2PCG33496FC735762 up to2PCG33495GC736077 incl.
and vehicle 4RKG33499G9737275
From 2PCH33496FC712695 up to 2PCH33497GC713324 incl.

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.

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.

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WB16-02B
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MATERIAL NEEDED

ELECTRICAL COMPONENTS – CORRECTIVE MEASURES
H3 + X3 Series: Order 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

DRIP EDGES INSTALLATION
For H3 Series, order Drip Edges kit #7770177 that includes the following parts:
Part No.

Description

Qty

470218

DRIP EDGE, UPPER

1

470219

DRIP EDGE, LOWER

1

504339

RIVET, POP DOME OPEN END 1/8" x 3/8

35

For X3 Series, order Drip Edges kit #7770178 that includes the following parts:
Part No.

Description

Qty

470278

DRIP EDGE, UPPER

1

470152

DRIP EDGE, LOWER

1

504339

RIVET, POP DOME OPEN END 1/8" x 3/8

33

504610

RIVET, MGL PRDG SS 1/4" x 5/8

4

Other required parts:
Part No

Description

Qty

506869

NOTE : One (1) roll is enough to repair nine (9) vehicles

1

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ROLL, DOUBLE FACE SELF‐ADHESIVE FOAM TAPE, 1/32 x 1/4 x 300ft
500583

SCREW, #6x½ BINDING HEAD PHILLIPS TAPPING

5

NOTE
Material can be obtained through regular channels.

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)

 DONE

3.

DRIP EDGES INSTALLATION
3.1

H3 SERIES

3.2

X3 SERIES

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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1.

MULTIPLEX SOFTWARE UPDATE

1. A Multiplex software update must 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

NOTE: your vehicle may already have the appropriate stud adapter and jumper cable version

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.
FIGURE 3

5. If the stud adapter hex part is too short
(about 13/16"), install stud adapter #564590
included in kit #7770176.

CORRECT

(part #564590)

Using improper stud adapter leaves jumper cable
lug improperly tightened and does not provide
good electrical conductivity between the lug and
the alternator stud.
FIGURE 4

INCORRECT

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(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 dia.= 5/16" CORRECT
Rev.B lug terminal through hole dia.= 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 anti-corrosion compound or
Color Guard Rubber Coating on alternator
terminals, cable lugs and nuts.

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2.2

ALTERNATOR 24VD (DIRECT) ON PIN #4 CHANGED FOR 24VI (INDIRECT)
NOTE: this corrective measure may have already been performed on your vehicle

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

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. Crimp the terminal
included with the kit to the end of wire and the
seal (see FIGURE 15).

FIGURE 14

FIGURE 15

FIGURE 16 : WIRING DIAGRAM PAGE 5.1

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3.0

DRIP EDGES INSTALLATION

3.1

H3 SERIES (see section 3.2 for X3 Series drip edges installation)

Special tool needed: