NHTSA ID Number: 10120432
Manufacturer Communication Number: SP16-316C
TSB/Document Date: 2017-10-21
Summary
On the vehicles affected by this bulletin, the front fuel tank support needs to be improved to prevent fatigue cracks.
SP16-316C
Special Bulletin
Date
Expiration
Release
Page
07.2016
07.2018
4
1(27)
Rev C:
This revision replaces all previous releases
July 19, 2016
Crack repair details added / Cosmetics in IT50004
FUEL TANK FRAME FRONT SUPPORT WELD
Prevost
vehicles
DESCRIPTION
On the vehicles affected by this bulletin, the front fuel tank support needs to be improved to prevent
fatigue cracks.
MODEL YEAR(S) AND VEHICLES INVOLVED
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
Fleet Number
VIN
X3-45 Commuter
From 2PCG33495CC735053 up to
2PCG33495CC735232 incl.
Model Year : 2012 - 2012
From 2400 up to
2489, 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.
MATERIAL NEEDED
Order kit SP16-316:
Part No.
Description
Qty
240036
Gusset
8
NOTE
Material can be obtained through regular channels.
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SP16-316C
Special Bulletin
TOOLS
ROTARY GRINDER TOOL
Date
Expiration
Release
Page
07.2016
07.2018
4
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MIG Welding machine
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.
1. Disconnect all electronic modules to prevent any damage prior to welding.
Refer to MULTIPLEX MODULE DISCONNECTION PROCEDURE in Appendix B.
2. Raise vehicle with mobile lifting columns.
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3. Support the fuel tank frame on
stands.
Figure 1
4. Locate the front fuel tank
supports under the vehicle
frame (Fig. 2).
Figure 2
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Special Bulletin
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07.2018
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5. Remove tank frame mounting hardware. Reserve for re-use.
6. Remove existing weld on the mounting ears by grinding. (Fig. 3). If a crack is visible, it needs to be
cleaned and prepared to a depth that reaches the root of the crack.
Figure 3 Weld removed.
7. Repair according to "Crack Repair" in Appendix D. All Weld must meet IT750004 requirement in
Appendix C.
Figure 4
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SP16-316C
Special Bulletin
Date
Expiration
Release
Page
07.2016
07.2018
4
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WELDING OVERVIEW
8. Four gussets #240036 will be
added on the existing ears, on
both sides. (Fig. 4)
9. Refer to welding
Appendix A.
drawing
in
Figure 5
10. Welding Fillet dimension is
3mm (1/8") everywhere. (Fig. 6 &
7)
Perform welding according
procedure in Appendix D.
to
All Weld must meet IT750004
requirement in Appendix C.
Figure 6
Figure 7
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SP16-316C
Special Bulletin
11.
Prepare all welding surfaces by grinding.
12.
Begin by welding the rear gussets.
Date
Expiration
Release
Page
07.2016
07.2018
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Figure 8
13.
Then, weld the front gussets
Figure 9
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SP16-316C
Special Bulletin
14.
Date
Expiration
Release
Page
07.2016
07.2018
4
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Re-install Tank frame mounting hardware
Tighten to 50-60 lb-ft (67-81 Nm)
Figure 10
15.
Remove stands supporting the tank.
16.
Re-connect all electronic modules. Refer to MULTIPLEX MODULE DISCONNECTION
PROCEDURE in Appendix.
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)
ESTIMATED TIME
The time required to perform this special bulletin is approximately two hour.
OTHER
VBC Bulletin
N/A
Fail Code
18.08
Defect Code
09
System Condition
B
Causal Part
221592
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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Appendix A
Reference drawing
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Appendix A
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Appendix B
Multiplex Module
Disconnection Procedure
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PROCEDURE NO: PR060041
Material:
N/A
Equipment(s):
Phillips-head screwdriver
REVISION 01
Ratchet handle
3/8" socket
Electric tape
Long nose pliers
Reference schematics:
N/A
Safety rules:
- Wear safety goggles
- Set the battery master switch to the OFF position first
Recommendations: This procedure should be performed by qualified personnel only.
Effective
Revision 00 : New procedure for cooling 2007
Revision 01 : Modified for EPA 2010
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PROCEDURE NO: PR060041
X3-45 Coaches
2.00*
Location: Rear Electrical Panel and Dashboard
Set the battery master switch to the OFF position
Place the ignition switch to the OFF position.
2.05*
Location: Rear Junction Panel
Lift cover, trip circuit breakers CB2-CB4-CB6 located
on junction panel.
Push the red button to open the circuit
Page 12 de 27
REVISION 01
PROCEDURE NO: PR060041
2.10*
Location: Rear Electrical Panel
Disconnect the electronic ground terminals from this
stud.
Use electric tape; make sure that cables do not touch
each others and the vehicle body.
Note :
With disconnection of the electronic ground
terminals, disconnecting the engine ECM,
transmission TCM and the dashboard electronic
components (telltale module, HVAC module,
radio, control head …) is not required.
2.15*
Location: Rear Electrical Panel
Disconnect the electronic modules:
Disconnect all I/O A, I/O B modules.
Disconnect C717
Disconnect 3 connectors from each I/O A module
Disconnect 3 connectors from each I/O B module
Disconnect C397
Page 13 of 27
REVISION 01
PROCEDURE NO: PR060041
2.20 *
Location: Front Electrical Compartment
Disconnect the I/O A, I/O B, ABS, master ID, VECU,
CECM, BERU, Volvo Link, Gsecu modules.
Disconnect 3 connectors from I/O B and I/O A
modules
Disconnect 4 connectors from the ABS
module
Disconnect connector from master ID
Page 14 of 27
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TSB/Document ID: SP16-316C
Replacement Service Bulletin Number:
MFR Communication Date: 2016-07-19
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY
MFR Component System:
MFR Component Subsystem:
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