WARRANTY
BULLETIN
DATE :
EXPIRATION:
SUBJECT :

REVISION H:
Released: July.2018

MAY 2016
MAY 2018

WB16-02H
SECTION :

06 - Electrical

CHARGING SYSTEM IMPROVEMENT

THIS WARRANTY BULLETIN SUPERSEDES PREVIOUS VERSION.
Nut M8 #5001787 cancelled and changed, use nut #5001983 instead

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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MATERIAL NEEDED

ELECTRICAL COMPONENTS – CORRECTIVE MEASURES
H3 + X3 Series: Order kit #7770335 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

060297

ADAPTER, STUD

1

5001341

WASHER, FLAT M8 STAINLESS STEEL

3

5001983

NUT, M8 STAINLESS STEEL NSS

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

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

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SCREW, #6x½ BINDING HEAD PHILLIPS TAPPING

5

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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

IMPORTANT: Make sure that the

adapter included in the kit is the
appropriate adapter for the installation.
4. Inspect the stud adapter included in your kit.
The hex section (between two flat surfaces)
must measure 5/8 inch (16mm) (FIGURE 3).
5. If the stud adapter hex section measures 1/2
inch (13mm), DO NOT INSTALL THAT
ADAPTER. You absolutely must get the
appropriate adapter #060297.
The use of an inappropriate adapter leaves jumper
cable lug improperly tightened. Moreover, the
contact surface with the power cable is insufficient
to ensure good electrical conductivity. Damage
to the terminal of the alternator and the lug are
likely to occur. Melting of these components may
occur.

FIGURE 3

CORRECT (part #060297)

FIGURE 4

INCORRECT (part #564590)

FIGURE 5

INCORRECT (part #564159)

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6. Before installing the jumper cable, make sure
that the nut that secures the alternator stud is
properly tightened.

FIGURE 6

7. Reinstall the jumper cable #067835 revision C
included in kit #7770335 (FIGURE 7, FIGURE 8).
Rev.C lug terminal through hole dia.= 5/16" CORRECT
Rev.B lug terminal through hole dia.= 13/32" INCORRECT
FIGURE 7

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 9).
FIGURE 8

FIGURE 9

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8. Reinstall appropriate jumper cable B
(i.e. rev.C) with appropriate stud adapter.
Refer to FIGURE 10.

Note: M8 nut “E” formerly #5001787 is
canceled. Use nut #5001983 instead.

FIGURE 10
B : JUMPER CABLE #067835 revision C
C : STUD ADAPTER #060297 torque: 10 lbf-ft
D: FLAT WASHER #5001341
E: NUT M8 #5001983 torque: 10 lbf-ft

9. Reinstall power cable A. To do so, connect
power cable A to the upper alternator B1+ stud
terminal. Refer to FIGURE 11.

Note: M8 nut “E” formerly #5001787 is
canceled. Use nut #5001983 instead.

FIGURE 11
A : POWER CABLE
D: FLAT WASHER #5001341
E: NUT M8 #5001983 torque: 10 lbf-ft

10. 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 12).
FIGURE 12 : VECR

2. Unplug connector no. 11 (green).

FIGURE 13

3. Using an extractor tool or a small flat
blade screwdriver, remove wire 24VDALT
from cavity H of connector no.11 (FIGURE
13 to FIGURE 16).

FIGURE- 14 : EXTRACTOR DELPHI 12094430

FIGURE 15

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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 18
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 18 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 17).

FIGURE 16

FIGURE 17

FIGURE 18 : WIRING DIAGRAM PAGE 5.1

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3.0

DRIP EDGES INSTALLATION