SAV.1E.2012MA

LI4642E

INFORMATION LETTER
REFERENCE:

Nova Bus Manuals

SECTION:

16: Electrical System

RS NO:

MQR 7621-1566

EFFECTIVE IN PROD.:

N/A

SUBJECT:

Bracket available to improve routing of the Niehoff alternator regulator connections.

JUSTIFICATION:

Addition of strain relief bracket to secure regulator connections against vibration.

LEVEL

APPLICATION DEADLINE: N/A

DIRECT CHARGES

DESCRIPTION

LABOUR

MATERIAL

TIME

1

Add strain relief bracket and improve routing.

Client

Client

1 hr

2

Replace ring terminals and Amphenol connector, if necessary.

Client

Client

0.5 hr

MATERIAL
QTY

PART NO

REV.

DESCRIPTION

REPLACES PART N°

1

N94643

–

STRAIN RELIEF BRACKET

–

4

N93898

–

SCREW M5X16 HEXFL SERRATED YP

–

2

N40492

B

SCREW M6X20 H YZ TRIV 96H 8.8

–

1

N84090-04

–

P-CLAMP ID 0.625"THK

2

N38593

A

NUT LOCKNYL M6

500mm

N74787

A

TAPE ELEC CLOTH 19 X 0.27 THK

4mL

N86688

A

THREADLOCKER 220

4

N37749

B

DUAL CLAMP TIE

1

N84090-05

–

P-CLAMP ID 0.750"THK 0.030"M8

1

N15140-03

–

RING, TERMINAL STUD #10

1

N15140-04

–

RING TERMINAL STUD 1/4"

3

N76294

–

TERMINAL SIZE 20 AMPHENOL PT

1

N76268

–

CONNECTOR AMPHENOL 10 PIN

LEVEL 1

LEVEL 2

–

DISPOSAL OF PARTS
REMOVED PARTS ARE:

DISCARDED *

RETAINED

Yes

–

* Dispose of the unused parts and the defective parts in
accordance with local environmental standards in effect.

REVISION HISTORY
REV.

DATE

NR

2019MR26

APPROVED BY:

CHANGE DESCRIPTION

Initial release

Daniel Theriault

WRITTEN BY

Devanand B
Digitally signed by Daniel Theriault
DN: cn=Daniel Theriault, o=Nova Bus, ou, email=daniel.theriault@volvo.com, c=CA
Date: 2019.06.10 20:45:58 -04'00'

PAGE 1 OF 8

INFORMATION LETTER
CLIENT

ORDER

ROAD NUMBER

SAV.1E.2012MA

LI4642E

VIN (2NVY/4RKY...)

TO

L773

—

—

L82JXD4500429 L82J6D4500430

2

Chicago Transit Authority - CTA - Illinois

L811

7902

7949

L82J6E4500509 L82J4E4500556

48

Chicago Transit Authority - CTA - Illinois

L837

7950

7999

L82J6E4500655 L82J1E4500708

50

Chicago Transit Authority - CTA - Illinois

L847

8000

8049

L82J1E4500773 L82JXE4500822

50

Chicago Transit Authority - CTA - Illinois

L848

8050

8099

L82JXF4500823 L82J1F4500872

50

Chicago Transit Authority - CTA - Illinois

L849

8100

8149

L82J5F4500874

L82J3F4500923

50

Chicago Transit Authority - CTA - Illinois

L850

8150

8199

L82J5F4500924 L82J6G9775013

50

Chicago Transit Authority - CTA - Illinois

FROM

TO

QTY

FROM

PAGE 2 OF 8

INFORMATION LETTER

SAV.1E.2012MA

LI4642E

WARNING

Follow your internal safety procedures.

PROCEDURE
1.1.

Park the vehicle on an even surface with transmission in neutral (N).

1.2.

Set the Master control switch in the STOP position (see Figure 1).
Master control switch in
STOP position

Figure 1 - Master Control Switch in STOP Position

1.3.

Lift the rear seat and open the engine access panel. Use 13mm socket. Keep hardware (see Figure 2).

Figure 2 - Engine Access Panel

PAGE 3 OF 8

INFORMATION LETTER
1.4.

SAV.1E.2012MA

LI4642E

Remove existing D+ and IGN connections on voltage regulator. Inspect and replace terminals if damaged
(see Figure 3).
1.4.1. D+ (front). Use 10mm socket. Terminal: N15140-04. Wire: 95-347
1.4.1.1. For certain configurations (L858, L891 and L935), regulator stud "P" (Alt In Load) is used
instead of D+. Terminal N15140-04. Wire: 95-273
1.4.2. IGN (rear). Use 8mm socket. Terminal: N15140-03. Wire: 95-272

Figure 3 - View of Regulator D+ / IGN Terminals

1.5.

Install new strain relief bracket on regulator (see Figure 4).
1.5.1. Remove the four bolts holding the regulator.
1.5.2. Install the new bracket (N94643) under the regulator with four new bolts (N93898) - Use 8mm deep
socket. Apply two drops of Loctite 220 to bolt threads. Torque to 8.5Nm.

Figure 4 - Installation of Strain Relief Bracket on Regulator
PAGE 4 OF 8

SAV.1E.2012MA

LI4642E

INFORMATION LETTER
1.6.

Route D+ and IGN wires in p-clamp as shown in Figure 5. If extra length is needed, follow the
harness until over-length bundle is found, cut tie wrap, pull extra length and re-attach to power cable.
If configuration has the P wire, secure it to the IGN wire using a double tie-wrap as close as possible to the
P-clamp. (see Figure 6).

1.7.

Install p-clamp mount (N84090-04), M6 bolt (N40492), M6 Locknyl (N38593).
1.7.1. Torque p-clamp M6 bolt to 11Nm
1.7.2. +MT-MS95D2: D+ (or P) on front connection in image above. Torque to 4.5Nm
1.7.3. +MT-MS95D2: IGN on rear connection in image above. Torque to 4.5Nm

Double Tie wrap

Figure 5 - Installation of P-clamp

Figure 6 - Installation of Double Tie Wrap

1.8.

Inspect circular connector MT-X95D2 for loose pins and loose connector back-shell.

1.9.

Replace pins N76294 or connector/back-shell N76268 if necessary. To ensure a proper crimping of the solid
terminal (N76294) for inspection criteria. (see Figure 7).

Crimping area-Cut view

Inspection window

Copper is visible

Figure 7 - View of Crimping of the Solid Terminal

PAGE 5 OF 8

INFORMATION LETTER
1.10.

SAV.1E.2012MA

LI4642E

On circular connector MT-X95D2, remove the strain relief parts and slide back the grommet. Use cloth tape
(N74787) and wrap several layers around the wires where the strain relief grommet is positioned, the goal
is for the added tape to fit snugly inside the strain relief grommet to hold the wires tightly. (see Figure 8).

Grommet

Additional tape

Figure 8 - Replacement of Pin and Connector

1.11.

Re-install strain relief hardware and test for movement. Install more tape if movement is present. (see Figure 9).

Figure 9 - Re-installation of Strain Relief Hardware

PAGE 6 OF 8

INFORMATION LETTER

SAV.1E.2012MA

LI4642E

1.12.

Re-install the circular connector, ensure that it clicks (bayonet locking feature) into place.

1.13.

When routing the circular connector wires, make sure no sharp bends are present where the wire exits the
strain relief. (see Figure 10).

Dual tie N37749

Figure 10 - Installation of Butterfly Tie-Wraps to the Power Cable

1.14.

Inspect the two circular connectors on the regulator to ensure they are properly locked (top connector). For
bottom connector (Niehoff harness), hand-tight + ¼ turn using strap wrench or similar. (see Figure 11).

Figure 11 - Tightening the Connectors on Regulator

PAGE 7 OF 8

INFORMATION LETTER
1.15.

SAV.1E.2012MA

LI4642E

Install P-clamp (N84090-05), M6 bolt (N40492), M6 Locknyl (N38593) to secure 0000 AWG positive power
cable going to the alternator B+ terminal. (see Figure 12).

Figure 12 - Installation of P-clamp to the Alternator

1.16.

Turn ON cut off and master switch. Check for error messages on ACTIA dashboard.

1.17.

Reinstall and close engine trap panel.

1.18.

Bus can be returned to service.

PAGE 8 OF 8