SP22-303 Service Bulletin/Repair Instructions

SP22-303
Special Bulletin

Date
Expiration
Release
Page
03.2022
03.2024
1
1(7)
First Release
05-14-2022

ALTERNATOR LOOSE CONNECTORS
Prevost vehicles

DESCRIPTION

On the vehicles affected by this bulletin, the positive terminal (main power cable) may not be fully

tightened at the back some the alternators.

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
VIN
X3-45 Commuter

Model Year : 2021 - 2023
Specific vehicles within the following range

From 4RKJ33492M9737751 up to

4RKJ33490P9738062 incl.
Fleet Number

From 1300 up

to1595, incl.
This bulletin does not necessarily apply to all the above-mentioned vehicles, some vehicles may have been modified

before delivery.
MATERIAL NEEDED

Order the following parts:

Part No.
Description
Qty
684013
COLOR GUARD RUBBER COATING
5001983
NUT HEX NYRT SS NSS M8X1.25
2
560811
WASHER, ELECTRICAL CONDUCTOR
3
Writer: mg
As Req.
SP22-303
Special Bulletin

Date
Expiration
Release
Page
03.2022
03.2024
1
2(7)
REQUIRED TOOLS

3/8” TORQUE WRENCH
3/8” DRIVE SOCKET, METRIC 13MM & 5/8”
13MM & 5/8” CROW FOOT
3/8”DRIVE RATCHET
NOTE

Material can be obtained through regular channels.
SAFETY PRECAUTIONS

•
Eye protection should always be worn when working in a shop.
•
Rules for Personal Protection Equipment should always be respected. Wear your PPE

including but not limited to the following:
Safety First!
PROCEDURE

Writer: mg
SP22-303
Special Bulletin

Date
Expiration
Release
Page
03.2022
03.2024
1
3(7)
DANGER

Park vehicle safely, apply parking brake, stop the 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.

Lockout & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to

your local procedure for detailed information regarding the control of hazardous energy.
1. Locate the positive alternator cable at the

back of the upper RH alternator (alternator

#2 Figure 1 & 2).
Figure 1: First alternator to be checked
Figure 2: Problematic cable & terminal upper RH
2. Remove the terminal protective color guard

(black rubber) (Figure 3).
Figure 3: Black color guard on terminal post
Writer: mg
SP22-303
Special Bulletin

Date
Expiration
Release
Page
03.2022
03.2024
1
4(7)
3. Inspect the terminal and the alternator stud.

Look for any color change or heat damage (see

example Figure 4).
IMPORTANT: If heat damage is present, STOP

AT THIS STEP and contact the Prevost field

service manager and NYCT representative to

further inspect the damage, parts may need to be

replaced.
Figure 4: Example of discoloration caused by heat damage
4. If no damage is detected:

−
remove top nut, flat washer, power cable,

stud extension, flat washer and jumper

cable.
−
Discard top nut and flat washer.
−
Clean all the contact surfaces making sure

there is no color guard left (alternator back,

cable terminals and extension stud).
Figure 5: Torque adaptor stud + Top nut to 132 lb-in
5. Re-assemble in this order:

−
Jumper cable terminal to alternator stud
−
Flat Washer
−
Stud extension torque the stud extension

to 132 lb-in (Figure 5)
−
Power cable terminal to stud extension.
−
Flat Washer
−
Top nut torque the top nut to 132 lb-in

(Figure 5 & 6)
Figure 6: Torque top nut to 132 lb-in
HOLD THE CABLE WHILE TIGHTENING TO

AVOID ROTATION
Writer: mg
SP22-303
Special Bulletin

Date
Expiration
Release
Page
03.2022
03.2024
1
5(7)
6. Re-apply color guard to the stud and

terminal (Figure 7).
Figure 7: Color guard re-application
7. Repeat this procedure for the LH alternator

(alternator # 1, Figure 8 & 9).

8. Remove color Guard (rubber coating) &

inspect terminal.

IMPORTANT: If heat damage is present, STOP

AT THIS STEP and contact the Prevost field

service manager and NYCT representative to

further inspect the damage, parts may need to be

replaced.
Figure 9: Problematic cable & terminal LH alternator
A.
Top Nut
B.
Flat Washer
C.
Power (positive) Cable
D.
Extension Stud (adapter)
Figure 8: Second alternator to be checked
Writer: mg
SP22-303
Special Bulletin

Date
Expiration
Release
Page
03.2022
03.2024
1
6(7)
9. If no damage is detected:

−
remove top nut, flat washer power cable &

stud extension.
−
Discard top nut and flat washer.
−
Clean all the contact surfaces making sure

there is no color guard left (alternator back,

cable terminals and extension stud).
Figure 10: Torque adaptor stud & top nut to 132 lb-in
10. Re-assemble in this order:

−
Stud extension torque the stud extension

to 132 lb-in (figure 10)
−
Power cable terminal to stud extension.
−
Flat Washer
−
Top nut torque the top nut to 132 lb-in

(Figure 10 & 11)

Figure 11: Torque top nut to 132 lb-in
HOLD THE CABLE WHILE TIGHTENING TO

AVOID ROTATION
11. Re-apply color guard to the stud and

terminal (Figure 12).
Figure 12: Color guard re-application
Writer: mg
SP22-303
Special Bulletin

Date
Expiration
Release
Page
03.2022
03.2024
1
7(7)
12. Do not repeat this procedure for the lower

RH alternator (Figure 13).

Proceed to a visual inspection and report

anything suspicious and contact the

Prevost field service manager and NYCT

representative to further inspect the

problem.
Figure 13: Lower RH alternator VISUAL INSPECTION ONLY
13. Remove the lockout/tag out devices, start the engine and confirm correct charging voltage.
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 30 minutes (0.5) hour.
OTHER

VBC Bulletin

Fail Code
N/A
06.01
Defect Code
09
Syst. Cond
B
Causal Part
560748
Access all our Service Bulletins on
http://techpub.prevostcar.com/en/

or scan the QR-Code with your smart phone.
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.
Writer: mg

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