BS1905ER1

SAV.1E.2012MA
BS1905ER1
SERVICE BULLETIN
REFERENCE:
Nova Bus Manuals
SECTION:
16: 24-Volt electrical system
RS NO:
MQR 7621-113 and 7621-356
EFFECTIVE IN PROD.:
L554-01 (2010SE15)
SUBJECT:
Corrosion behind battery disconnect switch and power distribution box (PDB) failure.
JUSTIFICATION:
Corrosion may create poor electrical conductivity.
Excessive current passing through the main disconnect switch may lead to the failure of
the PDB.
LEVEL
APPLICATION DEADLINE:
2014JL22
DIRECT CHARGES
DESCRIPTION
1
Replace the battery disconnect switch and modify the electrical
circuit of the PDB.
2
–
TIME
LABOUR
MATERIAL
Nova Bus
Nova Bus
1h45
–
–
–
MATERIAL
QTY
PART NO
REV.
DESCRIPTION
REPLACES PART N°
LEVEL 1
1
N55066-01
–
Disconnect switch
N49987
2
N44885-03
–
Screw M8 X 30
–
2
N43233
–
Bolt M8
–
2
G5900719
–
Terminal
–
1
N41493
–
Connector
–
1
N25889-04
–
Connector lock
–
2
N11681
–
Connector cavity plug
–
1
N64175-60
–
60 Amp fuse assembly
N33410-04
1
N66236
–
Supply cable 4/0 AWG
N57095
1
N66237
–
Bottom nylon block
N48091
1
N66238
–
Top nylon block
N48094
1
N33090-08
Terminal
–
–
–
LEVEL 2
–
–
–
Materials will be available within 126 days. To order, please contact Prevost Parts by phone at 1‑800‑771‑6682, by fax at
1‑888‑668‑2555 or by email at [email protected]. Specify document number, quantity of parts required
and shipping address.
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
2012SE21
Initial release
Luc Carignan
R1
2013MR01
Terminal N10273 replaced by G5900719 and connector
lock N25892-04 replaced by N25889-04
Luc Carignan
APPROVED BY:
CHANGE DESCRIPTION
Karine Allonce
Digitally signed by Karine Allonce
DN: cn=Karine Allonce, o=Novabus, ou,
[email protected], c=CA
Date: 2013.03.18 11:43:57 -04'00'
WRITTEN BY
PAGE 1 OF 7
SERVICE BULLETIN
CLIENT
ORDER
ROAD NUMBER
FROM
SAV.1E.2012MA
BS1905ER1
VIN (2NVY/4RKY...)
TO
FROM
TO
QTY
Arrow Coach Line - Arkansas
L494
—
—
L82U793000397
L82U793000397
1
BC Transit - BCT - British Columbia
L463
9319
9333
L82U093000273
L82U093000287
15
BC Transit - BCT - British Columbia
L481
9334
9353
L82U794000004
L82U094000023
20
BC Transit - BCT - British Columbia
L484
9370
9403
L82U494000090
L82U494000123
34
BC Transit - BCT - British Columbia
L486
9354
9369
L82U294000024
L82U494000039
16
BC Transit - BCT - British Columbia
L487
9404
9433
L82U094000149
L82U794000178
30
Belleville Transit - Ontario
L542
—
—
L82UXA3000088
L82U8A3000090
3
Brampton - Ontario
L501
0917
0921
L82U893000506
L82UX93000510
5
Brampton - Ontario
L501
0922
0926
L82U693000519
L82U893000523
5
Brantford - Ontario
L547
10101
10105
L82X6A3000082
L82X3A3000086
5
Grand River Transit - GRT - Ontario
L464
20901
20913
L82U193000296
L82U493000308
13
Grand River Transit - GRT - Ontario
L560
21001
21009
L82U2A3000246
L82U1A3000254
9
Lethbridge - Alberta
L489
165
169
L82U493000454
L82U193000458
5
Marketing Sales Demo - MSD 1 ISB Hybrid
L548
—
—
L82X5A3000087
L82X5A3000087
1
Niagara Falls - Ontario
L499
2986
2989
L82U093000564
L82U693000567
4
Peterborough - Ontario
L490
—
—
L82UX93000345
L82U593000348
4
Regina - Saskatchewan
L476
625
628
L82U893000313
L82U393000316
4
Regina - Saskatchewan
L561
—
—
L82U8B4000003
L82U5B4000010
8
Regina - Saskatchewan
L561
—
—
L82U4B4000013
L82UXB4000018
6
Saskatoon - Saskatchewan
L551
1005
1007
S92UXA3000178
S92U8A3000180
3
Stratford - Ontario
L493
—
—
L82U2A3000019
L82U2A3000019
1
Strathcona County Transit - Alberta
L523
2010
2010
L82U693000603
L82U693000603
1
Strathcona County Transit - Alberta
L524
3005
3010
L82X593000604
L82X493000609
6
Sudbury - Ontario
L465
791
795
L82U593000317
L82U793000321
5
Sudbury - Ontario
L552
801
808
L82U3A3000238
L82U0A3000245
8
Thunder Bay - Ontario
L488
—
—
L82U193000332
L82U593000334
3
Timmins - Ontario
L475
—
—
L82U493000311
L82U693000312
2
Timmins - Ontario
L550
—
—
L82U8A3000171
L82UXA3000172
2
University of Alabama - Alabama
L479
479-1
479-1
L82U394000002
L82U394000002
1
University of Alabama - Alabama
L480
480-1
480-1
L82U594000003
L82U594000003
1
Walt Disney World - Florida
L535
1204
1213
L82UXA4000003
L82U0A4000012
10
Woodstock - Ontario
L460
—
—
L82U693000309
L82U693000309
1
Woodstock - Ontario
L492
—
—
L82U4A3000040
L82U6A3000041
2
PAGE 2 OF 7
SAV.1E.2012MA
BS1905ER1
SERVICE BULLETIN
WARNING
Follow your internal safety procedures.
PROCEDURE
1.1.
Open the battery compartment access door and the engine compartment side access door. See Figure 1.
Engine compartment
side access door
Battery compartment
access door
Figure 1 - Access Doors to Open
1.2.
Unlock the battery tray and swivel it outwards.
1.3.
Ensure that the vehicle's power supply has been deactivated; disconnect the battery terminals.
1.4.
Remove and discard the upper and lower nylon blocks, located on the battery compartment bulkhead, to the
right of the batteries (see Figure 2). Retain the hardware.
1.5.
Remove and discard the supply cable connected to the first terminal of the distribution box and the disconnect
switch. See Figure 2.
1.6.
Remove and discard the battery disconnect switch. See Figure 2.
Lower nylon block
Upper nylon block
Supply cable
Heater cable for the air
intake grill
Battery disconnect
switch
Fuse BCR- FU61A
Figure 2 - Existing Connections for the Power Distribution Box
PAGE 3 OF 7
SERVICE BULLETIN
1.7.
SAV.1E.2012MA
BS1905ER1
Once the switch has been removed, it is necessary to enlarge the hole on which it was installed. The most
appropriate tool to accomplish this task is a knock-out punch tool. See Figure 3.
Figure 3 - Typical Knock-Out Punch Tool
1.8.
The size of the existing hole is 0.79 in. (20 mm). This must be enlarged to 2.8 in. (71 mm) See Figure 4.
1.9.
Drill two holes at 30 degrees from the horizontal axis of the 71 mm hole, using the new battery cut-off switch
(N55066-01) as a drilling template. See Figure 4.
Drill 23/64 in.
(9 mm)
30° from the horizontal axis
Horizontal Axis
71 mm ø
Figure 4 - Dimensions for the Modified Hole and Locations of the Attachment Holes
PAGE 4 OF 7
SERVICE BULLETIN
SAV.1E.2012MA
BS1905ER1
1.10. Place the new battery cut-off switch N55066-01 in the enlarged hole. Attach using screws N44885-03 and
bolts N43233. See Figure 5.
1.11. Install a terminal G5900719 on wire 61-871, and another terminal G5900719 on wire 61-872. See Figures 5
and 6.
1.12. On connector N41493 (see Figure 5):
• Insert wire 61-871 in pin # 4
• Insert wire 61-872 on pin # 1
• Install lock N25889-04
• Install plugs N11681
1.13. Affix connector N41493 to the connector of the battery disconnect switch.
1.14. Install the fuse assembly N64175-60 at position A1 of the battery disconnect switch. See Figure 5.
1.15. Cut the existing terminal on cable C183 and install the new terminal N33090-08.
1.16. Connect cable 61-C183 to the fuse assembly N64175-60. See Figure 5.
Part of harness
N63061
Connector N41493
Terminal G5900719
Plug N11681
Lock N25889-04
Cable C322
(N66236)
13 to 16 lb-ft
(18 to 22 N•m)
Replace the terminal
with N33090-08
on cable 61-C183
Disconnect
switch
N55066-01
Cable C324
(N49976)
13 to16 lb-ft
(18 to 22 N•m)
Fuse assembly
N64175-60
9 lb-ft (12 N•m)
Part of harness
N63061
Cable C183
Figure 5 - Modified Installation
PAGE 5 OF 7
SAV.1E.2012MA
BS1905ER1
SERVICE BULLETIN
+PDB
-FU87A
N40404-08
300A
F101
FUSE
MAIN
.DISCONNECT
.SWITCH
01
+PDB 88A
RL87A
1.18 88
24 VDC, 300A
RELAY
DISTRIBUTION
02
+PDB
-FU87K
N36473-10
10A
F110
FUSE SW
POWER
MASTER
ON
MAIN
DISCONNECT
SWITCH
200A
01
XC109
XC102
XC101
+PDB
-X61A
X
Cable
N66236
C322
0000/GY-RD
N49974
XC109
+PD8
-X61A
01
XC109
+PDB
-X61A
3
1
XC109
+PDB
-X61A
+18
-X6199A
9
C325
0000/GY-RD
N49977
New
+BCR
-JB81A
Remove
+BRS
-X1311A
01
01
JS-5
00/RD
N47816
Remove
Modified
L1
New
-
+EN
-MS61B
HLDI
11
43
16-010
16/RD
+1B
-X6199A
BATTERY
ASM
SIDE
RIGHT 12
VDC
+CSP
-X0189A
+
C315
0000/BK-BL
N48082
61-C183
6/BK-RD
+8CR
-BT81A
N40320
B2
C5
01-001
18/WH
70A
F110
FUSE SW
POWER
MASTER
ON
B1
89-097
18/WH
02
+BCR
SW 61A
CUT-OFF
SWITCH
2000A
1.3
D1
+TP
-X1101A
+BCR
-FU61A
N33410-04
If a heater cable for
the air intake grill is
installed, remove
from position 2 and
place on position 3.
11-001
18/WH
CUT-OFF
SWITCH
200A
1.7
13-018
18/WH
A2
XC103
J4
61-872
A1
C324
0000/GY-RD
N49976
C326
6/BK-RD
N55147
+BCR
SW61A
N49987
+1B
-X9913A
XC102B
12
99-006
18/WH
Replace
2
02
61-011
16/WH
New
+PDB
-FU87L
N36473-15
15A
F111
FUSE
VOLTAGE
REGULATOR
02
61-871
14/RD
S1
+PDB
SW87A
N40412
+8CR
-BT81B
N40320
BATTERY
ASM
SIDE
LEFT 12
VDC
+
-
Figure 6 - Vehicle's Modified Wiring Diagram
PAGE 6 OF 7
SAV.1E.2012MA
BS1905ER1
SERVICE BULLETIN
1.17. Install the new lower nylon block N66237 using the retained hardware.
1.18. Connect the new cable N66236 to the battery disconnect switch and to the second terminal from the right of
the power distribution box. Apply a torque as indicated in Figure 7.
NOTE: If a heater cable for the air intake grill is installed, then disconnect the heater cable that is 		
connected to terminal # 2 from the right of the power distribution box, and reconnect it to 				
terminal # 3. Apply a torque as indicated in Figure 7.
Tighten to a maximum of
12 lb-ft ±5% (17 N•m ±5%)
3
Heater cable for the air intake
grill
Disconnect from the 2nd terminal
and reconnect to the 3rd terminal.
2
1
Supply cable
Disconnect from the 1st terminal and
from the disconnect switch and discard.
Connect new cable N66236 to the
2nd terminal and to the disconnect switch
Figure 7 - Tightening Torque of the Power Distribution Box Terminals
1.19. Remove and discard the supply cable from fuse BCR-FU61A (red 6-gauge wire)
1.20. Remove the fuse assembly BCR-FU61A. See Figure 2.
1.21. Return the battery tray to its locked position.
1.22. Close all access doors.
PAGE 7 OF 7