Ft4867R1

FT4867R1 Hydraulic level sensor defective
Technical writer name
Devanand
First Level Parts (100% of 438 vehicles)
Material
Part Number
SENSOR LEVEL HYDRAULIC
CABLE TIE (8428098,99,8877976)
N99760
G5007994
Manual section
09
Nb hours Level 1
0.25 hr
1
1
LOCTITE THREAD SEALANT WHITE
Note:
N37086 (LOCTITE THREAD SEALANT WHITE)
1 ea = 250ml
2 ml / Bus
876 ml for 438 buses
3.5~4 Tubes for entire campaign
Client
San Antonio Texas
San Antonio Texas
San Antonio Texas
San Antonio Texas
San Antonio Texas
San Antonio Texas
Capital Area Transportation Authority Michigan - CATA
Capital Area Transportation Authority Michigan - CATA
Halifax - Nova Scotia
Halifax - Nova Scotia
Halifax Nova Scotia
Chicago Transit Authority - CTA - Illinois
N37086
Order
LA10
LA22
LA34
LA35
LB26
LB43
LC07
LC08
LB61
LB70
LC11
LB58
7621-1684
Disposal of parts
Removed parts are:
Shop Supply (100% of 438 vehicles)
Material
Part Number
MQR
QTY
Discarded
X
Retained
-
When the retained check box is check, the parts must be retained
and returned in accordance with the usual warranty procedure to be
reimbursed,
QTY
2 ml
Road numbers
422
446
447
555
556
580
581
691
692
735
970
987
6012
6015
700
718
1277
1284
1285
1299
1300
1334
8325
8349
QTY Lang. Customer Target market Plant Config moteur Model
VIN
L82K9G9775628 L82K8G9775653 25
E
US
PLB
TD
40
Us-Prv
L82K8H9775654 L82K0H9775762 109
E
US
PLB
TD
40
Us-Prv
L82K0H9775857 L82K8H9775881 25
E
US
PLB
TD
40
Us-Prv
L82KXH9775882 L82K8H9775993 111
E
US
PLB
TD
40
Us-Prv
L82KXJ9776536 L82K6J9776579 44
E
Us-Prv
US
TD
40
PLB
L82K1J9776828 18
E
US
TD
40
L82K4J9776791
Us-Prv
PLB
S92J5K9777269 S92J5K9777272
4
E
US
TD
60
US-Prv
PLB
L82J7K9777278
L82J8K9777306 19
E
US
TD
40
US-Prv
PLB
L82J9J9776664
E
CA
TD
40
L82J6J9776671
8
PLB
L82J4J9776829
L82J9J9776843
15
E
CA
TD
40
PLB
L82JXK9777310 L82J5K9777344 35
E
CA
TD
40
PLB
E
US
TD
40
L82J7J9776906
L82J8J9776946
25
US-Prv
PLB
Jean-Nicolas Fournier
NR
x
x
x
x
x
x
x
x
x
x
x
x
R1
x
x
x
x
x
x
x
x
x
x
x
x
R2
Digitally signed by Jean-Nicolas Fournier
DN: cn=Jean-Nicolas Fournier, o=Nova Bus,
[email protected], c=CA
Date: 2020.08.12 12:57:04 -04'00'
MQR 7621-1684
Removal Of Hydraulic Oil Level Sensors
 Field Instructions
18/07/2019
DQT, , CONFIDENTIAL
Date created: Latest update:
WARNING : Follow your internal safety procedures.
A) VEHICLE PREPARATION
STEPS:
1.
2.
3.
4.
Park the vehicle on an even surface with transmission on neutral (N) and apply the parking brake.
Set the Master Control Switch in STOP position (see figure 1).
Before starting any work on the vehicle, make sure that the vehicle is completely and securely stationary.
Disconnect the starting circuit on the control box at the rear of the vehicle and place the battery disconnect switch in OFF position.
Figure 1 – Master Control Switch in STOP Position
DQT, , CONFIDENTIAL
Date created: Latest update:
MQR-1684 - Bill Of Materials
Items required for removal of hydraulic oil level sensor
DEUTSCH (DT series) Connector
ACTIV. ZIP-TIE SHRINK CAPPING CONNECTOR
BRASS PLUG
ITEM NOVA PN
MFG PN
1
-
0444620
2
N37086
56541
3
N31229-04
DT06-3S-E008
4
N11681
114017
5
N25892-03
W3-S
6
N82227-13
ATUM-24/6-0-STK
7
N56339
T120R6TZK2
8
-
21348
DQT, , CONFIDENTIAL
Date created: Latest update:
DESCRIPTION
MANUFACTURER
QUANTITY
COMMENTS
PLUG M-NPT- 1/4
PARKER
1
HYDRAULIC TANK
THREAD SEALANT WHITE
LOCTITE
2 ml
or 1 Tube per 125 Buses
(250 ml/Tube)
FOR THE THREAD PLUG
3-WAY CONNECTOR WITH BOOT ADAPTER
DEUTSCH
1
MATING PLUG
SEALING PLUG - DEUTSCH
DEUTSCH
3
WITH MATING PLUG
SECONDARY LOCK - DEUTSCH
DEUTSCH
1
WITH MATING PLUG
TE CONNECTIVITY
40mm
HELLERMANN TYTON
1
TUBING HEATSHRINK DUAL WALL
TEFZEL CABLE TIES
LOCTITE SF 7649 PRIMER 4.5OZ.
HENKEL
0.09 Oz
TO ATTACH MATING
CONNECTOR
1 Can per 60 buses
MQR-1684 – Hydraulic Sensor Location
Engine compartment
Field Instructions
Steps :
1. Open the engine compartment rear door to access the hydraulic tank (see figures
#2 and #3).
2. Disconnect the hydraulic oil level sensor electrical connector (see figure #3).
Oil Sensor
Electrical Connector
Figure 2 – Rear Door Compartment
DQT, , CONFIDENTIAL
Date created: Latest update:
Figure 3 – Hydraulic Tank Location
MQR-1684 – Removal of the Hydraulic Oil Level Sensor
Hydraulic tank modification
3. Spray on an even amount of Loctite Thread Activator 7649 onto the threads of the
brass plug (P/N 0444620). Allow to air dry. Next, apply a bead of Loctite 565 thread
sealant (P/N N37086) onto male threads of hex head brass plug (P/N 0444620)
starting two threads from the end (see figure #4).
4. Unscrew and remove the oil sensor from the hydraulic oil tank (see figure #5).
(Return the removed hydraulic oil level sensor wire kit to Prevost.)
Oil Sensor Location
Thread Sealant
Figure 4 – Hex Head Plug
Figure 5 – Hydraulic Oil Tank
DQT, , CONFIDENTIAL
Date created: Latest update:
MQR-1684 – Removal of the Hydraulic Oil Level Sensor
Hex head plug installation
5. Use a clean rag or cloth to catch any fluid that may escape the hydraulic oil tank sensor
threaded hole.
6. Immediately insert hex head brass plug into the hole and quickly fasten it finger tight (see
figure #6).
7. Torque to 2 turns past finger tight using an appropriate wrench.
8. Apply torque seal bead once tightened.
Figure 6 – Hex Head Plug Insertion
DQT, , CONFIDENTIAL
Date created: Latest update:
MQR-1684 – Capping Connector Assembly
DEUTSCH
10. DEUTSCH CONNECTOR SCENARIO (P/N N31229-04)
A. Insert a secondary lock to prevent the mating seal from falling (P/N N25892-03).
B. Seal each of the 3 cavities with a cavity plug (P/N N11681).
C. Install 1.5 inch of heat shrink tubing (P/N N82227-13) over the capping connector
shrink boot adapter located on the wire entry side. Then seal the connector end
by pinching the heat shrink tubing with pliers while heating (see figure #9).
D. Plug the capping connector on the mating harness #64 breakout (+EN-X64HF).
Insert Cavity Plugs At This
Connector End With
Orientation Shown
Secondary Lock
Figure 9 – Deutsch Capping Connector
Mating Seal
DQT, , CONFIDENTIAL
Date created: Latest update:
No water intrusion is possible
since the pinched heat shrink
tubing is environmentally sealed
with a melting adhesive liner
MQR-1684 – Harness #64 Breakout Wiring Management
DELPHI & DEUTSCH
11. Use a zip-tie (P/N N56339) to properly stow and secure harness breakout (+ENX64H□) as shown in the following pictures (see figures #10 and #11). Connector
could be Deutsch or Delphi variant depending on build configuration.
Figure 10 – Modified Harness #64 Breakout (+EN-X64H□)
Figure 11– Modified Harness #64 Breakout (+EN-X64H□) Close-Up View
Heat-shrunk capping connector not shown on the pictures above
DQT, , CONFIDENTIAL
Date created: Latest update:
MQR-1684 – Harness #64 Breakout Wiring Management
DELPHI & DEUTSCH
12. Remove the 10A circuit breaker (N11690.10) from the
rear interior back panel (99) position +IB-CB99AK2 to
disconnect the power feed to the sensor assembly.
DQT, , CONFIDENTIAL
Date created: Latest update: