FT4960R2

FT4690R2 Hydraulic level sensor defective
Technical writer name
Devanand
First Level Parts (100% of 138 vehicles)
Material
Part Number
PLUG M-NPT-1/4
3 PIN WITH SHRINK BOOT
SECONDARY LOCK
PLUG, SEALING DEUTCH CONN
TIE TEFZEL CABLE TIES
0444620
N31229-04
N25892-03
562288
N56339
Shop Supply (100% of 138 vehicles)
Material
Part Number
TUBING HEATSHRINK DUAL WALL
N82227-13
LOCTITE THREAD SEALANT WHITE
N37086
LOCTITE ACTIVATOR 7649
N8905622
Note:
N82227-13 (TUBING HEATSHRINK DUAL WALL)
1 ea = 4 ft (1219.2 mm)
60 mm/bus
8280 mm/138 buses
6.79 ~ 7 tubes for the entire campaign
Manual section
09
Nb hours Level 1
0.25 hr
MQR
7621-1684
QTY
1
1
1
3
1
Disposal of parts
Removed parts are:
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
60 mm
2 ml
0.075 oz
N37086 (LOCTITE THREAD SEALANT WHITE)
1 ea = 248.418 ml
2 ml/bus
276 ml/138 buses
2 tubes for the entire campaign
N8905622 (LOCTITE ACTIVATOR 7649)
1 ea = 4.5 oz
0.075 oz/bus
10.35 oz/138 buses
3 tubes for the entire campaign
Client
Burlington - Ontario
Burlington - Ontario
Houston - Texas
Houston - Texas
Houston - Texas
Oakville - Ontario
Oakville - Ontario
Oakville - Ontario
Ottawa - OC Transpo
Ottawa - OC Transpo
Order
LB35
LC18
LB63
LB72
LC55
LA55
LB93
LC57
LB80
LC16
Road numbers
7033-18
7036-18
1901
1907
2050
2050
2051
2069
2070
2079
—
—
—
—
—
—
4601
4609
4610
4682
VIN
QTY Lang. Customer Target market Plant Config moteur Model
2
E
CA
TD
40
L82J9J3751432
L82J0J3751433
Metrolinx
STE
L82J9K3752095
L82J0K3752101
7
E
CA
TD
40
metrolinx
STE
L82K2J9776708
L82K2J9776708
1
E
US
TD
40
Us-Prv
PLB
E
US
TD
40
L82K6J9776887
L82K4J9776905
19
US-Prv
PLB
L82KXK9777378 L82K0K9777387 10
E
US
TD
40
US-Prv
PLB
E
Metrolinx
CA
TD
40
L82J6H3750880
L82J5H3750885
6
PLB
L82J3K3751749
L82J5K3751753
5
E
CA
TD
40
STE
L82J6K3752121
L82J5K3752126
6
E
CA
TD
40
Metrolinx
STE
L82J0J3751576
L82J3J3751586
9
E
CA
TD
40
STE
L82J7K3751771
L82JXK3751912 73
E
CA
TD
40
STE
Jean-Nicolas Fournier
NR
x
x
x
x
x
x
x
x
x
x
R1
x
x
x
x
x
x
x
x
x
x
R2
x
x
x
x
x
x
x
x
x
x
R3
Digitally signed by Jean-Nicolas Fournier
DN: cn=Jean-Nicolas Fournier, o=Nova Bus,
[email protected], c=CA
Date: 2020.10.08 11:06:00 -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: