FT4949

MQR 7621-2121
Accelerator Pedal Not Responding (1242 Fault Codes)
FT4949 Field Instruction – Splice Connectors Modification (Rev03)
September 16, 2020
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
WARNING: Follow your internal safety procedures.
A) VEHICLE PREPARATION
STEPS:
1.
2.
3.
4.
5.
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.
Disconnect the battery negative (chassis ground) cable to eliminate the risk of an electrical short circuit that could damage the engine ECM.
(Follow your internal safety procedure before disconnecting battery cables).
Figure 1 – Master Control Switch in STOP Position
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
2
MQR 7621-2121 – Accelerator Pedal Not Responding
Bill Of Materials
LEVEL 1:
ITEM
NOVA PN
MFG PN
1
N56339
T120R6TZK2
2
N82227-02
ATUM-4.5/1.5-0-STK
ITEM
NOVA PN
MFG PN
1
N/A
1010-020-1206
2
N83365
3
DESCRIPTION
MANUFACTURER
QUANTITY
HellermanTyton
5
TE / Raychem
2 Inches
MANUFACTURER
QUANTITY
DT SERIES ORANGE MATING SEAL
TE / Deutsch
1
DT06-12SB-C015
CONNECTOR 12WAY DEUTSCH
TE / Deutsch
2
N38291-04
DT04-12PB-P030
CONNECTOR CAP SPLICE SEALED BLK
TE / Deutsch
1
4
N92382
W12S-P012
CONNECTOR WEDGE LOCK GRN
TE / Deutsch
2
5
N11681
114017
CAVITY PLUG
TE / Deutsch
6
6
N31233-03
0462-201-1631
DEUTSCH TERMINAL SOCKET - 16 GOLD
TE / Deutsch
16
7
N38291-06
DT04-12PB-P026
CONNECTOR CAP SPLICE SEALED BLK
TE / Deutsch
1
8
N31233-02
0462-221-1631
DEUTSCH TERMINAL SOCKET - 16 for drain
TE / Deutsch
2
9
N75513
DT12S-BT
BOOT DT PLUG 12-WAY
TE / Deutsch
2
TEFZEL CABLE TIES
TUBING HEAT SHRINK DUAL WALL
LEVEL 2:
DESCRIPTION
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
3
MQR 7621-2121 – Accelerator Pedal Not Responding
Splice Connectors Modification
Field Instruction
NOTE: This installation procedure covers the worst case scenario that corresponds
to the 4-way splice connectors configuration. Follow the same logic for a 2- or 3-way
splice connectors configuration.
1. Lift and secure the vehicle onto the safety stands.
2. Locate the splice connectors cluster (see figure 2).
3. Remove the bolt that retains all splice connectors and
then remove the upper splice connectors (see figure 3).
Remove
Splices connectors location
Figure 2 – Splice Connectors Cluster Location
Figure 3 – Splice Connectors Location
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
4
MQR 7621-2121 – Accelerator Pedal Not Responding
Splice Connectors Modification
4. Move the 2 lower splice connectors with wire entry already facing down so that they are
positioned and reassembled at the single tie mount location (see figures 4, 5 & 6). Before
fastening, ensure that the mounting hardware parts stacking is the same as on figures 5 & 6.
Single tie mount location
Move
Nut
Tie Mount
Bolt
Brackets
Figure 5 – Brackets Installation (Top View)
Splice connectors already facing down
Figure 6 – Brackets Installation (Side View)
Figure 4 – Splice Connectors with Wire Entry Already Facing Down
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
5
MQR 7621-2121 – Accelerator Pedal Not Responding
Splice Connectors Modification
5. Move the upper splice connectors and inspect the terminals,
seals and wedge locks for signs of corrosion (see figure 7).
a) Move away the grey boot.
b) Remove the connector cap and the connector wedge lock.
c)
Inspect the connector cap jumper, the terminals and the seals.
6. If no sign of corrosion is found, then go to step 8.
7. Else if there are some signs of corrosion, go to step 11
and/or step 12 (depending on affected splice connectors).
8. Clean all parts thoroughly with contact cleaner.
9. If the connector mating seal is worn, damaged or missing,
replace it with a new seal (Deutsch P/N 1010-020-1206).
10. Extract the drain wire terminals of splice connector SC95N
(see figure 8 for the terminal positions) and add 25mm of
heat shrink tubing P/N N82227-02 over the extended
terminal crimp area (see figure 9 on next slide).
Go to step 13.
Figure 7 – Examples of Corrosion and Damaged Mating Seal
Splice
SC95N
Drain Wire Terminal
Positions
6
7
Figure 8 – Drain Wire Terminal Positions
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
6
MQR 7621-2121 – Accelerator Pedal Not Responding
Splice Connectors Modification
11. Replacement of the corroded / damaged parts of the +MT-SC95N splice connector:
a)
Remove the connector cap.
b)
Using the extraction tool (Deutsch P/N DT-RT1), remove all terminals from the connector.
c)
Cut all the terminals while keeping the maximum possible length.
d)
Insert a new grey boot P/N N75513 over the wires.
e)
On both cables, crimp a new terminal P/N N31233-03 on all wires except for the drain wires (colored insulated wires only).
f)
Crimp a new terminal P/N N31233-02 on both drain wires.
g)
Add 25mm of heat shrink tubing P/N N82227-02 over the extended terminal crimp are (see figure 9).
h)
Insert the following wires into a new connector P/N N92381-03:
I.
CAB095VP red wire at position 1.
II.
CAB095VP black wire at position 10.
III. CAB095VP white wire at position 4.
IV. CAB095VP drain wire at position 7.
V.
CAB095VS red wire at position 11.
VI. CAB095VS black wire at position 2.
VII. CAB095VS white wire at position 8.
VIII. CAB095VS drain wire at position 6.
IX. Wire 95-291 at position 12.
X.
N82227-02
Figure 9 – Heat Shrink Tubing Applied
Over Drain Wire Extended Terminal Crimp Area
Wire 95-294 at position 5.
i)
Insert a cavity plug P/N N11681 at positions 3 & 9.
j)
Install a new wedge lock P/N N92382 at the splice connector end.
k)
Insert the connector into a new connector cap P/N N38291-04.
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
7
MQR 7621-2121 – Accelerator Pedal Not Responding
Splice Connectors Modification
12. Replacement of the corroded / damaged parts of the +MT-SC95K splice connector:
a) Remove the connector cap.
b) Using the extraction tool (Deutsch P/N DT-RT1), remove all terminals from the connector.
c)
Cut all the terminals while keeping the maximum possible length.
d) Insert a new grey boot P/N N75513 over the wires.
e) On both cables, crimp a new terminal P/N N31233-03 on all wires.
f)
Insert the following wires into a new connector P/N N92381-03:
I.
Wire 95-288 at position 3.
II.
Wire 95-289 at position 10.
III. Wire 95-290 at position 2.
IV. Wire 95-291 at position 1.
V. Wire 95-292 at position 4.
VI. Wire 95-293 at position 5.
VII. Wire 95-294 at position 6.
VIII.Wire 95-371 at position 11.
g) Insert a cavity plug P/N N11681 at positions 7, 8, 9 & 12.
h) Install a new wedge lock P/N N92382 at the splice connector end.
i)
Insert the connector into a new connector cap P/N N38291-06.
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
8
MQR 7621-2121 – Accelerator Pedal Not Responding
Splice Connectors Modification
13. Install the remaining splice connectors with the previously removed hardware inside the left slot
of the main mounting bracket (first slot starting from motor side). See figures 10 & 11 for the
parts stacking order. Splice connectors support brackets must be placed between the nut and
the main mounting bracket.
Washer
Bolt
Splice
connectors
brackets
(not shown)
Nut
Figure 10 – Hardware Modification
Figure 11 – Left Splice Connectors Securement
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
9
MQR 7621-2121 – Accelerator Pedal Not Responding
Splice Connectors Modification
14. Using blue cable ties P/N N56339, secure the splice
connectors wiring to the main harness bundle.
15. Confirm that the grey boots cannot slip or easily
move down in order to protect the connector wire
entries from water, dust or dirt projections.
16. Confirm that the throttle pedal is working and then
return bus to service.
Figure 12 – Final Installation – View 1
Figure 13 – Final Installation – View 2
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16
10
DQT, Kévin Lalancette, CONFIDENTIAL
Date created: 2020-07-02 Latest update: 2020-09-16