ITS60378
Service Bulletin Details
Public Details for: ITS60378
This technical instruction describes how to upgrade the delco alternator indicator lamp ring terminal.
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Models from 2022
| 2022 MCI D4500 |
Models from 2021
| 2021 MCI D4000 ISTV |
| 2021 MCI D4500 |
Models from 2020
| 2020 MCI D4500 |
Models from 2019
| 2019 MCI D4500 |
Models from 2018
| 2018 MCI D4500 |
Models from 2017
| 2017 MCI D4500 |
Models from 2016
| 2016 MCI D4500 |
INSTRUCTION TO SERVICE ITS60378 March 23, 2022 SECTION: 292-Electrical Harness WRITTEN BY: Aditya Gadepalli SUBJECT: Alternator Ring Terminal Rework The ring terminal connected to the indicator light terminal on the back of the ISSUE: Delco alternator could be corroded and cause intermittent issues. Changing the ring terminal to a more whether friendly part on the indicator light terminal will either resolve or prevent the intermittent issue. This ITS provides SUMMARY: the steps to discard the existing terminal and crimp a new better version terminal. ITS60378 Ref. NHTSA Recall No. Not Applicable Ref. Transport Canada Recall No. Not Applicable THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED TO FOR FUTURE MAINTENANCE UNTIL THE PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND MAINTENANCE STAFF GOING FORWARD. This document and the contents discussed herein are the confidential and proprietary information of New Flyer Industries Canada ULC and New Flyer of America Inc. and are disclosed by New Flyer in confidence. This document and the contents herein are not to be disclosed by the intended recipient without the prior written authorization of New Flyer. Any unauthorized disclosure, reproduction or other distribution of this document or information strictly prohibited and may result in action being taken against the party making the unauthorized disclosure. This document and all copies hereof must be returned to New Flyer upon request. INSTRUCTION TO SERVICE ITS60378 PROCEDURE: 1. Set park brake and chock wheels. 2. Turn the main battery disconnect switch to the “OFF” position. 3. Open the engine door. Open engine door ITS60378 Page 2 of 8 March 23, 2022 INSTRUCTION TO SERVICE ITS60378 4. Locate wire ID 0208 behind the top alternator connected to the stud “I”. Remove and save the nut securing the wire. 5. Cut and discard the ring terminal on wire 0208. Cut the ring terminal on wire ID 0208 connected to stud “I” 6. Crimp 4” of 18 AWG black wire, MCI P/N: 19-11-1251, to the 0208 wire using splice connector, MCI P/N: 1911-3775, and heatshrink, MCI P/N: 19-11-1465. Crimp 4” black wire using splice connector and heatshrink NOTE: Follow instruction in step 14 to crimp wire using splice connector. 7. Crimp #10 ring terminal, MCI P/N: 19-11-402, to the other end of the added wire using heatshrink, MCI P/N: 19-11-1465. Crimp #10 ring terminal using heatshrink NOTE: Follow instruction in step 15 to crimp ring terminal. ITS60378 Page 3 of 8 March 23, 2022 INSTRUCTION TO SERVICE ITS60378 8. Re-install the modified 0208 wire to the “I” stud using existing hardware and torque the nut to 15-25 In-Lbs. Connect the modified wire to stud “I” and torque to 15-25 In-Lbs 9. Locate wire ID 0207 behind the bottom alternator connected to the stud “I”. Remove and save the nut securing the wire. 10. Cut and discard the ring terminal on wire 0207. Cut the ring terminal on wire ID 0208 connected to stud “I” 11. Crimp 4” of 18 AWG black wire, MCI P/N: 19-11-1251, to the 0207 wire using splice connector, MCI P/N: 1911-3775, and heatshrink, MCI P/N: 19-11-1465. Crimp 4” black wire using splice connector and heatshrink NOTE: Follow instruction in step 14 to crimp wire using splice connector ITS60378 Page 4 of 8 March 23, 2022 INSTRUCTION TO SERVICE ITS60378 12. Crimp #10 ring terminal, MCI P/N: 19-11-402, to the other end of the added wire using heatshrink, MCI P/N: 19-11-1465. Crimp #10 ring terminal using heatshrink NOTE: Follow instruction in step 15 to crimp ring terminal. 13. Re-install the modified 0207 wire to the “I” stud using existing hardware and torque the nut to 15-25 In-Lbs. Connect the modified wire to stud “I” and torque to 15-25 In-Lbs ITS60378 Page 5 of 8 March 23, 2022 INSTRUCTION TO SERVICE ITS60378 14. Wire Splicing Procedure ITEM 1 2 3 4 5 6 7 ITS60378 DECRIPTION Using wire strippers, strip the wires 0.250 inch. Crimp one wire. Orient and slide the heatshrink over the crimped wire. Crimp the other wire. Solder the center of the crimp joint. Proceed to solder both ends. Orient and center the heat shrink over the butt splice. Using a heat gun, shrink down all the way until the melted glue is visible. Page 6 of 8 March 23, 2022 INSTRUCTION TO SERVICE ITS60378 15. Ring Terminal Crimping and Sealing Procedure: Ring terminal to be crimped, soldered and heat shrink applied as detailed below. The applied heat shrink for non-insulated terminal ends shall not extend into the ring contact area and shall cover wire insulation by at least .25 inches. The ring contact area is defined as the area within the outer terminal ring circumference shown by the red dotted circle in the figure below. ITS60378 Page 7 of 8 March 23, 2022 INSTRUCTION TO SERVICE ITS60378 LABOUR ESTIMATE Operation 1 Number of Technician(s) 1 Alternator Ring Terminal Rework Hours 0.5 Labor Time T X HR 0.5 PARTS REQUIRED Description Qty. per Coach 2 Units Item Part Number 1 19-11-402 Ring Term_Solistrand #10_22-16 AWG 2 19-11-3775 Splice-Butt,Molex,22-18 AWG 2 EA 3 19-11-1251 GXL_16AWG_Blk 8 IN 4 19-11-1465 Heatshrink, 2” 4 EA Notes EA SPECIAL TOOLS REQUIRED Item Part Number Qty. Description Units Notes 1 ITS60378 Page 8 of 8 March 23, 2022