Repair Procedure Instruction Sheet #TBB RECALL #07V-544
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3 Repair Procedure Instruction Sheet #TBB RECALL #07V-544 MODEL: SUBJECT: ER, HD, HDX, MVP-EF, & FS-65 PRINTED CIRCUIT BOARDS, CIRCUIT PROTECTION, & POWER CABLE REPLACEMENT PAGE: 1 OF 4 Read entire document before beginning the procedure. This document replaces all the printed circuit board mounted auto-reset circuit breakers with either fuses or manual reset circuit breakers and replaces the printed circuit board battery power supply jumper cable for either the two or three Printed Circuit Board configuration. The vehicles affected are as follows: Saf-T-Liner ER, HD, and HDX produced from January 1, 2000 to January 15, 2008; MVP-EF produced from February 18, 2004 to January 15, 2008; FS-65 produced from April 17, 2003 to August 1, 2007 States that specify Circuit Breakers: Alabama Florida Maine Maryland Ohio South Carolina Texas Virginia West Virginia Abbreviations used in this document: PCB = Printed Circuit Board, CB = Circuit Breaker Your vehicle may be equipped with either a two PCB or a three PCB configuration in the front left exterior Electrical Side Panel and depending on option content originally ordered for the bus, may have a combination of fuses and auto-reset circuit breakers installed on the circuit boards. This procedure will guide you through replacing the PCB battery power jumper cable and PCB circuit protection devices with either PCB configuration. Figure 1 shows the two PCB configuration and Figure 2 shows the three PCB configuration. These figures are typical configurations and will be used as a reference for parts identification. rev. 03/13/08
4 PAGE: 2 OF 4 Fuses &Circuit Breakers PCB #2 PCB #1 Battery Jumper Cable Battery Post Figure 1 Two PCB Configuration PCB #2 PCB #3 PCB #1 Battery Post Battery Jumper Cable Figure 2 Three PCB Configuration
5 PAGE: 3 OF 4 PCB Inspection Procedure: 1. Shut down the engine, set the parking brake, and chock the tires. 2. Disconnect the batteries at the negative terminal. 3. Open the left front exterior electrical side panel door to gain access to the printed circuit boards. 4. If equipped, remove the fasteners that secure the PCB covers and the PCB covers. Save the fasteners and covers. 5. Document what the fuse or circuit breaker values are in each position of the PCB. Use drawings listed in the reference material section as a guide. Replacement of Auto-Reset Circuit Breakers with Manual Reset Circuit Breakers or Fuses: 1. For vehicles that require a circuit breaker option and have the auto reset circuit breaker installed, replace them with the manual reset circuit breaker of the appropriate value shown in the parts section of this PSB. The following nine states require circuit breakers to be installed: 1) Alabama 2) Florida 3) Maine 4) Maryland 5) Ohio 6) South Carolina 7) Texas 8) Virginia 9) West Virginia 2. If the vehicle does not require circuit breakers from any State specification, and has circuit breakers installed, replace them with fuses. Replacement of the PCB Power Jumper Cable: 1. Label the cables and wires attached to each PCB battery post stud and remove the locknut. 2. Remove the PCB Jumper Cable, and discard, see Figures 1 and With all the wiring removed from the battery post, place the new Cable, #TBB for the two PCB configuration or #TBB for the three PCB configuration, as the first cable installed and in the orientation shown in Figures 3 and 4. If there are additional wires installed on this battery post stud, be sure to slightly stagger the terminals so they are setting flat on each other, and will not side load the battery post stud when the locknut is tightened. There should not be more than three separate terminals attached to the battery post stud. 4. Once the wires are oriented on the battery post stud from step 3, install the flat washer and locknut. Torque the locknut to 65 in-lbs. Torque nuts to 65 in/lbs. PCB Battery Cable, TBB Figure 3 PCB Battery Cable, TBB Figure 4
6 PAGE: 4 OF 4 Checking the Installation: 1. Connect the negative terminal to the battery. 2. Test that there is battery voltage at the battery post on each PCB. 3. Start the engine and check that all the electrical systems powered by PCB 1 and PCB 2 operate properly. 4. Install the PCB covers, if applicable. REFERENCE MATERIAL NEEDED FOR REPAIR PROCEDURE: (PCB 1 LABEL) FOR PCB (PCB 1 LABEL) FOR PCB (PCB 2 LABEL) FOR PCB (PCB 2 LABEL) FOR PCB (PCB 3 LABEL) FOR PCB REFERENCE ONLY PART: TBB , LOCKNUT, NYLON, M8 X 1.25 (PCB STUD LOCKNUT, IF NEEDED) MATERIALS REQUIRED: PART NUMBER QTY. DESCRIPTION TBB PCB BATTERY CABLE, TWO PCB CONFIGURATION (4 AWG) OR TBB PCB BATTERY CABLE, THREE PCB CONFIGURATION (4 AWG) TBB AR FUSE ATC 3 AMP TBB AR FUSE ATC 5 AMP TBB AR FUSE ATC 7.5 AMP TBB AR FUSE ATC 10 AMP TBB AR FUSE ATC 15 AMP TBB AR FUSE ATC 20 AMP TBB AR FUSE ATC 25 AMP TBB AR CIRCUIT BREAKER/MANUAL RESET 8 AMP TBB AR CIRCUIT BREAKER/MANUAL RESET 10 AMP TBB AR CIRCUIT BREAKER/MANUAL RESET 15 AMP TBB AR CIRCUIT BREAKER/MANUAL RESET 20 AMP TBB AR CIRCUIT BREAKER/MANUAL RESET 25 AMP
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