Service Bulletin No. 2870

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Bruno Randall
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1 MODEL TYPE SECTION/GROUP DATE SUBJECT D4000 / D4500 / E4500 / J4500 Series Coaches Product Improvement MP BOOST PUMP RESISTOR 7--Electrical Aug 1, 2003 CONDITIONS Parts may be purchased from MCI Service Parts, Louisville, Kentucky or from MCI ServiceParts,Newcastle,Ontario. Description: Effective with unit number on D4000 / D4500 series coaches, unit number on E4500 series coaches and unit number on J 4500 series coaches, MCI has made design changes to the MP boost pump installation. The addition of the pump resistor will improve the reliability and performance of the MP boost pump. Parts Qty. New P/N Description Harness - Pump Resistor Terminal - Female, 14 Ga, Socket Tyrap Seal - Wire Connector - 2 Pos Weatherpack Screw #4 x 3/8 Tap, P/H, C/R ( required for D coach and E/J non - multiplexed coach installation ) Rivet - 1/8 Dia, Aluminum ( required for E/J multiplexed coach installation ) Service Information: 1. New parts will be available for service replacement. Service Procedure: General notes Read this entire procedure before beginning work. UseSafeShopPracticesAtAllTimes. SERVICE PROCEDURE A INSTALLING PUMP RESISTOR ON E / J SERIES COACHES A 1. Turn the main battery disconnect switch to the OFF position. Chock both sides of the tires. A 2. Open the battery compartment door. A 3. Locate wire 1242 in connector PF---3A ( fuse box ). A 4. Using wire cutters, cut the wire 1242 four inches into the powerfeed harness. A 5. Using wire strippers, expose 3/16 inch of the end of the 1242 wire in the PF3 connector. Crimp a packard socket ( part number ) with wire seal ( part number ) to the wire. A 6. Insert into position A of the packard with plug ( part number ). A 7. Using wire strippers, expose 3/16 inch of the end of the 1242 wire in the powerfeed harness. Crimp a packard socket ( part number ) with wire seal ( part number ) to the wire. A 8. Insert into position B of the packard with plug ( part number ). A 9. Connect to the pump resistor harness assembly. A 10. For non--multiplexed coaches: a. using a 3/32 drill bit, match drill two holes using the resistor as a template, b. using two screws ( part number ), mount the resistor to the compartment wall ( Figures 1 and 2 ). NOTE Use a drill bit guard, to avoid drilling into fuel tank.

2 DATE AUG 1, 2003 PAGE 2 Figure 1. Non--multiplexed E / J coaches. Figure 2. Non--multiplexed E / J coaches.

3 DATE AUG 1, 2003 PAGE 3 A 11. For multiplexed coaches: a. using a 1/8 drill bit, match drill two holes using the resistor as a template, b. using a rivet gun and two rivets ( part number ), install the resistor to the compartment wall ( Figures 3 and 4 ). NOTE Use a drill bit guard, ensuring no damage to interior components. Figure 3. Multiplexed E / J coaches. Figure 4. Multiplexed E / J coaches.

4 DATE AUG 1, 2003 PAGE 4 pump resistor Figure 5. Multiplexed E / J coaches. SERVICE PROCEDURE A complete.

DATE AUG 1, 2003 PAGE SERVICE PROCEDURE B INSTALLING PUMP RESISTOR ON D NON-MULTIPLEXED COACHES B 1. Turn the main battery disconnect switch to the OFF position. Chock both sides of the tires. B 2.

5 DATE AUG 1, 2003 PAGE SERVICE PROCEDURE B INSTALLING PUMP RESISTOR ON D NON-MULTIPLEXED COACHES B 1. Turn the main battery disconnect switch to the OFF position. Chock both sides of the tires. B 2. Open the roadside rear side service compartment door. Remove the cover from the rear junction box compartment ( Figure 6 ). Figure 6. B 3. Locate wire 24VB-BK-16 that runs from the 15A heater fuse assembly. B 4. Using wire cutters, cut the 24VB-BK-16 wire thirty inches from the fuse assembly. B 5. Using wire strippers, expose 3/16 inch of the end of the wire remaining in the fuse assembly.. Crimp a packard socket ( part number ) with wire seal ( part number ) to the wire. B 6. Insert into position A of the packard with plug ( part number ). B 7. Using wire strippers, expose 3/16 inch of the end of the 24VB-BK-16 wire in the harness. Crimp a packard socket ( part number ) with wire seal ( part number ) to the wire. B 8. Insert into position B of the packard with plug ( part number ). B 9. Connect to the pump resistor harness assembly. B 10. Using a 3/32 drill bit, match drill two holes using the resistor as a template ( Figure 7 ). NOTE Use a drill bit guard, ensuring that only 1/8 inch of the drill bit goes through the rear junction box wall, avoiding damage to the sidewall. B 11. Using two screws ( part number ), mount the resistor to the side wall of the rear junction box. B 12. Re---install the cover on the rear junction box compartment. Close the roadside rear side service compartment door. 5

6 DATE AUG 1, 2003 PAGE 6 pump resistor location on side wall of rear junction box. Figure 7. Non--multiplexed D coaches. SERVICE PROCEDURE B complete.

DATE AUG 1, 2003 PAGE 7 SERVICE PROCEDURE C INSTALLING PUMP RESISTOR ON D MULTIPLEXED COACHES C 1. Turn the main battery disconnect switch to the OFF position. Chock both sides of the tires. C 2.

7 DATE AUG 1, 2003 PAGE 7 SERVICE PROCEDURE C INSTALLING PUMP RESISTOR ON D MULTIPLEXED COACHES C 1. Turn the main battery disconnect switch to the OFF position. Chock both sides of the tires. C 2. Open the #3 baggage bay compartment door. Remove the cover from the rear junction box compartment ( Figure 8 ). Figure 8. C 3. Locate wire 8585 in position B6 of the rear junction box fuse block. C 4. Using wire cutters, cut the 8585 wire four inches from the fuse assembly. C 5. Using wire strippers, expose 3/16 inch of the end of the wire remaining in the fuse assembly.. Crimp a packard socket ( part number ) with wire seal ( part number ) to the wire. C 6. Insert into position A of the packard with plug ( part number ). C 7. Using wire strippers, expose 3/16 inch of the end of the 8585 wire in the harness. Crimp a packard socket ( part number ) with wire seal ( part number ) to the wire. C 8. Insert into position B of the packard with plug ( part number ). C 9. Connect to the pump resistor harness assembly. C 10. Using a 3/32 drill bit, match drill two holes using the resistor as a template through the rear junction box (Figure 9). NOTE Use a drill bit guard, to avoid damage to interior components. C 11. Using two screws ( part number ), mount the resistor to the rear junction box wall. C 12. Re---install the cover on the rear junction box compartment. Close the #3 baggage bay compartment door.

8 DATE AUG 1, 2003 PAGE 8 SERVICE PROCEDURE C complete. Figure 9. Multiplexed D coaches.

Service Bulletin No. 2899

Service Bulletin No. 2899 MODEL TYPE SECTION/GROUP DATE E4500 / J4500 Series Coaches Product Improvement 7--Electrical April 1, 2005 SUBJECT CONDITIONS ENGINE COMPARTMENT MAGNETIC SWITCH Parts may be purchased from MCI Service