NHTSA ID Number: 10172460
Manufacturer Communication Number: 2020-0044
Summary
To replace the disconnect to EP4 Board Power Cable.
2 Affected Products
Vehicles
Date: February 24, 2020
Service Bulletin
Bulletin No.: 2020-0044
Product Models Affected:
Aerotech 240
Purpose:
To remove and install the Disconnect to EP4 Board Power Cable.
Warranty Status:
Standard warranty coverage for all product models.
Tool(s) / Equipment Required:
Chocks
Safety Glasses (PPE)
Hearing Protection (PPE)
Gloves, Cut Resistant (PPE)
Bump Cap (PPE)
Open/Closed End Wrench Set
Screwdriver, Phillips #2
Torque Wrench 3/8”
3/8” Drive Socket Set
Part(s) / Material Required:
| Description | Part Number | Quantity |
| Power Cable | 0030695-06 | 1 |
| Contactor, Solid State | 68059 | 1 |
| Rubber Boot | 68058 | 1 |
| Zip-ties | N/A | A/R |
| Expandable Foam, Fire Retardant | N/A | A/R |
| Dielectric Grease (or equivalent) | E54598 | A/R |
Estimate Time-To-Complete:
2 hours
General:
- Park the vehicle on a flat level surface.
- Chock wheels of the vehicle.
- Ensure that the product use date is not greater than one (1) year from the expiration/manufacturing date of adhesives and sealants. Ensure product handling and storage processes meet manufacturer requirements.
- Protect adjacent areas, from weld spatter and debris from grinding during hot work operations.
- Protect adjacent areas, from overspray of paints and adhesives during assembly/finish operations.
- Disconnect battery(ies), PCM/ECM/Modules, and other electrical device connections as described in the Ford
Service Manual for welding, or performing other service work, on the chassis. - Reconnect battery(ies), PCM/ECM/Modules, and other electrical device connections as described in the Ford Service Manual for welding, or other service work on the chassis only after completing all process operations.
- Wear appropriate PPE during rework process operations.
- Ensure a fire extinguisher or other fire control apparatus are available during hot work operations.
- Follow OEM instructions regarding the removal and re-installation, or protection of alternate fuel cells and/or components of the alternate fuel system installed on the vehicle when completing hot work operations.
- Move any hoses, electrical harnesses or wire, or other components from the immediate work area where hot work, or other service work, operations may be performed.
- Follow appropriate industry standards and best practices for welding operations.
- Follow manufacturer instructions for the handling and use of adhesives, sealants, and other materials used in sub-assembly and assembly processes.
Procedure:
- Disconnect positive terminal from all batteries installed in vehicle.
- Locate Disconnect in Battery Tray/Step Tray.
- Remove Power Cables from Disconnect. Reference Image 1.
- Locate the Fuse in the Battery Tray/Step Tray.
- Remove the Disconnect to EP4 Power Cable from the Fuse.
- Remove Disconnect from chassis and discard old Disconnect.
- Install new Disconnect by reversing tasks completed in Step 6.
- Pull EP4 Power Cable through back of battery box. Continue pulling Power Cable out of P-Clamps along bottom of chassis. Reference Images 2 – 5.
- Inside bus, remove screws from ABS behind and above driver to expose the electrical harness. Reference Images 6 – 8.
Note: ABS located above the driver may not need to be removed if the ABS behind the driver and above the driver are not one piece.
- Locate harness behind driver once ABS is removed. Free electrical harness from zip-ties and/or Pclamps. Continue pulling harness through the hole in the floor. Reference Image 9.
- Open electrical panel door above driver. Reference Image 10.
- Remove EP4 Board by removing the 4 screws securing the Board. Reference Image 11.
- Disconnect the L-shaped connector on back of the EP4 board. Reference Image 12.
- Pull the electrical harness out from behind the electrical panel and discard harness.
- Install new Power Cable reversing tasks completed in Steps 3 – 5 and 8.
Note: Ensure L-shaped connector is located behind the electrical panel above the driver.
Note: Ensure electrical harness is bundled using zip-ties and all P-clamps are installed and secured to prevent chafing of power cable.
Note: Ensure there is enough slack in power cable behind electrical panel to avoid pulling on Lshaped connector to Board connection during attachment.
- Connect L-shaped Connector to back of EP4 Board.
- Install EP4 Board by reversing tasks completed in Step 12.
- Place Power Cables back onto the Fuse mounting stud, and torque to 13 ft/lb. Reference Image 15 for proper placement of power cables on fuse block.
- Torque seal nut after completion of the torque operation.
- Inspect heat shrink on ring/eyelet to ensure heat shrink does not extend over the ring portion of the eyelet.
- Cut back the heat shrink, as necessary, allowing the nut to sit flat on the ring/eyelet and post. Reference Image 14.
- Place the Power Cables onto the new Disconnect mounting studs, and torque to 13 ft/lb. Reference Image 1.
Note: Ensure there is enough slack in the power cable to allow the Battery Tray to freely move, as applicable.
Note: Ensure the power cable is bundled and secured to avoid chafing of the cable during vehicle operation and/or Battery Tray open/close operations.
- Torque seal nut after completion of the torque operation.
- Apply dielectric grease to the Fuse and Disconnect mounting studs. Reference Image 15 and 1.
- Reconnect positive terminals to batteries installed in vehicle, reversing tasks completed in Step 1.
- Torque the post terminal clamps to 7 ft/lb.
- Close and latch/secure the Battery Tray/Step Tray.
- Turn ignition key to ignition on.
- Inspect EP4 Board for illumination of LED status light. Reference Image 16.
- Close Electrical Panel Door.
- Spray Expandable Foam in the pass-thru hole in the floor behind driver. Reference Image 9.
- Install ABS behind the driver, and above the driver as applicable, reversing tasks completed in Step 9.
Contact Information:
Contact ElDorado Customer Service, 1655 Wall Street, Salina, KS 67401; or by calling (785) 827-1033 / (800) 955-9086; or by Email: [email protected]; or by Fax: (785) 823-9471.
Bulletin No.: 2020-0044
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