SB-10044259-1842

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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 IS 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
SECTION:

MODEL:

TYPE:

292

30FT

35FT

40FT

60FT

HIGH FLOOR

Electrical
Harnesses

DSL

CNG

LNG

ELEC

LOW FLOOR

ITS:

4902

WRITTEN BY:
Kevin Robinson

OBJECTIVE/SUBJECT:
Remove, replace and secure the muffler sensor harness.
PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Locate the harness going to the sensors on the muffler and disconnect it from the sensors.
3. Measure back 24 inches from the connectors and remove the loom and cut the coach
harness and push the coach side harness back into the AC compartment. Ensure the six
wires (four single and one twisted pair) are marked with their circuit names. Refer to wiring
schematics and trace as required to label the wire with the correct circuit name. Discard the
harness segment that plugs into the sensors.
4. On the coach side harness locate the black 18 gauge wire labeled EN46#8BK and strip the
wire 3/16 inch and install the terminal seal (NF PN 108872) then crimp on the supplied socket
(NF PN 108874).
5. Repeat step 4 for the remaining five wires.
6. Populate the supplied six circuit weather pack connector (NF PN 102874) with the sockets
added to the wires in steps 4 and 5. Refer to Figure 1 for required wire locations in the
connector.

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ITS:

4902

EN46#8BK
EN46#8WH
EN46N
EN46P
EN46R
EN46T

Figure 1: Wire Locations - 6 Circuit Weather Pack
7. Connect the supplied harness (NF PN 6406768) to the sensors on the muffler and plug the
connectors on the harness into them.
8. Wrap the harness in the engine compartment with the thermal wrap to prevent burning during
operation of the bus.

Figure 2: Thermal Wrap over Connectors
9. Route the other end of the harness with the weather pack pins on it through the hole that the
previous harness was routed through.

Figure 3: Routing Through Bulkhead
10. Populate the six circuit weather pack connector that was attached to the harness with the pins

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ITS:

4902

on the supplied harness (NF PN 6406768) and connect it to the mating six socket connector
added to the coach side harness in previous steps.

Figure 4: Connection in AC Compartment
11. Secure the loose harness in the AC compartment.

Figure 5: Harness Secure
12. Secure the harness to the coach frame as required to ensure the harness is clear of the
muffler throughout its routing.

Figure 6: Harness Routing in Muffler Compartment
13. Remove all tools and debris and return bus to service condition.
14. Turn the main battery disconnect switch to the “ON” position.

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ITS:

4902

LABOUR ESTIMATE
Operation
1

Remove and replace damaged section of muffler

Men

Hours

1

1.0

Labour Time
M X HR
1.0

sensor harness.

PARTS REQUIRED
Description

Qty.
per
Coach
1

Units

Item

Part Number

1

6406768

HARNESS-MUFFLER SENSORS

2

108874

SOCKET-18-20AWG WP

6

EA

3

102874

CONN-6CCT TWR WEATHER PACK

1

EA

4

165544

LOOM-THERM-L WRAP 36"

2

EA

5

108872

SEAL-CABLE WP

6

EA

EA

Notes