SB-10045580-1857

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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:
260

MODEL:

TYPE:

30FT

35FT

40FT

60FT

XCELSIOR

DSL

CNG

LNG

ELEC

LOW FLOOR

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WRITTEN BY:
Mike Pearson

Battery

OBJECTIVE/SUBJECT:
Inspect OK6 Rooftop Oil Cooler Harness for UV Damage prevention.
PROCEDURE:
1. Park the vehicle on a level ground.
2. Set the Battery Disconnect switch to the “OFF” position.
3. Inspect the exposed sections of the wire insulation on the rooftop oil cooler harness (Figure 1)
for cracking or embrittlement of insulation (Figure 2). Insulation that is flexible without
cracking but has faded is to be covered to prevent deterioration.

Figure 1: Rooftop Oil Cooler

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Figure 2: Main Harness Damage

4. Disconnect the harness at each fan and remove the fan connector from the shroud.
5. If the insulation is brittle, replace main harness. Request for replacement harness – NF P/N
6390681 (EMP P/N 3170025006). See Appendix A – Harness Replacement for
instructions. If the wires on the fan side harness are brittle (Figure 3), request for fan
assembly NF P/N 6406658 (EMP P/N 1050016062). See Appendix B – Fan Replacement.
If there is no brittleness, install wire protection as follows:

Figure 3: Fan Harness Damage

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ITS:
a. Clip and remove zip tie on fan harness near the fan motor (Figures 4 through 7).

Figure 4: Clip Zip Tie

Figure 6: Removal of Zip Tie (2)

Figure 5: Removal of Zip Tie

Figure 7: Zip Tie Removed

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b. Slide wire sheathing away from fan to expose insulated wires (Figure 8).

Figure 8: Exposed Wires

c. Using Scotch Super 33+ electrical tape wrap wire bundle from header back a couple
inches (Figures 9 and 10).

Figure 9: Scotch Super 33+ Tape

Figure 10: Fan Harness Taped

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d. Slide existing Braided Sleeve material over wire header (Figures 11 and 12). The Braided
Sleeve will lock into place once over the “barb” of the header.

Figure 11: Sleeve Near Header

Figure 12: Sleeve Over Header

e. Install new Fir Tree Zip Tie N/F P/N 6406889 (EMP P/N 3330010025) to secure harness
to the fan guard (Figures 13 through 15).

Figure 13: New Zip Tie

Figure 14: Installing Zip Tie into Guard

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Figure 15: Securing and Trim of Zip Tie

f.

Tape Connector Side of Fan Harness (Figures 16 and 17). After taping no wire should be
exposed.

Figure 16: Exposed Wires on Fan Harness

Figure 17: Taped Harness

g. Cut 9” to 10” of Braided Sleeve Material N/F P/N 6406657 (EMP P/N 3389158008) and
slide it over the Main Harness (Figure 18).

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Figure 18: Braided Material Over Main Harness

NOTE:

If you are NOT replacing the harness then you will need to wrap the exposed

wires on the Main Harness close to the connector. Use Scotch Super 33+. If you are
replacing the Main Harness then this step is NOT necessary.

h. Use di-electric grease on connectors before assembly. Also, grease on the blue seal will
aid installation and help ensure a proper fit/seal (Figures 19 and 20).

Figure 19: Di Electric Grease on Connector

Figure 20: Smear Grease Over all Pins

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ITS:
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Inspect blue seal on main harness to ensure it is oriented properly on the connector
before installation and is not damaged. Rotate Seal as required. Applying a thin film of
grease or lubricant to the seal will aid in the installation process (Figure 21 and 22). If the
Seal is damaged it will need to be replaced N/F P/N 6406669 (EMP P/N EXP11110002).

Figure 21: Perfect Orientation

j.

Figure 22: Improper Orientation

Connect Main Harness to Fan Harness. When the connector is seated you will hear or
feel a “click”. Make sure the seal is not visible. If there is blue seal visible after the
connector is seated then the connection will not be sealed and be compromised (Figures
23 and 24).

Figure 23: No Seal Visible, Correct

Figure 24: Seal Visible, Incorrect

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k. Once connected properly, insert Zip Tie N/F P/N 6406664 (EMP P/N 3330036029)
through the wire bundle on the fan side and then through the harness side. Tighten zip tie
to secure connector and trim excess (Figures 25 and 26).

Figure 25: Zip Tie Inserted

l.

Figure 26: Zip Tie Secured and Trim

After connector is secured with a zip tie then slide the Braided Sleeve over the connector
and Main Harness side with Zip Tie N/F P/N 6406191 (EMP P/N 333022090). There
needs to be approximately 1” overlap (Figures 27 and 28).

Figure 27: Two Zip Ties Needed

Figure 28: Zip Tie Protective Sleeve on Harness

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There is an existing zip tie on the Main Harness. When securing the zip tie for

the protective cover make sure it is on the upstream side (away from the connector) of the
existing zip tie. This will ensure a mechanical lock and prevent the cover from slipping off.

m. Repeat same procedure on Fan Harness side of the connector. Make sure to extend the
Braided Sleeves to their max length to ensure the maximum amount of overlap. Use Zip
Tie N/F P/N 6406191 (EMP P/N 3330022090) to secure the Braided Sleeves and trim
excess (Figures 29 through 32).

Figure 29: Braided Sleeve Before Extension

Figure 31: Secure with Zip Tie

Figure 30: Braided Sleeve After Extension

Figure 32: Trim Zip Tie

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ITS:
n. Confirm each of the fan connections looks like Figure 33.

Figure 33: Protective Sleeve for Fan Connection

6. UV Protection completed, refer to Appendix B for fan assembly installation.
7. Turn the main battery disconnect switch to the “ON” position.

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Appendix A – Harness Replacement

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Harness Installation:

NOTE:

When replacing the Main Harness (EMP P/N 3170025006) perform steps 5.a

through 5.n for each fan connection. These steps will provide additional UV protection
for the new harness.

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Appendix B – Fan Replacement

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LABOUR ESTIMATE
Operation
1

Inspect OK6 Rooftop Oil Cooler Harness for UV

Men

Hours

1

1.5

Labour Time
M X HR
1.5

Damage prevention.

PARTS REQUIRED
Item

Part Number

1

6390681

Description
HARNESS ASSEMBLY

Qty.
per
Coach
1

Units
EA

Notes
ORDER AS
REQUIRED

2

6406658

FAN ASSEMBLY

6

EA

ORDER AS
REQUIRED

3

6406657

SLEEVE-BRAIDED

5.0

FT

ORDER AS
REQUIRED

4

6406669

CONNECTOR SEAL, BLUE

6

EA

ORDER AS
REQUIRED

5

6406191

ZIP TIE WRAP, 8”

12

EA

ORDER AS
REQUIRED

6

6406664

ZIP TIE WRAP, 11”

6

EA

ORDER AS
REQUIRED

7

6406889

FIR TREE ZIP TIE

6

EA

ORDER AS
REQUIRED