INSTRUCTION TO SERVICE
ITS: 58480
SECTION:

405

ARTIC JOINT.

WRITTEN BY:

Michael Rooney

SUBJECT:

Inspect & if Necessary Replace A/C Hoses.

ITS58480
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERED TO FOR FUTURE MAINTENANCE UNTIL
THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A
RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND
MAINTENANCE STAFF GOING FORWARD.
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 UNAUTHOIZED 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.

PROCEDURE:
Inspection of A/C Hoses.
1.

Turn the main battery disconnect switch to the “OFF” position.

2. Remove the false ceiling inside the articulated joint area of the bus. Refer to Section 7.3 of the Articulated Joint
chapter in the Maintenance Manual for removal procedure.
3. Locate hose P/N 435213 and 435287. See Figure #2.
a.

Inspect the hose end connector fittings on each hose to ensure that they are equipped with crimped fittings.
Any P/N 435213 or 435287 hoses found with 2 PC fittings should be replaced with new hoses with crimped
connectors. Note that the larger -24 hose adjacent to these hoses does have 2 PC fittings.

Crimped Style Connector.

2 PC Style Connector.

Figure 1: Crimped vs 2 PC Connectors
4. Check that the fittings on hoses 435213 and 435287 line up with the alignment marks that are laser etched on
the front and rear bulkheads. It is important that the fittings align with the marks so the hoses nest nicely
together and do not pull or bind on each other as the articulated joint moves through its range of motion. If the
fittings are not properly aligned with the marks, the fittings should be adjusted to correct the alignment.
WARNING:

Evacuate the A/C lines prior to moving the bulkhead connectors. Refer to the Thermo
King Maintenance Manual for procedure. Observe all safety precautions and
environmental regulations.

5. If the hose fittings and fitting alignments are correct, re-install the false ceiling inside the articulated joint area
of the bus. Refer to Section 7.3 of the Articulated Joint chapter in the Maintenance Manual for installation
procedure.
6. Remove all tools and debris and return the bus to service condition.
7. Turn the main battery disconnect switch to the “ON” position.

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Front Bulkhead

Alignment Marks

Alignment Marks

P/N 435287
P/N 435213

Alignment Marks
Alignment Marks
Rear Bulkhead

P/N 435287
P/N 435213

Figure 2A & 2B: Bulkhead Hose Fitting Alignment Marks.

Replacement of A/C Hoses if Necessary.
8. Turn the main battery disconnect switch to the “OFF” position.
9. Remove the false ceiling inside the articulated joint area of the bus. Refer to Section 7.3 of the Articulated Joint
chapter in the Maintenance Manual for removal procedure.
WARNING:

Evacuate the A/C lines prior to disconnecting from the bulkhead connectors. Refer to
the Thermo King Maintenance Manual for procedure. Observe all safety precautions
and environmental regulations.

10. Locate the center clamp that secures the center point of the hoses in the articulated joint. Mark all the hoses
at the point where they pass through the clamp at the forward edge to facilitate re-assembly later.
11. Remove the bulkhead covers to access the copper lines behind the bulkheads. Use a backup wrench on the
nuts on the copper lines to prevent damage due to twisting when the hoses are being removed.

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12. Locate hoses NF P/N 435213, P/N 435287. Disconnect these hoses at the front and rear bulkheads of the
articulated joint.
13. Locate the orings inside the connectors at the bulkheads. Replace them with new orings. The -16 oring is NF
P/N 010630 and the -20 oring is NF P/N 010629.

Center Clamp Bolts

Rear Bulkhead

Front Bulkhead

Hose P/N 434969
Hose P/N 435213
Hose P/N 435287

Figure 3: Artic Joint Hoses Viewed from Above.
14. Remove the bolts that secure the two halves of the center clamp and loosen the center bolt so the two hoses
can be removed.
15. Lay out the new replacement hoses NF P/N 435213, P/N 435287 on a table and mark the point where the
hoses will be clamped by the forward edge of the center clamp.

P/N 434969
P/N 435213
P/N 435287

Figure 4: Locations to Mark A/C Hoses.

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16. Install the new replacement hoses in their respective positions in the center clamp, aligning the marks with the
forward edge of the center clamp. Reinstall the center clamp end bolt but leave the bolts loose.
17. At the forward bulkhead, reconnect the hoses to their respective connection points. Note that there are
alignment marks on the bulkhead for orienting hose P/N 435213 & P/N 435287. Figure 3.

a.

The alignment marks for hose P/N 435213 are 10 deg upward from horizontal.

b.

The alignment marks for hose P/N 435287 are 10 deg downward from horizontal.

NOTE:

It is important that the hose fittings are oriented correctly to prevent binding and
interference of hoses which may result in damage due to pulling and chaffing when the artic
joint moves through its range of motion.
Forward Bulkhead

Fitting Alignment Marks

P/N 435287

P/N 435213
P/N 434969

Figure 5: A/C Hoses & Alignment Marks at Forward Bulkhead.
18. At the rearward bulkhead, reconnect the hoses to their respective connection points. Note that there are
alignment marks on the bulkhead for orienting hose P/N 435213 & P/N 435287. Figure 4.
a.

The alignment marks for hose P/N 435213 are 10 deg downward from horizontal.

b.

The alignment marks for hose P/N 435287 are 10 deg upward from horizontal.

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Fitting Alignment Marks

Rearward Bulkhead

P/N 435287
P/N 434969
P/N 435213

Figure 6: A/C Hoses & Alignment Marks at Rearward Bulkhead.
19. Torque all the hose fitting nuts to spec. Figure 7. Take care that the hose fittings do not rotate and remain
aligned with the marks on the bulkheads.
Figure 7: ARTIC JOINT HOSE TORQUE SPECIFICATIONS
DESCRIPTION
P/N 435213
P/N 435287

TORQUE
125 – 140 FT - LBS (WET)
92 – 100 FT - LBS (WET)

20. After installation, cover exposed connections on hose P/N 435213 with Butyl Cork Tape NF P/N 022973.
21. Ensure that all the hoses are correctly positioned at the center clamps using the alignment marks applied
previously then torque the bolts on the ends of the center clamp to 15 ft-lb (20 Nm).
22. Replace the dehydrator (drier) unit with a new unit NF P/N 6316018. The Dehydrator is located in the ceiling
at the forward end of the front carriage ahead of the condenser. There is an access hatch in the ceiling
adjacent to the SDS box. Refer to Thermo King Maintenance Manual for procedure.
23. Recharge A/C system. Refer to Thermo King Maintenance Manual for procedure.
24. Re-install the false ceiling inside the articulated joint area of the bus. Refer to Section 7.3 of the Articulated Joint
chapter in the Maintenance Manual for installation procedure.
25. Remove all tools and debris and return the bus to service condition.
26. Turn the main battery disconnect switch to the “ON” position.

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LABOUR ESTIMATE
Operation
1

Inspect & if Necessary Replace A/C Hoses.

Men

Hours

1

5.0

Labour Time
M X HR
5.0

PARTS REQUIRED
Item

Part Number

1

435213

ASSY – HOSE REFRI - STAR – 16 FL86.77

Qty.
per
Coach
1

2

435287

ASSY – HOSE REFRI - STAR – 20 FL86.44

1

EA

If Necessary

3

022973

TAPE BUTYL - CORK

2.5

FT

If Necessary

4

6316018

DEHYDRATOR

1

EA

If Necessary

5

010630

ORING 16

2

EA

If Necessary

6

010629

ORING 20

2

EA

If Necessary

Description

Units

Notes

EA

If Necessary

SPECIAL TOOLS REQUIRED
Item

Part Number

1

N/A

Description

Qty.
per
Coach

Notes
Units

A/C Refrigerant Recharging Equipment

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