1511

1579

S92U4D4500333

S92U8D4500402

69

Marketing Sales Demo - MSD 6 Houston

L628

—

—

L82U8C4500003

L82UXC4500004

2

PAGE 3 OF 9
NQF772002 VERSION 3

LI4909E

INFORMATION LETTER
WARNING

FOLLOW YOUR INTERNAL SAFETY PROCEDURES.

PROCEDURE
1.1.

Park the vehicle on a leveled surface and set the transmission shift selector to neutral (N).

1.2.

Apply the parking brake.

1.3.

Set the master control switch to the eng stop position (o).

1.4.

Disconnect the starting circuit on the control box at the rear of the vehicle.

1.5.

Set the battery disconnect switch to the disable position (OFF) in the battery compartment.

1.6.

Lift the vehicle.
CAUTION

For information on hoisting and towing of the vehicle, see section 18: hoisting and towing in the Nova Bus
maintenance manual. Use appropriate hoisting equipment for your protection and to prevent damage to
the vehicle.

1.7.

In the battery compartment, release the anchor bolt holding the battery tray in close position. With the handle,
pull out and pivot the tray out of the vehicle. Insert tray's pin in plate's hole to secure the battery tray in open
position (Figure 1).
Hinge

Anchor
bolt

Handle

Pin
(located on the
back when the
tray is open)
Hole to secure tray in open position
Figure 1 - Battery Tray Opening Overview

PAGE 4 OF 9
NQF772002 VERSION 3

INFORMATION LETTER
1.8.

LI4909E

Locate the Wire Harness Assembly (WHA) 64 inside the battery compartment.

Figure 2 - Location of WHA 64 in Battery Compartment
(Typical Installation ─ Some Components Removed for Clarity)

PAGE 5 OF 9
NQF772002 VERSION 3

INFORMATION LETTER

LI4909E

CUT AND INSTALL A NEW CONNECTOR ON WHA 64
1.9.

From the left side, cut all wires of the breakout of the harness 64 approximately at the dimension shown
in Figure 3.

Approx
17.7 in
(450 mm)

Cut here

Figure 3 - Cut WHA 64 (Typical Installation)

1.10.

For the left section of the WHA 64 (section going towards the center of the vehicle), remove the wires from the
convoluted tubing up to the dual clamp tie (the tape and the convoluted tubing can be removed) (Figure 4).

Dual clamp tie

Figure 4 - View of the Cut Section of WHA 64 Removed from the Convoluted Tubing

PAGE 6 OF 9
NQF772002 VERSION 3

LI4909E

INFORMATION LETTER
1.11.

On each wire crimp a socket terminal G5900714.

1.12.

Insert all wires in the new connector N98386 following the pinout shown in Table 1.
PIN #

WIRE# (GAUGE / COLOR)

PIN #

WIRE# (GAUGE / COLOR)

A

64-221 (16 / WH)

H

─

B

64-224 (16 / WH)

J

64-225 (16 / BK)

C

64-947 (16 / WH)

K

64-223 (16 / WH)

D

64-219 (16 / WH)

L

64-1102 (16 / WH)

E

64-220 (16 / BK)

M

64-946 (16 / WH)

F

64-222 (16 / WH)

N

CAB064FG (YL)

G

64-906 (16 / WH)

P

CAB064FG (GN)

Table 1 - Pinout for New Connector

1.13.

Insert a cavity plug N11681 position H of the connector.

1.14.

Insert all wires back into the convoluted tubing and wrap with Coroplast tape N74787 up to the new connector.

INSTALL CONNECTOR BRACKET
1.15.

Position the new connector bracket N98377 as shown in Figure 5 and mark the two mounting holes position.

1.16.

Drill the two holes at the dimension shown in Figure 5 and install the bracket with the two rivets N31595.

13.6 in
(346 mm)

Drill 2x
0.196 in
(4,978 mm)
(#9)

1.13 in (29 mm)

Figure 5 - New Connector Bracket Position and Holes Dimension

PAGE 7 OF 9
NQF772002 VERSION 3

INFORMATION LETTER
1.17.

LI4909E

Insert connector into connector bracket and secure with lock washer N47411-02 and nut N47411-01 (Figure 6).

Lock washer and nut

Connector bracket
Figure 6 - Connector Installation on Connector Bracket

REPLACEMENT OF THE DAMAGED SECTION OF WHA 64
1.18.

Remove and discard the cut section of the WHA 64 going into the engine compartment, around the
after-treatment system (Figure 7).
NOTE

Please note the original installation since the new wire kit will follow the same route and use the same
securement points.

Figure 7 - Section of WHA 64 in Engine Compartment (Typical Installation)

PAGE 8 OF 9
NQF772002 VERSION 3

INFORMATION LETTER
1.19.

LI4909E

Connect the new wire kit N632000763 to the connector installed on the connector bracket (Figure 8).

New wire kit

Figure 8 - Connect New Wire Kit

1.20.

Secure the wire kit with the harness bundle using a dual cable tie N37749 where needed (not shown).

1.21.

Route the wire kit in the engine compartment like the removed old section of the WHA 64. Connect all
connectors and secure (ref. Figure 7).

RETURN VEHICLE IN SERVICE
1.22.

In the batteries compartment, lift the pin securing the battery tray in open position. Pivot and push the battery
tray to slide it in the battery compartment. Tight the anchor bolt to secure the tray in close position.

1.23.

Lower the vehicle.

1.24.

Set the battery disconnect switch to the enable position (ON).

1.25.

Connect the starting circuit on the control box at the rear of the vehicle.

1.26.

The vehicle can return in service.

PAGE 9 OF 9
NQF772002 VERSION 3