INSTRUCTION TO SERVICE
ITS: 59161

01-Feb-2021

SECTION:

273-Exterior Lighting

WRITTEN BY:

Mike Pearson

SUBJECT:

Inspect and install headlamp harness assembly as required.

ISSUE:

Too high of a current draw at a low voltage supply creating too much heat.

SUMMARY:

Add new harness assembly to limit high voltage draw condition.

ITS-59161

THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED 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 unauthorized disclosure,
reproduction or other distribution of this document or information 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
ITS59161

PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Locate and open the exterior wiper motor and defroster access doors.
4. Locate and open the interior LH lower panel access door.

Existing defroster
access door

Curbside front
headlamp assembly

Curbside front
headlamp assembly

Figure 1: Headlamp Assembly and Defroster Access Door Locations
5. Inspect the date stamp on the existing curbside and street side headlamp assemblies, an inspection mirror may
be needed to view the date stamp location, see Figure 2 for date stamp location.
6. If the headlamp assembly date stamp is between 26-June-2019 and 14-October-2020 a new headlamp harness
will need to be installed.

Date stamp
location

Figure 2: CS and SS Headlamp Assembly Date Code Location

ITS59161

Page 2 of 5

March 4, 2019

INSTRUCTION TO SERVICE
ITS59161
7. Disconnect the street and curb side headlamp assembly harnesses from the main dash harness.

Street and
curbside front
headlamps

Disconnect the street
and curb side
headlamp harnesses

Street and
curbside front
headlamps

Figure 3: CS and SS Headlamp Assembly Adapter/Main Harness Location
WARNING:

When drilling into the driver’s defroster frame wall, a drill stop gauge set to max. ½”
depth must be used to avoid damaging the driver’s defroster.

8. Position and orient the converter from the streetside headlamp harness assembly (part of Kit p/n 6487018) at
position shown in Figure 4 and using the converter holes as a template drill a 0.177 dia clearance hole (#16 drill
bit) thru the outer driver’s defroster frame, typ 2 plcs. Secure converter to the frame using supplied # 8 (x2)
hardware (part of Kit p/n 6487018) as shown.
9. Connect the appropriate end connector of the new streetside harness assembly to the headlamp assembly
adapter harness and the other to the main dash harness.
10. Secure to the loose harness to existing hoses or structure as needed using tyraps (part of Kit p/n 6487018).

ITS59161

Page 3 of 5

March 4, 2019

INSTRUCTION TO SERVICE
ITS59161

Secure streetside
converter, part of
harness assembly
to the frame
using supplied # 8
hardware (x2)

View A

Secure to existing
harnesses and/or
hoses
Existing driver’s
defroster hinge
frame
Center on surface
and flush with edge
View A
Figure 4: Streetside Headlamp Assembly Harness and Converter Installation
11. Position and orient the converter from the curbside headlamp harness assembly (part of Kit p/n 6487018) at
position shown in Figure 5 and using the converter holes as a template drill a 0.177 dia clearance hole (#16 drill
bit) thru the outer driver’s defroster frame, typ 2 plcs. Secure converter to the frame using supplied # 8 (x2)
hardware (x2) (part of Kit p/n 6487018) as shown.
12. Connect the appropriate end connector of the new curbside harness assembly to the headlamp assembly
adapter harness and the other to the main dash harness.
13. Secure to the loose harness to existing hoses or structure as needed using tyraps (part of Kit p/n 6487018).
Flush with radius
Secure curbside
converter, part of
harness assembly
to the frame using
supplied # 8
hardware (x2)

View B

Secure to existing
harnesses and/or
hoses

Existing driver’s
defroster hinge
frame

Approx.
4”

View B

Figure 5: Curbside Headlamp Assembly Harness and Converter Installation

ITS59161

Page 4 of 5

March 4, 2019

INSTRUCTION TO SERVICE
ITS59161
14. Remove all tools and debris and return the bus to service condition.
15. Close the exterior wiper motor and defroster access doors.
16. Close the interior LH lower panel access door.
17. Turn the main battery disconnect switch to the “ON” position.

LABOUR ESTIMATE
Operation
1

Inspect and install headlamp harness assembly as required.

Number of
Technician(s)
1

Hours
1

Labor Time
T X HR
½ hr per side

PARTS REQUIRED
Item

Part Number

1

6487018

ITS59161

Description
Kit-Converter- Harness, New Flyer

Page 5 of 5

Qty.
per
Coach
2

Units

Notes

EA

March 4, 2019