BS5285E

SERVICE BULLETIN
REFERENCE:

Nova Bus Manuals

SECTION:

16: Electrical System

RS NO:

MQR 7621-N/A

APPLICATION DEADLINES: 2024JA15
CLAIM REFERENCE NUMBER: WB5285

EFFECTIVE IN PROD.: LE62 (2022MA)
SUBJECT:

Headlights

JUSTIFICATION:

Installed headlights do not have heated lens.

LEVEL

1

DIRECT CHARGES

DESCRIPTION

Replace the installed headlights with headlights with heated lens.

2

TIME

LABOUR

MATERIAL

Nova Bus

Nova Bus

15 min

–

–

–

–

MATERIAL REQUIRED PER VEHICLE
QTY

PART NO

REV.

DESCRIPTION

N84518

B

HEADLAMP DIALIGHT 7" W/HT

–

–

LEVEL 1

1
LEVEL 2

–

–

Materials will be available within 14 days once your order has been placed.
To order, please contact novabus.parts@volvo.com
Or by phone for CANADA 1-800-771-6682, for USA 1-877-999-8808
Specify document number, quantity of parts required and shipping address.

DISPOSAL OF PARTS
REMOVED PARTS ARE:

DISCARDED

RETAINED *

–

Yes

* To be reimbursed, the parts must be retained and returned in
accordance with the usual warranty procedure.

REVISION HISTORY
REV.

DATE

NR

2022DE15

APPROVED BY:
NQF772001 version 5

CHANGE DESCRIPTION

Initial release

WRITTEN BY

Annie St-Jacques

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SERVICE BULLETIN
CLIENT

ORDER

ROAD NUMBER
FROM

TO

BS5285E

VIN (2NVY/4RKY...)
FROM

TO

QTY

Ann Arbor Area Transportation Authority
Michigan - AAATA

LE73

2200

2207

L82JXN9778509 L82J7N9778516

8

Capital Area Transportation Authority Michigan
- CATA

LE04

731

737

L82J2N9778519 L82J8N9778525

7

Capital Area Transportation Authority Michigan
- CATA

LE05

6019

6020

S92J8N9778517 S92JXN9778518

2

Chicago Transit Authority - CTA

LD76

8434

8448

L82JXN97788482 L82J8N9778443

15

NFTA - Buffalo, New York

LE03

2261

2270

L82J3N9778433 L82J8N9778458

10

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SERVICE BULLETIN

BS5285E

WARNING

FOLLOW YOUR INTERNAL SAFETY PROCEDURES.

PROCEDURE
1.1.

Park the vehicle on an even surface with the transmission on neutral.

1.2.

Apply the parking brake and set the master control switch to the stop position.

1.3.

Set the battery disconnect switch in the battery compartment to the off position.

1.4.

Replace the headlights. Follow the procedure issued by Dialight and shown in the next pages.

NOTE

The following procedure is provided by Dialight. Nova Bus cannot be held responsible for its content.

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BS5285E

Replacing HLD734CB803112, Non Heated lens, headlight with HLD734CB803H12 Heated Lens
Part numbers HLD734CB803112 and HLD734CB803H12 are mechanically and optically interchangeable.
The sole difference is that part umber HLD734CB803H12 contains an internal heater strip on the lens
and internal circuitry to control and activate the heated when needed. In viewing the light from the
front 5 screws may be visible. Two (2) of those screws are used for headlight alignment and the other
three (3) are used to mount the headlight in the mounting bucket that is attached to the vehicle. The
following process should involve only the trim ring, three (3) screws, and three (3) nylon washers that
are utilized to secure the headlight to the bucket with the trim ring. This process assumes proper
alignment of the headlights when installed originally on the vehicle and that the alignment is still within
the specification limits of the vehicle manufacturer. Please read through this procedure in its entirety
prior to starting the headlight replacement processed

1) Refer to the above illustration during this process for mounting bucket features
2) Once access to the headlight is achieved, locate the three (3) screws that secure the headlight
trim ring to the headlight mounting bucket. The screws will go through mounting tab features
on the trim ring as shown below.

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BS5285E

3) Remove the three (3) mounting screws from the headlight trim ring. Underneath the mounting
tab on the trim ring are nylon washers. As you remove the mounting screws be sure to also
locate the nylon washers saving the three (3) screws and three (3) washers to use later installing
the replacement headlight.

4) After removal of all three (3) screws and washers, carefully remove the trim ring from the
headlight. Hold the headlight in place so that the headlight does not drop out of the bucket as
this may cause unnecessary stress on the product / vehicle wire harness. Put the trim ring aside
with the previously saved screws and washer for later installation
5) Gently lower the headlight to expose the wire harness that is internal to the headlight mounting
bucket. The headlight is connected to the vehicle harness with a Delphi Metri-pak 280 sealed /
polarized connector
6) Disconnect the headlight at the connector interface. Note that the connector also contains a
locking feature to secure the two sides of the connectors together. You may need a small flat
tool to aid in lifting and releasing this locking feature.
7) Once removed place the headlight aside for return.
8) Remove the new headlight from the box it was delivered in and inspect for any potential
damage to the headlight that might have occurred in transit, damage to the packing box is not
necessarily an indication of any damage to the headlight. If any damage to the headlight is
observed do not use, replace in the original box for return to the supplier and obtain another
replacement headlight.
9) Connect the new headlight wire harness to the vehicle wiring harness by plugging together the
mating harness. The connectors are polarized so they can only properly connect in the correct
configuration. Use firm pressure in order to insure the connectors are properly connected and
sealed against moisture. You may hear an audible click during this process indicating proper
seating of the locking mechanism on the connector. Gently pull apart the connectors to test for
proper connector locking. DO NOT PULL VIA THE WIRES.
10) Reposition the headlight into the mounting bucket observing the “TOP” indication on the lens
be sure the wire harness remains behind the light during insertion so that it does not interfere
with the proper seating of the headlight in the mounting bucket. There are three features on the
back of the headlight that mate to features on the headlight mounting nest. When properly
seated these should prevent the headlight from rotation when held in place.
11) Place the previously saved trim ring over the headlight aligning the mounting tabs with the
mounting holes in the headlight mounting bucket
12) Attach the trim ring and secure the headlight to the vehicle using the previously saved mounting
screws and nylon washers. Be sure the trim ring mounting tab is captured between the nylon
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BS5285E

washer and mounting screw heads as shown in an earlier photo. Do not fully tighten each screw
until all three are initially loosely installed as this will simplify the proper installation of the nylon
washers. Then tighten all three firmly to the headlight bucket, not exceeding 6-8 in lbs.
13) Placed the removed headlight in the box from the new headlight for return to the supplier.
14) If properly aligned at the start of this process, the headlight likely does not need re-alignment,
but a quick alignment check is recommended be performed per the vehicle manufacturer’s
guidelines. If, for some reason, adjustments to the vehicle alignment screws occurred during
this replacement process then a proper headlight alignment procedure, following the vehicle
manufacturer’s guidelines, must be completed.

1.5.

The vehicle can return in service.

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