BS3873E

SAV.1E.2012MA
BS3873E
SERVICE BULLETIN
REFERENCE:
Nova Bus Manuals
SECTION:
19: Fire suppression system
RS N :
MQR 7621-919
EFFECTIVE IN PROD.:
N/A
SUBJECT:
Engine compartment ventilation
JUSTIFICATION:
Engine compartment may have high temperature issues due to inadequate heat
dissipation.
O
LEVEL
1
APPLICATION DEADLINE: 2018DE12
CLAIM REFERENCE NUMBER: WB-3873
DIRECT CHARGES
DESCRIPTION
Install a ventilation fan in the engine compartment and reprogram
the V-BEA system.
2
–
TIME
LABOUR
MATERIAL
Customer
Nova Bus
5h
–
–
–
DISPOSAL OF PARTS
REMOVED PARTS ARE:
DISCARDED *
RETAINED
Yes
–
* Dispose of the unused parts and the defective parts in
accordance with local environmental standards in effect.
REVISION HISTORY
REV.
DATE
NR
2017JL12
CHANGE DESCRIPTION
Initial release
APPROVED BY: Daniel Theriault
WRITTEN BY
André Pelletier
Digitally signed by Daniel Theriault
DN: cn=Daniel Theriault, o=Nova Bus, ou, [email protected], c=CA
Date: 2017.07.13 10:48:16 -04'00'
PAGE 1 OF 16
SAV.1E.2012MA
BS3873E
SERVICE BULLETIN
MATERIAL
QTY
PART NO
REV.
DESCRIPTION
REPLACES PART N°
1
N84446
B
BRACKET SENSOR ASSEMBLY
–
2
N38593
–
NUT FLANGED WITH INSERT
–
1
N87563
–
GRILL LOUVER (no paint)
–
4
N16646
–
WASHER FLAT M6 SS DIN125A
–
1
N80438
C
FAN AXIAL W BRUSHLESS DC MOTOR
–
14
N56339
–
TIE TEFZEL CABLE TIES
–
8
N44890
A
NUT LOCKNYL M6 FL SSA2 C70
–
4
N71491
–
SCREW M6X35 MACH BUTT ALLEN SS
–
1
N44884-01
–
SCREW M6X20 FL SSA2 C70 D6921
–
2
N57040
A
TIECABLE MOUNT HI-HEAT
–
1
N28219
–
WASHER OVERSIZE M8
–
1
N43233
–
NUT HEX M8 FLANGED WITH INSERT
–
1
N43774
–
SCREW M8X25 FL SSA2 C70 D6921
–
1
565969
–
SENSOR TEMP
–
1
N28734-02
–
RESISTOR ASM 1K 2WATT
–
1
2394308
B
BRACKET CLIP
–
2
N44881-02
–
SCREW M6X25 FL YP C8.8 D6921
–
6
N75179
–
RIVET 3/16X1.0 BLIND DOMED ALU
–
1
N11690-30
–
CIRCUIT BREAKER 30A GREEN
–
1
N632000531
A
WIRE KIT #1 FAN ENGINE
–
1
N90944
DECAL SMALL STRIP CTTRANSIT
–
*Note 1
N87007
–
JIG REAR DOOR CUT-OUT ASSEMBLY
–
–
–
–
–
LEVEL 1
LEVEL 2
–
Materials will be available within 125 days once your order has been placed. To order, please contact Prevost Parts by phone
at 1‑800‑771‑6682, by fax at 1‑888‑668‑2555 or by email at [email protected]. Specify document number,
quantity of parts required and shipping address.
*Note 1: only 1 jig will be supplied to perform this service bulletin and service bulletin BS3974E.
CLIENT
CT Transit - Connecticut
ORDER
L554
ROAD NUMBER
VIN (2NVY/4RKY...)
FROM
TO
FROM
TO
1041
1065
S92U1A4000139
S92U0A4000164
QTY
PROGRAM
REV
25
FB_ CONN60D_MRC
F
TO OBTAIN THE SOFTWARE REVISION REQUIRED (''F'' OR LATER), CONTACT YOUR AFTERSALES REPRESENTATIVE.
PAGE 2 OF 16
SERVICE BULLETIN
CLIENT
CT Transit - Connecticut
ORDER
L554
ROAD NUMBER
SAV.1E.2012MA
BS3873E
VIN (2NVY/4RKY...)
FROM
TO
FROM
TO
1041
1065
S92U1A4000139
S92U0A4000164
QTY
25
PAGE 3 OF 16
SERVICE BULLETIN
SAV.1E.2012MA
BS3873E
WARNING
Follow your internal safety procedures.
WARNING
Disconnect the batteries prior to starting any work on the vehicle. See Nova Bus maintenance manual
section 16: Batteries.
PROCEDURE
ENGINE FAN INSTALLATION
1.1.
Turn off power switch in battery compartment. Disconnect the negative battery cable.
1.2.
Install a protection blanket in the engine compartment to collect debris.
1.3.
Position jig N87007 on the engine door. Use the openings in the jig to line up with decal position. Adjust and
reposition the jig as needed. See Figure 1.
1.4.
Use the jig to mark the circle and drill the four 5/16 in. (7.94 mm) diameter holes and the six 3/16 in. (4.76 mm)
diameter holes.
1.5.
Drill a hole inside the marked area and cut the circular opening. The use of a jig saw is recommended.
1.6.
Remove sharp edges with sandpaper or a file. Clean both sides.
Jig N87007
Figure 1 - Install the Jig on the Engine Compartment Access Door
PAGE 4 OF 16
SERVICE BULLETIN
SAV.1E.2012MA
BS3873E
1.7.
Install temporarily grill louver N87563-01 onto the engine door. The openings must be pointing down on the
outside.
1.8.
Wash and degrease all surfaces prior to installing decal N90904-02 on the grill and aligning it with the decals
on the vehicle.
1.9.
Remove the grill and apply a clear coat after installation. Allow time to dry.
1.10.
Install grill louver N87563-01 onto the engine door. Install the six rivets supplied.
1.11.
Install electric fan N80438 on the inside with four N71491 bolts, N16646 washers and N44890 nuts. Install
cable tie mount N57040 onto the upper curbside screw. See Figures 2 and 3.
1.12.
Apply thread locker 9985283 or equivalent and torque the nuts to 7.3 lb-ft (10 N•m).
N16646 Washer
N44890 Nut
Torque 7.3 lb-ft
(10 N•m)
N71491 Bolt
N87563-01 Grill
Louver
(Openings Pointing
Down)
N80438 Fan
Figure 2 - Install Grill Louver and Electric Fan
Install Cable Tie Mount on
Upper Curbside Screw
Curbside
Add Rivets (6 PLACES)
Street Side
Figure 3 - Install Cable Tie Mount
PAGE 5 OF 16
SERVICE BULLETIN
SAV.1E.2012MA
BS3873E
HARNESS INSTALLATION
Temperature Sensor
N78869
View From the Outside
Routing of Red
Wires 64-114, 64-115,
64-116
+IB-X6499A
Routing of Yellow
Wire 64-2027
To Be Ground
On The Structure,
See Figures 5 and 9
Routing of Green
cable +EN-CAB064BM
Temperature Sensor
N78869
View From the Inside
Figure 4 - Routing of New Harness N632000531
PAGE 6 OF 16
SERVICE BULLETIN
1.13.
Drill 21/64 in. (8 mm) hole in the bracket of the structure for ground installation.
1.14.
Remove the paint and clean the surface for proper ground contact. See Figures 5 and 9.
SAV.1E.2012MA
BS3873E
Bracket Location
3/8 in. (9.75 mm)
Dia.
21/64 in.
(8 mm)
1 in. (25 mm)
Figure 5 - Drill 21/64 in. (8 mm) hole for Ground
PAGE 7 OF 16
SERVICE BULLETIN
1.15.
SAV.1E.2012MA
BS3873E
Connect the electric fan connector to the N632000531 harness connector and attach the fan connector with
an N56339 high temperature cable tie to the N57040 cable tie mount. Ensure that the harness is centered
in the built-in fan channel and secure with cable tie N56339. See Figure 6.
Center Harness in Channel
High Temperature Cable Tie
N56339
Figure 6 - Connect Harness to the Fan
1.16.
Route N632000531 harness by following existing license plate harness towards main engine harness 64
on the curbside and then up to the IB-X6499A connector. See Figure 4.
1.17.
Secure harness N632000531 to the main harness with N56339 cable ties until temperature sensor location
is reached.
PAGE 8 OF 16
SERVICE BULLETIN
SAV.1E.2012MA
BS3873E
1.18.
Install the N57040 cable tie mount onto the 2394308 harness bracket with an N44881-02 bolt and N44890
nut. See Figure 7.
1.19.
Use the rear seat hatch to access the engine compartment. Install the 2394308 harness bracket with existing
hardware. See Figure 7.
1.20.
Install bracket sensor assembly N84446 over the +MT-X9564A connector bracket.
1.21.
Connect the heat sensor to the harness as indicated in the electrical wiring diagram. See Figure 8. Install
the sensor. See Figure 7.
N44881-02 Bolt
N44890 Nut
N84446 Bracket
Sensor Assembly
N44881-02 Bolt
N44890 Nut
2394308 Harness
Bracket
N57040 Cable
Tie Mount
N78869 Sensor
Temperature
N632000531
Harness
Figure 7 - Install and Connect Temperature Sensor
PAGE 9 OF 16
SAV.1E.2012MA
BS3873E
SERVICE BULLETIN
Install harness as shown in the electrical wiring diagram. See Figure 8.
18 / BK
18 / WH
03
16 / BK
16 / RD
1.22.
Affix ground to structure, See Figure 5 and 9
Figure 8 - Electrical Diagram
PAGE 10 OF 16
SERVICE BULLETIN
1.23.
SAV.1E.2012MA
BS3873E
Connect wire 64-2027 (10 BK) to the vehicle structure. Make sure there is no paint between the ground and
the structure. See Figures 5 and 9. Apply N35450 Maxi-Coat corrosion inhibitoror or equivalent to protect
electric connection.
Figure 9 - Install Ground
LOCATION: ENGINE COMPARTMENT IB CONNECTOR IB-X6499A
1.24.
Connect wire 64-115 (16 RD) to connector +IB-X6499A at position 67.
1.25.
Connect wire 64-114 (16 WH) to connector +IB-X6499A at position 68.
1.26.
Connect wire 64-116 (10 RD) to connector +IB-X6499A at position 54.
1.27.
Connect wire CAB064BM (16 RD) to connector +IB-X6499A at position 71.
1.28.
Connect wire CAB064BM (16 BK) to connector +IB-X6499A at position 74.
LOCATION: AT THE REAR INSIDE OF THE VEHICLE IN THE IB ELECTRICAL PANEL.
Connector IB-X6499A. Pinning wires. See Figure 10.
1.29.
Connect wire 99-080 (16 RD) to connector +IB-X6499A at position 67.
1.30.
Connect wire 99-1563 (18 WH) to connector +IB-X6499A at position 68.
1.31.
Connect wire 99-1561 (10 RD) to connector +IB-X6499A at position 54.
1.32.
Connect wire CAB099KB (18 BK) to connector +IB-X6499A at position 74.
1.33.
Connect wire CAB099KB (18 WH) to connector +IB-X6499A at position 71.
Module 53. See Figure 10.
1.34.
Connect wire 99-1683 (18 RD) to IOB module 53 connector +IB-X99A1 (HPO) at position 11.
Module 53. See Figure 10.
1.35.
Connect wire 99-1563 (18 WH) to IOA module 53 connector +IB-X99A1 (HDI) at position 01.
PAGE 11 OF 16
SERVICE BULLETIN
SAV.1E.2012MA
BS3873E
Module 54. See Figure 10.
1.36.
Connect wire CAB099KB (18 WH) to IOB module 54 connector +IB-X99B1 at position 14.
1.37.
Connect wire CAB099KB (18 BK) to IOB module 54 connector +IB-X99B1 at position 17.
Module 53
IB-X99A1
Module 54
IB-X99B1
Connector
IB-X6499A or
IB-X6199A
Figure 10 - IB Compartment
PAGE 12 OF 16
SERVICE BULLETIN
SAV.1E.2012MA
BS3873E
Splice
connector
IB-SC99A
Terminal block
IB-TB99A
Resistor
IB-Res99AG1AH1
Figure 11 - IB Panel
1.38.
Connect wire 99-1561 (10 RD) to +IB-CB99AE1.
1.39.
Install the N11690-30 circuit breaker at location +IB-CB99AE.
Terminal block. See Figure 11.
1.40.
Install the N28734-02 resistor across locations +IB-TB99A H1 and G1.
1.41.
Connect wire 99-1683 (18 RD) to +IB-TB99A at position H1.
1.42.
Connect wire 99-080 (16 RD) to +IB-TB99A at position H1.
1.43.
Connect wire 99-1560 (16 BK) to +IB-TB99A at position G1.
Splice connector. See Figure 11.
1.44.
Connect wire 99-1560 (16 BK) to splice connector +IB-SC99A at position C.
Wiring completion and testing.
1.45.
Route the wires along the existing harness. Use high cable ties to secure the wires.
1.46.
Reconnect the negative battery cable. Turn on power switch in battery compartment.
Install the program.
1.47.
Re-program the V-BEA system using the program listed in the client list (page 2 of this document) in accordance
with section 16: Electrical system of the Nova Bus maintenance manual.
1.48.
When the vehicle is started, the fan will turn for 10 seconds if the wiring is correct and the program properly
installed.
PAGE 13 OF 16
SERVICE BULLETIN
SAV.1E.2012MA
BS3873E
Validation of fan functions.
1.49.
Raise sensor temperature above the applicable threshold. The use of a heat gun and thermometer gun is
suggested.
1.50.
Under this condition, the engine fan will operate at low speed (20%).
1.51.
Raise temperature to 150 ºF (65 ºC). The engine fan will operate at maximum speed (100%).
Fan operating conditions.
At ambient cold temperature, below 55 ºF (13 ºC). If the HVAC clutch is activated. Engine running.
1.52.
When engine compartment temperature is below 135 ºF (57 ºC), the fan does not operate.
1.53.
When engine compartment temperature is 135 ºF (57 ºC), the fan operates at low speed (20%).
1.54.
When engine compartment temperature is between 135 ºF (57 ºC) and 150 ºF (65 ºC), the speed of operation
increases gradually.
1.55.
When engine compartment temperature is 150 ºF (65 ºC) or above, the fan operates at maximum speed
(100%).
1.56.
Use cold air to lower the ambient sensor temperature below 55 ºF (13 ºC).
1.57. Use a heat gun on the engine compartment sensor to raise temperature from 135 ºF (57 ºC) to 150 ºF (65 ºC).
At ambient hot temperature, above 55 ºF (13 ºC), with HVAC clutch not activated, and engine running.
1.58.
When engine compartment temperature is below 95 ºF (35 ºC), the fan does not operate.
1.59.
When engine compartment temperature is 95 ºF (35 ºC), the fan operates at low speed (20%).
1.60.
When engine compartment temperature is between 95 ºF (35 ºC) and 150 ºF (65 ºC), the speed of operation
increases gradually.
1.61.
When engine compartment temperature is 150 ºF (65 ºC) or above the fan oprates at maximum speed (100%).
1.62.
Use a heat gun to raise temperature from 95 ºF (35 ºC) to 150 ºF (65 ºC).
1.63.
Read % of fan speed on the multiplex at two temperatures. At a temperature of 95 ºF (35 ºC), the fan operates
at low speed (20%). At 150 ºF (65 ºC), the fan operates at maximum speed (100%).
Master run switch on and engine not running.
1.64.
When engine compartment temperature is above 110 ºF (43 ºC), the fan operates at low speed (20%).
1.65.
When engine compartment temperature is below 110 ºF (43 ºC), the fan does not operate.
1.66.
Read % of fan speed on the multiplex at two temperatures.
PAGE 14 OF 16
SERVICE BULLETIN
SAV.1E.2012MA
BS3873E
Figure 12 - Logic of Fan Operation
PAGE 15 OF 16
SERVICE BULLETIN
1.67.
Remove the two dust pans circled in Figure 13.
1.68.
Remove the center mud flap (may be reinstalled for the winter months). See Figure 14.
1.69.
Put the vehicle back in service.
SAV.1E.2012MA
BS3873E
Figure 13 - Remove theTwo Dust Pans
Figure 14 - Remove the Center Mud Flap
PAGE 16 OF 16