Engine Door Fan Connector may Overheat – 2011-2019 Nova LFS City Buses

SEOCONTENT-START

REFERENCE:
Nova Bus Manuals
SECTION:
09: Engine and Cooling
RS NO:
MQR 7621-1695
EFFECTIVE IN PROD.:
LC32 (2019MR)
NHTSA RECALL NO.:
19V274
TC RECALL NO.:
2019171
MATERIAL
QTY
NOVA PN
REV.
PREVOST PN
DESCRIPTION
REPLACES PART NO.
LEVEL 1
1
N77235
–
N8910118
HDSCS Connector Plug – Power – Series 6.3
–
2
N97874-01
–
N8908509
HDSCS Terminal Socket
–
1
N77185
–
N8910119
HDSCS Connector Receptacle – Power – Series 6.3
–
2
N97874-02
–
N8908508
HDSCS Terminal Pin
–
1
N82710
–
N82710
DT Connector Male 2 Pos. w/ Boot
–
2
G5900714
–
N8910153
Terminal Female (Socket) Deutsch Size 16 Solid
–
1
N25892-01
–
N25892-01
DT Secondary Lock (Wedge Lock) 2 Pos. Male Side
–
1
N82711
–
N82711
DT Connector Female 2 Pos. w/ Boot
–
2
G5900719
–
562286
Terminal Male (Pin) Deutsch Size 16 Solid
–
1
N26398
–
562487
DT Secondary Lock (Wedge Lock) 2 Pos Female Side
–
4
G5007996
–
G5007996
Black Nylon Tie Wrap.
–
4
N77237
–
993749
HDSCS Seal Blue for 12 AWG
–
10.5 in
N82227-04
–
N82227-04
Tubing Heat Shrink Dual Wall
–
6 in
N82227-13
–
N82227-13
Tubing Heat Shrink Dual Wall
–
40 in
N74787
A
N74787
Electrical Cloth Tape
–
LEVEL 2
5%
N91996
–
N91996
Fan Axial BLDC
–
SPECIAL TOOLING
1
–
–
N8910120
HDSCS 6.3 Crimping Hand Tool
–
1
–
–
N8910121
HDSCS 6.3 Die Set
–
1
–
–
–
Deutsch DT Crimping Hand Tool (not included)
–
LEVEL
DESCRIPTION
DIRECT CHARGES
TIME
LABOUR
MATERIAL
1
Replacement of the connectors and terminals on the fan and bus wiring sides.
Nova Bus
Nova Bus
1.5 hr
SUBJECT:
Engine Door Fan Connector Replacement.
JUSTIFICATION:
Connectors, terminals and wiring damaged due to excessive heat.
APPROVED BY:
APPLICATION DEADLINE: N/A
CLAIM REFERENCE NUMBER: SR-4613
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CLIENT
ORDER
ROAD NUMBER
VIN (2NVY/4RKY…)
QTY
FROM
TO
FROM
TO
CT Transit – Connecticut
L554
1041
1065
S92U1A4000139
S92U0A4000164
25
CT Transit – Connecticut
L571
1101
1110
S92YXB4000144
S92Y4B4000169
10
York Regional Transit – Ontario
L562
1080
1082
S92U2A3000420
S92U6A3000422
3
York Regional Transit – Ontario
L572
1083
1094
S92U3A3000569
S92U2A3000580
12
York Regional Transit – Ontario
L654
1370
1390
S92U1D3000946
S92U2D3000986
21
York Regional Transit – Ontario
L761
1391
1396
S92U6D3001008
S92UXD3001013
6
REVISION HISTORY
REV.
DATE
CHANGE DESCRIPTION
WRITTEN BY
NR
2019-07-05
Initial Release
Yuvaraj
DISPOSAL OF PARTS
REMOVED PARTS ARE:
DISCARDED *
RETAINED
* Dispose of the unused parts and the defective parts in accordance with local environmental standards in effect.
Yes
–
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PROCEDURE
VEHICLE PREPARATION
1.1. Park the vehicle on an even surface with transmission on neutral (N) and apply the parking brake.
1.2. Before starting any work on the vehicle, make sure that the vehicle is completely and securely stationary.
ENGINE FAN TEST
1.3. Start the vehicle and confirm that the engine fan is working.
1.4. If the engine fan connector and/or terminals are too damaged to test the engine fan, replace the damaged
fan with a spare known working fan PN N91996.
WARNING
Follow your internal safety procedures.
Figure 1 – Master Control Switch in STOP Position
Master control switch in
STOP position
ENGINE FAN CONNECTORS REPLACEMENT
1.5. Set the Master Control Switch in the STOP position (see figure 1).
1.6. Disconnect the starting circuit on the control box at the rear of the vehicle and place the battery disconnect
switch in the OFF position.
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Figure 2 – Typical Engine Door Fan Delphi Connectors Installation
Removal of Delphi Connectors
1.7. Open the engine compartment door and locate the engine fan Delphi connectors (see figure 2).
Door Open Position
Delphi Connectors
1.8. Cut the two black cable ties from the harness side wiring and one at the Delphi connectors (see figure 3).
1.9. Remove the heat shrink tubing and the Coroplast tape from the connectors (see figure 3) and then disconnect
the connectors. To help removing the heat shrink tubing, trace a shallow line on the heat shrink tubing with
a sharp cutting blade (X-ACTO tool or equivalent) and then, using a heat gun, heat the tubing until it splits.
Figure 3 – Cut Cable Ties at Delphi Connectors and on Harness Side Wiring and Remove Heat
Shrink Tubing on Delphi Connectors
Heat Shrink Tubing
Black Cable Ties
1.10. On the fan side, extract the four wire terminals inside the connector using a Delphi extraction tool or a small
flat blade screwdriver. Then cut the terminals keeping the maximum wire length (see figure 4). Remove black
protective sleeve segment on the outer part of the fan protection shroud (see figure 5) and clean the wires
with contact cleaner, if glue or dirt is present.
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Figure 4 – Fan Side Connector Removal and Tool Options for Terminals Extraction from the
Connector Housing
OR
Figure 5 – Black Protective Sleeve Segment Removal
Remove Black
Protective
Sleeve Segment
Four Wire Terminals
Inside the Connector
Black Protective
Sleeve
1.11. On the harness side, cut the connector with the terminals directly at the back end of the connector housing
(see figure 6) and clean the wires with contact cleaner, if glue or dirt is present.
Figure 6 – Harness Side Connector Removal
Cutting Area on the
Connector
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Installation of HDSCS Connector at Fan Side
1.12. Using the HDSCS crimping tool (see figure 7), crimp the socket terminal PN N97874-01 with the blue seal
PN N77237 on both RED and BLACK power wires (see figure 8). Refer to the figure below showing a typical
HDSCS terminal crimp example and to Annex 1 for more information about the HDSCS connectors terminal
crimping quality guidelines.
1.13. Insert 1.75 in (total of 3.5 in) of heat shrink tubing PN N82227-04 over both RED and BLACK power wires.
Then, using a heat gun, apply the small heat shrink tubing PN N82227-04 over the power wires while leaving
a 1/8 in gap with respect to each seal in order to avoid any interference with the terminal wire seals.
1.14. Insert 1.5 in of large heat shrink tubing PN N82227-13 over the power wires bundle but do not shrink immediately.
1.15. Insert the RED wire terminal into position 1 and the BLACK wire terminal into position 2 of the HDSCS plug
connector PN N77235 (see figure 9). Make sure that the yellow secondary lock of the plug connector is
completely pressed (to move it from the unlocked to the locked position) after inserting both terminals. Refer
to Annex 2 for detailed instructions about terminals insertion and secondary lock.
Figure 7 – TE Connectivity HDSCS Crimping Hand Tool
Figure 8 – TE Connectivity HDSCS Socket Terminal and Blue Seal
Blue Seal
Crimping Area Cut View
(Crimping Target Reference)
Socket Terminal
1.16. Using a heat gun, apply the large heat shrink tubing PN N82227-13 starting from the boot adapter of HDSCS
plug connector finishing directly over the smaller heat shrink tubes previously installed on the power wires
(see figure 9). Make sure to fill any gap between the two power wires with the inner adhesive liner glue (do
not apply heat shrink tubing over tape or loom).
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Installation of DT Connector at Fan Side
1.17.
Using the Deutsch DT crimping tool (see figure 10), crimp the socket terminal PN G5900714 on both WHITE and YELLOW control wires (see figure 11). Refer to the figure below showing a typical Deutsch DT solid socket terminal crimp example and to Annex 3 for more information about the TE Connectivity’s Deutsch DT solid terminals crimping quality guidelines.
Figure 9 –
Heat Shrink Tubing Installation on HDSCS Plug Connector Wiring at Fan Side
Figure 10 –
Deutsch DT Crimping Hand Tool
Figure 11 –
Deutsch DT Socket Terminal
Crimping Area Cut View
(Crimping Target Reference)
Inspection Window
Socket Terminal
Heat Shrink Tubing (N82227-13)
HDSCS Plug Connector Boot Adapter
HDSCS Plug Connector with Yellow Secondary and Slide Locks (N77235)
Heat Shrink Tubing (N82227-04)
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1.18.
Insert a single 1.75 in length of heat shrink tubing PN N82227-04 over the paired WHITE and YELLOW control wires. Then, using a heat gun, apply the small heat shrink tubing PN N82227-04 over the paired control wires while leaving a 1/4 in gap with respect to the terminals in order to avoid any interference or stress on the DT connector back end wire seal.
1.19.
Insert 1.5 in of large heat shrink tubing PN N82227-13 over the control wires bundle but do not shrink immediately.
1.20.
Insert the WHITE wire terminal into position 1 and the YELLOW wire terminal into position 2 of the DT plug connector PN N82710. Insert the wedge lock PN N25892-01 into the DT plug connector (see figure 12).
1.21.
Using a heat gun, apply the large heat shrink tubing PN N82227-13 starting from the boot adapter of DT plug connector finishing directly over the smaller heat shrink tube previously installed on the paired control wires (see figure 13). Make sure to fill any gap with the inner adhesive liner glue (do not apply heat shrink tubing over tape or loom).
Figure 12 –
Wedge Lock Insertion into Deutsch DT Plug Connector
Figure 13 –
Heat Shrink Tubing Installation on DT Plug Connector Wiring at Fan Side
1.22.
Apply Coroplast tape PN N74787 over the exposed wiring / heat shrink tubing on the fan side both HDSC and DT plug connector.
DT Plug Connector Boot Adapter
Heat Shrink Tubing (N82227-13)
Heat Shrink Tubing (N82227-04)
Wedge Lock (N25892-01)
DT Plug Connector (N82710)
DT Plug Connector Boot Adapter
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Installation of HDSCS Connector at Harness Side
1.23. Using the HDSCS crimping tool (see figure 7), crimp the pin terminal PN N97874-02 with the blue seal PN
N77237 on both RED and BLACK power wires (see figure 14). Refer to the figure below showing a typical
HDSCS terminal crimp example and to Annex 1 for more information about the HDSCS connectors terminal
crimping quality quidelines.
1.24. Insert 1.75 in (total of 3.5 in) of heat shrink tubing PN N82227-04 over both RED and BLACK power wires.
Then, using a heat gun, apply the small heat shrink tubing PN N82227-04 over the power wires while leaving
a 1/8 in gap with respect to each seal in order to avoid any interference with the terminal wire seals.
1.25. Insert 1.5 in of large heat shrink tubing PN N82227-13 over the power wires bundle but do not shrink immediately.
1.26. Insert the RED wire into position 1 and the BLACK wire into position 2 of the HDSCS receptacle connector
PN N77185. Make sure that the yellow secondary lock of the plug connector is completely pressed (to move
it from the unlocked to the locked position) after inserting both terminals (see Figure 15). Refer to Annex 2
for detailed instructions about terminals insertion and secondary lock.
Figure 14 – TE Connectivity HDSCS Pin Terminal and Blue Seal
Figure 15 – TE Connectivity HDSCS Receptacle Connector
HDSCS Receptacle Connector Boot
Adapter
HDSCS Receptacle Connector with
Yellow Secondary Lock (N77185)
Crimping Area Cut View
(Crimping Target Reference)
Pin Terminal
Crimping of Pin Terminal
1.27. Using a heat gun, apply the large heat shrink tubing PN N82227-13 starting from the boot adapter of HDSCS
receptacle connector finishing directly over the smaller heat shrink tubing previously installed on the power
wires (see figure 9). Make sure to fill any gap between the two power wires with the inner adhesive liner glue
(do not apply heat shrink tubing over tape or loom).
Blue Seal
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Installation of DT Connector at Harness Side
1.28.
Using the Deutsch DT crimping tool (see figure 10), crimp the pin terminal PN G5900719 on both WHITE and RED control wires (see figure 16). Refer to the figure below showing a typical Deutsch DT solid socket terminal crimp example and to Annex 3 for more information about the TE Connectivity’s Deutsch DT solid terminals crimping quality guidelines.
1.29.
Insert a single 1.75 in length of heat shrink tubing PN N82227-04 over the paired WHITE and RED control wires. Then, using a heat gun, apply the small heat shrink tubing PN N82227-04 over the paired control wires while leaving a 1/4 in gap with respect to the terminals in order to avoid any interference or stress on the DT connector back end wire seal.
1.30.
Insert 1.5 in of large heat shrink tubing PN N82227-13 over the control wires bundle but do not apply immediately.
1.31.
Insert the WHITE wire terminal into position 1 and the RED wire terminal into position 2 of the DT receptacle connector PN N82711. Insert the wedge lock PN N26398 into the DT receptacle connector (see figure 17).
Figure 16 –
Deutsch DT Pin Terminal
Figure 17 –
Wedge Lock Insertion into Deutsch DT Receptacle Connector
Pin Terminal
Crimping Area Cut View
(Crimping Target Reference)
Inspection Window
1.32.
Using a heat gun, apply the large heat shrink tubing PN N82227-04 starting from the boot adapter of DT receptacle connector finishing directly over the smaller heat shrink tube previously installed on the paired control wires (see figure 18). Make sure to fill any gap with the inner adhesive liner glue (do not apply heat shrink tubing over tape or loom).
DT Receptacle Connector (N82711)
DT Receptacle Connector Boot Adapter
Wedge Lock (N26398)
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Figure 18 –
Heat Shrink Tubing Installation on DT Receptacle Connector Wiring at Harness Side
Figure 19 –
Black Cable Tie Securing the Wiring at Fan Side
Final Preparation
1.34.
Secure the fan wiring pigtail with a black cable tie PN G5007996 (1x) (see figure 19).
1.35.
Connect both connector mating parts on the fan side. While mating the HDSCS connector, press the yellow slide lock of the plug connector to latch and lock both connectors together.
1.33.
Add Coroplast tape PN N74787 over the exposed wiring / heat shrink tubing on the harness side HDSCS and DT receptacle connector.
Heat Shrink Tubing (N82227-04)
Heat Shrink Tubing (N82227-13)
DT Receptacle Connector Boot Adapter
Black Cable Tie (G5007996) (1x)
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1.36. Remove and retain the four nuts around the fan and rotate it counter clockwise (for the fiber door
configuration) (see figure 20) to have the engine door fan routed horizontally wiring at the middle right and
reinstall the four fan nuts.
1.37. Secure the wiring at the connectors and on the fiber door at harness side with black cable ties PN G5007996
(3x) (see figure 20).
Figure 20 – Black Cable Ties Securing the Fan Wiring at Harness Side
1.38. Test the fan with the final configuration.
1.38.1. Set the Master Control Switch in the START position.
1.38.2. Reconnect the starting circuit on the control box at the rear of the vehicle and place the battery
disconnect switch in the ON position.
1.38.3. Start the vehicle and confirm that the engine fan is working.
1.39. If no issues are found, bus is ready for service.
NOTE
The HDSCS and DT connectors should be both installed towards the door to avoid any interference with
the belt guard.
Black Cable Ties (G5007996) (3x)
Nut (4x)
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NOTE
The following procedure is provided by (TE Connectivity). Nova Bus cannot be held responsible for its content.
Annex 1 – HDSCS Connectors Terminal Crimping Quality Guidelines
All specifications subject to change. Consult TE Connectivity for VI latest specifications.
Catalog 1654326-1
Issued 11-2013
Heavy Duty Sealed Connector Series (HDSCS)
Quality Guidelines
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All specifications subject to change. Consult TE Connectivity for latest specifications. VIICatalog 1654326-1Issued 11-2013Heavy Duty Sealed Connector Series (HDSCS)Quality Guidelines
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Annex 2 – HDSCS Connectors How-To Instructions
PAGE 29INDUSTRIAL & COMMERCIAL TRANSPORTATION /// HDSCS CONNECTOR SERIESCONTACT INSERTIONHOW-TO INSTRUCTIONSSTEP 1:Grasp crimped contact approximately one inch behind the contact barrel.STEP 2:Make sure the contact is in the correct orientation. Verify the integrated secondary lock is in the unlocked position.STEP 3:Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.STEP 4:Push the integrated secondary lock into the locked position with a DT-RT1 or a screwdriver.STEP 1:Using a DT-RT1 or a screwdriver, unlock the integrated secondary lock. CONTACT REMOVALSTEP 2:Using the appropriate extraction tool, insert the blades into the contact cavity until they stop.STEP 3:Pull contact wire assembly out of connector.HDSCS CONNECTORSHDSCS CONNECTORS
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Annex 3 – Deutsch DT Solid Terminal Crimping Quality Guidelines
PAGE 175helpful hintDEUTSCH Common ContactsCRIMPING CONFIGURATIONSStamped & formed contacts use a folded type of crimp (Fig. 1) while solid contacts use a 1, 2, or 4 indent crimp (Fig. 2). In both styles of crimps, the wire strands and the contact material are formed together in a solid mass creating a reduction of the wire strand area. The reduced wire strand area creates a minimum of voids allowing for excellent conductivity. Crimping may be accomplished with hand tools or power tools.CrimpingCrimping is defined as the act of joining a conductor to a pin or socket contact using a mechanical tool tocompress and displace metal. In a good crimp joint, there is mutual flow of metal, causing a symmetrical distortion of wire strands. Stamped & Formed StyleCross-Section Across AxisFigure 1Solid StyleIndenter Crimp Cross-Section Across AxisFigure 2NoteThe use of dielectric grease is not recommended. BENEFITS OF CRIMPED CONTACTSMechanically crimping contacts is the leading wire terminationmethod for some very good reasons:•With smaller wire, the crimp is as strong as the wire itself.•The joint can be visually inspected. Viewing the wire through an inspection hole in the contact makes inspection quick and easy, both by the operator and the inspector.•Plating thickness is not restricted, as in solder joints, so better corrosion resistance and contact reliability are achieved.•Crimping can be done anywhere, without special preparation. Terminations are replaced or modified in the field exactly the same as in the shop, using the same tools and the same techniques, and with the same ease of operation and certainty of results. •Total installed and maintenance costs are lower.Solder should not be added to DEUTSCH terminals.
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INDUSTRIAL & COMMERCIAL TRANSPORTATION /// TERMINALS AND CONNECTORSDEUTSCH Common ContactsCRIMP INSPECTIONCrimping tools provide lower total installation and maintenance costs. However, controls are requiredto help confirm that the proper crimp tools designed for the type and size contact are used, the pin or socket is properly inserted into the tool, the wire insulation is stripped properly, and the wire fully inserts into the contact.When a crimp is completed, correct termination can be visually inspected. The inspector should check for:•The removed insulation should expose a conductor length that will pass beyond the inspection hole in the contact and still reveal the appropriate length of conductor between the contact and the insulation on the wire. •Wire strands intact.•All wire strands enter the contact barrel.•Wire inserted to the proper depth in the contact.When the correct crimp tool and process are used, a good termination results.SOLID CONTACT CRIMPSTAMPED & FORMED CONTACT CRIMPNoteFor more detailed crimp dimensions please request a drawing. Conductor strands not visibleBirdcageBirFlayed wire t All strandscapturedBare wire strands extended from conductor crimpInsulation spaced from conductor crimp areaCrimp centered between the inspection hole and crimp barrel endConductor strands are visible through inspection holeCorrect insulation gap (.100” max)Conductor strands not visible on both sides of conductor crimpConductor strands bent and not completely capturedor Conductor strand not capturedAcceptable CrimpAcceptable CrimpUnacceptable CrimpsUnacceptable Crimps
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