SB-10044779-3069

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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 IS 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
SECTION:

MODEL:

ITS:

WRITTEN BY:

TYPE:

221

30FT

35FT

40FT

60FT

HIGH FLOOR

Propulsion
System

DSL

GAS

LNG

ELEC

LOW FLOOR

4932

Shaun Cardinal

OBJECTIVE/SUBJECT:
Ultra Capacitor (UCAP) Circuit Board Cover
PROCEDURE:
COACH PREPARATION
1. Ensure the coach is parked on a flat surface with the park brake engaged.
2. Ensure the main battery disconnect switch is turned to the “OFF” position.
WARNING: ALWAYS discharge the Ultra Capacitors before performing high voltage
system maintenance on this vehicle. Refer to Section 5 of the Service
manual under 2.17 Discharging The Ultra Capacitors for the discharge
procedure.

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ITS:
UCAP PREPARATION
3. Remove Ultra Capacitor tie down straps. See Fig 1

Figure 1: Ultra Capacitor

4932

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ITS:

4932

4. Remove perimeter hardware on the UCAP cover to access capacitor assembly and circuit
board, disconnect fire suppression harness from bottle. Fig 2

Perimeter Hardware
Fire Suppression Harness

Figure 2: Unmodified Ultra Capacitor
5. Using compressed air, blow out any debris and moisture inside the UCAP assembly. Fig 3
6. Clean all contacts inside the UCAP assembly using electrical contact cleaner. Ensure the
street side support structure is cleaned thoroughly to provide a good ground. Blow off with air
one more time to ensure all debris is out. Fig 3

Figure 3: Capacitor Prep

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ITS:

4932

CIRCUIT BOARD ASSEMBLY
7. Begin removing harnesses from the circuit board, ensure that after the harnesses are
modified, they are plugged into the same connection points. Fig 4 and 5

Relay’s

HV Cable
Temp sensor harness

Figure 4: Circuit Board Overall

Circuit Board

Temp sensor harness
Figure 5: Circuit Board Detail

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ITS:

4932

8. Remove EVCU/RDU. See Fig 6

Removed EVCU/RDU

Figure 6: Removed EVCU/RDU
9. Remove circuit board by unscrewing connections on rear face of UCAP box (both connection
sides). See Fig 7.

Removed hardware for
circuit board

Figure 7: Removed Hardware

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ITS:

4932

10. Remove P-Clamp that holds the high voltage cable to the bottom of the UCAP box, remove
the stud by unscrewing it. If stud is seized, cut off flush to the bottom of the box. See Fig 8

Remove clamp and
stud

Figure 8: Clamped HV Cable
11. Remove the cable tie holding the relay harness to the board by removing the hardware
securing it. Refasten the hardware after removing the tie. See Fig 9 and 10

Secured harness

Figure 9: Secured Harness

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ITS:

4932

Harness removed and
fastener re-installed

Figure 10: Secured Harness Removed

12. Using the LF-MT-2001 drill jig, drill out the holes to secure the circuit board cover. Clean out
any debris left inside the box (potential for short circuits/faults). Ensure locating surfaces of
the jig are free of silicone/debris. See Fig 11.

Figure 11: LF-MT-2001 Drill Jig Location Reference

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ITS:

4932

13. Reconfigure the circuit board harnesses per Fig 12, 13, 14, and 15 following New Flyer
Engineering Drawings (for harnesses) 470600, 469480, 470801, and 470846.

Figure 12: UCAP Circuit Board Harness Reference 470600

Figure 13: UCAP Relay Harness Reference 469480

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ITS:

4932

Figure 14: Temp Sensor Harness Re-pinned Reference 470801

Figure 15: Temp Sensor Jumper Harness Reference 470846

14. Install circuit board harness (Ref 470600, Fig 12), re-pinned temp sensor harness (Ref
470801, Fig 14), and Temp Sensor Jumper Harness (Ref 470846, Fig 15) on circuit board
cover door (468996) per Fig 16.

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ITS:
UCAP circuit board
harness

4932

Relay
Harness

Grounds

Re-pinned temp sensor
harness
Figure 16: Harnesses on door Reference 468680

15. Re-install circuit board by reversing actions in Step 9.
16. Add rubatex seal 5964906 around mating face of the cover assembly to the UCAP box (front
and bottom. Fig 17

Seal bottom
Seal around perimeter

Figure 17: Installed Cover

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ITS:

4932

17. Add rubatex seal 5964906 around mating face of the cover door and cover assembly. Fig 18

Seal around all mating
surfaces

Figure 18: Cover Door Prep

18. Install circuit board cover assembly, seal around perimeter of box with silicone to ensure no
water gets between circuit board cover assembly and UCAP box (that may trickle onto the
board). Plug in all harnesses outlined in Step 14 into the circuit board and fasten door to
cover assembly with 10-24UNC hardware. Ensure there are no voids that could allow water
to intrude. Fig 19

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ITS:

4932

Seal around all mating
surfaces w/ silicone

Figure 19: Cover Door Install

19. Install new Relay Harness 469480 (see Fig 13) and Temp Sensor Jumper Harness 470846
(see Fig 15) and tywrap fan temp sensors to fan temp sensor bracket per Fig 19. Fasten with
¼-20 UNC Ny-Lock nut, and 10-24 UNC hardware

Figure 20: Installed Cover

20. Re-Install UCAP cover and modified air intake system per ITS-4557.

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ITS:

4932

LABOUR ESTIMATE
Operation
1

UCAP Circuit Board Cover Install

Men

Hours

1

2

Labour Time
M X HR
2

PARTS REQUIRED
Description

Qty.
per
Coach
.5

Units

Item

Part Number

1

401722

SEALANT-PROFLEX CLEAR

2

5957793

SEAL, RUBATEX 1”W X .06”THK

12

FT

3

N/A

CLEANER-ELEC CONTACT

2

EA

Notes

EA

Carmenita
Truck
center part
# is 91843

CLEANER-RUBBING ALCOHOL

.5

EA

162459

KIT-3CCT SHR DT GY

8

EA

6