SB-10045620-2958

INSTRUCTION TO SERVICE
ITS: 5086
SECTION:

549

WRITTEN BY:

Shaun Cardinal

SUBJECT:

Carrier 91-00397-00 Suppressor/Filter/Battery Grounding Installation

HVAC

ITS5086

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 UNAUTHOIZED 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.

PROCEDURE:
1. Turn the main battery disconnect switch 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.

2. Mounting Plate Installation
a.

Modify mounting plate NF PN 6407306 per Fig 1. Ensure any exposed steel is touched up with supplied
zinc primer and undercoating (Corasheild).

Figure 1: Modified mounting plate

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b.

Position plate against shore box mounting tab and coach structure tube. Secure w/ ¼-20 UNC hardware.
Eight NF PN 10B04024 bolts, sixteen NF PN 10W04000 washers, and eight NF PN 40N04000 nuts. See
Fig 2 and 3.

Position mounting plate flush
against structure tube

Position mounting plate flush
against shore box mounting
tab
Figure 2: Modified mounting plate positioned

Figure 3: Modified mounting plate installed

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3. HV Filter Installation
a.

Remove existing mounting plate found inside the new filter box NF PN 6406242 and modify per Fig 4.

Figure 4: Modified filter mounting plate

b.

Install filter NF PN 460459 to modified mounting plate. See Fig 5

Figure 5: Mounted filter assembly

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c.

Modify filter box NF PN 6406242 per Fig 6. Drill 2x holes 1-1/16” in diameter. Ensure all burrs are
cleaned up. Wipe off mating surface of Strain Relief NFI PN 268193 Jam Nut with Sika Cleaner NFI PN
055702. Allow cleaner to flash off for 5-10mins.

Figure 6: Modified Filter Box

d.

Install strain relief NF PN 268193 on the new Filter Box holes and seal with SIKA NFI PN 055701 to
prevent water intrusion. See Fig 7

NOTE:

For Filter Boxes with additional open holes, see Appendix A for capping and

sealing instructions.

Figure 7: FULLY ASSEMBLED BOX

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e.

Install mounted filter assembly into HV filter box using existing hardware. See Fig 5

Figure 5: Mounted Filter

f.

Strip the HV 4 wire Cable NFI PN 6406371 per Fig 6

NOTE:

Trim L3 wire back to orange cable insulation beginning on both ends. L3 will not

be used on both HV cables.

Figure 6: High Voltage Cables

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g.

Pre assemble HV 4 wire Cable NFI PN 6406371 to filter, ensure HV Ferrule Crimps are installed. See
Fig 7 (refer to Wiring Diagram Fig 12 for details)

NOTE:

HV cables use 8 AWG ferrule NFI PN 640552 for L1 and L2. Ground wires use NFI

PN 037577.

Cable 1
(to Inverter)
HV Ferrule Crimps

Cable 2
(to Breaker)

Figure 7: Filter Wiring
h.

Install the filter box assembly to the mounting plate using 4 rubber isolators NF PN 6407362 per Fig 8

Rubber Isolator
NF PN 6407362

Figure 8: Mounted Filter Box Assembly

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4. Shore Box Modification
a.

For the Suppressor (NFI PN 6402166) and HV Cable Strain Relief (NFI PN 268193) holes, drill three 1
1/16” holes on the shore box per Fig 9 and ensure all burrs are cleaned up.

b.

For the ground stud (NFI PN 6350408) hole, drill out a ¾” diameter hole in shore box per Fig 9 and
ensure all burrs are cleaned up.

c.

Wipe off mating surface of new holes Sika Cleaner NFI PN 055702. Allow cleaner to flash off for 510mins.

(Ground Stud) (b)
(a) (Cable to INV 1)

EXISTING
(Suppressor) (a)
(a) (Cable to Breaker)

Figure 9 – Shore Box Modification

d.

Install ground stud NF PN 6350408 and secure with two 10-24 screws (NF PN 15S00012), washers (NF
PN 10W00000), and nuts (NF PN 40N00000). Install HV Cable Strain Relief (NFI PN 268193) and seal
jam nuts with SIKA NFI PN 055701 to prevent water intrusion.

Figure 10: Shore Box Ground Stud

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5. HV Suppressor Installation
a.

Install suppressor assembly (NFI PN 6402166) into predrilled hole on shore box (refer to Fig 9 for hole
location of suppressor) and seal with SIKA NFI PN 055701 to prevent water intrusion.

b.

Secure suppressor assembly and ensure orientation is per Fig 11

Figure 11: Suppressor Orientation

6. HV Suppressor and Filter Wiring
a.

Wire up Surge Suppressor and Filter per Fig 12 (Diagram 91-00397-00). Ensure Single and Single to
Double High Voltage ferrules are crimped onto the bare ends wire ends. Refer to Fig 7 for pictorial view
of filter and 13 for pictorial view of suppressor. . Use supplied 10 AWG Black Wire NFI PN 158826 to
replace existing shore box wiring.

NOTE:

On connections to 1L1 and 3L2 of breaker use the 2 AWG ferrules (NFI PN

6407441) to crimp both Surge Suppressor and ISE Inverter wires together. Will need to follow same
step with Filter wires to resistor for Carrier Inverter #1 ( L2,L1).

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USE
SINGLE
FERRULE
CRIMPS

USE SINGLE
AND DOUBLE
FERRULE
CRIMPS WHERE
APPLICABLE

USE
DOUBLE
FERRULE
CRIMPS

USE
SINGLE
FERRULE
CRIMPS

Figure 12: Suppressor and Filter Wiring Diagram (Shore Box 91-00397-00)

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Figure 13: Suppressor and Shore Box 91-00397-00 Details

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7. Battery Ground installation
a.

Modify the battery switch box by drilling a 1-1/8” diameter hole per Fig 14. Ensure no burrs are inside the
switch box after drilling.

Figure 14: New Shore Box Wiring

b.

Install strain relief for ground cable NF PN 268193. See Fig 15

Figure 15: Strain Relief

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c.

Cut 30 inches of black ground cable NF PN 037511 and strip back 0.5 inches of insulation on each end
and run through the strain relief. Using appropriate crimp tool, crimp lug NF PN 5946527 on both ends of
the cable and seal exposed wire with heat shrink NF PN 251703. Fasten to ground stud inside battery
switch box. See Fig 16 and 17.

Figure 16: Ground Cable

Figure 17: Ground Cable Installed

d.

Install other end of ground cable to the new shore box grounding lug. See Fig 10.

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8. ISO Fault Test
a.

With the UCAP’s still discharged, connect the laptop to the ISE Diagnostic Port located on the rear PLC
panel (rear of bus)

b.

Start the CRT software and name the file and location to save the logged file to

c.

Start the bus and when the contactor test is completed, start the data log by going to “Transfer Selection”
at the top of the screen and selecting “Send ASCII”. Select file to retrieve from. Click on desktop, and
then double-click on “ISO data logger text folder”.

d.

When the bus goes into hybrid mode, start the A/C System and let it run for 1 min

e.

After 1 min, type dl, followed by the “enter” key. This will stop the data log

f.

Open the log file as a text document and review column 3 (ISO RESULT)

g.

Ensure that Column 3, ISO RESULT, has a value greater than 900 after the bus goes into Hybrid Mode.
See Fig 18

Figure 18: ISO RESULT

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