INSTRUCTION TO SERVICE
ITS: 5769
SECTION:

209

WRITTEN BY:

Jermie Marasigan

SUBJECT:

Remove and replace Power Steering Pump and Motor

POWER STEERING

ITS5769

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.
2. Ensure all power has been removed from the high voltage electrical system and that the motor is not
operating.
3. Open the engine access door.
4. Raise coach in accordance with the New Flyer Service Manual if required.
WARNING:

The hydraulic pump is attached to the accessories motor, which operates at 230vac.
Therefore follow all high voltage safety procedures when working in the accessories
motor area. Failure to observe high voltage safety guidelines can result in death or
serious injury.

CAUTION:

Escaping hydraulic fluid under pressure can have sufficient force to penetrate your
skin causing serious injury. This fluid may also be hot enough to burn. Serious
infection or reactions can develop if proper medical treatment is not administered
immediately.

5. Remove Power Steering Pump (NF P/N: 462423):
a.

Drain the hydraulic reservoir.

b.

Place a clean container under the power steering pump to remove the inlet and pressure lines. Plug the
lines to prevent contaminating fluid.

c.

Disconnect the hoses, pump supply NF P/N: 471395, P/S supply NF P/N: 466443 and quick fill line NF
P/N: 466272 from the existing power steering pump. Set aside and cover the Quick fill hose to be reinstalled later.

d.

Remove the mounting bolts attaching the power steering pump to the driving motor and remove the
pump. Set aside the old pump NF P/N: 462423 and return to New Flyer Warranty Department.

6. Remove the Electric Motor (NF P/N: 507524):
a.

Remove belt guard.

b.

Loosen tension on belts and remove belts from the electric motor pulley.

c.

Remove the 4 bolts underneath the motor bracket and then remove complete assembly.

d.

Remove belt pulley clutch assembly. Set aside belt pulley clutch assembly to be installed on the new
motor.

e.

Remove electric motor from the bus. Set aside the old motor NF P/N: 507524 and return to New Flyer
Warranty Department.

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Figure 1: POWER STEERING MOTOR AND PUMP INSTALLATION

7. Install New Electric Motor (NF P/N: 507524):
a.

Apply never seize NF P/N: 5928660 on the new motor shaft. Install belt pulley clutch assembly NF P/N:
468672 on the new motor before installing the pump. Position tab on the clutch between the bumpers.
Torque ½ bolt with loctite 242 to 60 ft-lbs. See Figure 2.

b.

Install the new motor assembly on the motor mounting bracket using four 3/8-16 bolts that were
removed from step 6-c. Do not torque the bolts yet.

c.

Install belts and ensure that motor pulley is aligned properly to the compressor pulley and set belt
tension to 90 to 100 lbs. for ½” deflection of the belt. See Figure 3 for reference.

d.

Torque four 3/8 bolts with never seize NF P/N: 5928660 to 22 ft-lbs.

e.

Reinstall belt guard.

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8. Install New Power Steering Pump (NF P/N: 462423):
a.

Pre-assemble the new power steering pump NF P/N: 462423 and Tee NF P/N: 462480 prior to
installation. Torque the Tee to 40 – 43 ft-lbs. See Figure 1.

b.

Ensure that the mating surface between the power steering pump and electric motor are scraped clean.

c.

Lubricate the male spline on power steering pump and female spline on air compressor driveshaft with
Molykote “G” grease (Chevron 23003, GR-25 or equivalent).

d.

Install the new power steering pump NF P/N: 462423 onto the electric motor NF P/N: 507524. Ensure
spline on pump shaft mate correctly with motor.

e.

Apply loctite-243 to bolts and install bolts (NF P/N: 10B06016) and washers (NF P/N: 20W06000).
Torque bolts to 22 ft-lbs. (30 N-m).

Figure 2: CLUTCH AIR COMPRESSOR INSTALLATION

Figure 3: MAXIMUM ALLOWABLE BELT MISALIGNMENT

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9. Connect hoses and fittings to pump as shown in Figure 1. Torque fittings per NFIL Spec 331883.
10. Refill hydraulic system and bleed the system.
11. Reinstall the shield under the motor mount assembly before returning the vehicle to service.
12. Lower coach in accordance with the New Flyer Service Manual.
13. Turn the main battery disconnect switch to the “ON” position.

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APPENDIX A
NF SPEC 331883

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LABOUR ESTIMATE
Operation
1

Remove and replace Power Steering Pump and Motor

Men

Hours

2

4.0

Labour Time
M X HR
8.0

PARTS REQUIRED
Item

Part Number

Description

1

507524

MOTOR-ELECTRIC, 7.5HP, 230V, 19A

2

462423

PUMP-POWER STEERING IXETIC

Qty.
per
Coach
1

Units

1

EA

Notes

EA

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