INSTRUCTION TO SERVICE
ITS: 58508
SECTION:

219

ENGINE & TRANSMISSION.

WRITTEN BY:

Michael Rooney

SUBJECT:

Retrofit new PEM Motor mounting & Fuel Cell mounting hardware.

ITS58508
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERED TO FOR FUTURE MAINTENANCE UNTIL
THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A
RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND
MAINTENANCE STAFF GOING FORWARD.
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. Review and perform the steps in the High Voltage Service Preparation Section #4 1.6 of the Service Manual
before beginning work on the bus. Ensure that personnel have the appropriate High Voltage training and High
Voltage protective (PPE) equipment.
2. Open the curbside rear access door and locate the 24/12 volt battery switch and high voltage interlock switch.
a.

Review the De-energizing Procedure section #4 1.6.4.1 of the Service Manual.

b.

Rotate the 24/12 volt battery switch to the OFF position. Lock and tag the switch and retain key.

c.

Switch the High Voltage Interlock Switch to the HV OFF position. Lock and tag the switch and retain key.

d.

Ensure the Energy Storage System (ESS) Manual Service Disconnect cap is removed per the following
steps and stowed in a locked location to which you only have access.
1) Using the clamp-on current probe and DMM, ensure that there is no current flowing in the cables
connecting to the ESS Manual Disconnect Plug.
WARNING:

NEVER remove the ESS Manual Disconnect Plug while current is flowing

through it. The High Voltage may create a long enough ionized gas path, during circuit
interruption, to bridge the contacts of the switch base and therefore continue current flow.
This ionized gas is very hot and can cause burns, fire & electrical shock.
2) Remove the manual Service Disconnect (MSD) cap from receptacle by pressing on tabs and pulling.
NOTE: For removal of MSD press on tabs located on side and pull – up half way and press on
tab located mid-way and pull up.
3) Install a color-coded insulating cover, that is open circuited, in the Manual Disconnect receptacle.

Figure 1: Location of 12/14 Volt & High Voltage Interlock Switches.

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3. Raise the bus in accordance with the procedures in the NF Maintenance Manual.
4. Locate the electric drive motor (PEM) located centrally behind the rear suspension.

PEM Motor

Mounts

Figure 2: PEM Motor Mounts.
5. One at a time, replace the four PEM Motor mounting bolts and nuts using the following procedure at each
mounting location.
a.

Remove the 5/8” nut and washer on the underside of the mount. Set the washer aside for reinstallation
later.

b.

Remove the 5/8” x 4.5” bolt from the top. Do not lose the 66 MM washer on top of the rubber isolator
under the bolt head.

c.

Insert a new 5/8” x 4.5” bolt NF P/N 10B10072 from the top.

d.

Reinstall the washer set aside earlier then install a new 5/8” nut NF P/N 40N10000. Torque the nut to
160 ± 10 FT-LBS (DRY).

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Bolt P/N 10B10072
66 MM Washer (re-use)

Washer (re-use)
Nut P/N 40N10000

Figure 3: PEM Motor Mount Bolt
6. Locate the fuel cell power plant at the center rear of the bus. There are two rubber isolated mounts at the front
of the fuel cell and two more at the rear of the fuel cell.

Front Curbside Mount

PEM Motor
Front Streetside Mount

Fuel Cell
Rear Fuel Cell Mounts

Figure 3: Fuel Cell Mounts.
7. Remove and replace the front mount hardware one at a time using the following procedure on each mount.
a.

Remove the 5/8” nut and washer on the underside of the mount. Discard both.

b.

Remove the 5/8” x 4.25” bolt from the top. Do not lose the 66 MM washer on top of the rubber isolator
under the bolt head.

c.

Insert a new 5/8” x 4.50” Bolt NF P/N 10B10072 from the top.

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d.

Install a new hardened Washer NF P/N 20W10000 and a new 5/8” Nut NF P/N 40N10000. Torque the
nut to 106 FT-LBS (DRY).
Bolt P/N 10B10072
66 MM Washer

Hardened Washer NF
P/N 20W10000

Nut NF P/N 40N10000

Figure 4: Front Fuel Cell Mount (Part of Bracket Removed for Clarity).
8. Remove and replace the rear mount hardware one at a time using the following procedure on each mount.
a.

Remove the 5/8” nut on the top of the mount. Remove the 66 MM washer and set it aside for reuse.

b.

Remove the 5/8” x 4.25” bolt from the bottom through the opening in the cross member. Discard the bolt
and the washer under the bolt head.

c.

Install a new Hardened Washer NF P/N 20W10000 on a new Bolt NF P/N 10B10072 then insert the bolt
through the cross member and isolators from the bottom.

d.

Reinstall the 66 MM washer removed earlier and then install a new Hardened Washer NF P/N
20W10000 and new Nut NF P/N 40N10000. Torque the nut to 106 Ft – LBS (DRY).

66 MM Washer

Nut NF P/N 40N10000
Hardened Washer NF
P/N 20W10000

Hardened Washer NF
P/N 20W10000

Bolt NF P/N 10B10072

Figure 5: Rear Fuel Cell Mounts (Chassis Cross Member Removed for Clarity).
9. Lower the bus in accordance with the procedure in the NF Maintenance Manual.
10. Use the following Energizing Procedure (Section #4 1.6.4.2 in Service Manual) to re-establish power to the
bus.

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WARNING:

DO NOT touch cable terminations until checking to ensure there is no
voltage between any of these cables and with respect to vehicle chassis.
While connecting HV cables continuously monitor with the DMM for the
inadvertent appearance of HV. If HV appears, dress in PPE and trouble
shoot why the HV appeared and resolve.

a.

Remove the color coded insulating cover.

b.

Install the ESS Manual Disconnect cap.

c.

Close all HV access panels, doors, enclosures.

d.

Remove the lock/tag from the 24/12 volt Battery Disconnect Switch. Rotate the 24/12 volt battery switch
to the ON position.

e.

Remove the lock/tag from the High Voltage Interlock Switch. Rotate the HV Interlock to the ON position.

f.

Remove Safety barricade with warning lights and “Danger High Voltage” signs around the vehicle
perimeter.

11. Close and secure the outside access doors.

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LABOUR ESTIMATE
Operation
1

Retrofit new PEM Motor mounting & Fuel Cell mounting
hardware.

Men

Hours

1

1.5

Labour Time
M X HR
1.5

PARTS REQUIRED
Description

Qty.
per
Coach
8

Units

Item

Part Number

1

10B10072

BOLT – HEX 5/8 UNC X 4.50

2

40N10000

NUT – HEX LOCK 5/8 UNC

8

EA

3

20W10000

HARDENED WASHER – 5/8

6

EA

Notes

EA

SPECIAL TOOLS REQUIRED
Item
1

Part Number

Description

Qty.
per
Coach

Notes
Units

No Special Tools Required

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