NHTSA ID Number: 10161608
Manufacturer Communication Number: Odyne Service Bu
TSB/Document Date: 2019-06-24
Summary
Odyne Systems, LLC has issued a service bulletin 00029C to address potentially loose Traction Motor Companion Flange bolts/Lovejoy set screws. (If these set screws become loose, then the Traction motor could be damaged.)
The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in
proper vehicle service. Warranty Policy documentation determines Warranty coverage unless stated otherwise in the TSB article. The information in
this Technical Service Bulletin (TSB) was current at the time of printing. Odyne Systems, LLC reserves the right to supersede this information with
updates. The most recent information is available through Odyne on-line technical resources.
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Motor Companion Flange Upgrade 00029C
Doc Rev 05.10.19
SERVICE BULLETIN
6. Pull flange up tight against the hardened washer. Torque two cap screws on the flange to
43 ft. pounds after Blue Loctite is applied to threads. Return Screws to original locations.
Overview Diagram
Cap Screws
Bolt
Hardened
Washer
Flange
40664
7. Re-mark the head of the traction motor companion flange bolt and washer after torqued as shown
below.
Bolt
Flange
40664
Bolt and Washer: Marked
The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in
proper vehicle service. Warranty Policy documentation determines Warranty coverage unless stated otherwise in the TSB article. The information in
this Technical Service Bulletin (TSB) was current at the time of printing. Odyne Systems, LLC reserves the right to supersede this information with
updates. The most recent information is available through Odyne on-line technical resources.
Page |5
Motor Companion Flange Upgrade 00029C
Doc Rev 05.10.19
SERVICE BULLETIN
Checking Alignment (both vertical and horizontal)
Specification:
1.
Optimally, the PTO flange face and the motor flange face should be parallel with 0 degree
difference between the measurements of each flange.
2.
Because of space restraints and limitations to drilling the chassis hole, the preference is that the
flanges are between 0.0 and 0.3 degree; the maximum difference allowed is 1.0 degree.
Procedure:
1. Place an inclinometer (digital level) on the PTO flange and record the value. You will only be
able to measure it vertically until other tools have been developed.
2. Compare this value with the value written on or near the PTO (or possibly written on the frame
near the PTO), note any differences.
3. In some cases, the PTO flange angle may be written on the frame closer to the cab but still near
the PTO, and in other cases, the angle might be covered in dirt or on a hard to see surface.
4. Place an inclinometer on the Motor flange and record the value.
5. In some cases the motor flange angle might be written on the frame near the motor or in some
cases the angle might be covered in dirt or on a hard to see surface.
6. For horizontal alignment take measurements from the motor/inverter bracket to the nearest Cross
member and make sure they are equal.
Correcting Alignment:
1. Support the electric motor with a hydraulic jack.
2. Remove one chassis bolt from the motor inverter bracket to chassis connection.
3. Remove the same bolt on the opposite side to create a pivot axis (see examples “a” through “d”
below).
a.
Bottom forward hole on the driver side = Bottom forward hole on the passenger side.
b.
Bottom rearward hole on the driver side = Bottom rearward hole on the passenger side.
c.
Top forward hole on the driver side = Top forward hole on the passenger side.
The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in
proper vehicle service. Warranty Policy documentation determines Warranty coverage unless stated otherwise in the TSB article. The information in
this Technical Service Bulletin (TSB) was current at the time of printing. Odyne Systems, LLC reserves the right to supersede this information with
updates. The most recent information is available through Odyne on-line technical resources.
Page |6
Motor Companion Flange Upgrade 00029C
Doc Rev 05.10.19
SERVICE BULLETIN
Top rearward hole on the driver side = Top rearward hole on the passenger side, proceed to
method 2, step 16.
d.
4. Once a suitable new frame hole location is found, use the Motor Bracket as a guide and
mark/punch a new hole on each side on the inside of the chassis frame rail.
5. Use the same hole on opposite side to create a pivot axis (see examples “a” through “d” below).
a.
Bottom forward hole on the driver side = Bottom forward hole on the passenger side.
b.
Bottom rearward hole on the driver side = Bottom rearward hole on the passenger side.
c.
Top forward hole on the driver side = Top forward hole on the passenger side.
d.
Top rearward hole on the driver side = Top rearward hole on the passenger side.
6. Drill a pilot hole (1/8”) from the inside of the frame rail at each of the 2 marked locations.
7. Using a frame drill and the pilot holes, drill an M16 clearance hole (41/64”) from the outside of the
frame rail at each of the 2 pilot holes.
8. Place hardware in these two holes Blue Loctite, tighten, and torque Chassis Rail Hardware to 121
foot pounds.
9. Loctite and tighten to 121 foot pounds any other motor/inverter bracket to frame hardware
that was removed.
10. Use the inclinometer to verify that the motor is approximately 0.3 degree over PTO.
11. Reinstall drive shaft.
(METHOD 2)
12. Slot one pair of the chassis mounting holes in the motor/inverter bracket.
a.
Determine which existing pair of holes will be the pivot axis.
b.
The other pair of holes in use will be slotted.
c.
For pivoting up:
i.
Upper holes are preferred for slotting and should have material toward the front of the truck
removed to allow the motor/inverter bracket to pivot up.
ii.
Lower holes are not preferred for slotting but if necessary the material should be removed going
toward the rear of the truck allowing the motor/inverter bracket to pivot upward.
d.
For pivoting down:
The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in
proper vehicle service. Warranty Policy documentation determines Warranty coverage unless stated otherwise in the TSB article. The information in
this Technical Service Bulletin (TSB) was current at the time of printing. Odyne Systems, LLC reserves the right to supersede this information with
updates. The most recent information is available through Odyne on-line technical resources.
Page |7
Motor Companion Flange Upgrade 00029C
Doc Rev 05.10.19
SERVICE BULLETIN
i.
Upper holes are preferred for slotting and should have material toward the back of the truck
removed to allow the motor/inverter bracket to pivot down.
ii.
Lower holes are a second choice for slotting the material should be removed going toward the front
of the truck allowing the motor/inverter bracket to pivot down.
13. It will likely be necessary to weld a spacer into place on the motor inverter bracket to ensure that
the motor/inverter bracket stays at this new location.
14. Once a suitable new motor/inverter slot location is found, use the previously used Chassis hole
as a guide and mark the material to be removed using the chassis frame rail as a guide.
15. Repeat the previous step on the opposite side (see examples “a” through “d” below).
a.
Bottom forward hole on the driver side = Bottom forward hole on the passenger side.
b.
Bottom rearward hole on the driver side = Bottom rearward hole on the passenger side.
c.
Top forward hole on the driver side = Top forward hole on the passenger side.
d.
Top rearward hole on the driver side = Top rearward hole on the passenger side.
16. Remove the motor/inverter bracket if necessary.
17. Drill or machine out the slots that were marked in the previous step.
18. Replace the motor/inverter bracket if necessary.
19. Replace the pivot axis bolts if necessary.
20. Place hardware in the two new slots Blue Loctite, tighten, and torque Chassis Rail Hardware
to121 foot pounds.
21. Apply Loctite and tighten to 121 foot pounds any other motor/inverter bracket to frame hardware
that was removed.
22. Use the inclinometer to verify that the motor is approximately 0.3 degree over PTO.
23. Rotate motor shaft until the set screws on the Lovejoy are facing the tooling access window.
24. Remove one set screw at a time and replace it with Blue Loctite applied, and 48 foot pounds of
torque.
25. Reinstall drive shaft.
26. Grease Driveshaft Zerk locations.
27. Follow regular maintenance intervals stated in owner’s manual.
The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in
proper vehicle service. Warranty Policy documentation determines Warranty coverage unless stated otherwise in the TSB article. The information in
this Technical Service Bulletin (TSB) was current at the time of printing. Odyne Systems, LLC reserves the right to supersede this information with
updates. The most recent information is available through Odyne on-line technical resources.
Page |8
Motor Companion Flange Upgrade 00029C
Doc Rev 05.10.19
SERVICE BULLETIN
Reinstall Driveline
1. Apply Red Loctite to the four driveline bolts.
2. Install the bolts securing the driveline to the motor companion flange, and torque to 63 Ft-Lbs.
Installation Tip: Feed the bolt from the flange side, and feed the lock washer and nut from the
driveline side.
3. Re-mark the head of each of the four driveline bolts and nuts after torqued, as shown below.
Lock Washer
Nut
Bolt Head
Driveline to Companion Flange Bolts: Marked
4. Align driveline per Odyne Driveline alignment Service Procedure:
Proper alignment of the drive line is necessary to ensure optimal functionality of the hybrid
system.
Overview:
The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in
proper vehicle service. Warranty Policy documentation determines Warranty coverage unless stated otherwise in the TSB article. The information in
this Technical Service Bulletin (TSB) was current at the time of printing. Odyne Systems, LLC reserves the right to supersede this information with
updates. The most recent information is available through Odyne on-line technical resources.
Page |9
Motor Companion Flange Upgrade 00029C
Doc Rev 05.10.19
SERVICE BULLETIN
Parts Required:
Part Number
Shop Supply
Shop Supply
90011
40664
Description
Red Loctite
Blue Loctite
Parts kit
Traction Motor Companion Flange
Quantity
1
1
1
1
Warranty Information:
Code
Description
Time
00029C
Motor Companion Flange Upgrade
1.0
Odyne Service Support Resources:
To request technical assistance, contact [email protected].
To request parts, contact [email protected].
The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in
proper vehicle service. Warranty Policy documentation determines Warranty coverage unless stated otherwise in the TSB article. The information in
this Technical Service Bulletin (TSB) was current at the time of printing. Odyne Systems, LLC reserves the right to supersede this information with
updates. The most recent information is available through Odyne on-line technical resources.
P a g e | 10
Motor Companion Flange Upgrade 00029C
Doc Rev 05.10.19
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TSB/Document ID: Odyne Service Bu
Replacement Service Bulletin Number:
MFR Communication Date: 2019-05-10
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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