Before removing, dismantling or maintaining any electrical component, the electrician should take the
necessary precautions to avoid any risk of personal injury or damage to the equipment.

1.5. Open the rear engine door.
1.6. | Open the belt guard.
1.7. Locate the power cables and the junction bus bar (see figure 3).

Location of the Corroded
Junction Bus Bar

Figure 3 - Rear View of Engine Compartment

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NQF772001 VERSION 3

NOVvaBUS SERVICE BULLETIN BS4848ER1
REMOVAL OF THE ENGINE BOX

Ayes

Make sure to disconnect the ground cable from the structure or batteries and ensure that the ground cable
lug is isolated (see figure 4).

Disconnect the super capacitor control connector and ensure OV voltage at the bus bar near the engine box
(see figure 5).

Figure 5 - View of the Super Capacitor Control Connector to Disconnect

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NQF772001 VERSION 3

NOVvaBUS SERVICE BULLETIN BS4848ER1

1.8. | Remove the 2 upper M6 nuts that hold the engine box to the mounting bracket (see figure 6).
1.9. _ Remove the 2 lower M6 nuts that hold the engine box to the mounting bracket (see figure 6).

Upper Nuts

Figure 6 - View of Upper and Lower M6 Nuts

Avon

The Metri-Pack connector is retained and secured with a bolt.

1.10. Carefully remove the engine box from the mounting studs and then disconnect the two connectors at the
back (see figure 7).

Figure 7 - Engine Box Removal

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NQF772001 VERSION 3

NOvVvaBUS SERVICE BULLETIN BS4848ER1
REMOVAL OF THE POWER CABLE LUGS

1.11.
1.12.
1.13.
1.14.

Remove and retain the junction bus bar plastic cap.
Remove and retain the nuts that hold the 3 power cable lugs on the junction bus bar (see figure 8).
Remove the lowest cable to have a better access to the other 2 upper power cables.

Once the lowest cable is removed, pull as far as you can the lugs of the 2 upper power cables that are still
on the junction bus bar.

_
Remove

Figure 8 - Junction Bus Bar and Power Cables

AN NOTE

if one of the power cables and/or the junction bus bar has been damaged or is severely corroded (beyon

jany possible cleaning or repair), then replace it by using the corresponding Level 2 BOM replacement parts,
Otherwise, continue with the following steps of the procedure.

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NQF772001 VERSION 3

NOVvaBUS SERVICE BULLETIN BS4848ER1
CLEANING OF THE CABLES AND JUNCTION BUS BAR

& CAUTION

Apply the recommended personal precautions (e.g. adequate ventilation) and wear Personal Protective

Equipment (PPE) such as chemical splash goggles and neoprene gloves, as specified in each product Safety
Data Sheet (SDS).

1.15. Using the CRC Citrus Degreaser remove the dirt (see figure 9) and the grease from both sides of each power
cable lug, from the junction bus bar and from the hardware nuts.

1.16. Using a nylon bristle brush and the CRC QD Contact Cleaner product, remove the corrosion (see figures 9
& 10) from both sides of each power cable lug, from the junction bus bar and from the hardware nuts.

Dirt Accumulation

Corrosion

Figure 9 - Junction Bus Bar and Power Cable Lug

CRE

ee
Ed

Figure 10 - Corrosion Cleaning Brush and Contact Cleaner Product
1.17. Once all the parts are cleaned, reinstall the 3 power cables on the junction bus bar with the nuts and torque
to 21.5Nm (do not apply yellow torque seal at this point).

1.18. Remove the black plastic cap from the fuse holder located to the right of the engine box removed earlier
(see figure 11).

1.19. Remove and retain the nuts of the power cable lugs and of the 250A fuse.
1.20. Remove the 250A fuse to clean it.

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NQF772001 VERSION 3

NOVvaBUS SERVICE BULLETIN BS4848ER1

1.21. Using the same degreaser and corrosion cleaning products specified earlier, repeat steps 1.15 and 1.16 to
clean fuse holder power cables lugs and fuse holder metal contact parts.

1.22. Once all parts are clean and dry reinstall the 250A fuse and the power cables with the nuts and apply a
torque of 20Nm.

Plastic Cap

Figure 11 - Fuse Holder Black Plastic Cap

APPLICATION OF THE DOLPH ER-44 PRODUCT

Ave

Ensure that you allow 10 minutes for each coat to dry before applying the next coat.

1.23. Apply 3 thin coats of the Dolph ER-44 product over the exposed metal surfaces of the junction bus bar, power
cable lugs, fuse terminals, fuse holder terminals and nuts (see figure 12).

1.24, After the last Dolph ER-44 coat has dried, apply the yellow torque seal on each nut, Then, reinstall the
protective plastic caps over the junction bus bar and the fuse holder.

Figure 12 - Dolph ER-44 and Yellow Torque Seal Applied

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NQF772001 VERSION 3

NOVvaBUS SERVICE BULLETIN BS4848ER1
REINSTALLATION OF THE ENGINE BOX

Aves

Ensure that the Metri-Pack connector is retained and secured with the bolt.

1.25. Screw the Metri-Pack connector middle bolt until the plastic clips on both sides of the connector are correctly
positioned. Torque to 7Nm and apply yellow torque seal.

1.26. Reinstall the engine box after reconnecting the two connectors at the back.

1.27. Tighten three of the four M6 nuts while retaining the fourth M6 nut holding the upper left corner for later
assembly, to complete the deflector bracket installation.

Aves

Ensure that the first three M6 nuts are properly secured (no torque specified).

INSTALLATION OF THE DEFLECTOR BRACKET

1.28. Remove and discard the p-clamp lock nut holding the lower power cable (see figure 13).

Lock Nuts
PN N44887

Figure 13 - View of Power Cables and Junction Bus Bar

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NQF772001 VERSION 3

NOvVvaBUS SERVICE BULLETIN BS4848ER1

1.29.

1.30.

1.31.
1.32.

1.33.
1.34.
1.35.

Install the new deflector bracket PN N100476 on existing studs (see figure 14).

Deflector Bracket
PN N100476

Cable Tie
PN N57807

Figure 14 - Installation of the Deflector Bracket

Adjust the deflector bracket to avoid any electrical contact with the junction bus bar and power cable lugs
exposed metal surfaces connected to the 24V alternator power distribution.

Install lock nuts PN N44887 on the engine box and p-clamp studs and torque to 14.5+1 Nm (see figure 13).

Install the cable tie mount PN N57807 on the deflector bracket hole in order to secure the alternator cable
(see figure 14).

Reconnect the batteries ground cable and the super capacitor contro! connector.
Set the battery disconnect switch in the battery compartment to the ON position.
The vehicle may be returned to service. #

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NQF772001 VERSION 3