NHTSA ID Number: 10215527
Manufacturer Communication Number: ITS60345
TSB/Document Date: 2022-07-07
Summary
Technical Instruction describing how to rework the high voltage receptacle assembly.
INSTRUCTION TO SERVICE
ITS: 60345
NOV/5/2021
SECTION:
260-BATTERY COMPARTMENT
WRITTEN BY:
Ilan Kizner
SUBJECT:
Rework – High voltage receptacle assembly.
ISSUE:
SUMMARY:
Failing DC Contactors
Issue identified as low-quality crimping of lugs on the receptacle side
ITS60345
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED 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 unauthorized disclosure,
reproduction or other distribution of this document or information 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.
INSTRUCTION TO SERVICE
ITS60345
Contents
INSTRUCTION TO SERVICE ....................................................................................................................................1
1.
SAFETY PROCEDURE ......................................................................................................................................3
2.
Rework Procedure - remove curb side receptacle assembly: ............................................................................4
3.
Rework Procedure - remove street side receptacle assembly ...........................................................................6
Appendix A – Receptacle assembly rework procedure. .............................................................................................9
Appendix B - Cable rework criteria ...........................................................................................................................12
Appendix C – reference drawings ............................................................................................................................15
Appendix D - Tools and labor ...................................................................................................................................17
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WARNING:
Only trained personnel shall supervise and perform High Voltage system testing,
checkout and troubleshooting. Two personnel (one called the Checker & the other
called Monitor/Recorder) shall perform Checkout Procedures, together, to ensure
safety of themselves, others nearby & for the protection of vehicle & property.
Refresher training shall be provided to these personnel on a regular basis and
when new systems are to be checked by them. The training of the personnel shall
consist of:
1. SAFETY PROCEDURE
1.1. Turn the master run switch to the off position and wait 5 minutes before proceeding.
1.2. Turn the 12/24V battery disconnect and HV Interlock switch to the “OFF” position.
1.3. Lock and Tag the electrical system of the bus out and retain the key. See Figure 1.
1.4. Install a Lockout/Tagout Steering wheel cover as require
NOTE:
Refer to the Lockout/Tagout Procedure in section 1 of your Preventive Maintenance
Manual or section 9 of your Service manual for additional information.
NOTE:
Use commercially available lock out equipment and tags being sure to follow any local
laws or workplace procedures.
NOTE:
Refer to New Flyer High Voltage Safety Guidelines and Procedures Document 532295
when completing installation or service work on high voltage power cables.
Figure 1: Lockout tagout location reference
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2. Rework Procedure - remove curb side receptacle assembly:
2.1. Locate receptacle assembly behind CS fuse box access door.
2.2. Open charge box cover by removing 4 screws and washers
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2.3. Disconnect the two positive and negative HV cables from the DC contactors, ground
cable and signals plug and remove front cover plate and receptacle.
2.4. Detach receptacle assembly from front cover plate by removing the following 4 screws
2.5. Refer to Appendix A for receptacle assembly rework procedure.
2.6. Refer to Appendix B – Cable rework criteria for cable inspection.
2.7. Refer to Appendix C – reference drawing for additional information.
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3. Rework Procedure - remove street side receptacle assembly
3.1. Locate the receptacle assembly behind heater access door.
3.2. On the receptacle box remove 4 front cover plate screws.
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3.3. Disconnect the positive and negative HV cables from the contactors
3.4. Disconnect ground wire from bottom of the receptacle box and the two signal plugs RECEPT1 and
RECEPT2
.
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3.5. Detach receptacle from box assembly by removing the following 4 screws:
3.6. Refer to Appendix E install 751729 for additional information.
3.7. Refer to Appendix A on how to rework the receptacle assembly.
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Appendix A – Receptacle assembly rework procedure.
** Note: the following rework applies to both positive and negative receptacle assemblies High
Voltage cables (674318 and 752163). The maximum length that can be cut from the existing cable
should not exceed 3” inches in total.
1. Remove heat shrink from the HV positive and negative ring terminals cables.
2. Cut existing ring terminal using cable cutter 6490350.
3. Remove outer insulation jacket and shield 5" back from cable using cable slitter 6490351.
4. Use heat shrink NFI part number 136365 to cover outer insulation and exposed shield extending to the HV
cable.
5. Strip 1” inch of the exposed cable and visually inspect for signs of heat damage and discoloration. Please
refer to Appendix B – Cable rework Criteria on how to visually inspect a damaged cable.
6. Use crimping tool 6490348 to crimp ring terminal 640366 on striped wire.
Note 1: For ring terminal 640366, strip length should be 1” inch.
Note 2: The maximum length that can be removed from the cable should not exceed 3” inches.
7. Install the terminal lug on the end of the cable, ensuring no copper strands extrude past the end of the barrel.
8. Ensure wire strands are visible at the ring terminal inspection window.
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9. Open the crimping tool upper cover by pressing the release lever (1).
10. Install Panduit Hex Die adapter set (3). You should hear a click sound when the die are secured in place.
11. Attach the Panduit CD-2001 (NF P/N 6490349) Die set on top of existing Dies.
12. Insert cable with ring terminal into the die and close upper cover.
13. Latch the top cover in place with a clicking sound.
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**Note: For the following ring terminal and cable a double crimp should be applied. Crimp should be
in order 1, 2 as shown in the pictures below:
14. Align the ring terminal on location 1 and press the trigger to start crimping. The head will release itself when
crimping is complete. After the crimping is complete, release the trigger.
15. After the first crimp is done press the release button to release the cable, align the ring terminal to position 2
and repeat the crimping operation again. If for some reason the crimp process is stopped then use the upper
trigger to release the crimp head.
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Appendix B - Cable rework criteria
During the rework inspect cable assembly and follow these guidelines:
Note: inspection will be based on visually inspecting the cable assembly
1. Ring terminal - Signs of discoloration around the ring terminal and the ring terminal itself.
2. Heat shrink – Discoloration, signs of melting or any damage caused by excessive heat.
3. Cable – Discoloration, signs of heat damage.
Ring terminal discoloration:
Discoloration
differences
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Damaged
Heat Shrink
Cable damage:
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Note: Damage to the cable will be determined during the ring terminal replacement described in Appendix A:
Visually inspect the cable strands for heat damage:
Damaged strands should show discoloration and excessive heat damage and/or in some cases, can result in
material fatigue and even fall apart.
If cable damage exceeds 3” inches away from initial ring terminal cutting point (maximum length allowed to be
removed from the cable) the entire assembly should be replaced.
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Appendix C – reference drawings
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Appendix D - Tools and labor
LABOUR ESTIMATE
Number of
Technician(s)
1
Operation
Rework receptacle assembly (one side)
Hours
Labor Time
T X HR
2.0
2.0
PARTS REQUIRED
Item
Part Number
Description
1
136365
TUBE-HEAT SHRINK .75 SS
2
640366
TERM-R M8 70MMSQ NIN
Qty.
per
Coach
1
Units
4
EA
Qty.
per
Coach
1
Units
Notes
FT
SPECIAL TOOLS REQUIRED
Item
Part Number
1
6490348
TOOL CRIMPING PANDUIT BLACKFIN
2
6490349
TOOL CRIMP DIES PANDUIT
1
EA
3
6490350
TOOL-NA CABLE CUTTING
1
EA
4
6490351
TOOL CABLE SLITTER 6 1/2 IN
1
EA
ITS60345
Description
Page 17 of 17
Notes
EA
November 5, 2021
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TSB/Document ID: ITS60345
Replacement Service Bulletin Number:
MFR Communication Date: 2022-06-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
MFR Component Subsystem:
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