INSTRUCTION TO SERVICE
ITS: 60823

October 2, 2023

SECTION:

290-ELECTRICAL SCHEMATICS

WRITTEN BY:

Ilan Kizner

SUBJECT:

Rework - OVHD charge cable rework to prevent water intrusion

ISSUE:

Low isolation faults present due to water entering the cable

SUMMARY:

Rework OVHD, HV positive and negative cables and adding securements

ITS-60823

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
ITS60823

PROCEDURE:
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.
1.
2.
3.
4.
5.

Turn the master run switch to the off position and wait 5 minutes before proceeding.
Turn the 12/24V battery disconnect and HV Interlock switch to the “OFF” position.
Lock and tag the electrical system of the bus out and retain the key. See Figure 1.
Use commercially available lockout equipment and tags being sure to follow local regulations.
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
(Appendix A) when completing installation or service work on high voltage power cables.

Figure 1: Lockout tagout location reference.

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October 2, 2023

INSTRUCTION TO SERVICE
ITS60823
6.

Locate the DC RL SW POS and DC RAIL NEG TO DC RL SW NEG cables and disconnect the quick
disconnect connectors from the overhead charge rail box. See Figure 2.

7.

Remove the cable ring terminal mounting hardware on each cable and set aside for re-installation. See
Figure 2.

8.

Remove any clamps and hardware securing the cables in place and set aside for re-installation.

9.

Using a hard plastic bristles cleaning brush (sourced locally) along with contact cleaner P/N – 1034975
remove any signs of corrosion from the Amphenol quick disconnect cable connectors and the OVHD
charge box mating connector.



NOTE: Use NFI approved respirator with organic vapor cartridges, and nitrile rubber gloves.



NOTE: If cleaning process does not remove the corrosion from the cable or the mating
connectors, replace the parts through the regular warranty procedure.



NOTE: The following sections applies for both positive and negative cables.

Remove Clamps &
Mounting Hardware.

Remove Cable
Mounting Hardware

Figure 2 - OVHD HV POS and HV NEG cables location reference.

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October 2, 2023

INSTRUCTION TO SERVICE
ITS60823
10. After removing the corrosion from the two HV cables, place them on a work bench or suitable work
surface. Install supplied O-Ring P/N – 1036285 as shown. See Figure 3.

Figure 3 - O-Ring installation location reference.

11. Locate the ring terminal on each cable and remove 756938 loom end cap 31.5mm and the heat shrink.
Clean ring terminal and cable sheathing with alcohol 134336 and a dry lent free cloth. See Figure 4.
12. Apply several coats of Scotchkote 1035894 on the portion where heat shrink was removed until void is
full. Allow applied Scotchkote to dry. See Figure 4.

Loom and End
Cap Removed.

Fill Void with Scotchkote.
Void Filled with Scotchkote.

Figure 1 - Scotchkote applied on lug and cable location reference.

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October 2, 2023

INSTRUCTION TO SERVICE
ITS60823
13. Apply heat shrink 251215 to the cable lug ends and over the cable sheathing. See Figure 5.

Heat Shrink 251215 Applied.

Figure 2 – Cable lug and sheathing heat shrink location reference.

14. Re-Install loom and apply heat shrink 028412, over the loom and the lug heat shrink. See Figure 6.

Heat Shrink 028412 Applied.

Figure 3 – Heat shrink applied over loom and lug heat shrink location reference.

15. Re-Install the loom end cap 756938 on top of the ring terminal and the loom. See Figure 7.

Loom End Cap 756938 Installed.

Figure 4 - Cable loom end cap installation location reference.

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October 2, 2023

INSTRUCTION TO SERVICE
ITS60823

16. Using the DC rail cable support bracket 1038376 as a template mark the hole locations shown below.
See Figure 8.
17. Drill the mounting hole locations using a drill and 25/64 drill bit. See Figure 8.

Box Connectors

Clamp Cover Plate.

Figure 8 – DC rail cable support bracket drill location reference.

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October 2, 2023

INSTRUCTION TO SERVICE
ITS60823
18. Install inserts 736408 using an insert tool in the locations shown below. See Figure 9.

Figure 9 – Bracket insert location reference.

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October 2, 2023

INSTRUCTION TO SERVICE
ITS60823
19. Secure DC rail cable support bracket 1038376 using 6 bolts 20B04010 and 6 washers 50W04000. See
Figure 9.
20. Install clamps 752906 (two per cable) as shown in figure 11. Secure each clamp using 2 x 20B04036
bolts, 2 x 50W04000 washer and 2 x 72N04000 nylon nuts.
 NOTE: Torque clamp and bracket screws to 4-5 FT-LB.
21. Re-connect the cable quick disconnect connectors to their respective connection points.
22. Re-connect the cable ring terminals to their respective connection points on the charge rail. Torque cable
lug hardware to 15 ft-lbs.
23. Re-install the cable clamps removed to complete the rework and torque to 6 ft-lbs.
24. Re-connect the plugs to the receptacles.
25. Ensure all tools and debris are removed from the work area and return the bus to service condition.

Figure 10 – Bracket and POS and negative HV cable securements

ITS60823

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October 2, 2023

INSTRUCTION TO SERVICE
ITS60823

LABOUR ESTIMATE
Operation
1

Number of
Technician(s)
2

Rework cables and adding securements

Hours

Labor Time
T X HR
5

5

PARTS REQUIRED
Qty.
per
Coach

Item

Part Number

1

20B04010

BOLT HEX. 1/4-20 x 0.625

6

EA

2

20B04036

BOLT-HEX 1/4-20 X 2.25 SS

4

EA

3

50W04000

WASHER-FLAT 1/4 NOM

14

EA

4

72N04000

NUT-NYLON LOCK SST 1/4-20

4

EA

5

736408

INSERT-PEM 1/4" AELS8-420-165BS

5