INSTRUCTION TO SERVICE
ITS: 60853

DATE 10/30/23

SECTION:

260U – Battery Compartment

WRITTEN BY:

Ilan Kizner

SUBJECT:

Rework ground cable for DC LINK DIST BOX

ISSUE:

Ground cable does not have enough clearance from box components

SUMMARY:

Revise cable routing and adding an additional bracket

ITS 60853
Ref. NHTSA Recall No.
Not Applicable

Ref. Transport Canada Recall No.
Not Applicable

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
ITS60853

Contents
1.

SAFETY PROCEDURE ......................................................................................................................................3

2.

PROCEDURE: ....................................................................................................................................................4

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INSTRUCTION TO SERVICE
ITS60853

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
(Appendix A) when completing installation or service work on high voltage power cables.

Figure 1: Lockout tagout location reference

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INSTRUCTION TO SERVICE
ITS60853

2. PROCEDURE:
2.1. Locate the DC link distribution box at the rear engine compartment.
2.2. Open the distribution box cover by removing 7 allen screw 835908

2.3. Remove the nut/nuts P/N 75NM05000 fastened to the ground studs of the fuse box as shown in Figure 1
Note: some box configurations might have 1 or 2 nuts

Figure 1 - Fuse box ground studs

2.4. Remove one end of ASSY-RR FUSEBOX GND P/N 859640 and other ground wires connected to the
ground studs.

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INSTRUCTION TO SERVICE
ITS60853

2.5. Install ASSY-WELD FUSEBOX GND P/N 1048317 and ground wires to the ground studs of the fuse box
using the nuts that were removed in step 2.4, as shown in Figure 2. install a new nut P/N 75NM05000 if
only one nut was removed in step 2.

Figure 2 - New ground bracket

2.6. use nut P/N 75NM05000 to fasten the loose end of ASSY-RR FUSEBOX GND wire P/N 859640 to the
ground stud of ASSY-WELD FUSEBOX GND P/N 1048317. Orient the terminal end of the wire so that it
is parallel to the cover of the fuse box as shown in Figure 2.

2.7. Torque the three nuts P/N 75NM05000 to 3.7 n-m (32 in-lbs).

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INSTRUCTION TO SERVICE
ITS60853

2.8. Loosen the nut P/N 75NM05000 on the cover end of ASSY-RR FUSEBOX GND. Re-orient the terminal
of the ground wire so that it is at 45 deg with the horizontal/bottom of the box as shown in figure 3.
Tighten and torque nut P/N 75NM05000 to 3.7 n-m (32 in-lbs).

Figure 3 - Ground connection to box cover

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INSTRUCTION TO SERVICE
ITS60853

LABOUR ESTIMATE
Operation
1

REWORK-ENG DC LINK DIST BOX ELFA3

Number of
Technician(s)
1

Hours
2

Labor Time
T X HR
2

PARTS REQUIRED

Item

Part Number

Description

1

75NM05000

NUT-M5X0.80 FLG CL10.9 ZN-NI

2

1048317

ASSY-WELD FUSEBOX GND

Qty.
per
Coach
2

Units

1

EA

Notes

EA

3
4
5
6
7
8
9

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October 30, 2023