ITS60838 Service Bulletin/Repair Instructions

INSTRUCTION TO SERVICE

ITS: 60838
DATE 10/27/2023
SECTION:
260U – Battery Compartment
WRITTEN BY:
Daniel Tice
SUBJECT:
Fuse Box Mounting Hardware Replacement.
ISSUE:
Potential for Loose Fuse Box Mounting Hardware.
SUMMARY:
Replace and Torque Fuse Box mounting Hardware.
ITS60838

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

ITS60838
PROCEDURE:

1. Turn the main battery disconnect switch to the “OFF” position.

2. Disconnect battery cables providing power to the fuse box.

3. Gain access to fuse box located on the curb side rear of the bus. See Figure 1.

Open Fuse Box Door
Figure 1: Curb side fuse box location reference.
ITS60838
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October 27,2023
INSTRUCTION TO SERVICE

ITS60838
4. Based on the fuse box assembly configuration to gain access to the mounting hardware removal of the

circuit breaker bracket assembly may be required. As required remove the circuit breaker bracket assembly

mounting hardware and set aside for re-installation. See Figure 2.

5. Move the circuit breaker bracket assembly out of the way to gain access to the fuse box upper mounting

hardware in locations #1 and #2 and remove and discard the hardware. See Figure 2.

Remove Mounting

Hardware and

Discard
Remove CB Bracket Assembly

Mounting Hardware
Figure 2: Fuse box circuit breaker bracket assembly location reference.
ITS60838
Page 3 of 9
October 27,2023
INSTRUCTION TO SERVICE

ITS60838
6. Locate item #7 upper fuse box bracket and apply item #3 Sika sealer around the upper studs and fuse box

plate mounting holes to seal them. Secure in place with items #6 Washers and item #5 Nuts applying one

or two drops of item #1 Loctite. Do not fully tighten. See Figure 3.

Note: Leave fuse box upper mounting loose until remaining hardware location are in place.
3,7
5,6,1
Item
Part Number
Description
1
081034
LOCTITE-243 MEDIUM 10ML
3
242702
ADHESIVE-SIKA 221 WHITE
5
50N06000
NUT SST 3/8 UNC
6
50W06000
WASHER FLAT SS 3/8 NOM
7
985180
PLATE-FUSEBOX MOUNTING UPPER
Figure 3: Upper fuse box mounting plate #1 & #2 location reference.
ITS60838
Page 4 of 9
October 27,2023
INSTRUCTION TO SERVICE

ITS60838
7. Remove the hardware in positions #3 and #4 and discard. See Figure 4.
Remove Mounting

Hardware and

Discard
Figure 4: Lower fuse box mounting hardware location reference.
ITS60838
Page 5 of 9
October 27,2023
INSTRUCTION TO SERVICE

ITS60838
Note: Mounting hardware is different in both lower mounting locations #3 and #4.

8. Locate new bolt item #2 and qty two of item #6 washers and item #8 lower fuse box mounting plates.

9. Apply item #3 Sika sealer around each plate to be installed on the inside and outside of the box in #4 rear

mounting hole location as needed to seal the hole. See Figure 5.

10. Install #2 bolt, #6 washer and #8 plate on the inside and secure with #8 plate, #6 washer and item #4 nut

on the outside. See Figure 5.

Note: Item #8 plates may be rotated for best fitment.

Note: Leave loose until remaining hardware location are in place.
Inside View Position #4
Outside View Position #4
Item
Part Number
Description
2
20B06024
BOLT SST 3/8 UNC x 1.5 LG
3
242702
ADHESIVE-SIKA 221 WHITE
4
42N06000
NUT-3/8-16 UNC NYLON LOCK SST
6
50W06000
WASHER FLAT SS 3/8 NOM
8
985831
PLATE-FUSEBOX MOUNTING LOWER
Figure 5: Lower rear fuse box mounting plate #4 location reference.
ITS60838
Page 6 of 9
October 27,2023
INSTRUCTION TO SERVICE

ITS60838
11. Locate item #9 fully threaded bolt, three of item #6 washers, one of #8 lower fuse box mounting plates and

one of item #10 outer fuse box mounting plate.

12. Apply item #3 Sika sealer around plate item #8 to be installed on the inside and #10 for the outside of the

box in #3 mounting hole location as needed to seal the hole. See Figure 6.

13. Install #9 bolt, #6 washer and #8 plate on the inside place item #10 outer fuse box mounting plate on the

outside and secure with #5 nut on the outside applying one or two drops of item #1 Loctite. Torque to 22

FT-LBS. See Figure 6.

Note: Item #8 plates may be rotated for best fitment.

14. Install item #6 washer on top of item #5 nut after torquing. Place the DEF tank shield over the bolt and

install another item #6 washer and item #4 nut on the bolt. Hold #9 bolt on the inside of the fuse box and

torque #4 nut to 22 FT-LBS. See Figure 6.

15. Once complete go back and torque positions #1, #2 and #3 to 22 FT-LBS.
Inside View Position #3
Side View Position #3
Item
Part Number
Description
1
081034
LOCTITE-243 MEDIUM 10ML
3
242702
ADHESIVE-SIKA 221 WHITE
4
42N06000
NUT-3/8-16 UNC NYLON LOCK SST
5
50N06000
NUT SST 3/8 UNC
6
50W06000
WASHER FLAT SS 3/8 NOM
8
985831
PLATE-FUSEBOX MOUNTING LOWER
9
1001266
BOLT SST 3/8-16 1.75 FULL THREAD
10
1001231
PLATE FUSE BOX MOUNTING OUTER
Figure 6: Lower front fuse box mounting plate #3 location reference.
ITS60838
Page 7 of 9
October 27,2023
INSTRUCTION TO SERVICE

ITS60838
16. Re-install the circuit breaker bracket assembly using the existing hardware. Apply one or two drops of item

#1 Loctite where locking nuts are not used. Figure 7.

17. Re-install battery terminals to the batteries torquing hardware to 15 FT-LBS and apply torque marks.

18. Remove all tools and debris and close and secure the fuse box door.

19. Turn the main battery disconnect switch to the “ON” position and return to service.
Item
Part Number
Description
1
081034
LOCTITE-243 MEDIUM 10ML
Figure 7: Fuse box circuit breaker bracket assembly location reference.
ITS60838
Page 8 of 9
October 27,2023
INSTRUCTION TO SERVICE

ITS60838
LABOUR ESTIMATE

Operation

1
Replace fuse box mounting hardware and add mounting plates.
Number of

Technician(s)

1
Hours

1.5
Labor Time

T X HR

1.5
PARTS REQUIRED

Qty.

per

Coach
Item
Part Number
Description
1
081034
LOCTITE-243 MEDIUM 10ML
2
20B06024
BOLT SST 3/8 UNC x 1.5 LG
3
242702
ADHESIVE-SIKA 221 WHITE
4
42N06000
NUT-3/8-16 UNC NYLON LOCK SST
5
50N06000
NUT SST 3/8 UNC
6
50W06000
WASHER FLAT SS 3/8 NOM
7
985180
PLATE-FUSEBOX MOUNTING UPPER
8
985831
PLATE-FUSEBOX MOUNTING LOWER
9
1001266
BOLT SST 3/8-16 1.75 FULL THREAD
10
1001231
PLATE FUSE BOX MOUNTING OUTER
0.010

1

0.010

2

3

7

1

3

1

1
Units
Notes
EA

EA

EA

EA

EA

EA

EA

EA

EA

EA
SPECIAL TOOLS REQUIRED
Item
ITS60838
Part Number
Qty.
Description
Page 9 of 9
Units
Notes
October 27,2023

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