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.

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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.

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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.

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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.

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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.

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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.

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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.

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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