WARNING

FOLLOW YOUR INTERNAL SAFETY PROCEDURES.

WARNING

This vehicle has an electrochemical power storage device composed of high-voltage (HV) batteries and
cables that can cause fatal electric shock or chemical burns, and damage to the vehicle. It is the customer’s
responsibility to read the manufacturer’s documentation to be aware of the risks associated with the system.
It is required to decommission and lock out the vehicle according to section 16: high-voltage electrical
system in the maintenance manual before working on the high-voltage system or in the high risk and
potential risk zones. As well, follow any transit authority, local, provincial/state, or federal safety procedures
should these take precedence.

WARNING

For lock out and decommission, see your maintenance manual setion 16, LFSE+ High Voltage Decommissioning
and manufacturer documentation for more information.

PAGE 3 OF 11
NQF772001 version 5

SERVICE BULLETIN

BS5438E

NOTE

The configuration of your vehicle may differ from that shown in this
document. Use only the parts required.

PROCEDURE
1.1.
1.2.

Park the vehicle on an even surface with the transmission on neutral.
Proceed to LOCK OUT and HIGH VOLTAGE DECOMMISSIONING of the vehicle.
WARNING

Follow the LFSE+ lock out and decommission procedure in your maintenance manual, section 16,
LFSE+ High Voltage Decommissioning.

1.3.

Locate the MPCS in the engine compartment (Figure 1).

Figure 1 - MPCS in the Engine Compartment

PAGE 4 OF 11
NQF772001 version 5

SERVICE BULLETIN

HVM
LV1

EM1-1

EM2-1
FM1-1

HV2
Motor

BS5438E

EM1-2

EM2-2

EM1-3

EM2-3

FM1-2

EM1-4

EM2-4

FM1-3

LV5

HV1

Figure 2 - MPCS - Connectors Position

EXISTING STRAIN RELIEF BRACKETS REMOVAL
1.4.

1.5.

Disconnect the HV cables at the positions shown in Figure 3.
a. Starting with the first row from the top, unscrew the HV cable twin clamps locknuts. Remove the twin
clamp cover plates and clamp top parts. Clean torque seal on cover plates. Keep cover plates and clamp
top parts. Discard locknuts.
b. Disconnect HV cables. Keep the bottom part of the twin clamps.
c. Unscrew the screws and remove the T-bracket and the L-bracket (Figure 4). Discard brackets, screws
and washers.
d. Repeat previous steps until the last row. Note: there are 2 types of twin clamp, see Figure 12 for detail.
Unscrew the screws and remove the second and third vertical strain relief brackets (Figure 4). Discard
brackets, screws and washers.

Figure 3 - Position of HV Cables to be Remove

PAGE 5 OF 11
NQF772001 version 5

SERVICE BULLETIN
1.6.

BS5438E

Remove the first vertical strain relief bracket (Figures 4, 5).
a. Unscrew the 2 single clamps locknuts to free the HV2 cable. Keep the single clamps. Discard screws
and locknuts.
b. Cut the cable tie securing the LV5 cable. Discard.
c. Open the HV1 cable twin clamp and remove. Keep the twin clamp and the cover plate. Discard the screw
and the locknut.
d. Unscrew screws and remove the third vertical strain relief bracket. Discard the bracket, screws and washers.
#1 Vertical Strain
Relief Bracket

#2 and #3 Vertical
Strain Relief Brackets

T-Brackets

L-Brackets

Figure 4 - Strain Relief Brackets to Remove

#1 Vertical Strain Relief
Bracket

HV2 Cable and
Single clamps

LV5 Cable and
cable tie

HV1 Cable and
Twin Clamp

Figure 5 - Strain Relief Bracket to Remove
PAGE 6 OF 11
NQF772001 version 5

SERVICE BULLETIN
1.7.

BS5438E

At the left end of the MPCS, remove any cables tie that might secure the LV1 cable to the first motor HV
cable (Figure 6).

Cable Tie with
Swivel

Figure 6 - Cable tie to Remove

NEW STRAIN RELIEF BRACKETS INSTALLATION

N107896 1x

N0073103 x8
N0113049 x8

N107965 x1

N107894 x8
N0073088 x10
N44887 x10

N44881-05 x1
N44887 x1
N109411 x1

N57807 x2

N0073004 x1
N44887 x1
N107959 x2
N0073088 x4
N44887 x4
Figure 7 - New Components Overview
PAGE 7 OF 11
NQF772001 version 5

SERVICE BULLETIN

BS5438E

1.8.

Install the 2 new vertical strain relief brackets N107896 and N107965 on the MPCS with 8 new screws
N0073103 and 8 new Belleville washers N0113049 (Figures 7, 8). Torque each screw at 12 lb-ft (16 N•m).
Apply torque seal.

1.9.

Secure the HV1 cable to the new installed bracket N107896 with the removed twin clamp, its cover plate, 1
new flange screw N0073004 and 1 new locknut N44887 (Figures 7, 8). Torque at 35.4 ±3.5 lb-in (4 ±0.4 N•m).
Apply torque seal.

1.10.

Install the new strain relief bracket N109411 (Figure 9).
a. Unscrew the 2 HV cable clamp screws. Clean torque seal on screw heads and on top of the clamp.

1.11.
1.12.
1.13.

b. Install the new strain relief bracket N109411 on top of the clamp with the 2 removed screws. Torque screws
at 15 ±0.3 lb-ft (20 ±0.5 N•m). Apply torque seal.
Secure the LV1 cable to the new installed bracket N109441 with a new mount fir tree cable tie N57807
(Figures 2, 10).
Secure the LV5 cable to the new installed bracket N109411 with 1 new mount fir tree cable tie N57807.
Secure the HV2 cable to the new installed bracket N109411 with the 2 existing single clamps, 1 new flange
screw N44881-05 and 1 new locknut. Torque at 35.4 ±3.5 lb-in (4 ±0.4 N•m). Apply torque seal.
8x Screw N0073103
8x Belleville Washer N0013049
Strain Relief Bracket
N107896

Strain Relief Bracket
N107965

Screw N0073004
Locknut N44887

Figure 8 - New Strain Relief Brackets Installation

PAGE 8 OF 11
NQF772001 version 5

SERVICE BULLETIN

Clamp screws to
remove

BS5438E

Strain Relief
Bracket N109411

Figure 9 - Screws to Remove for the New Strain Relief Bracket Installation

HV2 Cable
1x Screw N44881-05
1x Locknut N44887
2x Existing Single Clamp

LV1 Cable

LV5 Cable

1x Mount Fir Tree Cable Tie N57807

1x Mount Fir Tree Cable Tie N57807

Figure 10 - Securing Cables with the New Strain Relief Bracket N109411

PAGE 9 OF 11
NQF772001 version 5

SERVICE BULLETIN
1.14.

BS5438E

Reconnect the HV cables (refer to Figures 7, 11, 12 and 13).
a. At the bottom row, install 1 new strain relief bracket N107959 with 2 new flange screws N0073088 and 2
new locknuts N44887. Torque each screws at 15 ±0.3 lb-ft (20 ±0.5 N•m). Apply torque seal.
b. Install the bottom part of a removed UHMW twin clamp. Connect the HV cable and secure with the top
part of the UHMW twin clamp and 1 new locknut N44887. Torque the locknut at 53 ±5 lb-in (6 ±0.6 N•m).
Apply torque seal.
c. On the third row, install 1 new strain relief bracket N107959 and 2 new strain relief brackets N107894 with
new flange screws N0073088 and new locknuts N44887. Torque each screws at 15 ±0.3 lb-ft (20 ±0.5 N•m).
Apply torque seal.
d. On the new bracket N107959, install the second bottom part of a removed UHMW twin clamp. Connect
the HV cable and secure with the top part of the UHMW twin clamp and 1 new locknut N44887. Torque
the locknut at 53 ±5 lb-in (6 ±0.6 N•m). Apply torque seal.
e. On the 2 new brackets N107894, install the bottom part of a removed twin clamp. Connect the HV cable
and secure with the top part of the twin clamp, the cover plate and 1 new locknut N44887. Torque the
locknuts at 35.4 ±3.5 lb-in (4 ±0.4 N•m). Apply torque seal.
f. Proceed the same way for the second and first row:
i. Install 3 new strain relief brackets N107894 with new flange screws N0073088 and new locknuts
N44887. Torque each screws at 15 ±0.3 lb-ft (20 ±0.5 N•m). Apply torque seal.
ii. Install the bottom part of a removed twin clamp. Connect the HV cable and secure with the top part
of the twin clamp, the cover plate and 1 new locknut N44887. Torque the locknuts at 35.4 ±3.5 lb-in
(4 ±0.4 N•m). Apply torque seal.
1x Bracket N107894
2x Screw N0073088
2x Locknut N44887

1x Bracket N107959
2x Screw N0073088
2x Locknut N44887

Figure 11 - Strain Relief Brackets Installation for HV Cables

PAGE 10 OF 11
NQF772001 version 5

SERVICE BULLETIN

BS5438E

Torque
35.4 ±3.5 lb-in
(4 ±0.4 N•m)
Cover Plate
Top
Twin Clamp

Bottom

Torque 53 ±5 lb-in
(6 ±0.6 N•m)

Top

UHMW
Twin Clamp

Bottom

Figure 12 - Twin Clamp Types and Positions

Figure 13 - HV Cables all Connected

1.15.

Proceed to UNLOCK and HIGH VOLTAGE COMMISSIONING of the vehicle.

1.16.

The vehicle can return in service.

PAGE 11 OF 11
NQF772001 version 5