INSTRUCTION TO SERVICE

ITS61009
SECTION:
SUBJECT:
ISSUE:

SUMMARY:

May 01, 2024
260-BATTERY COMPARTMENT
CORRECT ORIENTATION AND TERMINATION OF NEG
CONTACTOR IN RR HV FUSE BOX
WRONG CONTACTOR TERMINATION CAUSING
OVERHEATING AND FAILURE OF CONTACTORS AND BUS
BAR INSULATION
BOM UPDATED WITH CORRECT ORIENTATION OF +A1 AND A2 CONTACTOR TERMINALS. REQUIRES CORRECTION IN THE
FIELD

ITS61009
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
ITS61009

Contents:
1. SAFETY PROCDEURE………………………………………………….3
2. REWORK PROCDEURE…………………………………………………4

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INSTRUCTION TO SERVICE
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SAFETY PROCEDURE:
1. Turn the MRS to the off position and wait 5 minutes before proceeding to the next step.
2. Turn the main battery disconnect and HV interlock switch to the “OFF” position.
3. Perform the Lock Out Tag Out procedure.
4. Perform the applicable de-energizing procedure before moving to the next step in this ITS
NOTE: Refer to the Lockout/Tagout Procedure and De-Energizing Procedures in section 9 of the
New Flyer Service Manual.
NOTE: Use commercially available lock out equipment and tags being sure to follow any local laws
or workplace procedures.

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INSTRUCTION TO SERVICE
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REWORK PROCEDURE:

5. Open the engine door to get access to rear HV fuse box
6. Unscrew the 4 screws holding the front cover and remove the front cover
7. Locate the Negative Contactor at the bottom right of the rear inverter rack as marked in fig. 2
below.

Fig 2: Rear HV Fuse Box
8. Use 13 mm socket to remove the nuts on both the contactor end of the upper bus bar
(PN:810776) and on ASSY-BUSBAR NEG CS (PN:822545)
9. Use 13 mm socket to remove the nuts on the contactor end of the lower bus bar (PN:825840) and
10mm socket for the nut on the other end of the bus bar.
10. Remove the M5-0.80 bolts holding the contactor and visually confirm the +A1 and A2- terminal
markings on the contactor as shown in Fig 3 below.

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INSTRUCTION TO SERVICE
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Fig 3: +A1 and A2- markings on the contactor terminals
11. Re-install the contactor so that its A1+ terminal is at the top while A2- terminal is below (see fig
4) and refasten the contactor to the Fuse Box chassis using the M5-0.80 bolts with a torque of 3.7
Nm.
12. Fasten the busbar (PN:810776) to the A1 terminal of the contactor at 10Nm and the other end of
the same bus bar on the ASSY-BUSBAR NEG CS (PN:822545) at 16 Nm torque.

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INSTRUCTION TO SERVICE
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Fig 4: Negative DC Contactor terminal orientation
13. Fasten the second busbar (PN:825840) to the A2- terminal of the contactor with a torque of
10Nm and its other end to Neg Receptacle Powerlock (PN822453)
14. Perform visual check to ensure the fuse box is closed with no debris, tools etc.
15. Reinstall the RR HV fuse box cover.
16. Remove the lockout/tagout from 12/24-volt Battery Disconnect switch and set the switch to the
ON position.
17. Set the Master Run switch to DAY-RUN or NIGHT-RUN position.

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INSTRUCTION TO SERVICE
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LABOUR ESTIMATE
Operation
1

Re-Orientation and termination of DC Contactor

Number of
Technician(s)
1

Hours
1

Labor Time
T X HR
1

in RR HV Fuse Box

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May 1, 2024