INSTRUCTION TO SERVICE
ITS: 61338

May 25, 2025

SECTION:

260-BATTERY COMPARTMENT

SUBJECT:

REWORK-HV DC CNTCR 250A

ISSUE:

Contactors mounted incorrectly causing 250A fuse fail

SUMMARY:

Updated HV DC charge box contactors to replace the existing GIGAVAC with
new RINCON contactor. The main advantages are:
1. Bi-directional power switching instead on one direction

ITS61338
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
ITS61338

Contents
INSTRUCTION TO SERVICE ....................................................................................................................................1
1.

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

Rework Instructions: ...................................................................................................................................................4

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WARNING:



1.

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:
This rework is to be performed only by personnel who have successfully completed the new flyer high
voltage safety training and with the necessary personal protective equipment.
High voltage safety guidelines & procedures P/N 532295 must be followed when completing installation .

SAFETY PROCEDURE
1.1.
1.2.
1.3.
1.4.

Turn the master run switch to the off position and wait 5 minutes before proceeding.
Turn the 12/24V battery disconnect and HV Interlock switch to the “OFF” position.
Lock and tag the electrical system of the bus out and retain the key. See Figure 1.
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
when completing installation or service work on high voltage power cables.

Figure 1: Lockout tagout location reference

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INSTRUCTION TO SERVICE
ITS61338
2.

Rework Instructions:

2.1. Locate and gain access the HV DC contactor box on the roof as shown. See Figure 1.

NOTE: Use fall protection and PPE.

Figure 1 - Rework location reference.

2.2. Remove the lid mounting hardware on the HV DC contactor box and set aside. See Figure 2.
2.3. Ensure no voltage is present before proceeding.
Remove Lid
and Hardware

Figure 2 - POS and NEG HV cable connection location reference.

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2.4. There will be two types of boxes for XE-35 and XE-40 foot as per Figure 3.

Figure 3 - Box 911118_F vs 980566_B

2.5. Access the HV DC contactor box and remove the two contactors LV connectors.
2.6. Disconnect the mating connector of the LV harness from that of the positive GIGAVAC contactors (see figure
4).
2.7. Unscrew the two M8 nuts mounting the busbars at both ends of the positive GIGAVAC 250A contactor (see
figure 4).
2.8. Unscrew the two socket head cap screws mounting the GIGAVAC contactor to the base of the box and
remove the contactor (see figure 4).

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Socket
M8

Figure 4 - Contactors Mounting screws

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2.9. Install supplied 1117873 Assy-contactor Rincon 600A (Item 1) at the location where the GIGAVAC contactor
was removed in step 2.8 using the same hardware.
3. Tighten the busbar in step 2.7 to both ends of the Rincon contactor using existing hardware (refer to figure 5).
3.1. Mate the LV harness connector disconnected in step 2.6 to that of Rincon contactors.

Figure 5 - New contactor installation

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LABOUR ESTIMATE
Operation
1

Number of
Technician(s)
1

REWORK - HV DC CNTCR 250A

Hours
2

Labor Time
T X HR
2

PARTS REQUIRED
Item

Part Number

Description

1

1117873

ASSY-CONTACTOR RINCON 600A

Qty.
per
Coach
1

Units

Notes

EA

2
3
4
5
6
7
8
9
10
11
12

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