NHTSA ID Number: 11032602
Manufacturer Communication Number: ITS61712
TSB/Document Date: 2026-05-13
Summary
This ITS provides instructions on how to replace the air intake assembly on certain fuel cells. This is required due to the air filter
for the original intake has been obsoleted by the supplier.
INSTRUCTION TO SERVICE
ITS: 61712
DATE 5/04/2026
SECTION:
219U – Propulsion Drive
SUBJECT:
Replace Fuel cell Air intake assembly
ISSUE:
Ballard obsoleted current Air filter assembly
SUMMARY:
Air filter obsoleted by Ballard, to accommodate new Air filter, filter housing
needs to be changed.
ITS61712
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
ITS61712
PROCEDURE:
Only trained personnel shall supervise and perform the High Voltage system testing,
servicing and troubleshooting contained in this procedure.
1.
2.
3.
4.
5.
6.
Ensure to apply the parking brake.
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.
Ensure to the wear proper PPE.
Install a Lockout/Tagout Steering wheel cover as required.
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
(Appendix A) when completing installation or service work on high voltage power cables.
Figure 1: Lockout Tagout location reference.
ITS61712
Page 2 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
Removal
7. Open rear fuel cell access door and gain access to fuel cell air intake system shown below. See figure 2.
Figure 2: FC Air intake system location reference
ITS61712
Page 3 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
8. Loosen the two clamps from each sleeve located at the base of the vertical air intake tube and FC vent intake
tube. See figure 3.
9. Remove hardware from saddle clamps and set aside for reinstallation. See figure 3.
FC vent
intake tube
Air intake tube
Sleeve
Sleeve
Loosen
Clamps
Loosen
Clamps
Remove
Saddle clamp
Hardware
Figure 3: Sleeve and saddle clamp location reference
ITS61712
Page 4 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
10. Loosen the clamp on the elbow on the outlet of the FC air intake tube and FC vent tube. See figure 4.
11. Turn off H2 fuel valve and remove hardware from H2 fuel hose support bracket as shown below and set aside
for reinstallation. See figure 5.
Loose
Clamp
Figure 4: FC outlet location reference
Turn OFF
valve
H2 fuel hose
to fuel cell
Remove
Hardware
Figure 5: H2 fuel hose location reference
ITS61712
Page 5 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
12. Remove the sleeves, clamps, reducer elbow, and tubes from the air intake tube, vent tube and immediately
tape both elbow at end of vent tube and intake tube to prevent entry of contaminants. set clamps and sleeves
aside for reinstallation. See figure 6.
Remove Air
intake tube
Remove sleeve
and Clamps
Remove tube
and Tape elbows
Remove
Vent
Tubes
Reducer
elbow
Remove FC
Air intake tube
Figure 6: Air intake and vent tube location reference
ITS61712
Page 6 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
13. Remove the bolts and washers from the air filter mounting brackets on the side of the air cleaner assembly.
See figure 7.
14. Carefully support the air cleaner assembly and remove from the vehicle.
15. Remove rest of hardware from air intake mounting bracket including air intake and vent tube support bracket,
set aside for reinstallation. Remove air intake bracket from the vehicle.
Remove
hardware
Remove
hardware
Remove
hardware
Figure 7: Air filter mounting and tube support bracket location reference
ITS61712
Page 7 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
Installation:
16. Inspect and clean the vertical intake pipe and vent pipe.
17. Install new mounting bracket on to rear FC mounting structure and secure as shown below. See figure 8.
New Mounting
BRKT PN
1125038
NEW BOLT P/N
10B04014
TORQUE TO 12 FT-LBS
Figure 8: Air filter mounting bracket location reference
ITS61712
Page 8 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
18. Install new air filter assembly along with new air intake tubes and secure it using existing clamps as shown
below. See figure 9.
19. Remove tape from elbow and secure FC air intake tube using same support bracket and hardware. See figure
9.
TORQUE CLAMP
TO 110 IN-LBS DRY
AT 75 RPM.
NEW TUBE
P/N 1124967
TORQUE CLAMP
110 IN-LBS DRY
AT 75 RPM
NEW AIR FILTER
ASSEMBLY
P/N 1115895
NEW ELBOW REDUCER
FROM 6” TO 4”
P/N 1119925
NEW BOLT P/N 10B05028
NEW WASHER P/N 10W05000
NEW NUT P/N 40N05000
TORQUE TO 12 FT-LBS
NEW CLAMP
P/N 113587
TORQUE TO
35 IN-LBS DRY
TORQUE
CLAMP TO
35 IN-LBS DRY
TORQUE
CLAMPS TO
110 IN-LBS
DRY
Existing Elbow
reducer
TORQUE
CLAMP TO
110 IN-LBS
DRY
Existing support
BRKT and hardware
NEW TUBE ASSEMBLY
PN 1125261
TORQUE TO 12 FT-LBS
Figure 9: Air filter and intake tube location reference
ITS61712
Page 9 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
20. Remove tape from the elbow and Install new FC vent tube, secure using clamps and torque as shown below.
See figure 10.
21. Reinstall saddle clamp on Air intake and vent tube using existing hardware. See figure 10.
Reinstall
Saddle
clamps
TORQUE
CLAMP TO 110
IN-LBS DRY
AT 75 RPM.
NEW TUBE
ASSEMBLY
P/N 1125097
TORQUE
CLAMPS TO
110 IN-LBS DRY
TORQUE TO
10 FT-LBS
CURRENT TUBE
P/N 1002514
Existing support
BRKT and hardware
TORQUE TO 12 FT-LBS
Figure 10: FC vent tube location reference
ITS61712
Page 10 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
22. Reinstall H2 fuel hose on vent tube bracket using existing hardware and apply 1-2 drops of Loctite-243 PN
081034 to the threads. Turn valve to ON position. See figure 11.
23. Clean up all tools and debris. close access door and return bus to service condition.
Turn valve
ON position
H2 Fuel
hose to Fuel
cell
Reinstall hardware
and apply 1-2 drop of
Loctite
Figure 11: H2 fuel hose location reference
ITS61712
Page 11 of 12
May 04,2026
INSTRUCTION TO SERVICE
ITS61712
LABOUR ESTIMATE
Operation
1
Number of
Technician(s)
1
Replace FC Air intake assembly
Hours
2
Labor Time
T X HR
2
PARTS REQUIRED
Qty.
per
Coach
Item
Part Number
Description
1
1125261
ASSY-TUBE AIR INTAKE FC
2
1125097
ASSY-WELD FC VENT TUBE
3
1125038
WELD-AIR FILTER BRACKET
4
1124967
TUBE-AIR INTAKE
5
1119925
ELBOW-REDUCER FC AIR INTAKE
6
1115895
ASSY-AIR FILTER FUEL CELL
7
113587
CLAMP-BREEZE 6.25"-7.13"
8
40N05000
NUT LOCK NYLON 5/16"
9
10W05000
WASHER-FLAT 5/16
10
10B05028
BOLT-HEX 5/16 UNC x 1.75
11
10B04014
BOLT-HEX 1/4 UNC x 0.88
12
081034
LOCTITE-243 MEDIUM 10ML
1
1
1
1
1
1
1
4
8
4
4
0.010
Units
Notes
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
SPECIAL TOOLS REQUIRED
Item
ITS61712
Part Number
Qty.
Description
Page 12 of 12
Units
Notes
May 04,2026
- DESIGNED TO EXCEED EXPECTATIONS: Red Line complete SI-1 fuel...
- PERFORM AND PROTECT: Fuel additive cleans injectors...
- EFFICIENT FUEL BURN: A gas treatment that enhances gasoline...
- EASY TO USE: Use one bottle of Redline Fuel System Cleaner...
- ENAHNCED ENGINE EFFCIENCY: Experience improved fuel economy...
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TSB/Document ID: ITS61712
Replacement Service Bulletin Number:
MFR Communication Date: 2026-05-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL/PROPULSION SYSTEM
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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