FT5294E

FT5294
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REFERENCE:
Nova Bus Manuals
SECTION:
09: Engine and Cooling
RS NO:
MQR 7621-2444
APPLICATION DEADLINE: 2024FE10
CLAIM REFERENCE NUMBER: WB5294
EFFECTIVE IN PROD.: LE88 (2023FE)
SUBJECT:
Powerex Electrical Air Compressor
JUSTIFICATION:
Upgrading NB04 junction box to prevent wire chafing and improve wire securement.
LEVEL
1
DIRECT CHARGES
DESCRIPTION
Inspect wires in NB04 junction box, add ferrules and heat shrink
over wire if needed. Add bracket and clamp to secure cable.
2
TIME
LABOUR
MATERIAL
Nova Bus
Nova Bus
3.5 h
–
–
–
–
MATERIAL REQUIRED PER VEHICLE
QTY
PART NO
REV.
DESCRIPTION
N8951223-BS
–
Powerex Retrofit Kit (ST981196AJ)
N8951224-BS
–
Electrical Tape (ST922032AV)
1 roll = 30 buses*
LEVEL 1
1
LEVEL 2
0.03
*WHEN YOU ORDER, SPECIFY THE NUMBER OF VEHICLES TO REPAIR.
Materials will be available within 37 days once your order has been placed.
To order, please contact [email protected]
Or by phone for CANADA 1-800-771-6682, for USA 1-877-999-8808
Specify document number, quantity of parts required and shipping address.
DISPOSAL OF PARTS
REMOVED PARTS ARE:
DISCARDED
*
RETAINED
Yes
–
* Dispose of the unused parts and the defective parts in
accordance with local environmental standards in effect.
REVISION HISTORY
REV.
DATE
NR
2023JA26
APPROVED BY:
NQF772004 VERSION 3
CHANGE DESCRIPTION
Initial release
WRITTEN BY
Annie St-Jacques
PAGE 1 OF 12
FT5294
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CLIENT
ORDER
ROAD NUMBER
VIN (2NVY/4RKY...)
FROM
TO
FROM
TO
QTY
New York City Transit New York - NYCT
LC78
9620
—
L82L4L9777581
L82L6L9777582
2
New York City Transit New York - NYCT
LC79
9623
9784
L82L1M9777782
L82L4M9777954
162
New York City Transit New York - NYCT Demo
LD23
—
9621
L82LXL9777634
L82L5L9777668
3
New York City Transit New York - NYCT
LD64
9785
9910
L82L0M9777871
L82L1M9778155
126
PAGE 2 OF 12
NQF772004 VERSION 3
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FT5294
WARNING
FOLLOW YOUR INTERNAL SAFETY PROCEDURES.
WARNING
This vehicle has an electrochemical power storage device and high-voltage cables that can cause fatal electric
shock and damage to the bus. It is the customer’s responsibility to read and understand the risks associated with
the maintenance, replacement, or repair of any particular system’s components. See your maintenance manual
section 16: LFS-e High Voltage Electrical System.
WARNING
Decommissioning, locking out the vehicle and using signage is mandatory when working on the high
voltage components. This prevents accidental reapplication of voltage and protects maintenance personnel
who may be called upon to work on high-voltage electrical connections. See your maintenance manual
section 16: LFS-e High Voltage Electrical System.
WARNING
Follow the Commissioning procedure from your maintenance manual section 16: LFS-e High Voltage Electrical
System.
NOTE
The following procedure is provided by Powerex. Nova Bus cannot be held responsible for its content.
PAGE 3 OF 12
NQF772004 VERSION 3
6/20/2022
3/3/2022
Russell Winfree
Operation:
Supervisor
Signature:
NB04 Rework
Rev #
Dept. manager
Signature:
NQF772004 VERSION 3
Reference Image
1
Remove the Junction box cover. Locate
terminal block (ST198600AV) in middle
of junction box.
5
Determine if harness is loose by moving
cable back and forth. If loose, conduit
nut will need to be tightened using 3/4
spanner wrench.
3
Make sure bus battery and power have
been disconnected and Lock out Tag out
procedures are being used.
Step Number and Instruction
Page 1 of 9
Reference Image
2
3
6
SAFETY NOTE: Before continuing, use
electrical safety gloves and a voltmeter to
verify that there is ZERO voltage in the
junction box.
4
Remove x4 junction box cover screws using
a T-15 torx driver. *Retain 2 of these screws
for re-install later*
Panel needs to be removed for access to
junction box. Loosen bolts and unhook
panel.
Step Number and Instruction
Model:
Area: Transportation
Document number: EC#: PXEC0500
SDCHS050020NB04 / N99055
Document Location: M:\QUALITY\Powerex Work Instructions\MTJ\Transportation\Nova Bus
Location: Mt. Juliet
Comments: Instructions for upgrading NB04 junction box to prevent wire chafing and improve wire securement.
(*at the request of NYCT Authority) . **Latest update to add in safety step for checking voltage once more at junction box.
Created By:
Implemented
Revised Date:
Nova Bus NB04 Junction Box Rework Work Instruction
PEC-39
Rev 10/17/2017
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FT5294
PAGE 4 OF 12
NQF772004 VERSION 3
Ferrule
Reference Image
7
Cut off uninsulated end of wire and restrip ~1/2". Insert bare wire ends into
ferrule connector (ST207300AV).
13
Remove x1 set screw (with flathead screw
driver) in terminal block for x1 set of dual
wires running into terminal block (Perform
one-at-a-time to prevent miswire
condition). Inspect motor wires for damage.
Retain hardware. Note: to re-install follow
wiring diagram on page 6.
11
Remove spiral loom from around motor
wiring.
9
Loosen 3 set screws with a flat head screwdriver
on the top side of the terminal block (incoming
power cable wires). Remove 1 bolt (using 5/16
nut driver) holding terminal block. Retain all
hardware.
Step Number and Instruction
Page 2 of 9
Reference Image
8
3
14
Crimp ferrule connector to secure wires
with Weidmuller PZ 10 Hex Crimp Pliers
12
Inspect motor wires for damage. If
insulation damage is found, place heat
shrink over damage (See steps 37-38 for
further details). If the damage extends
into the copper conductor, stop rework
process and contact supervisor. Motor
will need to be replaced.
10
Inspect green ground wire and torque
ground wire bolt into back of junction box
to 20-in-lbs.
Check incoming Power cable wiring for
damage. If insulation damage is found, place
heat shrink over damage (See steps 37-38
for further details). If the damage extends
into the copper conductor, stop rework
process until power cable is replaced.
Rev #:
Step Number and Instruction
PEC-39
Rev 10/17/2017
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FT5294
PAGE 5 OF 12
Reference Image
15
NQF772004 VERSION 3
Repeat Steps 11-19 for all additional
dual wire sets needing ferrules (Should
be x3 in all)
21
Tigthen set screw in terminal block to
(1.8 Nm / 16 in. lbs.)
19
Insert metal end of ferrule into
terminal block going back into same
port of the block wires started from.
See wiring diagram for reference.
17
Perform pull-test to ensure crimp was
effective and wires are not loose
Step Number and Instruction
Page 3 of 9
Reference Image
16
3
22
Locate motor ground wire and remove
wire lead from terminal block. With
ground wire out of the way, pull
terminal block outside of junction box
and wrap all motor wires with cloth
tape (ST922032AV)
20
Pull on wires to confirm that they have
been secured
18
Apply Loctite 242 (Blue) to terminal set
screws. *Loctite should not be dripping
from screws when installed. Only the
threads of the screws should be coated.
When re-inserting the set screw be sure
to keep bus bar in terminal block.
In the event that pull-test failed, repeat
Steps 13 & 14 with a new ferrule.
Rev #:
Step Number and Instruction
PEC-39
Rev 10/17/2017
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FT5294
PAGE 6 OF 12
Reference Image
23
NQF772004 VERSION 3
Line up Angled Pigtail Bracket holes with
to x2 open holes on the LEFT-SIDE of the
junction box
29
Seat the bushing by pushing it upward
all the way into the elbow (only tail-end
of bushing should be visible as shown)
27
For each incoming power cable wire,
remove the corresponding set screw, add
Loctite 242 to the set screw (same as step
18), insert the wire into the terminal and reinstall the set screw. (See wiring diagram on
Page 6 for correct wire position on the
terminal block.) Use torque wrench to
tighten set screws in terminal block to 16 inlbs.
25
Repeat same procedure (Steps 11-19)
for ground wire, except using single
ferrule connector (PE980403AV)
Step Number and Instruction
Page 4 of 9
Reference Image
24
3
30
Fasten bracket with x2 screws
(ST981195AV) from rework kit on the
LEFT-SIDE of the junction box with
Loctite 242 (Blue).
28
Replace rubber gasket (ST804010AV).
Reinstall junction box cover using x2 original
screws (retained from step 4) on the RIGHTSIDE of the junction box with Loctite 242
(Blue) (*Only thread the screws in by hand)
26
Install split bushing around incoming
pigtail wires (EC124800AV) into
conduit elbow(EC124800AV) at the
top of junction box
Reinstall terminal block with x1 bolt from
Step 7. Apply Loctite 242 (Blue) and torque
to 20 in. lbs. Make sure the ring terminal for
the braided wire goes behind the bracket
for the terminal block.
Rev #:
Step Number and Instruction
PEC-39
Rev 10/17/2017
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FT5294
PAGE 7 OF 12
Reference Image
NQF772004 VERSION 3
Aligned if
can see thru
clamp and
bracket
If wiring shows a small defect (small cut
or strained insulation), take a 1" piece
of heat shrink (ST922029AV) and slide
over wire and center over defect area.
37
Torque wire clamp bolt with 10mm
Socket to 53 in-lbs. (Spec. 0661_EI18061)
35
Rotate pigtail to Bracket, wrap Wire
Clamp around pigtail, line-up clamp
holes with bracket mount hole. It
may be necessary to push down on
the power cable to get the bolt
through the bracket.
33
Torque all junction box cover screws to
20 in. lbs in a star pattern as illustrated.
Add paint mark to screws once they are
torqued.
31
Step Number and Instruction
Page 5 of 9
Reference Image
Nut
38
Apply heat until heat shrink is tight on
wire and adhesive is coming out from
both ends
36
Rework Completed
34
Install bolt from top-side, spin on
nut from under-side, and fasten
wire, bracket, and clamp together.
32
0
Cut 1" wide strip of heat shrink
(ST922029AV). Cut slit across shrink, and
then wrap heat shrink around pigtail,
centering it with the bracket hole. (Be sure
to wrap heat shrink until fully used up, and
to where end does not uncoil when placing
clamp.)
Rev #:
Step Number and Instruction
PEC-39
Rev 10/17/2017
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FT5294
PAGE 8 OF 12
NQF772004 VERSION 3
Page 6 of 9
Terminal Block Wiring Diagram
PEC-39
Rev 10/17/2017
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FT5294
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PROJECTED LABOR
Operation
Process #
1
Number of
Technician(s)
Est. Time Req.
in Minutes
Labor Est.
(# of Tech.'s) x (Min.)
1
30
30
Qty. per Job
1
Units
EA
3
EA
1
EA
1
EA
Notes
Already on unit
NB04 Rework Kit
ST981196AJ
NB04 Rework Kit
ST981196AJ
NB04 Rework Kit
ST981196AJ
1
EA
NB04 Rework Kit
ST981196AJ
2
EA
NB04 Rework Kit
ST981196AJ
1
EA
Already on unit
1
EA
NB04 Rework Kit
ST981196AJ
NB04 Rework Procedure:
1. Add ferrules to motor wires
2. Apply cloth tape to motor wires
3. Split bushing to pigtail wiring
3. Install Pigtail bracket & clamp to junction box exterior
PARTS REQUIRED
Item
1
Part Number
ST198600AV
2
ST207300AV
3
PE980403AV
4
ST820063AV
5
SL380000AV
6
ST981195AV
7
EC124800AV
8
ST981191AV
9
ST981192AV
NUT, HEX
FLANGE, NYLOCK,
M6 x 1.0, 18-8 SS
1
EA
NB04 Rework Kit
ST981196AJ
10
ST177700AV
GROMMET FOR
FLEXIBLE METAL
CONDUIT AND
ARMORED CABLE,
1/2"
1
EA
NB04 Rework Kit
ST981196AJ
11
ST820062AV
HEAT SHRINK, 2:1,
PRE-SHRUNK ID
2", BLACK
1
in.
NB04 Rework Kit
ST981196AJ
ST922029AV
HEAT-SHRINK
TUBING, BLACK,
PRESHRUNK:
.293" ID
1
EA
NB04 Rework Kit
ST981196AJ
ST804010AV
MOTOR JB COVER
GSKT, BALDOR,
5HP IP54 MOTOR
(MC304101AV),
BALDOR PN:
37GS1003
1
EA
NB04 Rework Kit
ST981196AJ
12
13
Description
Terminal Block
Twin Ferrule
Connector
Blue 14 AWG
Ferrule
CLAMP, LINE, PA,
25.4 mm ID
NOVA BUS CORD
BRACKET
NB#N82522
SCREW, PIN-INTORX, 8-32, SS,
1/2
CABLE, POWER,
NOVA BUS
N100840
SCREW, HEX
FLANGE HEAD, M6
X 1.0 X 45mm, 18-8
SS
PAGE 10 OF 12
NQF772004 VERSION 3
FT5294
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Item
1
2
Part Number
Weidmuller Crimp Pliers
WIHA 2852 Torque Screwdriver
SPECIAL TOOLS REQUIRED
Description
PZ 10 HEX
1445070000
Qty.
Units
Notes
1
EA
Used to crimp ferrules
10-50 in. lbs.
1
EA
3
PIN-IN-TORX T-15 Driver Bit
N/A
1
EA
4
Flathead Screwdriver Bit
N/A
1
EA
5
5/16 Magnetic Nut Driver
N/A
1
EA
Calibrated
to 53 in.lb.
1
EA
Torque screwdriver for
various screws
For Junction box cover
screws
For Set Screws
For screw holding terminal
block bracket
For Wire Clamp
Installation
For Wire Clamp
Installation
For Wire Clamp
Installation
For thread locking
6
Torque Wrench
7
10mm Socket
10mm Hex Head
1
EA
8
10mm Wrench
10mm Wrench
1
EA
9
LOCTITE 242
Removeable (Blue)
~0.25 (Total)
oz.
10
Heatgun (no open flame)
N/A
1
EA
Use if wire damage is
found to apply heat shrink
1
EA
For wrapping wires
1
EA
11
12
ST922032AV
Wire stripper
13
Spanner Wrench
14
Paint Marker
ELECTRICAL
TAPE, COTTON
FRICTION
RESISTANT, 3/4"
WIDE, 1200V
N/A
3/4 Conduit Nut
Wrench
N/A
1
EA
1
EA
Stripping wires
For tightening incoming
power cable fitting
Marking torqued screws
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NQF772004 VERSION 3
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FT5294
BLANK
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NQF772004 VERSION 3