NHTSA ID Number: 10165605
Manufacturer Communication Number: SMB188
Summary
Service Manual Bulletin provides revised information for the Preventive Maintenance on specifically equipped vehicles with the Powerex belt driven air compressor.
64 Affected Products
Vehicles
NEW FLYER | XDE35 | 2010-2020 |
| NEW FLYER | XDE40 | 2009-2020 |
| NEW FLYER | XDE60 | 2013-2020 |
| NEW FLYER | XE35 | 2019-2020 |
| NEW FLYER | XE40 | 2013-2020 |
| NEW FLYER | XE60 | 2017-2020 |
| NEW FLYER | XHE40 | 2018-2020 |
| NEW FLYER | XHE60 | 2015, 2020 |
| NEW FLYER | XT40 | 2014-2020 |
| NEW FLYER | XT60 | 2014-2020 |
SMB-188
ISSUE DATE: Sep 20 2019
Belt Driven Scroll Air Compressor – Powerex
PM – PREVENTIVE MAINTENANCE
This bulletin provides revised information for the Preventive Maintenance on the Powerex Belt Driven air compressor.
This information supersedes any prior information on this subject already provided in your New Flyer Service Manual.
Make this Service Bulletin available to service personnel to inform them of changed information.
SEOCONTENT-START
SMB-188 1 of 8
SERVICE MANUAL BULLETIN
This Service Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. Refer to details below.
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
ISSUE DATE: Sep 20 2019
SMB-188
APPLICABILITY
VEHICLE LENGTH 30ft. 35ft. 40ft. 60ft. ALL
VEHICLE TYPE
Xcelsior® MiDi® Invero®
ALL
Low Floor High Floor
FUEL TYPE
Diesel Diesel/Electric CNG LNG
ALL
Fuel Cell Trolley/Electric Battery/Electric
SUBJECT Belt Driven Scroll Air Compressor – Powerex
SECTION TITLE PM – PREVENTIVE MAINTENANCE
DETAILS This bulletin provides revised information for the Preventive Maintenance
on the Powerex Belt Driven air compressor.
This information supersedes any prior information on this subject
already provided in your New Flyer Service Manual.
Make this Service Bulletin available to service personnel to inform them
of changed information.
2 of 8 SMB-188
SERVICE MANUAL BULLETIN
SMB-188
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
1. BELT DRIVEN SCROLL
COMPRESSOR
1.1. Preventive Maintenance Guide
Intervals are based on the manufacturer’s
recommendations which are expressed in
compressor operating hours.
Intervals listed in this bulletin were converted
from compressor operating hours to
mileage using an average vehicle speed of
12.5 mph and a compressor duty cycle of
50%. Adjust the service interval according
to actual operating conditions.
Compressors operating in a hot dusty environment
will need more frequent servicing.
1.2. 12,000 Miles (19,300 km)
Preventive Maintenance
1.2.1. Compressor Air Filter Inspection
Inspect the air compressor air filter element.
1. Remove air filter cover.
2. Inspect filter element for contamination.
3. Reinstall filter element and replace cover.
1.3. Yearly Preventive Maintenance
1.3.1. Compressor Orbital Scroll Bearing
Lubrication
Maintenance of high voltage equipment
must be performed by qualified personnel
only. Refer to your New Flyer Service
Manual for safety requirements.
Ensure that the High Voltage Interlock
and Battery Disconnect switches are
set to the OFF position and locked-out
and tagged-out.
Lubricate the orbital scroll (OS) bearing
yearly. Lubricate the bearing in the spring
before the high summer temperatures.
If the compressor needs to be removed
from the vehicle to access the lubrication
port, refer to Section 8 of your New Flyer
Service Manual for removal procedure.
1. Wipe off around dust cap. Remove plastic
dust cap for orbital scroll bearing grease
fitting. See “Fig. 1: Orbital Scroll Bearing
Lubrication” on page 3.
2. Rotate compressor pulley until grease fitting
lines up with lubrication port.
3. Obtain a grease gun kit with special adapters
and grease.
☞NOTE:
Contact New Flyer Parts for information on
the grease gun kit with special adapters
and grease cartridge.
PREVENTIVE MAINTENANCE GUIDE
12,000 mi.
(19,300 km) Yearly 60,000 mi.
(96,560 km)
120,000 mi.
(193,000 km)
250,000 mi.
(402,330 km)
Compressor Air
Filter Inspection
(500 hrs.)
Compressor Orbital
Scroll Bearing
Lubrication
Compressor Air
Filter Replacement
(2,500 hrs.)
Compressor Fan &
Duct Seal Cleaning
(5,000 hrs.)
Compressor Tip &
Dust Seal
Replacement
(10,000 hrs.)
Fixed Scroll Fin
Cleaning (2,500 hrs.)
Crank Pin Bearing
Lubrication
(10,000 hrs.)
Heat Insulation
Pipe Replacement
(10,000 hrs.)
SMB-188 3 of 8
SERVICE MANUAL BULLETIN
SMB-188
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
☞NOTE:
Pump grease gun to eliminate air from the
extension adapter before use.
4. Apply three full pumps of the grease gun to
deliver the correct amount of grease to the
bearings.
☞NOTE:
Each pump of the grease gun delivers 0.65
grams of grease.
5. Remove grease gun and reinstall plastic
dust cap.
1.4. 60,000 Miles (96,560 km)
Preventive Maintenance
1.4.1. Compressor Air Filter Replacement (if
equipped)
❒ Replace the air filter element.
1.4.2. Fixed Scroll Fin Cleaning
❒ Remove the fixed scroll cover and clean
the cooling fins using compressed air. See
“Fig. 2: Scroll Compressor Filter Replacement”
on page 3.
1.5. 120,000 Miles (193,500 km)
Preventive Maintenance
1.5.1. Air Compressor Cleaning, Lubrication
& Parts Replacement
Maintenance of high voltage equipment
must be performed by qualified personnel
only. Refer to your New Flyer Service
Manual for safety requirements.
Ensure that the High Voltage Interlock
and Battery Disconnect switches are
set to the OFF position and locked-out
and tagged-out.
1.5.2. Compressor Fan & Duct Seal Cleaning
Remove the blower fan cover and clean
the compressor fins and fan using compressed
air. Wipe the fan duct interior with
a clean cloth.
Fig. 1: Orbital Scroll Bearing Lubrication
Fig. 2: Scroll Compressor Filter Replacement
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4 of 8 SMB-188
SERVICE MANUAL BULLETIN
SMB-188
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
1.6. 250,000 Miles (402,330 km)
Preventive Maintenance
1.6.1. Crank Pin Bearing Lubrication
☞NOTE:
Contact New Flyer Parts for information on
the grease gun kit with special adapters
and grease cartridge.
1. Remove V-belts and fan cover.
2. Remove air end pulley and cooling fan
using a gear puller.
3. Remove the duct shroud.
4. Remove three grease caps. Do not attempt
to loosen or tighten bolt.
5. Grease all three crank bearings. Deliver
seven full pumps of grease to each grease
fitting. See “Fig. 3: Crank Pin Bearing
Lubrication” on page 4.
6. Reinstall all removed parts.
Fig. 3: Crank Pin Bearing Lubrication
1.6.2. Compressor Tip & Dust Seal
Replacement
1. Remove the scroll compressor assembly
from the vehicle. Refer to Section 8 of your
New Flyer Service Manual for removal procedure.
2. Remove the hardware from fixed scroll
assembly and separate from orbital scroll
assembly. See “Fig. 4: Scroll Compressor
Assembly” on page 5.
3. Remove old seal. Clean scroll using a
clean cloth and compressed air.
☞NOTE:
Tip seals for fixed scroll and orbital scroll
have opposing seal cut angles. To distinguish
between fixed scroll and orbital scroll
seals. See “Fig. 5: Seal Identification” on
page 6.
4. Insert tip seal with lip of the seal (grooved
bottom) facing bottom of scroll seal groove.
Ensure lip faces center of scroll. See “Fig.
6: Orbital Scroll Seal Installation” on
page 6.
During seal installation, it is important
to verify that a notch in the seal has
been achieved. Follow the procedures
carefully to prevent seal movement during
installation.
5. Insert a new high pressure tip seal from
the center of the orbital scroll as follows:
a. Make sure there is no gap at the tip,
and that the low pressure seal contacts
the high pressure seal inside the scroll
groove.
b. Insert approximately half of the low
pressure seal and then remove it to verify
that a notch in the seal has been
achieved. See “Fig. 7: Seal Installation”
on page 6.
c. Reinstall the portion of the seal
removed previously and complete the
installation of the remainder of the seal.
6. Repeat steps 4 & 5 for fixed scroll seal.
7. Remove the dust seal and backup tube on
outermost side of fixed scroll set.
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SMB-188 5 of 8
SERVICE MANUAL BULLETIN
SMB-188
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
8. Insert new backup tube in fixed scroll set.
Orient split in tube to the 6 o’clock position.
See “Fig. 8: Backup Tube Installation” on
page 6.
9. Insert new dust seal on backup tube. Face
seamed section of dust seal at the 3
o’clock position. See “Fig. 9: Dust Seal
Installation” on page 7.
☞NOTE:
DO NOT allow dust seal or tip seal to fall
out of position during installation.
10.Reassemble fixed scroll set to orbital
scroll.
11.Install and lightly tighten the six retaining
fasteners. Rotate crankshaft and confirm it
rotates smoothly.
12.Torque the fasteners in two stages.
❒ First Stage – 17 in-lb.
❒ Second Stage – 265 in-lb.
Fig. 4: Scroll Compressor Assembly
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6 of 8 SMB-188
SERVICE MANUAL BULLETIN
SMB-188
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
Fig. 5: Seal Identification
Fig. 6: Orbital Scroll Seal Installation
Fig. 7: Seal Installation
Fig. 8: Backup Tube Installation
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SMB-188 7 of 8
SERVICE MANUAL BULLETIN
SMB-188
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
1.6.3. Heat Insulation Pipe Replacement
1. Set the Battery Disconnect switch to the
OFF position.
2. Drain the vehicle air system.
3. Disconnect the discharge lines and fittings
from the long nipple on the compressor.
4. Unthread the long nipple from the compressor
housing. See “Fig. 10: Heat Insulation
Pipe” on page 7.
5. Pull out the heat insulation insert.
Fig. 9: Dust Seal Installation
Fig. 10: Heat Insulation Pipe
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8 of 8 SMB-188
SERVICE MANUAL BULLETIN
SMB-188
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
2. FLUID & LUBRICATION
GUIDE
2.1. Lubrication Chart
FLUID & LUBRICATION GUIDE
ITEM COMPONENT PROCEDURE INTERVAL LUBE TYPE
1 Orbital Scroll
Bearing
Lubricate Grease
Fittings
Yearly Powerex Grease
2 Crank Pin Bearing Lubricate Grease
Fittings
250,000 mi. (402,330 km)
(10,000 hrs.)
Powerex Grease
SMB188
- Reliable and efficient: Compared with the traditional air compressor, the inverter screw air compressor adopts soft start, lower noise, more stable air pressure, and can adjust the motor speed in real time according to the actual air consumption, which is more efficient and energy saving.
- Easy to install and maintain: The air compressor is easy to install, the machine is debugged, connected to the power supply, connected to the air system and ready to use. This greatly reduces installation time and allows you to start working immediately. Annual maintenance only requires changing the filter and oil at set intervals.
- Wide range of applications: Portable air compressors are used in tire pumping, home painting, woodworking nailing, automotive repair, pneumatic work, and all kinds of spraying work. They are powerful and suitable for many fields.Casters are mounted on the bottom of the air compressor for quick movement.
- After sales service: One year warranty for the whole machine, free replacement of spare parts during the warranty period; remote diagnosis and emergency spare parts replacement service.
- Product Parameters: Power: 10 horsepower; Input Voltage: 208-230V/60Hz; Air Flow: 38cfm; Max Working Pressure: 116 psi; Electrical ( Phase ) : 1phase; Output Pipe Diameter: NPT 1/2”; Motor: 3600rpm; Note: It is not possible to convert between single-phase and three-phase through a converter!!!
- Reliable and efficient: Compared with the traditional air compressor, the inverter screw air compressor adopts soft start, lower noise, more stable air pressure, and can adjust the motor speed in real time according to the actual air consumption, which is more efficient and energy saving.
- Easy to install and maintain: The air compressor is easy to install, the machine is debugged, connected to the power supply, connected to the air system and ready to use. This greatly reduces installation time and allows you to start working immediately. Annual maintenance only requires changing the filter and oil at set intervals.
- Wide range of applications: Portable air compressors are used in tire pumping, home painting, woodworking nailing, automotive repair, pneumatic work, and all kinds of spraying work. They are powerful and suitable for many fields.Casters are mounted on the bottom of the air compressor for quick movement.
- After sales service: One year warranty for the whole machine, free replacement of spare parts during the warranty period; remote diagnosis and emergency spare parts replacement service.
- ULTRA QUIET PERFORMANCE: The California Air Tools 4.0 HP Ultra Quiet & Oil-Free Air Compressor operates at only 75 decibels, making it one of the quietest air compressors in the industry. Perfect for noise-sensitive environments. Airflow 12.80 CFM @ 40 PSI and 10.60 CFM @ 90 PSI.
- POWERFUL TWIN MOTORS: Equipped with twin 2.0 HP motors running at only 1680 RPM, this ultra quiet air compressor creates less noise and wear. The SP Series motors are designed for increased duty cycle and longer continuous run times.
- OIL-FREE DUAL PISTON PUMP: The oil-free dual piston pump system provides high performance and durability, with a life cycle of over 3000 hours. Suitable for various temperatures and terrains, it ensures cleaner air and less maintenance.
- LARGE 60 GALLON STEEL TANK: The 60-gallon steel ASME air tank is perfect for shop or garage use, offering ample air capacity. This heavy duty portable air compressor features a 125 PSI maximum pressure and a regulator with a 3/8" port for efficient air flow.
- AUTO DRAIN VALVE: Factory installed, the EZ-1 Automatic Drain Valve eliminates the need for manual draining. The pre-set timer allows you to set the frequency and duration of the draining process, ensuring hassle-free maintenance. Product dimensions – L (21") x W/D (28.5") x H (66").
- 80-GALLON VERTICAL ASME TANK: Large-capacity vertical tank stores more compressed air for longer work periods while conserving valuable floor space in automotive service centers, garages, and professional shops.
- HIGH-VOLUME AIR PERFORMANCE: Delivers 16.0 CFM at 90 PSI and 17.3 CFM at 40 PSI, with a maximum operating pressure of 140 PSI to power demanding pneumatic tools for automotive repair and restoration.
- 5 HP SINGLE-PHASE MOTOR: Operates on 208-230V single-phase power and includes overload protection, with no special motor starter required for installation in a compatible professional shop electrical system.
- DURABLE CAST-IRON PUMP: Oil-lubricated, two-cylinder pump is engineered for dependable operation and extended service life, while a pump speed of 950 RPM supports smooth, quieter performance.
- BUILT FOR PROFESSIONAL SHOP TASKS: High air delivery supports demanding applications such as paint spraying, sanding, grinding, inflation, fastening, nailing, bolting, and tightening when matched to tool requirements.
- 2 Pistons & 4 Stages Powerful Compression: Designed by GX pump brand, this pcp air compressor utilizes a dual piston and 4 stages compression exclusive technology to reduce the fill time. With the powerful motor, you can fill to max 40mpa/5800psi pressure easily. Typically, for a rifle 2-3 min. Also with the 1200W max power, you can charge almost all sizes of large PCP /Paintball tanks in the market, even over 20L. Need to put 1 more burst disc if fill over 5000psi.
- Water + Fan Cooling System : The cooling system has a high water capacity combined with a built-in water pump,radiator and powerful cooling fan. There is a remaining water indicator on a side and you just need to open water tank cap to add water in time. Notice: we drained water tank for transport, before start compressor, you have to add full coolant into water tank first , or it cause damage!
- Two Stages Auto-Stop Setting and Moisture Filter: The automatic shut off is easily set by the twin indicator arms in the extra large easy to read Shock-resistant pressure gauge. When the desired pressure is reached the compressor shuts itself off automatically. The compressor will bleed off all moisture when releasing bleed valve. With these user friendly features one can attach his or her air cylinder or airgun push the on button and go eat dinner or watch television.
- Super Fast Filling Speed: Filling 6.8L pcp tank, just needs 45 minutes from 0-4500psi. 0.5L from 1000psi- 4500psi, just needs 2.5 minutes. 0.5L from 1000-3000psi, needs only 1.6 minutes. 1L from 1000psi-4500psi, takes 5minutes. 1L from 1000psi to 3000Psi, needs only 3.5minutes. Notice: We have exclusive design patent for the compression method , Patent No: US 9,726,165 B2 .Please consider carefully when selling such products
- New Grease Injection System: Pls note the grease tank has been added before factory. Package does not include spare grease needle anymore. After use up, suggest to buy Food Grade E.P. Grease. Notice: Never turn it for the first 6 hours of use as it will cause too much grease in the machine and cause bad air quality ! Every 6 hours, can turn 2/3 turn.
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