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
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