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NHTSA ID Number: 10165644
Manufacturer Communication Number: SMB186
Summary
Service Manual Bulletin providing revised, corrected or additional information for the Preventive Maintenance on buses specifically equipped with a Powerex direct drive 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-186
ISSUE DATE: Sep 20 2019
Direct Drive Scroll Air Compressor – Powerex
PM – PREVENTIVE MAINTENANCE
This bulletin provides revised information for the Preventive Maintenance on the Powerex Direct Drive 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-186 1 of 12
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-186
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 Direct Drive Scroll Air Compressor – Powerex
SECTION TITLE PM – PREVENTIVE MAINTENANCE
DETAILS This bulletin provides revised information for the Preventive Maintenance
on the Powerex Direct Drive 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 12 SMB-186
SERVICE MANUAL BULLETIN
SMB-186
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. DIRECT DRIVE 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.
PREVENTIVE MAINTENANCE GUIDE
12,000 mi.
(19,300 km) Yearly 48,000 mi.
(77,250 km)
96,000 mi.
(154,500 km)
120,000 mi.
(193,000 km)
400,000 mi.
(644,000 km)
Compressor
Air Filter
Inspection
(500 hrs.)
Compressor
Orbital Scroll
Bearing
Lubrication
Compressor
Air Filter
Replacement
(2,500 hrs.)
Compressor
Fan & Duct
Seal Cleaning
(4,000 hrs.)
Motor Bearing
Lubrication
(5,500 hrs.)
Discharge Valve
Replacement
(16,000 hrs.)
Crank Pin
Bearing
Lubrication
(4,000 hrs.)
Compressor
Tip & Dust Seal
Replacement
(4,000 hrs.)
Heat Insulation
Pipe
Replacement
(4,000 hrs.)
SMB-186 3 of 12
SERVICE MANUAL BULLETIN
SMB-186
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
1.3. 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 coupling with a screw
driver 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.
☞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.
Fig. 1: Orbital Scroll Bearing Lubrication
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s0700411b.svg
4 of 12 SMB-186
SERVICE MANUAL BULLETIN
SMB-186
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
1.4. 48,000 Miles (77,250 km)
Preventive Maintenance
1.4.1. Compressor Air Filter Replacement
❒ Replace the air filter element.
❒ Remove the fixed scroll cover and clean
the cooling fins using compressed air. See
“Fig. 2: Scroll Compressor Filter Replacement”
on page 4.
1.5. 96,000 Miles (154,500 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.
Fig. 2: Scroll Compressor Filter Replacement
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s0700571a.svg
SMB-186 5 of 12
SERVICE MANUAL BULLETIN
SMB-186
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
1.5.2. 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.
1.5.3. Crank Pin Bearing Lubrication
1. Remove scroll compressor assembly from
vehicle. Refer to Section 8 of your New
Flyer Service Manual for removal procedure.
2. Remove the six attaching fasteners and
separate the fixed scroll assembly from the
orbital scroll assembly.
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.
☞NOTE:
Pump grease gun to eliminate air from the
extension adapter before use.
4. Locate the three grease fittings on the
crank pin bearing and apply seven full
pumps of the grease gun to deliver the correct
amount of grease to the bearings. See
“Fig. 3: Crank Pin Bearing Lubrication” on
page 5.
☞NOTE:
Each pump of the grease gun delivers 0.65
grams of grease.
5. Reinstall all removed parts.
Fig. 3: Crank Pin Bearing Lubrication
1.5.4. 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 6.
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 7.
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 7.
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????????????????????????????????
s0700407a.svg
6 of 12 SMB-186
SERVICE MANUAL BULLETIN
SMB-186
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
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 7.
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.
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 7.
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 8.
☞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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s114307b.svg
SMB-186 7 of 12
SERVICE MANUAL BULLETIN
SMB-186
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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s114302b.svg
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s114313a.svg
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s114314a.svg
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s114310a.svg
8 of 12 SMB-186
SERVICE MANUAL BULLETIN
SMB-186
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. 9: Dust Seal Installation
1.5.5. 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 8.
5. Pull out the heat insulation insert.
6. Install a new heat insulation insert. Installation
is the reverse of removal.
Fig. 10: Heat Insulation Pipe
1.6. 120,000 miles (193,000 km)
Preventive Maintenance
1.6.1. Motor 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.
1. Locate the grease fittings at either end of
the motor and wipe the fitting and surrounding
area clean.
☞NOTE:
If a plug is installed at this location, remove
it and replace with a grease fitting.
2. Remove the motor housing drain plugs,
located on the bottom of the housing at
either end.
????????????????????????????????????
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s114309a.svg
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s0700379b.svg
SMB-186 9 of 12
SERVICE MANUAL BULLETIN
SMB-186
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
3. Add 5.0 grams of Mobil Polyrex EM
grease.
4. Run the motor for 15 minutes.
5. Reinstall the grease drain plugs.
1.7. 400,000 miles (644,000 km)
Preventive Maintenance
1.7.1. Air Compressor 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.
1.7.2. Discharge Valve Replacement
1. Set the Battery Disconnect switch to the
OFF position.
2. Drain the vehicle air system.
3. Locate the discharge valve on the outlet
side of the compressor. See “Fig. 11: Air
Compressor Discharge Valve” on page 9.
4. Disconnect the signal line and exhaust line
from the discharge valve.
5. Unthread the discharge valve from the discharge
fitting.
6. Place discharge valve in a vise and
remove the signal line connector and the
exhaust line nipple.
7. Install a new discharge valve. Installation is
the reverse of removal.
Fig. 11: Air Compressor Discharge Valve
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s0700378.svg
10 of 12 SMB-186
SERVICE MANUAL BULLETIN
SMB-186
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
1.7.2.1. Coupling Removal
1. Set the Battery Disconnect switch to the
OFF position.
2. Drain the vehicle air system.
3. Remove the air compressor coupling
guard to gain access to the coupling. See
“Fig. 12: Air Compressor Coupling” on
page 10.
DO NOT loosen the setscrew that
secures the drive hub to the compressor
shaft.
4. Remove the three socket head screws that
secure the coupling rubber element radially
to the motor shaft.
☞NOTE:
The hub is keyed to the compressor shaft
and secured with a setscrew. The relative
position of the hub and compressor shaft
must be maintained.
☞NOTE:
DO NOT loosen the four hex head bolts
that secure the motor adapter ring to the
faceplate.
5. Support the weight of the motor and
loosen the inner set of flat socket head
screws that hold the motor to the adapter
ring.
6. Carefully pull the motor straight back to
disengage the coupling.
7. Remove the three socket head screws that
axially secure the rubber coupling element
to the compressor hub.
☞NOTE:
DO NOT remove or reposition the drive
hub. DO NOT remove or reposition the
motor mounting ring.
Fig. 12: Air Compressor Coupling
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s114312a.svg
SMB-186 11 of 12
SERVICE MANUAL BULLETIN
SMB-186
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
1.7.2.2. Coupling Installation
1. Position new rubber coupling onto compressor
hub and install three socket head
screws.
☞NOTE:
Lubricate the body and under side of the
three socket head screws with light oil or
grease.
2. Torque bolts to 37 ft-lb. (50 Nm).
☞NOTE:
DO NOT apply threadlocker or adhesives
to the screw threads. DO NOT allow the
element to become twisted when tightening
the screws.
3. Carefully align and slide the motor onto the
faceplate adapter ring.
4. Tighten the inner set of flat head socket
screws that hold the motor to the adapter
ring.
5. Install the three socket head screws that
secure the coupling radially to the motor
drive hub. Torque the screws to 37 ft-lb. (50
Nm).
6. Reinstall the coupling guard.
7. Set the Battery Disconnect switch to the
ON position.
8. Start vehicle and check compressor operation.
12 of 12 SMB-186
SERVICE MANUAL BULLETIN
SMB-186
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
96,000 mi. (154,500 km)
(4,000 hrs.)
Powerex Grease
3 Motor Bearing Lubricate Grease
Fittings
120,000 mi. (193,000 km)
(5,500 hrs.)
Mobil Polyrex EM
Grease
SMB186
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- OIL-FREE DUAL PISTON PUMP TYPE: An oil-free pump for low maintenance, exceptional performance, and durability; boasting a life cycle of over 3000 hours, this oil-free air compressor is suitable for various temperatures and terrains, ensuring cleaner air
- POWERFUL 2.0 HP MOTOR: This ultra quiet air compressor is equipped with a powerful 2.0 HP horsepower motor that operates at only 1680 RPM, reducing noise and wear for a quieter, more durable performance
- 10 GALLON STEEL AIR TANK: This heavy duty air compressor with wheels features a 10-gallon steel air tank capacity; weighing 129 pounds, the steel cabinet features caster wheels making it easy to move: L (21") x W (26") x H (32)
- SOUND PROOF CABINET: The sound proof cabinet has two latching doors that allow for easy access; equipped with two cabinet exhaust fans that remove air from the cabinet to reduce heat and provide a cooler working condition for the air compressor
- High Efficiency Performance: This 60 gallon vertical air compressor delivers 135 max PSI, ensuring optimal performance for demanding tasks. With 10.2 CFM at 90 PSI, it provides steady airflow
- Durable Construction: Featuring a robust oil lubricated pump, this compressor is designed for long-lasting use. The 60 gallon ASME certified tank ensures safety and reliability during operation.
- Enhanced Safety Features: Equipped with a fully enclosed metal belt guard, this air compressor prioritizes user safety. The guard protects vital components and reduces the risk of accidental contact.
- Powerful Motor: Driven by a 3.7 HP motor, this 60 gallon air compressor provides the power needed for rigorous tasks. The 230V requirement ensures efficient energy use and reliable performance.
- Versatile Application: This 60 gallon vertical air compressor is suitable for various industrial applications. Its powerful specifications and durable build make it an indispensable tool.
- High Air Flow: This air compressor delivers high air flow with 17 cfm at 40 psi and 14.6 cfm at 90 psi, making it suitable for a range of pneumatic tools and applications, enhancing productivity.
- Powerful Performance: The 60 gallon air compressor is equipped with a 5 HP motor, delivering robust performance. It operates at a maximum of 175 max psi, ensuring high air flow for demanding tasks.
- Durable Construction: Built with a robust 60 gallon ASME tank, this air compressor ensures long-lasting durability and. The tank is designed for high-pressure applications, enhancing its reliability.
- Heavy Duty: 208-230 spread volt induction motor designed to operate at both 208 and 230 volt applications. It should be connected to a power supply that is 240 Volt, 60 Hz, AC only.
- Single Stage with 175 Max PSI: Our compressor features a robust single stage mechanism that can produce up to 175 max psi, providing the power needed for heavy-duty tasks.
- PLEASE NOTE: Our air compressor is designed with 3-phase power supply, primarily intended for commercial use. If you intend to use it with a single-phase power supply, please first purchase an additional inverter on your own.
- Large 80-Gallon Capacity: With an extensive 80-gallon tank, VEVOR air compressor ensures a continuous and dependable air supply. The oil-free design operates at a low noise level of 86 dB, minimizing disturbances in your work environment.
- High-Powered Efficiency: This air compressor features a powerful 6.5 HP oil-free motor coupled with a dual-stage compression system, enabling rapid inflation rates of up to 3300 rpm. It delivers an impressive 15.5 SCFM at 90 PSI, allowing you to achieve quick inflation results in just 6 minutes.
- Durable and Reliable Build: Constructed from a robust 4mm high-strength steel plate, this stationary air compressor is engineered for longevity, along with thorough inspections to ensure no gas leaks and superior sealing capabilities.
- Wide-Ranging Applications: This air compressor is perfect for nail guns, impact wrenches, spray guns, and more. It’s an excellent choice for industrial manufacturing, construction sites, and woodworking projects, providing a stable and consistent air supply to meet various industrial demands.
Last update on 2025-06-11 / Affiliate links / Images from Amazon Product Advertising API
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