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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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
ISSUE DATE: Sep 20 2019
SMB-186
APPLICABILITY
VEHICLE LENGTH ๏ฏ 30ft. ๏ฏ 35ft. ๏ฏ 40ft. ๏ฏ 60ft. ๏ฎ ALL
VEHICLE TYPE
๏ฎ Xcelsiorยฎ ๏ฏ MiDiยฎ ๏ฏ Inveroยฎ
๏ฏ ALL
๏ฏ Low Floor ๏ฏ High Floor
FUEL TYPE
๏ฏ Diesel ๏ฎ Diesel/Electric ๏ฏ CNG ๏ฏ LNG
๏ฏ ALL
๏ฎ Fuel Cell ๏ฎ Trolley/Electric ๏ฎ 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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
1. DIRECT DRIVE SCROLL
COMPRESSOR
1.1. Preventive Maintenance Guide
Intervals are based on the manufacturerโs
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 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 โFig. 1: Orbital Scroll Bearing
Lubricationโ 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.
โNOTE:
Contact New Flyer Parts for information on
the grease gun kit with special adapters
and grease cartridge.
โNOTE:
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.
โNOTE:
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
1.4. 48,000 Miles (77,250 km)
Preventive Maintenance
1.4.1. Compressor Air Filter Replacement
โ Replace the air filter element.
โ Remove the fixed scroll cover and clean
the cooling fins using compressed air. See
โFig. 2: Scroll Compressor Filter Replacementโ
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 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.
โNOTE:
Contact New Flyer Parts for information on
the grease gun kit with special adapters
and grease cartridge.
โNOTE:
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
โFig. 3: Crank Pin Bearing Lubricationโ on
page 5.
โNOTE:
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 โFig. 4: Scroll Compressor
Assemblyโ on page 6.
3. Remove old seal. Clean scroll using a
clean cloth and compressed air.
โNOTE:
Tip seals for fixed scroll and orbital scroll
have opposing seal cut angles. To distinguish
between fixed scroll and orbital scroll
seals. See โFig. 5: Seal Identificationโ 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 โFig.
6: Orbital Scroll Seal Installationโ on
page 7.
????????????????????????????????????????????????????????????
????????????????????????????????????????????????????
????????????????????????????????
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 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 โFig. 7: Seal Installationโ
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 oโclock position.
See โFig. 8: Backup Tube Installationโ on
page 7.
9. Insert new dust seal on backup tube. Face
seamed section of dust seal at the 3
oโclock position. See โFig. 9: Dust Seal
Installationโ on page 8.
โNOTE:
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.
โ First Stage – 17 in-lb.
โ 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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 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 โFig. 10: Heat Insulation
Pipeโ 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.
โNOTE:
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 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 โFig. 11: Air
Compressor Discharge Valveโ 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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 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
โFig. 12: Air Compressor Couplingโ 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.
โNOTE:
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.
โNOTE:
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.
โNOTE:
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 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.
โNOTE:
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).
โNOTE:
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 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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- Wide-Ranging Applications: This air compressor is perfect for nail guns, impact wrenches, spray guns, and more. Itโs an excellent choice for industrial manufacturing, construction sites, and woodworking projects, providing a stable and consistent air supply to meet various industrial demands.
- ULTRA QUIET PERFORMANCE: The California Air Tools Ultra Quiet and Oil-Free 4.0 HP Air Compressor (220v 60hz) operates at only 75 dB noise level, ideal for noise-sensitive environments; CFM Rating: 12.80 CFM @ 40 PSI 10.60 CFM @ 90 PSI
- 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 4.0 HP MOTOR: This ultra quiet air compressor is equipped with a powerful 4 HP horsepower motor that operates at only 1680 RPM, reducing noise and wear for a quieter, more durable performance
- 20 GALLON STEEL AIR TANK: This heavy duty air compressor features a 20-gallon steel air tank capacity; weighing 140 pounds, this compressor is perfect for the jobsite, shop, or garage
- LOW AMP DRAW: Operating on only 14 amps, this air compressor is compatible with 220v / 60 hz outlets; additional features: thermal overload protection, and pressure control gauges for convenience; product dimensions: L (39") x W (15") x H (28")
- ULTRA QUIET PERFORMANCE: The California Air Tools Ultra Quiet & Oil-Free Air Compressor in Sound Proof Cabinet operates at only 40 decibels, making it one of the quietest air compressors in the industry. Ideal for indoor environments where noise reduction is crucial. Airflow is 3.10 CFM at 40 PSI and 2.20 CFM at 90 PSI.
- POWERFUL OPERATION: The powerful 1.0 HP motor operates at only 1400 RPM creating less noise, vibration and wear. The CAT-MP100LF motor/pump is tested for a minimum of 4000 hours before service, offering 30% more operational life compared to standard compressors.
- OIL-FREE PUMP: The oil-free pump allows this 8 gallon air compressor to be used in a variety of temperatures without the need for maintenance. The large 8.0 gallon steel air tank is internally coated with epoxy for anti-rust durability.
- SOUND PROOF CABINET WITH WHEELS: The compressor's steel sound proof cabinet, constructed with sturdy metal and 1/4" acoustic foam, reduces noise by 30%, making it perfect for quiet workspaces while ensuring efficient cooling with dual exhaust fans.
- MOBILITY AND ACCESSIBILITY: Move and position your compressor effortlessly with four caster wheels and enjoy hassle-free access to internal components through two easy-to-operate latching doors, enhancing maintenance efficiency and convenience. Product dimensions โ L (21") x W (20") x H (32"). Weight 125 pounds.
- Parameters: Power:10HP / 7.5KW๏ผ230V/60Hz/3ph๏ผWorking Pressure : Max 125 psi /8 bar๏ผAir Flow : 33cfm๏ผMotor RPM : 3600. Note: It is not possible to convert between single-phase and three-phase through a converter
- Product Application: It can widely used for production, pharmaceutical, textile, auto repair, aviation, metallurgical and other industrial fields.
- Stable and Durable: Spin-on Air Oil Separator is an integrated separator with element and its own housing. It offers an easy and quick replacing solution for maintenance of air compressors. It significantly reduces oil content of compressed air and returned the filtered oil to compressor air end
- Spin-on Air Oil Separator: Air cooled after cooler to reduce discharge air temperatures with the spin-on oil filter and separator element, with the friendly compact structure speeds up your work and minimizes downtime.It can used safely in all applications of small and medium sized businesses
- Standard Service: HPDAVV Provided with one-year service, the air end with two-year service and lifetime maintenance. We also have some of the best air supplier are able to support the after-sales services.
- Parameters: Power: 10HP / 7.5KW; Voltage: Input Voltage ( V / Hz ): 460V / 60Hz; Electrical ( Phase ): 3ph; Air Flow: 33 cfm; Max Working Pressure: 125 psi / 8 bar; Full Load Amps: 24. Note: It is not possible to convert between single-phase and three-phase through a converter
- Product Application: It can widely used for production, pharmaceutical, textile, auto repair, aviation, metallurgical and other industrial fields
- Stable and Durable: Spin-on Air Oil Separator is an integrated separator with element and its own housing. It offers an easy and quick replacing solution for maintenance of air compressors. It significantly reduces oil content of compressed air and returned the filtered oil to compressor air end.
- Spin-on Air Oil Separator: Air cooled after cooler to reduce discharge air temperatures with the spin-on oil filter and separator element, with the friendly compact structure speeds up your work and minimizes downtime.It can used safely in all applications of small and medium sized businesses
- Standard Service: HPDAVV Provided with one-year warranty,the air end with two-year warranty and lifetime maintenance. We also have some of the best air supplier are able to support the after-sales services
- Replacement History: 55-102045-62S 55-102045-62 55-105043-02 55-23139-50 55-100835-25S 55-23139-50S 55-100835-14 ZR32K5-PFV-800 55-ZR32K5-PFV-800
- 55-100835-14S 55-21737-50 55-100835-23 55-100835-09 55-23140-13 55-23139-48 55-23139-48S 55-102045-70 55-102045-70S
- 55-100835-23S 55-100835-09S 55-100835-25 55-102045-70S 55-21737-48 55-100835-14S 55-100835-14 55-23140-13S ZR32K5-PFV-7M3 ZR32K5-PFV-7M3 ZR32K5E-PFV-7M3
Last update on 2025-04-18 / Affiliate links / Images from Amazon Product Advertising API
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