INSTRUCTION TO SERVICE
ITS: 58550
SECTION:

260 Battery Compartment

WRITTEN BY:

James Ashdown

SUBJECT:

Rooftop ESS Enclosure Sealing

ITS58550
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERED TO FOR FUTURE MAINTENANCE UNTIL
THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A
RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND
MAINTENANCE STAFF GOING FORWARD.
THIS DOCUMENT AND THE CONTENTS DISCUSSED HEREIN ARE THE CONFIDENTIAL AND
PROPRIETARY INFORMATION OF NEW FLYER INDUSTRIES CANADA ULC AND NEW FLYER OF AMERICA
INC. AND ARE DISCLOSED BY NEW FLYER IN CONFIDENCE. THIS DOCUMENT AND THE CONTENTS
HEREIN ARE NOT TO BE DISCLOSED BY THE INTENDED RECIPIENT WITHOUT THE PRIOR WRITTEN
AUTHORIZATION OF NEW FLYER. ANY UNAUTHOIZED DISCLOSURE, REPRODUCTION OR OTHER
DISTRIBUTION OF THIS DOCUMENT OR INFORMATION IS STRICTLY PROHIBITED AND MAY RESULT IN
ACTION BEING TAKEN AGAINST THE PARTY MAKING THE UNAUTHORIZED DISCLOSURE. THIS
DOCUMENT AND ALL COPIES HEREOF MUST BE RETURNED TO NEW FLYER UPON REQUEST.

PROBLEM DESCRIPTION:
Water intrusion into the rooftop ESS compartment has been observed.

SOLUTION:
Update the rooftop ESS enclosure design to improve water sealing capabilities.
Rooftop ESS enclosure – Before sealing modifications

Rooftop ESS enclosure – After sealing modifications

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The following assembly sequence is only to be performed by personnel that have successfully completed New
Flyer High Voltage High Voltage Safety Training and with the necessary personal protective equipment.
Only trained personnel shall supervise and perform High Voltage system testing, servicing and troubleshooting.
Two personnel (one called the Checker and the other called Monitor/Recorder) shall perform service,
troubleshooting and servicing procedures, together, to ensure safety of themselves, others nearby and for the
protection of the vehicle and property.
Refer to New Flyer High Voltage Safety Guidelines and Procedures Document 532295 (Appendix A) when
completing installation or service work on high voltage power cables.
Prior to proceeding with rework, ensure that:
•

Master Run Switch (MRS) is in the “OFF” position

•

High voltage interlock is in the “OFF” position and wait 10 minutes

•

Switch 24V battery shut off to the “OFF” position

•

Lock out/tag out high voltage system

•

Bus is not charging at any time during retrofit

•

The appropriate High Voltage PPE is available and used when required

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PROCEDURE:
1. Enter bus and turn the master run switch to the “OFF” position.

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2. Gain access to the roof of the bus and locate the ESS enclosure. Ensure that appropriate fall protection PPE
is used and appropriate safety procedures are followed per the New Flyer Service Manual. Refer to Figure 1.

Locate ESS enclosure
on roof of bus

Front of bus

Figure 1 – Locate rooftop ESS enclosure

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3. Open/remove side screens adjacent to the ESS enclosure and remove center rooftop cover on ESS by
carefully sliding off hinge pins. Retain all hardware. Refer to Figure 2 as well as the New Flyer Service
Manual.

Figure 2 – Remove side screens, center rooftop cover and pull MSD fuses

4. Locate and remove rooftop ESS enclosure Manual Service Disconnect (MSD) fuses x2 locations by pressing
on tabs and pulling upwards. Refer to Figures 2 and 3 as well as the applicable section of the New Flyer
Service Manual.

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MSD fuse location

Rooftop ESS
enclosure

Remove MSD fuses
by pressing tabs and
pulling upwards

Figure 3 - Locate and remove Manual Service Disconnect (MSD) fuses x2

5. Remove Flange Bolts (P/N 10B04012) x10 and Washers (P/N 10W04000) x10 from CS/SS access panels
and carefully remove panels (and insulation) from rooftop ESS enclosure. Retain all hardware.

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6. Cut Tyraps (P/N 5958112) x16 locations to disconnect LV Wire Harnesses from flanges on CS/SS Door
Support Rails. Refer to Figure 4.

LV Wire Harness

Remove Flange Bolts
(P/N 347979) x4 locations
total
Cut Tyraps (P/N 5958112) to
disconnect LV Harnesses –
16 locations total

Figure 4 – Cut Tyraps to disconnect LV Harnesses from Door Support Rails (SS location shown)

7. Remove Flange Bolts (P/N 347979) x4 locations on rooftop ESS enclosure and remove CS/SS Door Support
Rails. Retain all hardware. Refer to Figures 4 and 5.
Note: If required, disconnect any electrical harnesses from Door Support Rails before removal.

Door Support Rails
Front of bus

Remove Flange
Bolts (P/N 347979)
x4 locations total

Figure 5 – Remove flange bolts and disconnect CS/SS Door Support Rails

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8. In the ESS enclosure, visually inspect to ensure that all bus bar connection points have the correct boots/caps
(red and grey) installed. If missing, reinstall/replace before performing rework. Refer to Figure 6.

Figure 6 – Visually inspect all bus bar connection points for correct boots/caps
9. Use a lint free cloth to ensure that the top surfaces of all battery packs are free of dust and debris in
preparation of adhering Velcro strip. Refer to Figure 7.
Note: Do not use any chemicals or liquids to clean the top surfaces of battery packs.

Clean top surfaces of
batteries with a lint
free cloth. Do not use
any chemicals or
liquids.

LV Wire Harness

Velcro adhesive
strip position
(located under ESS
rubber roof sheet)

Figure 7 – Clean top surfaces of battery packs to prepare for Velcro strip application

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10. Position ESS Rubber Roof Sheets (P/N 761574) x2 centered forward/aft on battery packs. Additionally,
position sheets left to right to sufficiently cover the inboard low voltage harnesses. Following this, tuck sheets
under low voltage harnesses and cut a 3” maximum slit at interfering powerbar locations. Refer to Figures 8
and 9.
Tuck rubber sheets under low voltage
harnesses and cut a maximum 3” long slit
at interfering powerbar locations

Front of bus

Velcro adhesive strip
locations (under ESS
Rubber Roof Sheet)

ESS Rubber Roof
Sheet (P/N 761574)

Velcro adhesive strip
locations (under ESS
Rubber Roof Sheet)

ESS Rubber Roof
Sheet (P/N 761574)

Figure 8 – Position ESS Rubber Roof Sheets and tuck under low voltage harnesses

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Interfering powerbar
locations

Interfering powerbar
locations

Figure 9 –Cut a 3” maximum slit in rubber sheets at interfering powerbar locations

11. Once properly positioned, flip back half of ESS Rubber Roof Sheets (P/N 761574) x2, expose adhesive side
of Velcro strip (located under ESS sheet) and adhere in position on battery packs. Repeat for the second half
of the rubber sheet. Refer to Figures 8, 9 and 10.

Figure 10 – ESS rubber roof sheet in final position on battery packs

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12. Perform a visual inspection of existing black Rubatex Seal (P/N 5968183) on both ESS Enclosure Frame and
top flanges of Door Support Rails. Replace if sections are observed missing/badly damaged. Refer to Figure
11.

Black Rubatex Seal (P/N
5968183) on ESS Enclosure
Frame (Door Support Rails
not shown)

Figure 11 – Visually inspect existing Black Rubatex Seal (Door Support Rails not shown)

13. Cut continuous strips of Emseal Tape (P/N 761257) and adhere to existing black Rubatex Seal (P/N
5968183) along the outer perimeter of the ESS Enclosure Frame. Apply tape in full lengths with no seams
(except at corners). Refer to Figures 12 and 13.
Note: When applying Emseal Tape (P/N 761257), do not stretch tape around inside and outside corners of
stiffening channel notches. Let tape relax naturally to prevent it from expanding/tearing. Refer to Figure 13.

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Figure 13

Apply Emseal Tape (P/N 761257)
perimeter of ESS Enclosure Frame.
Use full length strips with no seams
(except at corners).
Figure 12 – Adhere Emseal Tape to existing black Rubatex Seal around perimeter of ESS Enclosure

Apply Emseal Tape
(P/N 761257)
perimeter of ESS
Enclosure Frame.

Do not stretch tape around inside/outside corners of
stiffening channel notches. Let tape relax naturally
to prevent it from expanding/tearing.

Figure 13 - Apply tape around inside/outside corners of stiffening channel notch

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14. Using existing hardware, reinstall CS/SS Door Support Rails with Flange Bolts (P/N 347979) x4 locations on
the rooftop ESS enclosure. Refer back Step 7, Figures 4 and 5.
15. Secure LV Wire Harnesses back to flanges on CS/SS Door Support Rails using Tyraps (P/N 5958112) x16
locations. Refer back to Step 6, to Figure 4.
16. Position Roof Seal Blocks (P/N 761202) x2 under Door Support Rail flanges, flush with the ESS Enclosure
Frame to create a continuous contact surface for Emseal Tape (P/N 761257). Clean bonding surfaces with
Isopropyl Alcohol (P/N 134336) and a lint free cloth. Perform at 8 locations total. Refer to Figure 14.
Note: Trimming Roof Seal Blocks (P/N 761202) may be required to ensure a correct fit.

17. Apply Sika 221 White (P/N 055701) to bonding surfaces and secure blocks to Door Support Rail flanges/ESS
Enclosure Frame. Perform at 8 locations total. Refer to Figure 14.
Note: Apply enough Sika 221 White (P/N 055701) around block to create a water tight seal.

Roof Seal Blocks (P/N 761202).
Apply enough Sika 221 White
(P/N 055701) around block to
create a water tight seal.

Create a continuous contact
surface for Emseal Tape
(P/N 761257)

Secure to Door Support
Rail top flanges/ESS
Enclosure Frame

Figure 14 – Position roof seal blocks under flanges, flush with frame (8 locations total)

18. Cut continuous strips of Emseal Tape (P/N 761257) and adhere to existing black Rubatex Seal (P/N
5968183) along top flanges on Door Support Rails. Refer to Figure 15.

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Cut continuous strips of Emseal Tape
(P/N 761257) and adhere along top
flanges of Door Support Rails
Front of bus

Figure 15- Adhere Emseal Tape along Door Support Rail top flanges
19. Insert Push Plugs (P/N 757560) x6 into existing holes in the CS Door Support Rail. Secure plugs with Sika
221 White (P/N 055701) to create a water tight seal. Refer to Figures 16 and 17.

Front of bus

Locations of existing holes
in the CS Door Support
Rail inside ESS Enclosure

Figure 16 - CS Door Support Rail – Insert plugs into existing hole locations

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Insert Push Plugs (P/N 757560)
and secure with Sika 221 White
(P/N 055701) to create a water
tight seal – 3 locations total.

Figure 17 – Insert plugs into existing holes and secure with Sika 221 White (3 locations total)

20. Reinstall CS/SS access panels (and insulation) on ESS enclosures using existing hardware and new Sealing
Washers (P/N 284236) x10 on tops of ESS panels. Torque hardware to 91 IN-LBS (7.58 FT-LBS) and apply
torque marks. Refer to Figure 18.
Note: Prior to reinstalling CS/SS access panels, puncture through Emseal Tape/Rubatex Seal to prevent
tearing while fasteners are reinserted.

Reinstall CS/SS access panels
using existing hardware and new
Sealing Washers (P/N 284236) –