SERVICE MANUAL BULLETIN
This Service Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. Refer to details below.

SMB-187
ISSUE DATE: Sep 13 2019

APPLICABILITY
VEHICLE LENGTH

 30ft.

 35ft.

 40ft.

 60ft.

 Xcelsior®

 MiDi®

 Invero®

 Low Floor

 High Floor

 Diesel

 Diesel/Electric

 CNG

 Fuel Cell

 Trolley/Electric

 Battery/Electric

 ALL

VEHICLE TYPE

FUEL TYPE

 ALL

 LNG
 ALL

SUBJECT

High Voltage Safety

SECTION TITLE

4 - ELECTRIC DRIVE SYSTEM

DETAILS

This bulletin stresses the need for safety when performing maintenance
on the High Voltage System on your New Flyer vehicle.
This information supersedes any prior information on this subject
already provided in your New Flyer Service Manuals. Make this Service
Bulletin available to service personnel to inform them of changed information.

SMB-187

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

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SERVICE MANUAL BULLETIN
SMB-187
1.

SAFETY

1.2.1.2. Stored Energy
Potential energy stored in electrochemical
or electrostatic devices such as batteries
or capacitors.

During component removal or installation, ensure that the vehicle is deengerized. Set the Master Run switch to
the STOP-SYSTEM position and the
Batter Disconnect switch to the OFF
position. On vehicles equipped with a
High Voltage Interlock switch, ensure it
is in the High Voltage (HV) OFF position. Lock and tag the switch and retain
the key. Failure to follow this procedure
may result in personal injury or component damage.

1.1.

High Voltage Safety

Personnel must always remember the
characteristics of these stored energy
devices and under what conditions they
retain energy and pose an electrocution
risk.

1.3.

Equipment Requirements
The following equipment is required:
❒ Personal Protection Equipment (PPE)
meeting Category 2 ratings for Arc Flash
protection. Refer to 1.5. “PPE Requirements” on page 3 in this bulletin for more
information on the category ratings
❒ Rubber Insulating Gloves meeting Class 0
ratings (0 to 1000 VAC/1500 VDC) for High
Voltage protection

The Electric Drive System uses hazardous High Voltage (HV) electrical energy.
There is a risk of electric shock. Only
trained service personnel should
access components of the High Voltage
Equipment. Failure to observe all HV
electrical safety precautions may result
in personal injury and/or death.

❒ Insulated rescue hook

The highest concerns are for the safety
of service personnel working on the
vehicle and others in the vicinity, and in
minimizing the potential for damage to
property.

❒ Clamp-on current probe, 1000 volt Category III, 600 volt Category IV

Death, serious injury, and significant
material damage will result if these
safety rules are not followed.

1.2.

1.2.1.

General Safety Guidelines &
Practices

❒ ABC fire extinguisher, 5 lb. minimum, at the
activity areas
❒ Digital Multimeter (DMM), 1000 volt Category III, 600 volt Category IV, 10 Megohm
impedance or greater with insulated case
or rubber holster

❒ High-Potential (Hi-Pot) dielectric strength
tester
❒ Phase rotation meter
❒ Adequate lighting
❒ HV insulated mat
❒ Safety barricade with warning lights and
“Danger High Voltage” signs

The following provides general guidelines
in relation to safety and best practices
when completing installation or servicing
work on any New Flyer Electric Drive System vehicle.

❒ Belt tool pouch (use only to carry small
components up/down a ladder)

Definitions

❒ Any other equipment required by applicable local and federal regulations

1.2.1.1. High Voltage (HV)

❒ Torque screwdriver set
❒ Spare HV and low voltage fuses

Any form of voltage that is greater than 50
volts.

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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

SMB-187

SERVICE MANUAL BULLETIN
SMB-187
1.3.1.

❒ Operation of High Potential (Hi-Pot) or
dielectric strength test equipment

Equipment Calibration
All test equipment must be within their calibration interval and recorded with the
respective serial numbers. These records
must be available to the Checker.

1.3.2.

❒ Operation of phase rotation meter
To ensure effectiveness of training, exams
of the trained material shall be required
with a high passing mark of at least 80%
and a retraining of the missed 20% on a
one to one basis.

Insulated Tools
Insulated tools should be visually
inspected for insulation damage before
and after each session of use.

1.5.

PPE Requirements

1.4.

Personnel Requirements

1.5.1.

General

1.4.1.

General
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
troubleshooting and servicing procedures,
together, to ensure safety of themselves,
others nearby and for the protection of
vehicle and property. Refresher training
shall be provided to these personnel as
required

1.4.2.

PPE voltage class, Arc Flash rating shall
be compatible with the voltage and arc
flash capability of the systems being
tested.
1.5.1.1. Gloves
Gloves used for High Voltage protection
are divided into 6 classes by maximum
voltage rating. Class 0 (0 to 1000 VAC/
1500 VDC) rated gloves are adequate for
all New Flyer High Voltage applications.

☞NOTE:

Leather protector gloves should always be
worn over rubber insulating gloves.

Training Requirements
The training of personnel shall consist of:

❒ HV and low voltage basics, intermediate
and advanced electricity

1.5.1.2. Arc Flash
PPE used in high voltage applications is
divided into 5 categories by Minimum Arc
ratings. Category 2 rated PPE is adequate
for all New Flyer High Voltage applications.
See “Fig. 1: PPE Categories” on page 4.

❒ HV and low voltage electrical systems of
the vehicle
❒ Shop safety practices and procedures
❒ First aid including CPR and the use of the
shop defibrillator
❒ How to release a victim that can’t let go of
HV
❒ Quickest method of shutting down HV
❒ Fire fighting and emergency procedures
❒ HV and arcflash safety
❒ Organized and tidy placement of equipment and tools allowing for unrestricted
movement

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1.5.2.

PPE Care & Testing
Rubber insulated PPE shall be periodically
cleaned and tested in accordance with 29
CFR 1910.137 and the appropriate ANSI/
ASTM standards. HV gloves, sleeves and
mats shall be tested every 6 months. PPE
apparel shall be cleaned and maintained in
accordance with the manufacturer’s
instructions. A record of the PPE testing
shall be maintained and available to the
users.

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 of 6

SERVICE MANUAL BULLETIN
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s142301c.svg

Fig. 1: PPE Categories
1.5.3.

Inspect PPE equipment, before use, for
any degradation or damage and ensure
that the HV gloves have been tested every
6 months. Also perform an air pressure
test on the HV gloves before and after
each use. If, during PPE use, a potential
damaging incident occurred to the PPE,
stop further testing and inspect the PPE. If
at any time the PPE is defective, reject it,
and obtain an accepted one.
1.5.4.

PPE Storage
PPE apparel should be stored lying flat,
undistorted, right-side out and not folded in
protective containers. The HV mats can be
rolled with an inside diameter greater than

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2 inches. Rubber HV gloves should be
stored in cool, dark, dry, and free from
damaging chemicals or vapors. The glove
cuffs should face downwards, without folding, in the appropriate glove bag and hung
vertically.

PPE Inspection

1.5.5.

Electrical Injuries
Electrical injuries should be immediately
reported to first aid personnel and the
supervisor. Even non-injurious electrical
shocks, originating from components in the
HV system, should be reported to the
supervisor. All incidents should be immediately investigated and documented to
determine the cause and prevent the
occurrence in the future.

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

SMB-187

SERVICE MANUAL BULLETIN
SMB-187
PPE CATEGORIES
CATEGORY 0

CATEGORY 1

CATEGORY 2

1.2 cal/cm2

4 cal/cm2

8 cal/cm2

Arc Rated Clothing:
Untreated cotton long sleeve
shirt and pants

AR long sleeve shirt and pants
or AR coverall

AR long sleeve shirt and pants
or AR coverall

AR flash suit hood or AR face
shield

AR flash suit hood or AR face
shield and AR balaclava

AR jacket, parka, rainwear or
hard hat liner (as needed)

AR jacket, parka, rainwear or
hard hat liner (as needed)

Other Equipment:
Hard hat

Hard hat

Hard hat

Safety glasses

Safety glasses or goggles

Safety glasses or goggles

Hearing protection

Hearing protection (with inserts)

Hearing protection (with inserts)

Heavy duty leather gloves

Heavy duty leather gloves

Leather footwear (as needed)

Leather footwear (as needed)

High Voltage Gloves rated Class
0 (0 to 1000 VAC/1500 VDC)

High Voltage Gloves rated Class
0 (0 to 1000 VAC/1500 VDC)

High Voltage Gloves rated Class
0 (0 to 1000 VAC/1500 VDC)

1.6.

Service Preparation
❒ The scope of the work must be accurately
defined such as a Servicing Procedure
that requires systematic steps with signoffs. Before servicing is performed, the
Supervisor, Checker and Monitor/Recorder
must conduct a briefing of what shall transpire, identify potential hazards and resist
pressures to speed through a procedure,
anticipate problems and question possible
events. If an unexpected electrical hazard
or fault occurs, during any service work, it
must be immediately reported to the
supervisor. After the work is completed the
same group should review the results and
processes and make proposed modifications to the procedures if required.
❒ Install Safety barricade with warning lights
and signs indicating “Danger High Voltage”
around the vehicle perimeter and ensure
no personnel are within the fenced perimeter during the service procedure.

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❒ It shall always be the goal to check the
systems as much as possible with all HV
power OFF and Locked Out/Tagged Out
and proven as de-energized by voltage
measurement using a Category III or better Digital Multimeter (DMM). The functionality of the DMM must be proved before
and after the verification of no HV present.
Then, if possible, the HV systems should
be challenged by trying to energize them
while checking that no HV appears.
❒ When it is necessary to perform tests of
HV systems with the power ON, then the
Working Live procedure must be followed.
Refer to 1.6.3. “Working Live” on page 6 in
this bulletin for procedure.
❒ The test personnel shall always rehearse
the actions required in case of any possible accident scenarios.
❒ Before beginning the Service procedure,
the test personnel shall remove all their
jewelry (including pierced ones), watches
and any electrically conductive objects on
them.

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

5 of 6

SERVICE MANUAL BULLETIN
SMB-187
1.6.1.

Prior to conducting any high voltage servicing, the vehicle must be visually
inspected to ensure all systems are properly maintained, paying special attention to
any evidence of fretting, chafing, or other
damage to HV cables or equipment.
1.6.2.

Lockout/Tagout Procedure
The Lockout/Tagout procedure should be
followed as specified in the respective service procedure.
When removing the lock and tag:

1. The locks and tags shall be removed by
the installer of the locks and tags or shall
be removed under her/his supervision.
2. If the installer of the locks and tags is not
available, then her/his supervisor:
a. Ensures that the installer of the locks
and tags is not in the facility.
b. Contacts the installer to inform her/him
that the locks and tags will be removed.

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c. Reminds the installer of the lock and
tag removal when she/he resumes
work.

Vehicle Inspection

1.6.3.

Working Live
To maximize safety, it is always important
to perform the maximum amount of HV
service in the de-energized state. Component removal and installation must always
be performed in a de-energized state.
When it is necessary to test HV equipment
while energized or to verify whether HV is
present, the utmost care and safety procedures must be used including:

❒ Wearing appropriate PPE including protector gloves over top of the HV rubber
gloves.
❒ Ensuring all personnel, other than the
Checker and Monitor/Recorder, are clear
of the vehicle.
❒ Standing on HV insulated mat.
❒ Covering any energized HV components
not being immediately worked on with an
HV insulated mat to limit exposure to live
parts.

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

SMB-187