INSTRUCTION TO SERVICE
ITS: 58960
SECTION:

260

Battery Compartment

WRITTEN BY:

Michel d’Auteuil

SUBJECT:

Rewire BDUs to match order to labels

ITS-58960

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.

PROCEDURE:
1. Only qualified technicians using the appropriate PPE should work on this bus. Please consult the Safety (GI-1)
section of the New Flyer Service Manual to review all requirements before working on the bus.

2. Turn the main battery disconnect switch to the “OFF” position and turn the HVIL switch to the HV “OFF” position.

Inside the Front Roof ESS Compartment
3. Gain access to the front ESS roof rack and locate HRNS-ESS RFTOP FRT BANK (see Figure 1 for reference).
4. Remove MSD4 and MSD5 from their receptacles.
5. Find the J1 connector on BDU4 and do the following:

6.

a.

Carefully depin wire 203EP01CD from cavity 4C.

b.

Carefully depin wire 203EP01CE from cavity 3C.

c.

Insert wire 203EP01CD into cavity 3C and 203EP01CE into cavity 4C.

Find the J1 connector on BDU5 and do the following:
a.

Carefully depin wire 203EP01CD from cavity 3C.

b.

Carefully depin wire 203EP01CC from cavity 4C.

c.

Insert wire 203EP01CD into cavity 4C and 203EP01CC into cavity 3C.

7. Put MSD4 and MSD5 back in place.

On the Roof Outside of the ESS Compartments
8. Locate connector XBHRFFT-TWR on the front pothead plate and depin wire 49EP01CC from cavity 6. Cut the
terminal and then cap the wire end using END CAP (PN 8111673).
9. Locate connector XESSFRT-TWR on the on the front ESS Rack and depin 49EP01CE and 49EP01CC from
cavities K and G respectively. Cut both terminals and then cap the wire ends using END CAP (PN 8111673).
10. Locate connector XESSMID-TWR on the on the front ESS Rack and depin 49EP01CF and 49EP01CE from
cavities K and N respectively. Cut both terminals and then cap the wire ends using END CAP (PN 8111673).
11. Locate connector XESSFRT-TWR on the on the front ESS Rack and depin 49EP01CE and 49EP01CC from
cavities K and G respectively. Cut both terminals and then cap the wire ends using END CAP (PN 8111673).

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12. Route new jumper HRNS-JMPR PRPLN ROOF (PN 853524) along the existing HRNS-PRPLN ROOF as shown
in Figure 1. Ensure the loom split is facing downward and that the harness is secures to the existing harness
using cable ties every 8-12 inches.

Figure 1: Isometric view of roof ESS and HRNS-PRPLN ROOF
13. Insert the terminated wire ends from the supplied jumper harness into the cavities of the existing harness as
follows:
a.

Insert the end of wire 99EP01GB labeled “XBHRFFT-TWR-6” into cavity 6 of connector XBHRFFT-TWR.

b.

Insert the end of wire 99EP01GA labeled “XESSFRT-TWR-G” into cavity G of connector XESSFRT-TWR.

c.

Insert the end of wire 99EP01GC labeled “XESSFRT-TWR-K” into cavity K of connector XESSFRT-TWR.

d.

Insert the end of wire 99EP01GB labeled “XESSMID-TWR-N” into cavity N of connector XESSMID-TWR.

e.

Insert the end of wire 99EP01GC labeled “XESSMID-TWR-K” into cavity K of connector XESSMID-TWR.

f.

Insert the end of wire 99EP01GA labeled “XESSRFRR-TWR-G” into cavity G of connector XESSRFRRTWR.

14. Ensure the roof ESS area is cleared off and compartments properly closed.
15. Turn the main battery disconnect switch to the “ON” position and turn the HVIL switch to the HV “ON” position.

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LABOUR ESTIMATE
Operation
1

Rewire the rooftop BDU HVIL harness to make the order

Men

Hours

1

4

Labour Time
M X HR
4

match the labels

PARTS REQUIRED
Item

Part Number

1

853524

HRNS-JMPR PRPLN ROOF

Qty.
per
Coach
1

2

8111673

END CAP .137BK – 14SXL

6

Description

Units

EA

Notes

EA

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