INSTRUCTION TO SERVICE
ITS: 58961
SECTION:

Electrical

WRITTEN BY:

Daniel Tice

SUBJECT:

DC Charge Rail Box Secondary Cover Replacement

ITS-58961
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.

PROCEDURE:
1.
2.
3.
4.
5.
6.

Turn the master run switch to the off position and wait 5 minutes before proceeding.
Turn the 12/24V battery disconnect and HV Interlock switch to the “OFF” position.
Wear proper PPE.
Ensure the bus is not charging.
Follow proper Lock Out Tag Out Procedure.
Use the buddy system and follow the High Voltage Safety Guidelines & Procedures referenced in appendix A



NOTE: Refer to New Flyer High Voltage Safety Guidelines and Procedures Document 532295
(Appendix A) when completing installation or service work on or around high voltage power systems.



NOTE: Refer to Appendix B for additional information regarding PPE.

Figure 1: Battery disconnect location reference.

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Gain access to the charge rail contactor box secondary cover. See Figure 2.
If possible, replace the Siemens charge rail box cover with the latest cover with a condensation valve before
replacing the secondary cover identified in this ITS. The Siemens cover can be changed at later time if
required.
9. Remove the mounting hardware in the corners of the existing secondary cover. See Figure 2.
10. Discard the old cover and mounting hardware.
7.
8.

Secondary Cover

Secondary Cover Location

Figure 2: Charge rail secondary cover location reference.
11. Attach item #1 and #4 Brackets as shown below with items #2 Screws, #3 Washers and apply 1 or 2 drops of
Loctite #5. See Figure 3.
1

2,3,5

4

Figure 3: Street side secondary cover bracket location references.
Item

Part Number

Description

1

827847

Bracket Protective, DC CNTR Box

2
3
4
5

34S04010

Screw ¼-20 x 5/8

50W04000

Washer Flat ¼

840641

Bracket Charge Box Cover

081034

Loctite 243 Med

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12. Using items #6 Tall bracket and item #7 Short bracket mark the mounting holes as close to the reference
dimensions shown below as possible on the DC rail frame. See Figure 4.
 NOTE: Dimensions are for reference only. Items #6 and #7 Brackets are to be positioned to work
in your application.
13. Drill a pilot hole with a 1/8” drill bit in the four marked locations then open up with a 25/64” drill bit and install
item #9 Rivnut with a rivnut tool. See Figure 4.
 NOTE: Ensure not to drill into any other components under the bracket or roof structure.
14. Install Items #6 and #7 Brackets as shown below with items #8 Screws, #3 Washers, item #10 Never Seize
and apply 1 or 2 drops of Loctite #5 See Figure 4.

These Views Are Rotated
to Provide A Side View
for Approximate
Locations.

7

3,5,6,9,10

6

3,5,7,9,10

Top View

DC Rail
Frame

Side View

Figure 4: Curb side secondary cover bracket location reference.

Item

Part Number

Description

3
5

50W04000

Washer Flat ¼

081034

Loctite 243 Med

6

840666

Tall Bracket DC Charge Box Cover

7
8

840713

Short Bracket DC Charge Box Cover

14S04010

Screw ¼ x 5/8

736408

Rivnut, ¼” – 20 UNC x 0.27/.125

5928660

Never Seize

9
10

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15. Mark and drill two 7/32” holes for the mounting hardware for the forward mounting brackets as shown below.
One on the left front .91” down from the bottom edge of the tubing and another on the right side 2.17 inches
down. Tap to ¼-20. See Figure 5.
Drill with 7/32”
drill bit and tap to
¼-20.

Street Side Front

Curb Side Front

Figure 5: Forward secondary cover bracket hole location reference.
16. Install Items #11 and #12 Brackets with items #3 Washers, #2 Screws, item #10 Never Seize and apply 1 or 2
drops of Loctite #5. See Figure 6.
2,3,5,10,12

2,3,5,10,11

Figure 6: Forward secondary cover bracket mounting location reference.
Item

Part Number

Description

2

34S04010

Screw ¼-20 x 5/8

3

50W04000

Washer Flat ¼

5

081034

Loctite 243 Med

10

5928660

Never Seize

11

853966

Bracket Protection

12

840891

Bracket Protection

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17. Apply item #14 Bulb Seal to item #15 Secondary cover along the edge that meets the ESS Unit. See Figure 7.
18. Place item #15 Secondary cover on the mounting brackets and press it against the ESS unit compressing
item #14 Bulb Seal slightly and hold pressure against it while reaching under the cover marking the hole
locations in the mounting brackets. See Figure 7.
19. Remove Secondary cover and drill the mounting holes to .281” or using a K size drill bit.

15

Mark hole locations
from underside of
cover. Cover removed
for clarity.

Mark hole locations
from underside of
cover.

14

Figure 7: Forward secondary cover mounting hole location reference.

Item

Part Number

Description

14

047925

Bulb Seal

15

840558

Secondary Cover

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20. Install item #15 Secondary cover using items #16 Bolt, #3 Washer, #13 Nut, #10 Never Seize and apply 1 or
2 drops of Loctite #5 See Figure 8.

15

3,5,10,13,16

Figure 8: Forward secondary cover mounting location reference.

Item

Part Number

Description

3

50W04000

Washer Flat ¼

5

081034

Loctite 243 Med

10

5928660

Never Seize

13

50N04000

Hex Nut SST ¼-20 Nut

15

840558

Secondary Cover

16

20B04010

Bolt Hex, ¼-20 x 5/8”

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21.
22.
23.
24.
25.
26.

Confirm that all hardware is tight.
Ensure that all tools and debris are clear from the work area.
Turn the 12/24 Volt battery disconnect switch to the “ON” position. See Figure 9.
Turn the high voltage interlock to the “ON” position. See Figure 9.
Remove any lock out tag out equipment.
Return the bus to service.

Figure 9: Battery disconnect location reference.

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Appendix A – NFIL Spec 532295 - High
Voltage Safety Guidelines & Procedures for
New Flyer Battery Bus
The following provides general guidelines in relation to safety and best practices
when completing installation or servicing work on any New Flyer battery bus
vehicle platform.
This document is not meant to supersede the actual released installation and