INSTRUCTION TO SERVICE
ITS: 58926
SECTION:

Electrical

WRITTEN BY:

Daniel Tice

SUBJECT:

DC Charge Rail and COM Box Lid Replacement and Inspection Requirement

ITS-58926
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.

Only trained personnel shall supervise and perform the High Voltage system testing,
servicing and troubleshooting contained in this procedure. Two personnel (one called
the Checker and the other called Monitor/Recorder) shall perform troubleshooting and
servicing procedures, together, to ensure the safety of themselves, others nearby and
for the protection of vehicle and property.
PROCEDURE:
Part A: DC Charge Rail and COM Box Lid Replacement.
1.
2.
3.
4.

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.
Lock and Tag the electrical system of the bus out and retain the key. See Figure 1.
Install a Lockout/Tagout Steering wheel cover as required.

 NOTE: Refer to the Lockout/Tagout Procedure in section 1 of your Preventive Maintenance Manual
or section 9 of your Service manual for additional information.
 NOTE: Use commercially available lock out equipment and tags being sure to follow any local laws
or workplace procedures.


NOTE: 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.

Figure 1: Lockout tagout location reference.

_________________________________________________________________________________________________________________
ITS: 58956
Page 2 of 17



Caution: Appropriate High Voltage PPE is required. Please refer to the safety section 1 of your
New Flyer Preventive Maintenance Manual or Service Manual for more information. (See Appendix B)
 Caution: No communication from observers with the H/V Tech and Checker while work is being
performed. If required all work must stop until communication has been completed.
5.

Identify the location of the Charge Rail Contactor Box and COM Box that will require work. See Figure 2.

COM
BOX

DC Rail
Junction
Box

COM BOX

CHARGE RAIL
CONTACTORS

DC RAIL
JUNCTION
BOX

Figure 2: DC charge rail and com box location reference.

_________________________________________________________________________________________________________________
ITS: 58956
Page 3 of 17

6.

Ensure the bus is not running or charging and gain access to the roof where the work is required. Ensure the
appropriate fall protection PPE is used and appropriate safety procedures are followed.
 Caution: Wear High Voltage PPE. Refer to your PM or Service Manual for PPE requirements.
 Caution: No communication from observers with the H/V Tech and Checker while work is being
performed. If required all work must stop until communication has been completed.

7.
8.
9.
10.
11.
12.
13.
14.

Review the scope of work to be completed with the Monitor/Recorder.
Review/rehearse the actions required in case of any possible accident scenarios.
Determine and organize the required tools neatly before work begins.
Gain access to the DC charge rail box and Com Box where required.
Confirm that no voltage is present before work begins.
Remove the existing mounting Screws, Sealing Washer and Lid. See Figure 3.
Remove the U-Seal and internal lanyard hardware when required.
Complete the steps in Part B of the High Voltage Cable and Torque Verification Inspection as required per
your application.
 Note: Set aside the lanyard hardware for re-installation.
Lid

Lid
Screw &
Sealing Washer
U-Seal

Lanyard

Figurer 3: DC charge rail box and com box hardware location reference.

_________________________________________________________________________________________________________________
ITS: 58956
Page 4 of 17

Part B: High Voltage Cable and Torque Verification Inspection.



Note: Fill out one High Voltage Cable and Torque Verification Inspection Form for each bus as you carry out
the inspection. Document any issues being as descriptive as possible and take quality pictures when required to
help communicate, grasp and visually understand the concern and its severity. These may be required to submit
to the RPSM. Please ensure all inspection forms are submitted to the RPSM after completion. Forms are in
Appendix C or the attachments of FSAR 200131-116166 for printing purposes. Completed forms are to be
uploaded by the RPSM to the RI for each property.
WARNING: Using appropriate PPE, confirm that there is no voltage present on any connection point .

15.
16.
17.
18.
19.
20.

Inspect and clean any water or moisture present inside the Rail Contactor Box. See Figure 4.
Thoroughly inspect all cables and wires for chafing/kinking.
Thoroughly inspect all connections for corrosion.
Ensure all cable gland retaining nuts and dome nuts are torqued to 11 ft-lbs dry. See Figure 4.
Ensure contactor hardware is torqued down to 22.1 ft-lbs dry. See Figure 4.
Ensure M12 hardware is torqued down to 40 ft-lbs dry. See Figure 4.



Note: Clean off the existing torque marks and apply new torque marks after each torque has been

verified.



Note: Note some applications have more or less power cable connections.
Torque Gland Retaining
Nuts at 11 FT- LB Dry.

Torque Gland Nuts
at 11 FT- LB Dry.

Cable Gland Retaining nuts and dome nuts.

Torque Contactor Hardware
to 22.1 FT- LB Dry.

Torque Contactor Hardware
to 22.1 FT- LB Dry.

Contactor Hardware.

Torque M12 Hardware
to 40 FT- LB Dry.

Contactor Hardware and M12 Hardware.
Figure 4: Charge rail and junction torque spec location reference.

_________________________________________________________________________________________________________________
ITS: 58956
Page 5 of 17

21. After confirming all inspections have been completed locate the appropriate replacement lid Kit(s) for your
application using the tables below.
22. Apply item #4 U-Seal to the appropriate box and gently work the U-Seal on the top edge of the box. Take care
not to stretch the seal while applying it. See Figure 5.
23. Ensure the corners make the contours of the box correctly.
24. Join the two cut ends together and trim to create a tight fit.

SR

SR QTY

New DC
Charge Rail
Box Lid PN

1682
2144
2143
2165
2145
2211
2297
2313
2315

2
1
1
5
1
5
3
2
8

852365
852394
852394
852394
852394
852365
852394
852394
852365

New Com Box
Lid PN

SR

n/a
n/a
852394
852394
852394
852394
852394
852394
n/a

2212
2318
2182
2213
2352
2363
2319
2382
2374

SR QTY

New DC
Charge Rail
Box Lid PN

New Com
Box Lid PN

5
4
2
40
8
15
1
15
2

852365
852394
852365
852365
852365
852365
852365
852365
852365

n/a
852394
852394
n/a
n/a
n/a
n/a
n/a
n/a

4

Lid Kit

Trim and Join to
Create Tight Fit.

Figurer 5: U-Seal location reference.
Item

Part Number

KIT

See Table

4

648045

Description
Lid Kit
Seal, U-Shaped Foam

_________________________________________________________________________________________________________________
ITS: 58956
Page 6 of 17

25. Re-attach the lanyard to the new lid with the existing hardware when required. See Figure 6.
26. Attach the lid to the box with items #2 Sealing Washer and item #1 Screws.



NOTE: Torque all the mounting screws to 1.1 FT LBS. See Figure 6.

Torque hardware
at 1.1 FT LBS.
1

2

Lid

Ref. Condensation
Valve #3.

Figurer 6: Lid and hardware mounting location reference.
Item

Part Number

Description

KIT

See Table

1

6483042

Screw DIN7985 – 5x50

2

648043

Seal M5 Washer, 3/8 SST

3

648044

Seal U-Shaped Foam

Lid Kit

_________________________________________________________________________________________________________________
ITS: 58956
Page 7 of 17

27.
28.
29.
30.
31.

Ensure that all tools and debris are clear from the work area.
Remove the lock out tag out equipment.
Turn the 12/24 Volt battery disconnect switch to the “ON” position. See Figure 7.
Turn the high voltage interlock to the “ON” position. See Figure 6.
Return the bus to service.

Figure 7: Lockout Tagout location reference.

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
assembly drawings and where conflicts arise, the released engineering drawings
take precedence.
_________________________________________________________________________________________________________________