INSTRUCTION TO SERVICE
ITS: 59008
SECTION:

260

BATTERY COMPARTMENT

WRITTEN BY:

Curtis Matthews

SUBJECT:

MSD replacement – SR-2212, 2213, 2315, 2363

ITS59008

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.

Contents
INSTRUCTION TO SERVICE .................................................................................................................. 1
1.0

SAFETY PROCEDURE .................................................................................................................. 3

2.0

Rear MSD Removal Procedure ........................................................................................................ 7

3.0

Inspection Procedure – Rear ESS .................................................................................................... 9

4.0

MSD Replacement Procedure – Rear ESS .................................................................................... 12

5.0

Roof MSD Removal Procedure ..................................................................................................... 15

6.0

Inspection Procedure – Roof ESS .................................................................................................. 16

7.0

MSD Replacement Procedure – Roof ESS .................................................................................... 17

Appendix A – NFIL Spec 532295 - High Voltage Safety Guidelines & Procedures for New Flyer
Battery Bus................................................................................................................................................ 21
Appendix B – NFIL PPE Categories ........................................................................................................ 26
Appendix C – Live Work Permit .............................................................................................................. 28
Appendix D – ESS HV Inspection Sheet .................................................................................................. 30

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WARNING:

Only trained personnel shall supervise and perform High Voltage system testing,
checkout and troubleshooting. Two personnel (one called the Checker & the other
called Monitor/Recorder) shall perform Checkout Procedures, together, to ensure
safety of themselves, others nearby & for the protection of vehicle & property.
Refresher training shall be provided to these personnel on a regular basis and
when new systems are to be checked by them. The training of the personnel shall
consist of:

1.0 SAFETY PROCEDURE



1.1

Fill out and submit a Live Work Permit to the shop lead. See Appendix C for a Live Work Permit.

1.2

Turn the master run switch to the off position and wait 5 minutes before proceeding.

1.3

Turn the 12/24V battery disconnect and HV Interlock switch to the “OFF” position.

1.4

Lock and Tag the electrical system of the bus out and retain the key. See Figure 1.

1.5

Install a Lockout/Tagout Steering wheel cover as require

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

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WARNING:

High Voltage PPE Category 2 is required. Please refer to Appendix B or the safety
section of your Preventive Maintenance Manual and Service Manual for more
information. There shall be no communication from observers with the 2 personnel
performing HV work. If required all work must stop until communication has been
completed.

1.6

Review the scope of work to be completed with the Monitor/Recorder.

1.7

Review/Rehearse the actions required in case of any possible accident scenarios.

1.8

Using an appropriate voltmeter as per appendix A, confirm that no voltage is present between
HVPOS_VEH_FB & HVNEG_VEH_FB before proceeding. See Figure 2. These connections are located
inside the HV Fuse box inside the inverter rack. See Figure 3 layout for location.

Figure 2: High voltage fuse box location reference

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1.9

Identify the location(s) of the ESS compartments that will require work. See Figure 3. (Refer to your
wiring schematic or schematics often located on the underside of the ESS enclosure lids)

ESS ABOVE CENTER
WHEELHOUSE

Figure 3: Battery pack string location reference
1.10 Ensure the bus is not charging and gain access to the roof of the bus ESS enclosures and the other
applicable ESS enclosure(s). Ensure the appropriate fall protection PPE is used and appropriate
safety procedures are followed when applicable.
1.11 Determine and organize the required tools neatly before work begins.
1.12 Before removing any MSD(s), confirm voltage is present between the positive in terminal on the
BDU and negative in terminal on the BDU. See Figure 5.

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1.13 Confirm that NO voltage is present between the positive out terminal on the BDU contactor and
negative out terminal on the BDU contactor. See Figure 4.

Figure 4: BDU and contactor location reference

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2.0 Rear MSD Removal Procedure
2.1

Gain access to the rear ESS compartment. See figure 5.

Open rear ESS
compartment
door

Figure 5: Rear of bus ESS compartment door

2.2

Loosen all rear ESS panel hardware x18, remove panel and set aside to be re-installed later. See
figure 6.

Loosen rear
ESS panel
hardware x18

Rear ESS panel

Figure 6: Rear ESS panels

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2.3

Locate and remove MSD plugs x2 in rear ESS. See figure 7.

Remove and
discard rear ESS
MSD plugs x2

Figure 7: Rear ESS MSDs

3.3

Remove rear ESS cover and set aside.
3.1.1

Unfasten and keep hardware on rear ESS cover plate mounting hardware, bolts +
washers. Keep bolts and washers. See figure 8.

3.1.2

Remove MSD closeout from rear ESS cover plate to be re-worked for new MSD
hardware positions.

Remove mounting
hardware
Remove MSD
closeout

Rear ESS
cover plate
Figure 8: Rear ESS cover plate and closeout

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3.0 Inspection Procedure – Rear ESS
Ensure you fill out the XE High Voltage Inspection Check Sheet for each bus. The ESS Inspection Sheet can be
found in appendix D as well as the attachments of FSAR 190819-115712 labeled “ITS-59020 ESS Inspection
Sheet.pdf”. Once complete, return to your local RPSM to upload into the attachments of the appropriate Reported
Incident that can be found linked to FSAR 190819-115712.

3.1

Remove the remaining covers highlighted below in figure 9. Replace at the end of section 3
torquing cover mounting hardware to 5 ft-lbs WET with Loctite PN: 081034.

Figure 9: Rear ESS With Outer Covers Removed

3.2

Inspect the two low voltage connections at the bottom of the BDU assemblies for securement and
make note on the inspection sheet. Remove the two low voltage connections at the bottom of both
BDU’s.

3.3

Remove the two BDU assemblies while saving the existing hardware to re-use. 4 bolts are used to
secure the BDU to the ESS and 4 nuts are used to secure the bus bars as seen below in figure 10.
3.3.1

Remove the 4 nuts securing the bus bars to the BDU as seen on the bottom of the left view
in Figure 10. ( 97 ±8 in-lbs for re-installment).

3.3.2

Remove the 2 bolts at the back side of the BDU assembly that mounts the BDU to the ESS.
These two bolts can be seen in the single circle on the right view of Figure 11. Certain

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surrounding cable securements may need to be removed in order to gain access to these
bolts. (torque to 50 in-lbs DRY for re-installment).
3.3.3

Remove the 2 bolts at the top of the BDU assembly. Replace at the end of section 3,
torquing mounting hardware to 10 ft-lbs WET with Loctite PN: 081034.

Figure 10: Rear BDU Assemblies

Figure 11: BDU mounting hardware

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3.4

Verify all busbar to battery connections highlighted in figure 12 below are torqued to 80 INCH-LBS.

Figure 12: Rear ESS Enclosure Battery Busbar’s

3.5

Re-install the BDU assemblies using the existing hardware. Ensure both J1 and J2 to BDU
connections circled in Figure 13 below are seated properly.

Figure 13: Rear ESS J1-BDU Connector Location

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4.0 MSD Replacement Procedure – Rear ESS
4.1

Unfasten and discard MSD receptacle mounting hardware x8. See figure 14.

MSD
receptacles x2

Remove and
discard MSD
receptacles
mounting hardware
x8

Figure 14: Rear ESS MSD Receptacles and bracket

4.2

Unfasten nuts from MSD receptacle studs x4 and keep hardware. Remove and discard MSD
receptacles x2. See figure 15.

Unfasten and keep
MSD stud mounting
hardware x4

Figure 15: Rear ESS MSD Receptacle underside

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3.4

Drill holes into MSD closeout and assemble new MSDs and bracket onto MSD closout.
3.4.1

Assure MSD closeout is removed from rear ESS compartment. Using bracket PN:
(853975) as a template, drill 6 holes as shown in figure 16.

3.4.1

Re-install MSD closeout onto rear ESS cover plate, and re-install rear ESS cover plate
using original hardware removed in step 3.1.1.

3.4.2

Discard 2 socket terminals and connector that come with each MSD receptacle PN:
(806450) and plug PN: (805480).

3.4.3

Using bolts PN: (822309) x8, washers PN: (260173) x8, nuts PN: (75NM06000) x8 and
spacer PN: (854046) x2, assemble MSD receptacles PN: (806450) x2 and plugs PN:
(805480) x2 onto bracket PN: (853975). Torque all MSD mounting hardware bolts x8 to
14 ft-lbs (DRY). See figure 17.

3.4.4

Feed HV cables through MSD closeout and fasten to new MSD receptacle PN: (806450)
x2 studs with nuts x4 kept from step 3.2, torque nuts to 80 in-lbs (DRY). See figure 17.

3.4.5

Install new MSD assembly onto MSD closeout using rivets PN: (60R03007) x6. See
figure 18.

Bracket
PN: 853975

MSD closeout

Drill 0.194-0.201 HOLE
THRU x6, install 6 rivets
MSD receptacles PN: 806450
and plugs PN: 805480 x2

Figure 16: Rear ESS MSD closeout bench assembly

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MSD receptacle PN: 806450
and plug PN: 805480 x2

MSD closeout

EP81HV5 POS

Fasten bracket
mounting hardware
x8 to 14 ft-lbs DRY

EP81HV10 NEG
EP82HV10 NEG

EP82HV5 POS

MSD spacer PN:
854046 x2
Figure 17: Backside of new MSDs mounted to MSD closeout

Rivets PN:
60R03007 x6

MSD assembly

MSD closeout

Figure 18: Rear ESS MSD final assembly

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5.0 Roof MSD Removal Procedure
5.1

Locate the front and rear rooftop ESS and open ESS battery panel. See figure 19.

Open ESS
battery panel

Figure 19: Front rooftop ESS

5.2

Locate, remove and discard the MSD plugs. See figure 20.
5.2.1

X2 in front rooftop ESS.

5.2.2

X2 in middle rooftop ESS.

5.2.3

X1 in rear rooftop ESS

Remove and
discard MSD plugs

Figure 20: Rooftop ESS MSD location

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6.0 Inspection Procedure – Roof ESS
6.1

Verify all battery to busbar connections are torqued to 80 INCH-LBS.

Figure 19: Roof ESS Enclosure

 NOTE: ESS layout will vary depending on location.
6.2

Ensure the J1 to BDU connections are seated properly. Refer to Figure 20 for J1-BDU connector
location examples.

Figure 20: Roof ESS J1 Connector Location Example

 NOTE: ESS layout will vary depending on location.
6.3

Repeat steps 6.1 to 6.2 for all roof ESS enclosures.

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7.0 MSD Replacement Procedure – Roof ESS
3.5 Locate rooftop MSDs in figure 21.

Front and mid rooftop
ESS MSDs x4

Rear rooftop ESS MSD x1

Figure 21: Rooftop ESS locations

3.6 Remove and discard rooftop MSD receptacles and brackets x5. See figure 22.
3.6.1

Unfasten bracket mounting hardware from rooftop ESS frame x2 bolts + washers + nuts.
Keep bolts, washers, and nuts.

3.6.2

Unfasten nuts from MSD receptacle studs x2 and keep hardware. Remove and discard
MSD receptacle and bracket.

3.6.3

Unfasten and discard MSD receptacle mounting hardware x4.

Remove and
discard bracket

Remove and
discard MSD