INSTRUCTION TO SERVICE
ITS: 60816

10/19/2023

SECTION:

260-Battery Compartment

WRITTEN BY:

Devin Draward

SUBJECT:

Install 4 Version 2 drains into each ESS compartment – 6 String ESS

ISSUE:

Should a leak occur, liquids can accumulate in the ESS compartment

SUMMARY:

Version 2 drains have been developed as a product improvement for
customers

ITS60816
Ref. NHTSA Recall No.
N/A

Ref. Transport Canada Recall No.
N/A

THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED 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 unauthorized disclosure,
reproduction or other distribution of this document or information 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.

INSTRUCTION TO SERVICE
ITS-60816

PROCEDURE:
Section 1 – Initial Prep Work
1. Set the park brake and chock the wheels.
2. Turn the main battery disconnect and HV interlock switch to the “OFF” position.
WARNING: The work detailed in this ITS involves working near exposed High Voltage (HV)
compartments, even after the bus has been locked out and tagged out. It is recommended that the service
personnel be trained in NFI HV safety practices, such as those included in Appendix A – NFIL Spec
532295 - High Voltage Safety Guidelines & Procedures for New Flyer Battery Bus.
3. Perform the Lock Out Tag Out and De-Energizing procedures found in the Electrical System Section of the
New Flyer Service Manual. Reference Figure 1 below.
WARNING: ENSURE MSD DUMMY PLUGS AND ARC FLASH GLOVES ARE AVAILABLE PRIOR TO
STARTING ANY HV DISASSEMBLY



NOTE: Use commercially available lock out equipment and tags being sure to follow any local laws or
workplace procedures.

Figure 1: HV and LV Disconnect Switch Location and Arc Flash Glove Reference

WARNING: ARC FLASH GLOVES MUST BE USED ANYTIME THE ESS HAS AN
UNCOVERED HOLE

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INSTRUCTION TO SERVICE
ITS-60816
Section 2 – ESS Access
4. Gain access to the rooftop ESS enclosures. Ensure that appropriate fall protection PPE is used and available
for the duration of the work.
Ensure appropriate safety procedures are followed for the duration of the work.
5. Open the rear access door to expose the drain ports (some components removed for clarity). You will need
special torque tools to access the ports on the rear ESS.



NOTE: At this point access to the ESS compartments is available.

Figure 2: Rear ESS Layout and rear drain locations

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INSTRUCTION TO SERVICE
ITS-60816
Section 3 – Drain Installation
6. Install an ESS drain cartridge assembly PN 1044209. Torque to 40 ft-lbs. Repeat for all 24 drains.

Figure 3: Drain Locations (four per ESS) – USE ARC FLASH GLOVES

7. Clean workspace and return coach to revenue service condition.

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INSTRUCTION TO SERVICE
ITS-60816

LABOUR – 6 STRINGS
Operation
1

Number of
Technician(s)
1

INSTALL 24 ESS DRAINS 6-STRING

Hours
1.25

Labor Time
T X HR
1.25

PARTS KIT – 6 STRINGS

Item

Part Number

1

1050112

Description
ASSY – DRAIN CARTRIDGE REWORKED

Qty.
per
Coach
24

Units

Qty.

Units

Notes

EA

TOOL KIT
Item

Part Number

1

6495077

TOOL-15 DEGREE OFFSET BOX END

1

EA

2

6495078

TOOL-1/4 DRIVE RATCHET

1

EA

3

6495079

TOOL-40FT LBS PRESET TORQUE WRENCH

1

EA

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Description

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Notes

Part of Tool Kit

10/19/2023

INSTRUCTION TO SERVICE
ITS-60816

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.

Introduction
The utmost concern, while working with High Voltage (HV) systems, is the safety of yourself, other personnel, and
the potential of damage to property. To minimize these risks, it is crucial to be properly trained and always
maintain a very alert, questioning, and disciplined attitude without fail. As soon as your guard is lowered, then the
potential of an accident is probable that can hurt or kill yourself or someone else and possibly damage property.

What is High Voltage (HV)?
Any form of voltage that is greater than 50 volts if the person’s skin at the electrical contact points is not
compromised and not wet.

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INSTRUCTION TO SERVICE
ITS-60816

Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000-volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000-volt Category III, 600 volt Category IV
High Pot Tester (Hi-Pot)
Phase rotation meter
Personal Protection Equipment (PPE) appropriate for 700volt DC & 230
volt AC with Class 00 or higher HV gloves with compatible leather over
gloves. Appropriate safety glasses as well as the face shield. The PPE
shall also meet the required Arc Flash & Arc Blast requirements. Before
use, inspect the PPE in accordance with this guideline.
Adequate lighting
HV insulated mat
Two fused HV clip leads 10 inches long
Safety barricade with warning lights & "Danger High Voltage" signs
Belt tool pouch (use only to carry small components up/down a ladder)
Torque Screwdriver set
Imperial torque nut driver set
Metric torque nut driver set

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

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INSTRUCTION TO SERVICE
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Personnel Requirement
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:
HV & low voltage basics, intermediate & advanced electricity
HV & low voltage electrical systems of the vehicle
Shop safety practices & procedures
First aide including CPR & the use of the shop defibrillator
How to release a victim that can’t let go HV
Quickest method of shutting down HV
Firefighting and emergency procedures
HV & arc flash safety
Organized & tidy placement of equipment & tools allowing for
unrestricted movement
Operation of Hi-pot

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.

Checker Function
(Caution: The Checker must not have any health conditions that can be exacerbated when startled and must not
have any electronic implants.)
Directed by the Monitor/Recorder
Performs all preparations & checks
Wears PPE as specified by the Checkout Procedure
Performs all restorations

Vehicle Inspection
It is necessary that the vehicle to be checked out, first be visually inspected of all systems, workmanship and with
special attention to ensuring there is no HV cable or equipment damage or chafing.

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INSTRUCTION TO SERVICE
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High Voltage Checkout Preparation
(1) The scope of the work must be accurately defined such as a Checkout Procedure that requires systematic
steps with sign offs. Before a Checkout is performed, the Supervisor, Checker and Monitor/Recorder must
conduct a briefing of what shall transpire, identify potential hazards, resist pressures of “is it done yet?”, anticipate
problems and question possible events. If unexpected
electrical hazard or fault occurs, during any time of the Checkout, it must be immediately reported to the
supervisor. After the Checkout is completed, the same group should review the results and processes and make
proposed modifications to the procedures if required.
(2) Install Safety barricade with warning lights & signs indicating "Danger High Voltage" around the vehicle
perimeter and ensure no personnel are within the fenced perimeter during the checkout procedure.
(3) 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 the 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.
(4) When it is necessary to perform tests of HV systems with the power ON, then the Working Live procedure
must be followed.
(5) The test personnel shall always rehearse the actions required in case of any possible accident scenarios.
(6) Before beginning the Checkout Procedure, the test personnel shall remove all their jewelry (including pierced
ones), watches and any electrically conductive objects on them.

PPE Requirements
The PPE voltage class, Arc Flash and Arc Blast rating shall be compatible with the voltage and Arc Flash
capability of the systems being tested. Appropriate leather glove protectors shall be worn over the HV rubber
gloves.

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.

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INSTRUCTION TO SERVICE
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PPE Inspection
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.

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 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.

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

Lockout/Tagout Procedure
The Lockout/Tagout procedure should be followed that is specified in the respective checkout procedure. When
removing the lock and tag:
(1) The locks and tags shall be removed by the installer of them or 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 in not in the facility
(b) Contacts the installer to inform her/him that the locks and tags will be removed
(c) Reminds the installer of the lock and tag removal when she/he resumes work

Stored Energy
Personnel must always remember the characteristics of stored energy devices such as capacitors and batteries
and when energy is available from.

Working Live
To maximize safety, it is always important to perform the maximum amount of HV checkout in the de-energized
state.
When it is necessary to work with HV equipment while energized or to verify whether HV is present, the utmost
care and safety procedures must be utilized including:
(1) Wearing appropriate PPE with protector gloves over top of the HV rubber gloves
(2) Ensure all personnel, except the Checker and Monitor/Recorder, are clear of the vehicle
(3) Kneeling or standing on HV insulated mat

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INSTRUCTION TO SERVICE
ITS-60816

Energizing & De-energizing Procedure
It is critical that before any HV system is energized that a visual check be performed to ensure that all possible HV
compartments are closed and there is no debris, tools or test equipment lying on HV terminations. If there is a
certain sequence of energizing and de-energizing the HV system, then all personnel involved must be trained in
this sequence. (CAUTION: Never try to connect or disconnect circuit components such as cables, fuses,
connectors, etc. while there is current flowing in the circuit.)

Electrical Injuries
Electrical injuries should be immediately reported to the first aide personnel and the supervisor. Other than
electrostatic shocks, even non-injurious electrical shocks should be reported to the supervisor. These should be
immediately investigated and documented to determine the cause and prevent the occurrence in the future.

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