INSTRUCTION TO SERVICE
ITS: 61111

08/12/2024

SECTION:

260-Battery Compartment

SUBJECT:

R&R rear mount and roof mount ESS assemblies

ISSUE:

ESS is missing internal ground strap kit and the Pre-Charge resistor need to be
upgraded.

SUMMARY:

R&R the rear mount and roof mount ESS assemblies to install the ground strap
kit and upgrade the pre-charge resistor.

ITS-61111
Ref. NHTSA Recall No.
Not Applicable

Ref. Transport Canada Recall No.
Not Applicable

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-61111

Warning
•Exposure to high voltages from a large modules or packs can cause shock,
burns or even death.
•The high voltage components in a large module or pack can only be serviced by
technicians with special high voltage training.
• Follow all necessary precautions before working on them.
• Always assume voltage is present on high voltage
cables until you have verified voltage has been removed.
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.
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.)

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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.

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.

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.

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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

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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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 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

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Section 2 – Rear ESS Assembly Removal.
4. Open the rear ESS access door to gain access to the rear ESS area.
5. Open streetside and curbside upper side corner panels. Remove the gas springs supporting the ESS access
door on the bus side and raise the access door in the up position. Tyrap the door to the bracket inside the
streetside and curbside side upper corner panels.
6. From top of the bus on the curbside corner, remove the access panel to gain access to the coolant line to the
roof ESS battery packs. Clamp off the supply and return rubber elbows using coolant hose clamp tools. See
figure 2.



NOTE: By clamping off these coolant hoses will minimize draining coolant from the ESS circuit.

Figure 2: Roof ESS coolant lines cut-off location reference.

7. Support the rear bumper with forklift, remove the four retaining bolts, and remove the rear bumper. Save all
mounting hardware for reuse later.

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8. Remove the lower corner pillars (including turn signals and brake lights) and brackets. Save hardware for
reuse. Reference figure 3 below.

Figure 3: Lower Corner Pillars and Rear Door Removed

9. From streetside rear corner, disconnect ESS grounding strap to bus frame. Reference figure 4 below.

Figure 4: ESS ground strap to bus frame location reference.

10. Disconnect HV cables from both ESS packs. Make notes of the positive and negative connections. See figure
5 below.

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Figure 5: HV cable connections reference.
11. From the curbside rear of the bus, place a 5 gal. bucket under the ¼ turn drain vent valve. Open the vent
valve to drain the coolant out of the rear ESS packs.
12. Remove the clear BTMS vent line from the ESS frame.

13. Disconnect and secure the low voltage harness connected to both ESS packs. Disconnect the supply and
return coolant lines from both ESS packs. See figure 6.

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Figure 6: Low voltage and coolant line connections reference.

14. Remove the hardware between the bumper beam and side structure. See Figure 7.
15. Remove the street side and curbside struts as follows: See Figure 7.

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a.

Loosen the jam nut and remove the 1” upper nut on the strut.

b.

Remove the ¾” lock nut, bolt, and washers that attach the lower end of the strut to the main frame rail
bracket.

c.

Remove the strut itself.

Figure 7: Rear Struts and Side Structure Hardware Removal

16. Using big tyraps, secure both struts along with, HV cables, and AC drain hoses above the ESS packs. See
figure 8.

Figure 8: Struts, HV cables and AC drain hoses securement reference.
17. Support the rear frame members with jack stands as seen in figure 9 below.

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Figure 9: ESS frame member jack stands reference.
18. Remove the hardware securing the ESS rack on the front and rear chassis. Should be 2 sets on each side.
Reference figure 10 below for details.

Figure 10: ESS pack assembly mounting hardware location reference.

19. Support ESS packs with forklift and remove ESS packs assembly from the bus. See figure 11.

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

NOTE: Before removal of the ESS, ensure no harnesses, cables, ground straps, or coolant hoses are
connected. Use a spotter to ensure the forks are captured within the pockets on the ESS frame and not resting on
the composite ESS enclosure. A c-clamp will ensure that the frame does not slide on the forks.

Figure 11: Rear ESS pack assembly removed from the bus reference.

20. Move the ESS battery packs to a clear and open workspace. Place block of wood under the ESS battery pack
assembly on each side and two in the middle for support. See figure 12.

Figure 12: ESS battery packs wooden block under the assembly reference.

Section 3: Rear ESS Hoisting and Separating Instructions.

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21. Remove fasteners securing the upper ESS packs to the frame (four fasteners on each side). See figure 13.

Figure 13: Upper ESS mounting hardware location reference (4 Places Each Side).
22. Use a forklift with appropriate hoist boom and straps (one in each corner), lift the upper ESS pack from the
frame assembly. Reference figure 14 below for proper rigging.

Figure 14: Rigging for lifting upper ESS battery pack.
23. Carefully move the upper ESS battery pack to a appropriate work station.

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NOTE: At this point, sufficient space to work has been obtained for the supplier to rework the ESS battery
packs. Supplier rework documents available upon request.
24. Once the upper ESS battery pack rework is complete, reinstall the upper battery pack back into the ESS rack
assembly. Secure battery pack using existing hardware (four fasteners on each side). Torque hardware to 69
ft-lbs.
NOTE: ESS battery pack assembly pressure test procedure should be performed prior to reinstall into the bus.
See Appendix-A below for pressure test procedure reference.
NOTE: During reassembling, replace any nylock nuts that may be damaged during removal.

Section 4: Reinstall rear ESS assembly into the bus.
25. Using a forklift, reinstall the ESS battery rack assembly inside the vehicle and align the mounting holes to the
vehicle structure. Secure the ESS battery rack assembly using existing hardware. Torque the 1/2” hardware
to 69 ft-lbs. (94 Nm). Torque 3/4” hardware to 245 ft-lbs. (339 Nm). Apply yellow paint torque marks.
Reference figure 15.

Figure 15: ESS Battery pack assembly securement hardware reference.
26. Reconnect the low voltage harnesses to the upper and lower ESS battery packs. Use zip ties (NF PN:
5962614) to secure harnesses.
27. Reconnect the coolant lines to the upper and lower ESS battery packs. Secure the coolant hoses using
existing clamps. Torque clamps to 80 in-lbs. (9 Nm).



NOTE: The orientation of clamps may vary to maximize clearance and access.

28. Reconnect the high voltage cables, and grounding strap to the bus frame. Torque ground strap hardware to
22 ft-lbs.

29. Secure corner pillar brackets to pillars using existing 3/8 in. hardware on each side of bracket (3 each per
side). Torque hardware to 28 ft-lbs. (38 Nm). Reference figure 16.

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Figure 16: Secure corner pillar brackets to pillars reference.
30. Reinstall curbside and streetside lower pillar mounting brackets. Secure using existing ½ inch bolt, flat washer
and nylock nut. Torque hardware to 69 ft-lbs. See figure 17.

Figure 17: Curbside and streetside lower pillar mounting bracket location reference.
31. Reinstall curbside and streetside tail light corner pillar and secure using existing hardware.
32. Support strut Installation – Reference figure 18:
a.

Thread a 1” nut on the upper end of the strut until it’s nearly bottomed out.

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b.

Install the threaded end of strut into upper mounting bracket and loosely install the upper nut.

c.

Align hole in lower end of strut with hole in main frame rail mounting bracket and secure strut to frame
rail bracket with 3/4" bolt, washers, and lock nut.

d.

Apply Never-Seize to bolt threads and torque lock nut to 250 ft-lb. (339 Nm).

e.

Ensure lower 1" nut is backed off, then tighten upper 1" nut until contact is made with upper mounting
bracket.

f.

Measure the distance between the lower frame rail and upper vehicle structure.

g.

Continue to tighten upper nut until the 44.84" (+/- 0.50) dimension is achieved, and then tighten an
additional two turns.

h.

Apply Never-Seize to threaded area of strut and tighten lower 1" jam nut to 426 ft-lb. (578 Nm).

Figure 18: Strut Tensioning

33. Reinstall rear bumper – retorque rear bumper hardware to 106 ft.-lbs. Apply 1-2 drops Loctite (NF PN:
081034) to the hardware threads. Additional instruction available within the Service Manual if panel gaps
require adjustment.