INSTRUCTION TO SERVICE
ITS: 61128

August 19, 2024

SECTION:

290-ELECTRICAL SCHEMATICS

WRITTEN BY:

Ilan Kizner

SUBJECT:

Rework - Rear ESS LV connector

ISSUE:

Corrosion damage to connector

SUMMARY:

Rework LV connector to prevent water intrusion and corrosion.

ITS-61128

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
ITS61128

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

PROCEDURE: ....................................................................................................................................................3

2.

Rework Instructions ............................................................................................................................................4

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INSTRUCTION TO SERVICE
ITS61128

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

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.
Use commercially available lockout equipment and tags being sure to follow local regulations.
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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INSTRUCTION TO SERVICE
ITS61128

2. Rework Instructions
2.1 Access the rear ESS and locate the LV (Low Voltage) connector as shown in figure 1.

Figure 1 - Rear ESS LV connector.

Note: D45e coaches will name this connector as EC-XBAT-45, and D45CRT/LE e will have that as
EC-XBAT-34. Will be marked as EX-XBATxx throughout the remaining document.
2.2 Disconnect the LV connector from the ESS.
2.3 Access the compressor compartment by releasing the latch in the engine compartment.
2.4 Install the provided saddle base 19-11-1008 on the location shown in figure 2. Attach the saddle by
drilling a ¼” inch hole at the location shown in figure 3.

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INSTRUCTION TO SERVICE
ITS61128

Figure 2 - location of added saddle base (CS, rear of the coach)

Figure 3 - Drilling location of saddle base.

2.5 Secure saddle base 19-11-1008 using rivet 19-13-291.

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INSTRUCTION TO SERVICE
ITS61128
2.6 Install the second provided saddle base 19-11-1008 on the location shown in figure 4. Attach the
saddle by drilling a ¼” inch hole at the location shown in figure 5 and securing the saddle to the
frame using rivet 19-13-291.

Figure 4 - Second saddle base location (view from engine compartment)

Rear
Figure 5 - Drill location of the second Saddle Base

2.7 Connect provided jumper harness 1088103 to EC-XBATxx. route harness through saddle tyrap and
secure connectors to prevent wire strain as shown in figure 6&7.

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INSTRUCTION TO SERVICE
ITS61128

Figure 6 - Jumper Harness securement (View from Engine compartment)

Figure 7 - securement of original EC-BATxx connector to jumper harness (top view)

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INSTRUCTION TO SERVICE
ITS61128

LABOUR ESTIMATE
Operation
1

Number of
Technician(s)
1

Rework exit door panel

Hours

Labor Time
T X HR
3

3

PARTS REQUIRED

Item

Part Number

1

1088103

HRNS-JMPR EC TO STRING

Qty.
per
Coach
1

2

19-13-291

RIVET - MONOBOLT, 1/4 SST

2

EA

3

19-11-259

TYRAP-13.38"LONG

2

EA

4

19-11-1008

SADDLE-TYE WRAP

2

EA

ITS61128

Description

Page 8 of 8

Units

Notes

EA

August 19, 2024