INSTRUCTION TO SERVICE
ITS: 61261

02/05/2025

SECTION:

260-Battery Compartment

SUBJECT:

Off-site vendor update of ESS packs

ISSUE:

Internal component upgrade by supplier.

SUMMARY:

Remove battery enclosure, ship to supplier for rework, replace with updated
reworked enclosure.

ITS-61261
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-61261

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 rework, and troubleshooting. Two
personnel shall perform rework 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.
(Caution: The employee completing the rework must not have any health conditions that can be exacerbated
when startled and must not have any electronic implants.)

ITS-61261

Page 2

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

Vehicle Inspection
It is necessary that the vehicle to be reworked, 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 Rework Preparation
(1) 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 rework procedure.
(2) 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.
(3) When it is necessary to perform tests of HV systems with the power ON, then the Working Live procedure
must be followed.
(4) The test personnel shall always rehearse the actions required in case of any possible accident scenarios.
(5) Before beginning the rework 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.

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

ITS-61261

Page 3

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

Lockout/Tagout Procedure
The Lockout/Tagout procedure should be followed that is specified in the respective rework 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 rework 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.

ITS-61261

Page 4

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

Juice Box ESS Enclosure Removal Beam
CAUTION: It is important that technicians involved in hoisting and rigging are trained in both safety and
operation procedures. Hoisting equipment should only be operated by trained personnel. Do not use
equipment that is suspected to be unsafe or unsuitable, until a competent person has verified its
suitability. The rated working load limits apply only to equipment and hardware in good condition. Any
equipment damaged in service should be taken out of service and repaired or destroyed.
CAUTION: Do not attempt to lift the ESS enclosure without the gasket and lid attached and all fasteners
applied and properly torqued.
 NOTE: It is strongly recommended to use a JB removal beam (NF PN: 6485763) with a forklift adapter
boom (NF PN: 6485514) to lift the ESS assembly to ensure safe load distribution and avoid damage to the
fiberglass lid. Minimum requirement for safe lifting is to use a spreader beam and is also acceptable. See
Illustration below for reference.



NOTE: Lifting device securement straps should be connected at no less than 60 degrees as shown
below to prevent strap damage to the ESS enclosure or connected to a lifting device wider than the ESS
unit being removed in a vertical position as shown below to prevent strap damage to the ESS enclosure.

JB removal beam and forklift adapter tool reference.

ITS-61261

Page 5

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

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. See Figure 1.
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.
4. Drain the coolant from the upper and rear ESS systems.
Note: If instructions are required a copy of the coolant drain and fill procedures may be viewed in the SR
service manual.

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

ITS-61261

Page 6

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

Section 2 – Upper ESS Assembly Removal.
5. Gain access to the upper side screens. Remove the hardware in the top of the side screens and tilt outwards
to access the ESS enclosures. Set the mounting hardware aside for re-installation. See Figure 2.
6. Locate the MSD’s and remove them from each ESS unit and install a dust cover. See Figure 2.
7. Remove the Pos and Neg HV cable quick disconnects from the ESS units. Remove the ESS Ground cable
and set washers aside for re-installation. See Figure 2.
 NOTE: When ground cable is secured with a nylock nut or bolts longer than ½” discard locknut and
bolts.
 NOTE: Bolts ½” in length may also be set aside for re-installation.
Open Side Screens

Remove MSD’s

ENCLOSURE
GROUND

HV
NEGATIVE

HV
POSITIVE

Figure 2: Side Screen and Upper ESS MSD Location Reference.

ITS-61261

Page 7

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

8. Remove HV charge rail as required. Move to following page if not required. HV cable clamps from street side
of charge rail and disconnect HV cable quick disconnects from charge box. Secure HV cables out of the way
for charge rail assembly removal. See Figure 3A.
9. Disconnect WLAN antenna from bus harness. Secure WLAN harness for charge rail assembly removal. See
Figure 3A.

Remove HV Cable Clamps Street Side
of Charge Rail and Disconnect Cables

Disconnect
WLAN Harness

Figure 3A: Charge Rail Removal Location Reference.

ITS-61261

Page 8

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

10. Remove curb side and street side charge rail heater clamps and wiring securement and set clamps and
hardware aside for re-installation.
11. Disconnect the curb side and street side heater wiring from charge rails and set hardware aside for reinstallation. See Figure 3B.
12. Remove the low voltage harness connections and clamps to the DC charge box and set camps and hardware
aside for re-installation. See Figure 3B.
13. Disconnect the temp sensor from under the DC charge rail box on the street side. See Figure 3B.
14. Secure the harnesses disconnected out of the way for charge rail assembly removal.
C/S View

Remove Charge Rail Heater Wiring
Securement
S/S View
Remove DC
Charge Box
Low Voltage
Wires and
Clamps and
Set Aside for
Re-Installation.

Disconnect and Remove
Temp Sensor Wiring
Figure 3B: Charge Rail Removal Location Reference.

ITS-61261

Page 9

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

15. Disconnect the charge rail ground cable to the body ground stud and set mounting hardware aside for reinstallation. See Figure 3C.
16. Disconnect the charge rail box ground to the body ground stud and set mounting hardware aside for reinstallation. See Figure 3C.
17. Remove the charge rail assembly mounting hardware to the roof structure and set hardware aside for reinstallation. See Figure 3C.
18. Connect an appropriate lifting device to the charge rail assembly and remove the assembly. See Figure 3C.

Remove
Grounds
From
Charge
Rail and
Charge
Box

Remove
Charge
Rail
Assembly
Mounting
Hardware
to Roof
Structure
4X
Locations

Figure 3C: Charge Rail Removal Location Reference.

ITS-61261

Page 10

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

19. Locate the coolant line supply and return hose connections at each ESS. Loosen the coolant hose clamps
and disconnect the hoses from each ESS unit. Set clamps aside for re-installation. Install coolant line caps on
the ends of each fitting. See Figure 4A.
20. Each ESS has a specific size restrictor/orifice based on ESS location that needs to be removed and reinstalled in the replacement unit. Remove the orifice at each ESS unit located in the inlet line shown below
and set aside at each unit location. Re-install the restrictor/orifice in the replacement unit for the same ESS
location. See Figure 4A. (Orifices only in upper ESS Units)
21. Disconnect the LV wiring connectors from each ESS unit and secure out of the way for ESS removal. See
Figure 4A.



NOTE: Ensure to use absorber material to capture any coolant lost during removal.

Orifices

Orifices

Orifice PN Ref By Location If Lost or Damaged

Remove Orifices & install in Replacement Unit

LV Connections
Coolant Hose
Supply and
Return
Connections

Cap
Connections
Once Hoses
are Removed.

Figure 4A: Upper ESS Coolant Line Removal and Upper ESS Assembly Lifting Device Location Reference.

ITS-61261

Page 11

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

22. Connect an appropriate lifting device to the ESS unit being removed. See Figure 4B.



NOTE: Lifting device securement straps should be connected at no less than 60 degrees as shown
below to prevent strap damage to the ESS enclosure or connected to a lifting device wider than the ESS
unit being removed in a vertical position as shown below to prevent strap damage to the ESS enclosure.

Figure 4B: Upper ESS Coolant Line Removal and Upper ESS Assembly Lifting Device Location Reference.

ITS-61261

Page 12

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

23. Locate ESS unit mounting hardware. Remove mounting bolts 8X each unit and set aside for re-installation.
See Figure 5.
24. Carefully remove the ESS units and place them on an appropriate shipping stand.

Remove ESS Mounting Bolts
and Set Aside for Re-installation.

Remove ESS Using
Appropriate Lifting
Device

Figure 5: Upper ESS Assembly Removal Location Reference.

ITS-61261

Page 13

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

25. Locate the serial number documentation form in Appendix A of this ITS or use the electronic version if
provided by your RPSM.
26. Then locate the serial number plates on the side of each unit being removed and installed and fill out the form
and return to the RPSM for warranty and S/N tracking removed and installed units. See Figure 6.



NOTE: Illustration for 40 and 60 FT units.

ESS 3 - Roof
(Front Most)

ESS 5 - Roof

ESS 4 - Roof

Front of Bus

ESS 6 - Roof

ESS 7 - Roof

60 FT Bus Only

Rear of Bus

Figure 6: Upper ESS Assembly Serial Number Documentation Location Reference.

ITS-61261

Page 14

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

27. Inspect the ESS units removed and to be installed for the correct ground cable securement.
A. If a ground stud as shown below is installed no further action is required. See Figure 7.
B. If a bolt is installed as shown below check the length of the bolt. If the bolt is ½ IN long no further action
is required. See Figure 7.
C. If a bolt is installed and the length is greater than ½” notify the RPSM and New Flyer Service Engineering
immediately. See Figure 7.



NOTE: Do not install a unit that has had a bolt longer than ½” installed without contacting Service
Engineering for guidance.

Ground
Cable Stud

Ground Cable
Bolt No More
Than ½ IN Long

Figure 7: Upper ESS Assembly Ground Stud Inspection Location Reference.

ITS-61261

Page 15

02/05/2025

INSTRUCTION TO SERVICE
ITS-61261

28. Locate the Replacement ESS to be installed and only after the serial number for each ESS has been
documented for the installation location to be installed and the ground stud inspection has been completed
should the following installation steps be taken.
29. Place the Replacement ESS in place on the roof and install the previously removed hardware plates and
secure with the existing bolts applying one or two drops of item #1 Loctite to their threads and torque to 80
FT-LBS. Apply torque marks after torquing. See Figure 8.

Torque Hardware to 80 FT-LBS.

Item