A. If a ground stud as shown below is installed no further action is required. See Figure 26.
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 26.
C. If a bolt is installed and the length is greater than ½” notify the RPSM and New Flyer Service Engineering
immediately. See Figure 26.



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 26: Rear ESS Assembly Ground Stud Inspection Location Reference.

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74. Remove the hardware 3 each from the lower side support assembly bracket from both sides and set
hardware aside for re-installation. See Figure 27A.
75. Remove the hardware 2 each from the upper horizontal supports from both sides and set horizontal supports
and hardware aside for re-installation. See Figure 27A.
76. Remove fasteners securing ESS1 to the frame assembly (four fasteners on each side) and hardware aside
for re-installation. See Figure 27A.
77. Use a forklift with appropriate hoist boom and straps (one in each corner), lift the lower ESS pack (ESS1)
from the frame assembly. See Figure 24 for proper rigging, typical for all packs.
78. Inspect each ESS unit removed and to be installed for the correct ground cable securement. Ref ESS1 and
ESS2. See Figure 26.

Remove ESS
Mounting Hardware

Remove Horizontal
Support Hardware

Remove Lower Side Support
Assembly Bracket Hardware

Figure 27A: Rear ESS Pack Assembly Removal and Installation Location Reference.

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79. Install one of the supplied replacement ESS units in the ESS1 (lower) position. Ensure enclosure orientation
matches that of how it was removed. See Figure 27B.
A.

Use hardware removed from OEM install applying item #10 never seize to bolt threads prior to
reinstallation.

B.

Replace Nylock nuts item #9 if damaged and torque to 69 ft-lbs. Apply torque marks after torquing.

C.

Ensure to record the ESS serial number on the tracking sheet in the replacement ESS1 location.

80. Re-install the upper horizontal support assembly and lower side support assembly bracket in the locations
they were removed from each side of the ESS lower frame assembly. See Figure 27B.
A.

Use hardware removed from OEM install applying item #10 never seize to bolt threads prior to
reinstallation.

B.

Replace the Nylock nuts item #9 if damaged and torque to 69 ft-lbs. Apply torque marks after torquing.

81. Install one of the supplied replacement units in the ESS2 (Upper) position. Ensure enclosure orientation
matches the lower ESS. See Figure 27B.
A.

Use hardware removed from OEM install applying item #10 never seize to bolt threads prior to
reinstallation.

B.

Replace the Nylock nuts item #9 if damaged and torque to 69 ft-lbs. Apply torque marks after torquing.

C.

Ensure to record the ESS serial number on the tracking sheet in the replacement ESS2 location.
Item

Part Number

Description

9

40N08000

Nut Nylon Lock ½ - 13

10

5928660

Never Seize

Re-install Hardware Applying Item #10 Never Seize to Bolt Threads Replacing Nylock Nuts Item #9 If Damaged

Figure 27B: Rear ESS Pack Assembly Removal and Installation Location Reference.

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Section 5: Rear ESS assembly Installation.
82. Using a forklift, install the ESS battery rack assembly back inside the vehicle and align the mounting holes to
the vehicle structure. See Figure 28.
A. Secure the rear of the ESS battery rack assembly using existing ½” hardware applying item #10 never
seize to bolt threads prior to reinstallation. See Figure 28.
B.

Replace the Nylock nuts item #9 if damaged and torque to 69 ft-lbs. Apply torque marks after torquing.
See Figure 28.

83. Align the mounting holes to the rear ESS AFT Ladder. See Figure 28.
A. Secure the rear of the ESS battery rack assembly using existing ¾” hardware applying item #10 never
seize to bolt threads prior to reinstallation. See Figure 28.
B.

Replace the Nylock nuts item #11 if damaged and torque to 245 ft-lbs. Apply yellow paint torque marks
after torquing. See Figure 28.
Re-install Hardware Applying Item
#10 Never Seize to Bolt Threads
Replacing Nylock Nuts Item #9 if
Damaged

Re-install Hardware Applying Item #10 Never Seize
to Bolt Threads Replacing Nylock Nuts Item #11 if
Damaged and Torque to 245 FT-LBS

Rear ESS
AFT Ladder

Item

Part Number

Description

9

40N08000

Nut Nylon Lock ½ - 13

10

5928660

Never Seize

11

42012000

Nut Nylon Lock 3/4

Figure 28: ESS Battery pack assembly securement hardware reference.

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84. Re-install the clear BTMS vent line to the ESS frame using existing hardware applying one or two drops of
item #1 Loctite. See Figure 29.
85. Reconnect the low voltage harnesses to the rear ESS packs. Use item #2 Zip ties to secure harnesses.
86. Reconnect the coolant supply and return hoses and install the existing clamps from each ESS unit. Torque to
See Figure 29.
87. Re-install the ESS pressure fill Replace the Nylock nuts item #8 if damaged and torque to 12 ft-lbs. Apply
torque marks after torquing. See Figure 29.
88. Reconnect the coolant hose to the pressure fill and install the existing clamp. Torque to 50 IN-LBS. Allow
clamps to rest for 30 min and re- torque to 50 IN-LBS. Apply torque marks after torquing. See Figure 29.
Re-install Coolant
Lines To ESS and
Torque Clamps Dry
to 80 IN-LBS. Let
Rest for 30 Min
and Re-torque to
80 IN-LBS.
Re-install LV
Connections.

Re-install
Coolant Lines To
Pressure Fill and
Torque Clamps
Dry to 50 INLBS. Let Rest for
30 Min and Retorque to 50 INLBS.

Re-install
BTMS Line

Re-install Pressure Fill
Torque to 12 FT-LBS.
Item

Part Number

Description

1

081034

LOCTITE 243

2

5962614

Zip Ties

8

42N04000

Nut Nylon Lock ¼-20

Figure 29: Low Voltage and Coolant Line Connections Location References.

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89. Connect the ground cable to the ESS unit using the correct hardware.





A.

For units with a ground stud application place cable on the ground stud with the existing flat washer and
Nylon nut item #3 and torque nut to 17 FT-LBS. Apply torque marks after torquing. See Figure 30.

B.

For units with the ground cable bolt mounting secure the ground cable to the unit with the existing
washer and ½ IN bolt item #4 and Torque to 22 FT-LBS. Apply torque marks after torquing. See Figure
30.

NOTE: Do not use mounting bolts longer than ½ IN.
NOTE: Ensure to validate the torque based on stud or bolt application.
NOTE: Apply item #6 Anti-corrosion compound to ground connections.

Ensure to validate the torque based on stud or bolt application.
90. Re-connect the Pos and Neg HV quick disconnects to each rear ESS unit. See Figure 30.
Ground
Cable Stud
Application
Torque Nut to
17 FT-LBS.

Re-connect HV Quick Disconnects to the Appropriate Connectors on the ESS Units

½” Bolt Application
Torque Bolt to 22 FT-LBS

Item

Part Number

Description

3

42N06000

Nut 3/8-16 UNC Nylon Lock SST

4

20B06008

Bolt Hex SS 3/8-16 UNC x ½” Long

5

50W06000

Washer Flat SS 3/8

6

8111767

Anti – Corrosion Compound NYK-77

Figure 30: Rear Upper and Lower ESS Assembly Ground Stud and HV Cable Re-installation Location Reference.

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91. Secure corner pillar brackets to pillars using existing 3/8” hardware on each side of the bus replacing the
nylock nuts item #3 if damaged and torque hardware to 28 ft-lbs. Apply torque marks after torquing. See
Figure 31.
92. From streetside rear corner, reconnect the ESS grounding strap to bus frame applying item #6 Anti-corrosion
compound and torque to torque to 22 FT-LBS. Apply torque marks after torquing. See Figure 31.

Replace Nylock
Nut Item #3 If
Damaged and
torque to 28
FT-LBS.

Re-connect Ground Strap Replacing Nylock Nut
Item #Applying Anti-Corrosion Compound and
Torque to 22 FT-LBS.

Item

Part Number

Description

3

42N06000

Nut 3/8-16 UNC Nylon Lock SST

6

8111767

Anti – Corrosion Compound NYK-77

Figure 31: ESS Ground Strap to Bus Frame and Corner Pillar Brackets to Pillar Location References.

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93. Re-install the curbside and streetside lower pillar mounting brackets. Secure using existing ½ inch bolts, flat
washers replacing Nylock nuts item #9 if damaged. Torque hardware to 69 ft-lbs. Apply Torque Marks. See
Figure 32.

Replace Nylock Nut
Item #9 if Damaged
and torque to 69
FT-LBS.

Item

Part Number

Description

9

40N08000

Nut Nylon Lock ½ - 13

Figure 32: Curbside and Streetside Lower Pillar Mounting Bracket Location Reference.

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94. Reinstall curbside and streetside taillight corner pillar and secure using existing hardware replacing nylon lock
nuts item #8 if damaged.
95. Support strut Installation – See Figure 33.
A.

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

B.

Install the threaded end of strut into upper mounting bracket applying item #10 Never Seize to its threads
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 applying item #10 Never Seize to the bolt threads. Replace item #11
¾” Nylock nut if damaged and torque lock nut to 250 ft-lb. Apply torque marks after torquing.

D.

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

E.

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

F.

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

G.

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

Part Number

Description

8

42N04000

Nut Nylon Lock ¼-20

10

5928660

Never Seize

11

40N12000

Nut Nylon Lock 3/4

Install Item
#10 Never
Seize and
Torque Nuts to
426 FT-LBS.
Nylock Nut
Item #3 and
torque to 28
FT-LBS.

Install Item #10
Never Seize and
Replace Nylock
Nuts Item 11 If
Damaged and
Torque Nuts to
250 FT-LBS.
Figure 33: Strut Tensioning Location Reference.

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96. Reinstall rear bumper – retorque rear bumper hardware to 106 FT-LBS. Apply 1-2 drops Loctite item #1 to
the hardware threads. Apply torque marks after torquing. Additional instruction available within the Service
Manual if panel gaps require adjustment.
97. Refill and de-aerate ESS coolant system according to NF Service Manual.
98. Check coolant connections, at the packs removed, for leaks and resolve as required.
99. Reinstall streetside and curbside, side screens securing using the existing hardware. Apply 1-2 drops of
Loctite item #1 to the threads of the hardware. Torque hardware to 50 in. lbs. Apply torque marks after
torquing.
100. Completed the starting checks in Appendix B.
101. Completed the charging checks in Appendix C.
102. After first full day in service check coolant levels and fill ESS coolant system according to NF Service Manual
as required.
103. Ship OEM battery enclosures to supplier using pallets the replacement units came with.



NOTE: Email a completed copy of the serial number documentation form to [email protected]

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