INSTRUCTION TO SERVICE
ITS: 61648

DATE 4/09/2026

SECTION:

260U – Battery System

SUBJECT:

HV Roof Junction Box Connection Unused Stud Removal

ISSUE:

Unused Junction Box Studs Coming Loose

SUMMARY:

Remove Unused Junction Box Studs

ITS61648
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
ITS61648

PROCEDURE:
Only trained personnel shall supervise and perform the High Voltage system testing,
servicing and troubleshooting contained in this procedure.
1.
2.
3.
4.
5.
6.

Ensure to apply the parking brake.
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.
Ensure to the wear proper PPE.
Install a Lockout/Tagout Steering wheel cover as required.

 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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7. Ensure no voltage is present before work begins. Using the appropriate fall protection, gain access to the upper
street side of the bus and remove the hardware securing the side screen in place to gain access to the HV
junction box. Set the side screen hardware aside for re-installation. See Figure 2.
8. Remove and set the junction box lid mounting hardware aside for re-installation and open the lid on the junction
box. See Figure 2.
9. Locate the unused studs shown below and remove and discard them. See Figure 2.
10. Ensure all tools and debris are removed from inside the box and close and re-secure the lid with the original
screws torquing them to 58 IN-LBS. See Figure 2.
11. Close and re-install the side screens.
12. Clean up all tools and debris and return bus to service condition.

Note: Illustration for reference only.

Remove Junction Box Lid
Screws. Torque 58 IN-LBS
When Re-installed

Remove
Unused
Studs

Figure 2: Street side upper junction box stud removal location reference.

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LABOUR ESTIMATE
Operation
1

Number of
Technician(s)
2

Remove Unused Junction Box Studs

Hours
.5

Labor Time
T X HR
1

PARTS REQUIRED
Item

Part Number

Qty.
per
Coach

Description

Units

Notes

Units

Notes

SPECIAL TOOLS REQUIRED
Item

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Part Number

Qty.

Description

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INSTRUCTION TO SERVICE
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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.
Equipment Required

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The following equipment shall be required:
Digital Multimeter (DMM), 1000 volt Category II, 600 volt Category IV, 10Megohm
impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000 volt Category II, 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
Imperial 1/4" torque drive socket set
Imperial 3/8" torque drive socket set
Insulated rescue hook
ABC Fire extinguisher, 5 lb minimum, at the activity areas
Spare HV and low voltage fuses
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

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Fire fighting and emergency procedures
HV & arcflash safety
Organized & tidy placement of equipment & tools allowing for unrestricted
movement
Operation of Hi-pot
Operation of Phase Rotation Meter
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.
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 an 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.

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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.
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.)

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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.

Appendix B – NFIL PPE Categories

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