R23-002 Liquid in Battery Packs May Cause Fire – 2021-2022 New Flyer XE35, 2021-2023 XE40, & 2021-2022 XE60 Electric Buses

SEOCONTENT-START

From:
To: Cc:
Subject: Date: Attachments: Tuesday, May 2, 2023 10:42:00 AM
Good morning,
This email is to follow up on conversations you’ve had with New Flyer staff related to the next steps in the solution to the recall of New Flyer’s Next-Gen ESS enclosure. As you should know by now, these next steps include the installation of ports in the ESS, which will followed by installation of drains. I’ve attached an updated customer notification letter, which contains the same information shared with you verbally but is the written communication. You will also receive aprint version of this letter in the mail. Thank you for your patience as we work through this issue-we are glad to be making progress and are eager to get the final remedy installed early this summer.
Thanks, Jim Jim Johnson
Manager, Vehicle Safety and Regulatory Compliance
New Flyer I MCI From: Jim Johnson
Sent: Friday, February 24, 2023 12:35 PM
Good afternoon,
This email is to follow up on a conversation New Flyer staff had with you related to a recall of New Flyer’s Next-Gen ESS enclosure. The official recall letter, which includes New Flyer’s next steps and instructions for customers, is attached and being mailed via First-class mail. Please know that we are putting all resources into a remedy for this issue and are committed to ensuring the safety of our vehicles. Feel free to reach out to your CPM, RPSM, RSM or the undersigned with any questions.
Thanks, Jim Jim Johnson
Manager, Vehicle Safety and Regulatory Compliance
New Flyer I MCI

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From:
To: Cc: Subject: Date:
Good Afternoon All: Many agencies operating New Flyer’s Xcelsior battery-electric vehicles have asked for more information regarding the NTSB investigation that occurred following the July 23, 2022, fire on a transit bus being operated by CTDOT. We wanted to share that the NTSB released its Docket, which contains a factual report of the investigation which does not include any recommendations from NTSB. That Docket is available at https://data.ntsb.gov/Docket/?NTSBNumber=HWY22FH011. As you are aware and the report confirms, New Flyer is implementing our recall solution on all affected 220 battery-electric buses in the field outfitted with the Energy Storage System (“ESS”) that includes a sealed fiberglass enclosure. The recall is intended to prevent accumulation of cooling liquid in the ESS which could lead to an electrical short, increasing the risk of a fire. This solution has been fully installed on the CTDOT buses, allowing them to return into service. We’re expecting completion of the recall solution for all affected buses by early fall. Similar recalls have been initiated by multiple other vehicle and bus manufacturers as the industry continues to learn and adapt these new technologies. We are confident that the efforts taken through this recall will continue to enhance our safety performance and deliver better outcomes for our customers and their riders. Thank you for your valued partnership as we work together on this zero-emission transition. Sincerely,
New Flyer Subject: RE: IMPORTANT SAFETY RECALL – New Flyer XE Good morning,
This email is to follow up on conversations you’ve had with New Flyer staff related to the next steps in the solution to the recall of New Flyer’s Next-Gen ESS enclosure. As you should know by now, these next steps include the installation of ports in the ESS, which will followed by installation of drains. I’ve attached an updated customer notification letter, which contains the same information shared with you verbally but is the written communication. You will also receive a print version of this letter in the mail. Thank you for your patience as we work through this issue—we are glad to be making progress and are eager to get the final r medy installed early this summer.
s,
er, Vehicle Safety and Regulatory Compliance
j
New lyer | MCI From
Sent: y, February 24, 2023 12:35 PM
To:
Cc:
Subject: IMPORTANT SAFETY RECALL – /New Flyer XE Good afternoon,
This email is to follow up on a conversation New Flyer staff had with you related to a recall of New Flyer’s Next-Gen ESS enclosure. The official recall letter, which includes New Flyer’s next steps and instructions for customers, is attached and being mailed via First-class mail. Please know that we are putting all resources into a remedy for this issue and are committed to ensuring the safety of our vehicles. Feel free to reach out to your CPM, RPSM, RSM or the undersigned with any questions.
s,
er, Vehicle Safety and Regulatory Compliance
New Flyer | MCI

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From:
To:
Cc:
Subject: – Recall Follow up – Please do not forward/confidential
Date: Friday, February 24, 2023 12:56:26 PM
Good afternoon Team,
Thank you for taking time to discuss the recall that affects the vehicles you have been delivered and are
in production. I apologize for the impacts of this issue, but please know we are committed to ensuring a
remedy in as timely a manner as possible and ultimately ensuring you the safest and best quality vehicle.
New Flyer has decided to issue a recall with National Highway Traffic Safety Administration (US
customers) and Transport Canada (Canadian Customers) for certain components used on select batteryelectric
vehicles that may result in an accumulation of liquid coolant in the battery area. If uncorrected,
this accumulation can lead to an electrical short, increasing the risk of a fire.
The recall affects the XE vehicles in production (or have not yet been accepted) that are outfitted with the
Next-Gen Energy Storage System (“ESS”) that includes a sealed fiberglass enclosure.
Providing instructions in the recall notification are followed, customers with buses that have the impacted
ESS in service can continue to operate these vehicles. We will not be able to ship your buses and/or
finalize acceptance of your buses until remedies are applied.
While recalls of this sort are never acceptable, similar recalls have occurred for multiple vehicle
manufacturers as the industry continues to learn and adapt these new technologies.
We are confident that the efforts taken through this recall will continue to enhance our safety performance
and deliver better outcomes for our customers and their riders.
We will ensure you are kept informed of all the latest developments and will provide an update on the
revised expected delivery timeline for your vehicles when possible. If you have questions, please do not
hesitate to contact me or , and be on the lookout for the recall letter from Jim Johnson.
Link to the NHTSA website: https://www.nhtsa.gov/vehicle/2023/NEW%252520FLYER/XE40#recalls
Have a great weekend,
Customer Program Manager
C
New Flyer | MCI

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From:
Sent: Friday, April 14, 2023 8:57 AM
To:
Subject: New Flyer ESS Recall Update – NHTSA Motor Vehicle Safety Recall 23V-083
Importance: High
Hi & Team,
In late February we contacted you to discuss a recall that New Flyer had decided to issue with the
National Highway Traffic Safety Administration (US Customers) for certain components used on select
battery-electric vehicles that may result in an accumulation of liquid coolant in the battery area. If
uncorrected, this accumulation could lead to an electric short increasing the risk of a fire. This recall
affected XE vehicles that your agency had in production or at your property.
As promised, we would like to keep you apprised of the pending recall resolution and upcoming rework
plans. New Flyer engineering is fully focused on a drain design. Simply put, drains will be installed at
each of the 4 corners of each Energy Storge System (ESS) enclosure. These drains are liquid activated
and will negate the purpose of the ESS enclosure leak detection sensors. The primary leak detection
method will still be active inside the main coolant reservoir. Programming will be updated to turn off
the ESS enclosure leak detection sensors. As part of the campaign, enhancements will also be made to
the warning decals at the coolant fill port.
Rework will happen in 2 phases. Phase one will include the installation of a port and plug at 4 locations
on each ESS enclosure. Phase two will include the removal of the plugs, the installation of the drains
into the ports, the update to the programming and the installation of the enhanced warning decals at
the coolant fill port. We expect parts for phase one to begin shipping to the field as early as week 17
(April 23-28). Phase two is dependent on the supply of the drain and is expected to commence in late
May or Early June. Your Regional Product Support Manager, , will be in touch with you
to arrange each phase of the rework.
We appreciate your patience and support as we work through this process together.
Sincerely,
Customer Program Manager
C 3
New Flyer | MCI

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From:
To:
Cc:
Subject:
Date: Wednesday, June 7, 2023 11:56:43 AM
Attachments:
As a follow-up to our previous communications on the Energy Storage System recall,
we are happy to report that New Flyer has final ized the drain design solution for the
ESS recall, and the design testing is complete.
We have begun production of the drain assemblies and are doing everything possible
to install drain assemblies on your buses as soon as possible. We are aiming to have
installations completed for all customers in the next few months.
I would like to schedule time with you to review the details of this drain solution and
discuss the timing specific to your vehicles. Please feel free to respond to me with
your availability for this meeting.
We appreciate your patience and support as we work to complete this rework.
Sincerely,
Customer Program Manager
New Flyer I MCI
-CONFIDENTIALITY STATEMENT: This communication (and any and all infonnation or material transmitted with this communication) is
confidential, may be privileged and is intended only for the use of the intended recipient. If you are not the intended recipient, any review,
retransmission, circulation, distribution, reproduction, conversion to hard copy, copying or other use of this communication, infonnation or
material is strictly proh bited. If you received this communication in error or if it is forwarded to you without the express authorization of
New Flyer, please notify us immediately by telephone or by return email and pennanently delete the communication, infonnation and
material from any computer, disk drive, diskette or other storage device or media. Thank you.
This communication (and any attachments) is directed in confidence to the addressee(s) listed above, and may not otherwise be
distributed, copied or used. The contents of this communication may also be subject to privilege, and all rights to that privilege are
expressly claimed and not waived. If you have received this communication in error, please notify us by reply e-mail or by telephone and
delete this communication (and any attachments) without making a copy. Thank you.
From: Jim Johnson <.J [email protected]>
Sent: Tuesday, May 2, 2023-
To:
Subject: RE: IMPORTANT SAFETY RECALL- / New Flyer XE
Good morning,
This email is to follow up on conversations you’ve had with New Flyer staff related to the next steps
in the solution to the recall of New Flyer’s Next-Gen ESS enclosure. As you should know by now,
these next steps include the installation of ports in the ESS, which will followed by installation of
drains. I’ve attached an updated customer notification letter, which contains the same information
shared with you verbally but is the written communication. Thank you for your patience as we work
through this issue—we are glad to be making progress and are eager to get the final remedy
installed early this summer.
Thanks, Jim
Jim Johnson
Manager, Vehicle Safety and Regulatory Compliance
New Flyer | MCI
From: Jim Johnson
Sent: Friday, February 24, 2023
To:
Cc:
Subject: IMPORTANT SAFETY RECALL – /New Flyer XE
Good afternoon,
This email is to follow up on a conversation New Flyer staff had with you related to a recall of New Flyer’s
Next-Gen ESS enclosure. The official recall letter, which includes New Flyer’s next steps and instructions
for customers, is attached and being mailed. Please know that we are putting all resources into a remedy
for this issue and are committed to ensuring the safety of our vehicles.
Feel free to reach out to your CPM, RPSM, RSM or the undersigned with any questions.
Thanks, Jim
Jim Johnson
Manager, Vehicle Safety and Regulatory Compliance
New Flyer | MCI
–

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Subject: IMPORTANT SAFETY RECALL – New Flyer XE
Date: Friday, February 24, 2023 1:33:00 PM
Attachments: 23V083
Good afternoon,
This email is to follow up on a conversation New Flyer staff had with you related to a recall of New Flyer’s
Next-Gen ESS enclosure. The official recall letter, which includes New Flyer’s next steps and instructions
for customers, is attached and being mailed via First-class mail. Please know that we are putting all
resources into a remedy for this issue and are committed to ensuring the safety of our vehicles.
Feel free to reach out to your CPM, RPSM, RSM or the undersigned with any questions.
Thanks, Jim
Jim Johnson
Manager, Vehicle Safety and Regulatory Compliance
C 256.453.7181
[email protected]
New Flyer | MCI

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IMPORTANT SAFETY RECALL
INTERIM NOTICE
24-February-2023 VIA US First Class Mail and email
ALBUQUERQUE INTERNATIONAL SUNPORT
ATTN: Josh Castellano-Gonzalez
Albuquerque International Sunport Airport
2200 Sunport Blvd. SE
Albuquerque, NM 87106
Subject: Motor Vehicle Safety Recall 23V-083 ESS liquid accumulation
To whom it may concern:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. New Flyer of America Inc. (New Flyer) has decided that a defect which relates to motor vehicle safety exists in certain 2021-2022 XE35, 2021-2023 XE40, and 2021-2022 XE60 battery electric vehicles. These vehicles are outfitted with an Energy Storage System (ESS) that is a fiberglass enclosure as depicted below. (Note that previous ESS versions that were metallic enclosures are not included in this recall.)
New Flyer has determined that the following vehicles, operated by the Albuquerque International Sunport Airport are affected by this recall action:
Make: New Flyer Heavy Duty Urban Transit Bus
Model: 2022 XE35
VINs: 5FYB8KJ03NF103994, 5FYB8KJ05NF103995
Fiberglass ESS Enclosure
If a leak occurs inside of an ESS and is uncorrected, liquid can accumulate, leading to an electrical short, increasing the risk of a fire.
As this is an interim notice, you will receive a second notification letter once the remedy has been determined. In the meantime, if you need additional information, please contact your New Flyer Regional Product Support Manager (RPSM) or another New Flyer contact.
Proper Personal Protective Equipment (PPE) must be used, and all safety protocol must be followed when working with and near/around high voltage (HV) components. Please refer to your Service Manual for details.
What New Flyer will do in the interim:
• New Flyer will work with customers to inspect each ESS on affected buses for liquid inside of each ESS. This visual inspection can be completed through the desiccant cap at the “front” of each ESS. (Each customer may choose to complete these inspections as well themselves to expedite the process.) See NOTE below if liquid is noticed in an ESS. Contact your RPSM to discuss next steps. If no liquid is present, the bus can be operated as normal.
What customers should do:
• In the interim, in an abundance of caution, if buses will be inoperable for more than 3 days, New Flyer recommends either draining the coolant from the Battery Thermal Management System (BTMS) or inspecting for normal coolant levels through the remote fill LEDs every 3 days the bus is parked, or visually inspecting for liquid through the desiccant cap every 3 days. Desiccant caps should not be left off if ESS’s are dry
• Customers must ensure their drivers and technicians are aware of the risk associated with coolant leaks inside the ESS. If an operator reports a yellow “LOW COOLANT” or a red “CRITICALLY LOW COOLANT” warning on the dash, all ESS’s must be inspected immediately to be sure a leak is not accumulating in the ESS. See NOTE below if liquid is noticed in an ESS. Contact your New Flyer Regional Product Support Manager (RPSM) to discuss next steps. If no liquid is seen, continue with normal procedures to address the cause of the dash warning per your Service Manual. After correction, the bus can then be operated as normal
• Customers must ensure their technicians and anyone who fills / tops-up coolant understands that low levels of coolant in the BTMS must be leak tested, root caused, and repaired prior to any top-ups of coolant. BTMS coolant top-ups cannot be performed without positive repairs or accumulation in the ESS may occur
• We recommend that customers refresh their personnel on the appropriate operating and maintenance procedures for battery-electric vehicles. Please contact your RPSM or another New Flyer contact with any questions
NOTE: If liquid is noticed inside the ESS:
• Leave the desiccant cap off (circled in blue in the picture above)
• Remove the MSD (Manual Service Disconnect) from the ESS (circled in red in picture above)
o Install a Plug, Blank Manual Service Disconnect (PN 869751) where the MSD was removed
• Coolant should be drained from the ESS cooling system
• Park bus in a safe outdoor location, away from other vehicles, structures, etc.
• The bus should be held from revenue service
• Do not charge the bus
• Additionally, customers should contact your New Flyer RPSM to discuss next steps
If you are a lessor of vehicles which are affected, it is required that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. If you no longer own this vehicle, or it has been removed from operation permanently, please inform the undersigned.
If you had this corrective action performed before you received this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall.
If you have any questions about this recall, please feel free to contact your RPSM. If New Flyer is unable to correct this defect within a reasonable time, you may submit a written complaint to the:
Administrator,
National Highway Traffic Safety Administration,
1200 New Jersey Ave. SE,
Washington, DC, 20590,
Or call 1-888-327-4236 (TTY: 1-800-424-9153);
or go to http://www.safercar.gov.
We regret any inconvenience which this action may cause you. However, we are concerned about the safety of your passengers and employees.
Thank you for your attention to this important matter.
Sincerely,
NEW FLYER OF AMERICA INC.
By: Jim Johnson
Vehicle Safety & Regulatory Compliance Manager
(256) 453-7181

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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: 60731 5/30/2023
SECTION:
260-Battery Compartment
WRITTEN BY:
Michel d’Auteuil
SUBJECT:
Install 4 drains into each ESS compartment – 6 String ESS
ISSUE:
Should a leak occur, liquids can accumulate in the ESS compartment
SUMMARY:
Install 4 drains into each of the 6 ESS compartments
ITS60731
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
23V083000
2023-073
INSTRUCTION TO SERVICE
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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 Appendix A – 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
WARNING: ARC FLASH GLOVES MUST BE USED ANYTIME THE ESS HAS AN
UNCOVERED HOLE
INSTRUCTION TO SERVICE
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Section 2 – ESS Access
4. Gain access to the rooftop ESS enclosures. Ensure that appropriate fall protection PPE is used and available for the duration of the work. Reference Figure 2 below for the upper ESS layout. Ensure appropriate safety procedures are followed for the duration of the work.
Figure 2: Upper ESS Layout
5. Open the rear access door to expose the drain ports (some components removed for clarity). You will need special torque tools to access the ports on the rear ESS.
 NOTE: At this point access to the ESS compartments is available.
Figure 3: Rear ESS Layout and rear drain locations
ESS3 ESS4 ESS5 ESS6
INSTRUCTION TO SERVICE
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Section 3 – Drain Installation
6. Remove plugs from the ESS and immediately install an ESS drain cartridge assembly PN 1025289. Torque to 40 ft-lbs. Repeat for all 24 drains.
Figure 4: Drain Locations (four per ESS) – USE ARC FLASH GLOVES
7. Add 3 supplied desiccant bags (PN 6492726) to the desiccant holder. The desiccant bags must not be left exposed to air longer than necessary. Reference Error! Reference source not found. for details.
INSTRUCTION TO SERVICE
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Figure 5: Desiccant Basket Location – USE ARC FLASH GLOVES
8. Clean workspace and return coach to revenue service condition. LABOUR – 6 STRINGS
Operation
Number of Technician(s)
Hours
Labor Time
T X HR
1
INSTALL 24 ESS DRAINS 5-STRING
1
2
2
PARTS KIT – 6 STRINGS
Item
Part Number
Description
Qty.
per Coach
Units
Notes
1
6492726
POUCH-DESICCANT SINGLE BAGGED
18
EA
ITS Parts
2
1025289
ASSY – DRAIN CARTRIDGE
24
EA
TOOL KIT
Item
Part Number
Description
Qty.
Units
Notes
1
6495077
TOOL-15 DEGREE OFFSET BOX END
1
EA
Part of Tool Kit
2
6495078
TOOL-1/4 DRIVE RATCHET
1
EA
3
6495079
TOOL-40FT LBS PRESET TORQUE WRENCH
1
EA
INSTRUCTION TO SERVICE
ITS-60731
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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.
INSTRUCTION TO SERVICE
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Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000-volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000-volt Category III, 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
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.
INSTRUCTION TO SERVICE
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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.)
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.
INSTRUCTION TO SERVICE
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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.
INSTRUCTION TO SERVICE
ITS-60731
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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
INSTRUCTION TO SERVICE
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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.

**************************************************************************************************************

, 1 ‘E:l?P INSTRUCTION TO SERVICE
NEW FLYER~
ITS: 60642G 4/21/2023
SECTION: 260-Battery Compartment
WRITTEN BY:
SUBJECT: Install 4 drain ports into each ESS compartment – 5 String ESS
ISSUE: Should a leak occur, liquids can accumulate in the ESS compartment
SUMMARY: Install 4 drain ports into each corner of all 5 ESS compartments
ITS60642
Ref. NHTSA Recall No. Ref. Transport Canada Recall No.
23V083000 2023-073
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED TO FOR FUTURE MAINTENANCE UNTIL
THE NEW FL YER 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 Ganada
ULC and New Flyer of America Inc. and are disclosed by New Flyer in confidence. This document and tile contents herein are not
to be disclosed by the intended recipient without tile prior written authorization of New Flyer. Any unauthorized disclosure,
reproduction or other distribution of this document or information strictly prohiMed and may result in action being taken against
the party making the unautllorized disclosure. This document and all copies hereof must be returned to New Flyer upon request
NEW FLYER,,
INSTRUCTION TO SERVICE
ITS-60642
ITS-60642G Page 2 of 30 4/21/2023
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 Appendix A – 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 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 Reference
NEW FLYER.
&
INSTRUCTION TO SERVICE
ITS-60642
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Section 2 – Roof ESS Compartment Access
4. Gain access to the rooftop ESS enclosures. Ensure that appropriate fall protection PPE is used and available
for the duration of the work. Reference Figure 2 below for the upper ESS layout.
Ensure appropriate safety procedures are followed for the duration of the work.
Figure 2: Upper ESS Layout
 NOTE: At this point access to the upper ESS compartments is available. Complete the rework in
Appendix C on each upper ESS before proceeding to Step 5.
ESS3 ESS4 ESS5
NEW FLYER.
NEW FLVERb
Section 3 – Rear ESS Compartment Access
INSTRUCTION TO SERVICE
ITS-60642
5. Gain access to the rear ESS area. Also support the rear frame members with jack stands as seen in Figure 3.
Keep in mind that access will be needed underneath the bus later in this section.
Figure 3: Support Rear Frame Members with Jack Stands
6. Drain the coolant from the ESS loop. Refer to the Cooling System Section of the New Flyer Service Manual
for the full procedure.
c:i>- NOTE: A coolant drain tool will be needed to ensure minimal mess.
7. Lay the rear access door flat on the forklift forks, loosen and remove hardware, and secure the hinges in the
extended position.
c:i>- NOTE: Remove door from hinges (leave hinges attached to bus frame).
8. Support the rear bumper with forklift, remove the four retaining bolts, and remove the rear bumper. Save all
mounting hardware for reuse later.
ITS-60642G Page 4 of 30 4/21/2023
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9. Remove the lower corner pillars (including turn signals and brake lights) and brackets. Reference Figure 4
below. Save hardware for reuse.
Figure 4: Lower Corner Pillars and Rear Door Removed
10. Disconnect and secure the high voltage cables, clamps, and grounding strap from both enclosures.
Reference Figure 5.
Figure 5: HV Connections and Ground Strap at Rear Street Side
NEW FLYER.
INSTRUCTION TO SERVICE
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ITS-60642G Page 6 of 30 4/21/2023
11. Disconnect and secure the low voltage harness and coolant hoses on the opposite side of the ESS
compartments. Reference Figure 6 below:
 NOTE: The clear BTMS vent line needs to be disconnected from the rear ESS frame.
Figure 6: LV Harness and Coolant Hose
NEW FLYER.
INSTRUCTION TO SERVICE
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ITS-60642G Page 7 of 30 4/21/2023
12. Remove mounting hardware and support the coolant fill panel. Ensure it clears the upper surface of the ESS
enclosure. See Figure 7.
13. Remove the hardware between the bumper beam and side structure. See Figure 7.
14. Remove the street side and curbside struts as follows: See Figure 7.
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.
15. Figure 7: Rear Struts and Side Structure Hardware Removal
16. Remove the hardware between the ESS rack and rear chassis end, with 2 sets on each side. Reference
Figure 8 below for details:
Figure 8: Hardware Between ESS Rack and Rear Chassis End
NEW FLYER.
NEW FLVERb
INSTRUCTION TO SERVICE
ITS-60642
17. From under the bus, remove the hardware between the front of the rear ESS rack and chassis. Reference
Figure 9 for details.
18. Support ESS rack with forklift. Remove both rear ESS compartments from the bus. Before removal of the
ESS, ensure no harnesses, cables, ground straps, or coolant hoses are connected. Reference Figure 9.
c:i>- NOTE: 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.
p :,
Figure 9: Rear ESS Compartments Removed from the Bus
19. Move the ESS enclosures into a clear and open workspace.
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20. To separate the ESS Compartments and gain clearance to the compartments, refer to Appendix B for details.
 NOTE: At this point, suitable access to the ESS compartments should be available. Complete the
rework in Appendix C before continuing to re-stack the rear ESS and then proceeding to Step 21.
21. Using a forklift or dolly place the ESS rack inside the vehicle and align the holes to the vehicle structure.
Torque the 1/2” hardware to 69 ft-lbs. (94 Nm). Reference Figure 10.
Figure 10: Installing ESS Enclosures
22. Place clamps over the upper and lower coolant line. Attach the coolant lines to the ESS and torque clamps to
80 in-lbs. (9 Nm) at 75 RPM or less.
23. After 30 minutes re-torque the clamps to 80 in-lbs. (9 Nm) at 75 RPM or less.
 NOTE: The orientation of clamps may vary to maximize clearance and access.
24. Connect the low voltage harnesses.
25. Connect the high voltage cables, clamps, and grounding strap securely.
NEW FLYER.
INSTRUCTION TO SERVICE
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26. Connect the corner pillar brackets and pillars with washers on each side of bracket and torque 3/8” bolt to 8 ftlbs.
(38 Nm). Reference Figure 11 for details.
Figure 11: Rear ESS Compartment Rack Installation
27. Support strut Installation – Reference Figure 12:
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 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-Seez 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. Refer figure 14.
g. Continue to tighten upper nut until the 44.84″ dimension is achieved, and then tighten an additional two
turns.
h. Apply Never-Seez to threaded area of strut and tighten lower 1″ jam nut to 426 ft-lb. (578 Nm).
~
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60642
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Figure 12: Strut Tensioning
28. Install rear access door and lower corner pillars. Use Loctite 243 on the rear access door hardware.
29. Install rear bumper – retorque rear bumper bolts 106 ft.-lbs. using Loctite 243. Additional instruction available
within the Service Manual if panel gaps require adjustment.
30. Once rework on enclosures is complete, refill ESS coolant system according to the instructions within the NF
Service Manual.
31. Install revised PLC program – obtain SR specific programming from RPSM.
32. Clean workspace and return coach to revenue service condition.
NEW FLYER.
UPPER NUT
44.84 ~8:68
0 0
NEW FLVERb
LABOUR – 5 STRINGS
Operation Number of
Technician(s)
1 INSTALL 20 ESS DRAIN PORTS 5-STRING 2
2 INSTALL PLC PROGRAM – OBTAIN FROM RPSM 1
PARTS KIT- 5 STRINGS
Qty.
per
INSTRUCTION TO SERVICE
ITS-60642
Hours Labor Time
TXHR
8 16
0.25 0.25
Item Part Number Description Coach Units Notes
1 6492726 POUCH-DESICCANT SINGLE BAGGED 15 EA
2 1017688 PORT-DRAIN PAL 20 EA ITS Parts
3 1019455 PLUG-HEX-12 ORB 20 EA
TOOL KIT
Item Part Number Description Qty. Units Notes
1 PS11-102 BOSCH 12V MAX 3/8IN ANGLE DRILL 1 EA
2 49-56-98 MILWAUKEE 1-1/4″ HOLE SAW 2 EA
3 XC-DJ-3073 PILOT HOLE FIXTURE 2 EA
4 TG7.016+2K BESSEY ADJUSTABLE CLAMP 1 EA
Part of Tool Kit
5 VIKG 87830 1/4″ STUB DRILL 4 EA
6 VIKG 34631 CUSTOM 1/4″ HEX SHANK DRILL 2 EA
7 36″ X 5″ WOOD SUPPORTS 2 EA
8 HOLE SAW CLEARING BLOCK 1 EA
ADHESIVE KIT
Item Part Number Description Qty. Units Notes
1 DP2X-400 PLEXUS APPLICATOR 1 EA
2 6470988 MIXING NOZZLE 490ML 3 AR As Required
3 892007 MA420 – 490ML 1 EA 490mL/bus
4 067196 PRIMER-PLEXUS PC120-QRT 0.01 AR As Required
5 6487253 ALCOHOL-CRC ISOPROPYL 99%-1602 0.01 AR As Required
6 SCOTCHBRITE 0.01 AR Source Locally
7 ADHESIVE DUCT TAPE 0.01 AR Source Locally
8 SHOP TOWELS 0.01 AR Source Locally
ITS-60642G Page 12 of 30 4/21/2023
NEW FLVERb
SPECIAL TOOLS
Item Part Number
1
2 2CDC6
3
4 5928660
5 081034
6
7
ITS-60642G
Description Qty.
COOLANT RECOVERY AND FILL TOOL
MILWAUKEE PORTABLE SHOP VAC
3200LBS VERTICAL RATED STRAPS 6
NEVER-SEEZ 0.01
LOCTITE 243 0.01
PLASTIC PUTTY KNIFE 1
HD NITRILE GROVES
Page 13 of 30
INSTRUCTION TO SERVICE
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Units Notes
Source Locally
Source Locally
EA Source Locally
AR
AR
EA Source Locally
AR Source Locally
4/21/2023
INSTRUCTION TO SERVICE
ITS-60642
ITS-60642G Page 14 of 30 4/21/2023
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.
NEW FLYER.
High voltage
INSTRUCTION TO SERVICE
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Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000-volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000-volt Category III, 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
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.
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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.)
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.
NEW FLYER.
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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.
NEW FLYER.
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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
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60642
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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.
NEW FLYER.
INSTRUCTION TO SERVICE
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Appendix B – Rear ESS Hoisting and Separating Instructions
DO NO USE METAL CLEVIS ON JB FEET
1. Stage ESS Enclosure on a flat and stable surface – Figure 13.
Figure 13: ESS Enclosures to be Reworked
2. Remove fasteners of the cross-brace and bolts that connect upper ESS enclosure to the lower frame (five
fasteners on each side). Reference Figure 14.
Figure 14: Remove Upper Cross-Brace Hardware (5 Places Each Side)
NEW FLYER.
INSTRUCTION TO SERVICE
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3. Use a forklift and appropriate straps (one in each corner) to lift the upper enclosure away from the frame.
Reference Figure 15 below for proper rigging.
Figure 15: Rigging for lifting Upper ESS Enclosure
4. Carefully move the upper ESS enclosure to a flat and stable surface. See Figure 16.
 NOTE: Rest ESS enclosure on the metal corners, and not the composite of the ‘tub’.
Figure 16: Lifting Upper ESS Enclosure
NEW FLYER.
INSTRUCTION TO SERVICE
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5. Remove the 8 bolts that secure the lower ESS enslosure to the frame (four bolts each side) per Figure 17.
Figure 17: Removing Hardware from ESS Enclosure Feet
6. Use forklift to lift the lower rack, then place the provided wood blocks under the metal corners of the ESS
enclosure. Lower the rack so that the ESS enclosure is supported by the wood blocks as seen in Figure 18.
Figure 18: Lower ESS Resting on Wooden Blocks
NEW FLYER.
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7. At this point, sufficient space to work has been obtained in order to rework the rear enclosures and the work
outlined in Appendix C can commence.
8. Once rework is complete, reassemble the rear ESS frame by reversing steps outlined above. Retorque all ½”
hardware to 69 ft. lbs. and apply a torque seal.
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60642
NEW FLVERb
Appendix C – Installing Drain Ports into Each ESS
1. Each ESS enclosure (rooftop and rear) will have four drain ports installed in the approximate locations
indicated below – two ports on the front side of each enclosure (not shown), and two ports on the rear side
of each enclosure (as shown below in Figure 19).
Front
Figure 19: Location of Drain Ports
2. The location of each hole is defined by fixture XD-DJ-3073 as shown in Figure 20. It will butt against the
cast feet, as well the lower surface of the enclosure.
Figure 20: Fixture XD-DJ-3073 (With and Without Clamp)
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NEW FLVERb
3. Align fixture XD-DJ-3073 to one corner support bracket as shown in Figure 21 below.
Figure 21 : Place Fixture Against Corner Bracket as Shown
4. Using the SUPPLIED 1/4″ STUB DRILL bit and BOSCH ANGLE DRILL attachment, drill a hole into the ESS
compartment through the preset hole in the fixture. Reference Figure 22 for details on the pilot hole operation.
&. WARNING: USE THE PROVIDED TOOLING ONLY AS THE FIXTUE AND TOOL
PREVENTS CUTTING TOO DEEP. DRILL THROUGH THE BUSHING IN THE FIXTURE.
SEATED FULLY
REARWARD IN
CHUCK
Figure 22: Pilot Hole Operation – PROVIDED ¼” STUB DRILL MUST BE SEATED FULLY REARWARD IN CHUCK
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5. Once the pilot hole is completed, remove fixture and switch to the provided 1-1/4” HOLE SAW. Make sure
hole is cut cleanly and no composite strands remain. Peck drill to clear cuttings. Reference Figure 23 below.
WARNING: USE THE PROVIDED TOOLING ONLY AS THE PROVIDED 1-1/4” HOLE
SAW PREVENTS CUTTING TOO DEEP. ENSURE TOOL TEETH ARE INTACT.
Figure 23: Hole Saw Operation
NEW FLYER.
Lt ——————————-
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6. Use a portable shop vac to clean out the cuttings per the right-most image in Figure 24. Clean bonding area
around newly drilled hole Isopropyl PN 6487253. Note if any Balsa-wood core is exposed and test fit each
hole with a port.
Figure 24: Vacuum Out Cuttings
7. Scuff the drain port insert PN 1017688 and the bonding area around the newly drilled hole in the
enclosure with scotchbrite. Clean scuffed insert and bonding area of the ESS enclosure with Isopropyl PN
6487253. The anodized port shown in Figure 25 is extremely resilient so only a light scuff is required (may not
show scuff marks).
Figure 25: Anodized Port
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60642
NEW FLVERb
8. Prime port with PC120 primer PN 067196. Reference Figure 26 for details on the difference between primed
and un-primed. Allow a minimum of 3 min flash-off time.
GOOD REJECT
Figure 26: Primed (left) Drain Port Insert Versus Un-primed (right)
9. Apply MA420 adhesive to the primed port insert and install it into the newly drilled hole as shown in
Figure 27. Ensure that the adhesive does not obstruct the threads of the insert.
~ NOTE: Eject a small amount of adhesive thru new tips to ensure product is adequately mixed. If
adhesive has sat in the tip for 4 minutes, eject fresh adhesive thru tip prior to continuing. Tool the bead of
adhesive with a plastic putty knife. Working time is approximately 4 minutes as adhesive will turn from
blue-to-green as it cures. If any Balsa-wood core is exposed, lightly coat exposed area with adhesive.
Figure 27: Adhesive Applied to Drain Port Insert and Installed-TOOL SQUEEZEOUT, ENSURE THREADS ARE CLEAR
ITS-60642G Page 28 of 30 4/21/2023
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INSTRUCTION TO SERVICE
ITS-60642
10. Secure the installed port with tape while the adhesive dries for a minimum of 30 minutes per Figure 28.
Figure 28: Secure Port with Tape for 30 minutes
11. After 30 mins elapsed, check again that there are no obstructions in the threads. Torque the supplied drain
plug PN 1019455 to 40 ft. lbs. per Figure 29 .. DO NOT OVERTORQUE.
TORQUETO
40 FT-LBS
Figure 29: Cross-Section of Port and Plug Assembly
12. Add ports to the remaining corners of the ESS enclosure (four total in each ESS enclosure).
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13. Add 3 supplied desiccant bags (PN 6492726) to the desiccant holder. The desiccant bags must not be left
exposed to air longer than necessary. Reference Figure 30 for details.
DESICCANT
BAGS
DESICCANT
HOLDER
REMOVABLE
SEALED CAP
Figure 30: Desiccant Basket Location
14. A completed ESS enclosure will contain four ports and plugs, and new desiccant, as shown in Figure 31.
Repeat for all strings on vehicle.
Figure 31 : Completed ESS Enclosure
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**************************************************************************************************************

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: 60795 08/25/2023
SECTION:
260-Battery Compartment
WRITTEN BY:
Devin Draward
SUBJECT:
Add pre-formed insulation to the ESS Ports and Drains – 6 String ESS
ISSUE:
Environmental conditions may cause the ESS drain to activate inadvertently
SUMMARY:
Add pre-formed insulation to the ESS Ports and Drains
ITS60795
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
23V083000
2023-073
INSTRUCTION TO SERVICE
ITS-60795
ITS-60795 Page 2 of 10 8/25/2023
PROCEDURE:
1. Set the park brake and chock the wheels.
2. Turn the master run switch, the main battery disconnect and the HV interlock switch to the “OFF” position.
WARNING: The work detailed in this ITS involves working near 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 Appendix A – 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
4. Gain access to the rooftop ESS drains. Ensure that appropriate fall protection PPE is used and available for
the duration of the work.
Ensure appropriate safety procedures are followed for the duration of the work.
5. Gain access to the to both the front and rear drains of the rear ESS. Reference Figure 2 on the following page
for an exemplar ESS with rear drains visible.
INSTRUCTION TO SERVICE
ITS-60795
ITS-60795 Page 3 of 10 8/25/2023
Figure 2: Complete ESS Enclosure – Rear Drains Visible
6. Using a lint-free cloth, carefully clean the exterior of the drain and port assembly with isopropyl. Ensure a flash-off time of 1 minute is followed. This is to ensure that the pressure sensitive adhesive on the foam puck bonds sufficiently to the port.
7. A complete ESS enclosure will contain four drains. Carefully peel the white backing off of the insulation and apply a pre-formed foam puck (PN 1040861) over the ESS port and drain assembly. Repeat for all ESS drains on vehicle. Reference Figure 3 below for an installed foam-puck. WARNING: Avoid covering the piston when applying the foam puck!!!
Figure 3: Remove White Backing (L) and Adhere Foam Puck to the ESS Port and Drain Assembly (R) – Repeat for all Drains.
INSTRUCTION TO SERVICE
ITS-60795
ITS-60795 Page 4 of 10 8/25/2023
LABOUR – 6 STRINGS
Operation
Number of Technician(s)
Hours
Labor Time
T X HR
1
INSULATE 24 ESS DRAINS 6-STRING
1
1.25
1.25
PARTS
Item
Part Number
Description
Qty.
per Coach
Units
Notes
1
1040861
PUCK-FOAM, EMERG DRAIN
24
EA
SPECIAL TOOLS
Item
Part Number
Description
Qty.
Units
Notes
1
6487253
ALCOHOL-CRC ISOPROPYL 99%-16OZ
Source Locally
INSTRUCTION TO SERVICE
ITS-60795
ITS-60795 Page 5 of 10 8/25/2023
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.
INSTRUCTION TO SERVICE
ITS-60795
ITS-60795 Page 6 of 10 8/25/2023
Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000-volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000-volt Category III, 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
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.
INSTRUCTION TO SERVICE
ITS-60795
ITS-60795 Page 7 of 10 8/25/2023
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.)
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.
INSTRUCTION TO SERVICE
ITS-60795
ITS-60795 Page 8 of 10 8/25/2023
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.
INSTRUCTION TO SERVICE
ITS-60795
ITS-60795 Page 9 of 10 8/25/2023
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
INSTRUCTION TO SERVICE
ITS-60795
ITS-60795 Page 10 of 10 8/25/2023
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.

**************************************************************************************************************

, 1 ‘E:l?P INSTRUCTION TO SERVICE
NEW FLYER~
ITS: 606430 4/21/2023
SECTION: 260-Battery Compartment
WRITTEN BY:
SUBJECT: Install 4 drain ports into each ESS compartment – 6 String ESS
ISSUE: Should a leak occur, liquids can accumulate in the ESS compartment
SUMMARY: Install 4 drain ports into each corner of all 6 ESS compartments
ITS60643
Ref. NHTSA Recall No. Ref. Transport Canada Recall No.
23V083000 2023-073
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 Fryer of America Inc. and are disclosed by New Flyer in confidence. This document and tile contents herein are not
to be disclosed by the intended recipient without tile prior written authorization of New Flyer. Any unautllorized disclosure,
reproduction or otller distribution of this document or information strictly prohiMed and may result in action being taken against
the party making the unautllorized disclosure. This document and all copies hereof must be returned to New Flyer upon request.
NEW FLYER,,
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 2 of 30 4/21/2023
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 Appendix A – 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 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 Reference
NEW FLYER.
&
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 3 of 30 4/21/2023
Section 2 – Roof ESS Compartment Access
4. Gain access to the rooftop ESS enclosures. Ensure that appropriate fall protection PPE is used and available
for the duration of the work. Reference Figure 2 below for the upper ESS layout.
Ensure appropriate safety procedures are followed for the duration of the work.
Figure 2: Upper ESS Layout
 NOTE: At this point access to the upper ESS compartments is available. Complete the rework in
Appendix C on each upper ESS before proceeding to Step 5.
ESS3 ESS4 ESS5 ESS6
NEW FLYER.
NEW FLVERb
Section 3 – Rear ESS Compartment Access
INSTRUCTION TO SERVICE
ITS-60643
5. Gain access to the rear ESS area. Also support the rear frame members with jack stands as seen in Figure 3.
Keep in mind that access will be needed underneath the bus later in this section.
Figure 3: Support Rear Frame Members with Jack Stands
6. Drain the coolant from the ESS loop. Refer to the Cooling System Section of the New Flyer Service Manual
for the full procedure.
c:i>- NOTE: A coolant drain tool will be needed to ensure minimal mess.
7. Lay the rear access door flat on the forklift forks, loosen and remove hardware, and secure the hinges in the
extended position.
c:i>- NOTE: Remove door from hinges (leave hinges attached to bus frame).
8. Support the rear bumper with forklift, remove the four retaining bolts, and remove the rear bumper. Save all
mounting hardware for reuse later.
ITS-60643D Page 4 of 30 4/21/2023
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 5 of 30 4/21/2023
9. Remove the lower corner pillars (including turn signals and brake lights) and brackets. Reference Figure 4
below. Save hardware for reuse.
Figure 4: Lower Corner Pillars and Rear Door Removed
10. Disconnect and secure the high voltage cables, clamps, and grounding strap from both enclosures.
Reference Figure 5.
Figure 5: HV Connections and Ground Strap at Rear Street Side
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 6 of 30 4/21/2023
11. Disconnect and secure the low voltage harness and coolant hoses on the opposite side of the ESS
compartments. Reference Figure 6 below:
 NOTE: The clear BTMS vent line needs to be disconnected from the rear ESS frame.
Figure 6: LV Harness and Coolant Hose
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 7 of 30 4/21/2023
12. Remove mounting hardware and support the coolant fill panel. Ensure it clears the upper surface of the ESS
enclosure. See Figure 7.
13. Remove the hardware between the bumper beam and side structure. See Figure 7.
14. Remove the street side and curbside struts as follows: See Figure 7.
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.
15. Figure 7: Rear Struts and Side Structure Hardware Removal
16. Remove the hardware between the ESS rack and rear chassis end, with 2 sets on each side. Reference
Figure 8 below for details:
Figure 8: Hardware Between ESS Rack and Rear Chassis End
NEW FLYER.
NEW FLVERb
INSTRUCTION TO SERVICE
ITS-60643
17. From under the bus, remove the hardware between the front of the rear ESS rack and chassis. Reference
Figure 9 for details.
18. Support ESS rack with forklift. Remove both rear ESS compartments from the bus. Before removal of the
ESS, ensure no harnesses, cables, ground straps, or coolant hoses are connected. Reference Figure 9.
c:i>- NOTE: 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.
p :,
Figure 9: Rear ESS Compartments Removed from the Bus
19. Move the ESS enclosures into a clear and open workspace.
ITS-60643D Page 8 of 30 4/21/2023
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 9 of 30 4/21/2023
20. To separate the ESS Compartments and gain clearance to the compartments, refer to Appendix B for details.
 NOTE: At this point, suitable access to the ESS compartments should be available. Complete the
rework in Appendix C before continuing to re-stack the rear ESS and then proceeding to Step 21.
21. Using a forklift or dolly place the ESS rack inside the vehicle and align the holes to the vehicle structure.
Torque the 1/2” hardware to 69 ft-lbs. (94 Nm). Reference Figure 10.
Figure 10: Installing ESS Enclosures
22. Place clamps over the upper and lower coolant line. Attach the coolant lines to the ESS and torque clamps to
80 in-lbs. (9 Nm) at 75 RPM or less.
23. After 30 minutes re-torque the clamps to 80 in-lbs. (9 Nm) at 75 RPM or less.
 NOTE: The orientation of clamps may vary to maximize clearance and access.
24. Connect the low voltage harnesses.
25. Connect the high voltage cables, clamps, and grounding strap securely.
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 10 of 30 4/21/2023
26. Connect the corner pillar brackets and pillars with washers on each side of bracket and torque 3/8” bolt to 8 ftlbs.
(38 Nm). Reference Figure 11 for details.
Figure 11: Rear ESS Compartment Rack Installation
27. Support strut Installation – Reference Figure 12:
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 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-Seez 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. Refer figure 14.
g. Continue to tighten upper nut until the 44.84″ dimension is achieved, and then tighten an additional two
turns.
h. Apply Never-Seez to threaded area of strut and tighten lower 1″ jam nut to 426 ft-lb. (578 Nm).
~
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 11 of 30 4/21/2023
Figure 12: Strut Tensioning
28. Install rear access door and lower corner pillars. Use Loctite 243 on the rear access door hardware.
29. Install rear bumper – retorque rear bumper bolts 106 ft.-lbs. using Loctite 243. Additional instruction available
within the Service Manual if panel gaps require adjustment.
30. Once rework on enclosures is complete, refill ESS coolant system according to the instructions within the NF
Service Manual.
31. Install revised PLC program – obtain SR specific programming from RPSM.
32. Clean workspace and return coach to revenue service condition.
NEW FLYER.
UPPER NUT
44.84 ~8:68
0 0
NEW FLVERb
LABOUR – 6 STRINGS
Operation Number of
Technician(s)
1 INSTALL 24 ESS DRAIN PORTS 6-STRING 2
2 INSTALL PLC PROGRAM – OBTAIN FROM RPSM 1
PARTS KIT- 6 STRINGS
Qty.
per
INSTRUCTION TO SERVICE
ITS-60643
Hours Labor Time
TXHR
8.5 17
0.25 0.25
Item Part Number Description Coach Units Notes
1 6492726 POUCH-DESICCANT SINGLE BAGGED 18 EA
2 1017688 PORT-DRAIN PAL 24 EA ITS Parts
3 1019455 PLUG-HEX-12 ORB 24 EA
TOOL KIT
Item Part Number Description Qty. Units Notes
1 PS11-102 BOSCH 12V MAX 3/8IN ANGLE DRILL 1 EA
2 49-56-98 MILWAUKEE 1-1/4″ HOLE SAW 2 EA
3 XC-DJ-3073 PILOT HOLE FIXTURE 2 EA
4 TG7.016+2K BESSEY ADJUSTABLE CLAMP 1 EA
Part of Tool Kit
5 VIKG 87830 1/4″ STUB DRILL 4 EA
6 VIKG 34631 CUSTOM 1/4″ HEX SHANK DRILL 2 EA
7 36″ X 5″ WOOD SUPPORTS 2 EA
8 HOLE SAW CLEARING BLOCK 1 EA
ADHESIVE KIT
Item Part Number Description Qty. Units Notes
1 DP2X-400 PLEXUS APPLICATOR 1 EA
2 6470988 MIXING NOZZLE 490ML 3 AR As Required
3 892007 MA420 – 490ML 1 EA 490mL/bus
4 067196 PRIMER-PLEXUS PC120-QRT 0.01 AR As Required
5 6487253 ALCOHOL-CRC ISOPROPYL 99%-1602 0.01 AR As Required
6 SCOTCHBRITE 0.01 AR Source Locally
7 ADHESIVE DUCT TAPE 0.01 AR Source Locally
8 SHOP TOWELS 0.01 AR Source Locally
ITS-60643D Page 12 of 30 4/21/2023
NEW FLVERb
SPECIAL TOOLS
Item Part Number
1
2 2CDC6
3
4 5928660
5 081034
6
7
ITS-60643D
Description Qty.
COOLANT RECOVERY AND FILL TOOL
MILWAUKEE PORTABLE SHOP VAC
3200LBS VERTICAL RATED STRAPS 6
NEVER-SEEZ 0.01
LOCTITE 243 0.01
PLASTIC PUTTY KNIFE 1
HD NITRILE GROVES
Page 13 of 30
INSTRUCTION TO SERVICE
ITS-60643
Units Notes
Source Locally
Source Locally
EA Source Locally
AR
AR
EA Source Locally
AR Source Locally
4/21/2023
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 14 of 30 4/21/2023
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.
NEW FLYER.
High voltage
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 15 of 30 4/21/2023
Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000-volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000-volt Category III, 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
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.
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 16 of 30 4/21/2023
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.)
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.
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 17 of 30 4/21/2023
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.
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 18 of 30 4/21/2023
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
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 19 of 30 4/21/2023
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.
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 20 of 30 4/21/2023
Appendix B – Rear ESS Hoisting and Separating Instructions
DO NO USE METAL CLEVIS ON JB FEET
1. Stage ESS Enclosure on a flat and stable surface – Figure 13.
Figure 13: ESS Enclosures to be Reworked
2. Remove fasteners of the cross-brace and bolts that connect upper ESS enclosure to the lower frame (five
fasteners on each side). Reference Figure 14.
Figure 14: Remove Upper Cross-Brace Hardware (5 Places Each Side)
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 21 of 30 4/21/2023
3. Use a forklift and appropriate straps (one in each corner) to lift the upper enclosure away from the frame.
Reference Figure 15 below for proper rigging.
Figure 15: Rigging for lifting Upper ESS Enclosure
4. Carefully move the upper ESS enclosure to a flat and stable surface. See Figure 16.
 NOTE: Rest ESS enclosure on the metal corners, and not the composite of the ‘tub’.
Figure 16: Lifting Upper ESS Enclosure
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 22 of 30 4/21/2023
5. Remove the 8 bolts that secure the lower ESS enslosure to the frame (four bolts each side) per Figure 17.
Figure 17: Removing Hardware from ESS Enclosure Feet
6. Use forklift to lift the lower rack, then place the provided wood blocks under the metal corners of the ESS
enclosure. Lower the rack so that the ESS enclosure is supported by the wood blocks as seen in Figure 18.
Figure 18: Lower ESS Resting on Wooden Blocks
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 23 of 30 4/21/2023
7. At this point, sufficient space to work has been obtained in order to rework the rear enclosures and the work
outlined in Appendix C can commence.
8. Once rework is complete, reassemble the rear ESS frame by reversing steps outlined above. Retorque all ½”
hardware to 69 ft. lbs. and apply a torque seal.
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
NEW FLVERb
Appendix C – Installing Drain Ports into Each ESS
1. Each ESS enclosure (rooftop and rear) will have four drain ports installed in the approximate locations
indicated below – two ports on the front side of each enclosure (not shown), and two ports on the rear side
of each enclosure (as shown below in Figure 19).
Front
Figure 19: Location of Drain Ports
2. The location of each hole is defined by fixture XD-DJ-3073 as shown in Figure 20. It will butt against the
cast feet, as well the lower surface of the enclosure.
Figure 20: Fixture XD-DJ-3073 (With and Without Clamp)
ITS-60643D Page 24 of 30 4/21/2023
INSTRUCTION TO SERVICE
ITS-60643
NEW FLVERb
3. Align fixture XD-DJ-3073 to one corner support bracket as shown in Figure 21 below.
Figure 21 : Place Fixture Against Corner Bracket as Shown
4. Using the SUPPLIED 1/4″ STUB DRILL bit and BOSCH ANGLE DRILL attachment, drill a hole into the ESS
compartment through the preset hole in the fixture. Reference Figure 22 for details on the pilot hole operation.
&. WARNING: USE THE PROVIDED TOOLING ONLY AS THE FIXTUE AND TOOL
PREVENTS CUTTING TOO DEEP. DRILL THROUGH THE BUSHING IN THE FIXTURE.
SEATED FULLY
REARWARD IN
CHUCK
Figure 22: Pilot Hole Operation – PROVIDED ¼” STUB DRILL MUST BE SEATED FULLY REARWARD IN CHUCK
ITS-60643D Page 25 of 30 4/21/2023
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 26 of 30 4/21/2023
5. Once the pilot hole is completed, remove fixture and switch to the provided 1-1/4” HOLE SAW. Make sure
hole is cut cleanly and no composite strands remain. Peck drill to clear cuttings. Reference Figure 23 below.
WARNING: USE THE PROVIDED TOOLING ONLY AS THE PROVIDED 1-1/4” HOLE
SAW PREVENTS CUTTING TOO DEEP. ENSURE TOOL TEETH ARE INTACT.
Figure 23: Hole Saw Operation
NEW FLYER.
Lt ——————————-
INSTRUCTION TO SERVICE
ITS-60643
ITS-60643D Page 27 of 30 4/21/2023
6. Use a portable shop vac to clean out the cuttings per the right-most image in Figure 24. Clean bonding area
around newly drilled hole using Isopropyl PN 6487253. Note if any Balsa-wood core is exposed and test fit
each hole with a port.
Figure 24: Vacuum Out Cuttings
7. Scuff the drain port insert PN 1017688 and the bonding area around the newly drilled hole in the
enclosure with scotchbrite. Clean scuffed insert and bonding area of the ESS enclosure with Isopropyl PN
6487253. The anodized port shown in Figure 25 is extremely resilient so only a light scuff is required (may not
show scuff marks).
Figure 25: Anodized Port
NEW FLYER.
INSTRUCTION TO SERVICE
ITS-60643
NEW FLVERb
8. Prime with PC120 primer PN 067196. Reference Figure 26 for details on the difference between primed and
un-primed. Allow a minimum of 3 min flash-off time.
GOOD REJECT
Figure 26: Primed (Right) Drain Port Insert Versus Un-primed (Left)
9. Apply MA420 adhesive to the primed port insert and install it into the newly drilled hole as shown in
Figure 27. Ensure that the adhesive does not obstruct the threads of the insert.
~ NOTE: Eject a small amount of adhesive thru new tips to ensure product is adequately mixed. If
adhesive has sat in the tip for 4 minutes, eject fresh adhesive thru tip prior to continuing. Tool the bead of
adhesive with a plastic putty knife. Working time is approximately 4 minutes as adhesive will turn from
blue-to-green as it cures. If any Balsa-wood core is exposed, lightly coat exposed area with adhesive.
Figure 27: Adhesive Applied to Drain Port Insert and Installed -TOOL SQUEEZEOUT, ENSURE THREADS ARE CLEAR
ITS-60643D Page 28 of 30 4/21/2023
NEW FLVERb
INSTRUCTION TO SERVICE
ITS-60643
10. Secure the installed port with tape while the adhesive dries for a minimum of 30 minutes per Figure 28.
Figure 28: Secure Port with Tape for 30 minutes
11. After 30 mins elapsed, check again that there are no obstructions in the threads. Torque the supplied drain
plug PN 1019455 to 40 ft. lbs. per Figure 29 .. DO NOT OVERTORQUE.
TORQUETO
40 FT-LBS
Figure 29: Cross-Section of Port and Plug Assembly
12. Add ports to the remaining corners of the ESS enclosure (four total in each ESS enclosure).
ITS-60643D Page 29 of 30 4/21/2023
INSTRUCTION TO SERVICE
ITS-60643
NEW FLVERb
13. Add 3 supplied desiccant bags (PN 6492726) to the desiccant holder. The desiccant bags must not be left
exposed to air longer than necessary. Reference Figure 30 for details.
DESICCANT
BAGS
DESICCANT
HOLDER
REMOVABLE
SEALED CAP
Figure 30: Desiccant Basket Location
14. A completed ESS enclosure will contain four ports and plugs, and new desiccant, as shown in Figure 31.
Repeat for all strings on vehicle.
Figure 31 : Completed ESS Enclosure
ITS-60643D Page 30 of 30 4/21/2023

**************************************************************************************************************

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: 60794 08/25/2023
SECTION:
260-Battery Compartment
WRITTEN BY:
Devin Draward
SUBJECT:
Add pre-formed insulation to the ESS Ports and Drains – 5 String ESS
ISSUE:
Environmental conditions may cause the ESS drain to activate inadvertently
SUMMARY:
Add pre-formed insulation to the ESS Ports and Drains
ITS60794
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
23V083000
2023-073
INSTRUCTION TO SERVICE
ITS-60794
ITS-60794 Page 2 of 10 8/25/2023
PROCEDURE:
1. Set the park brake and chock the wheels.
2. Turn the master run switch, the main battery disconnect and the HV interlock switch to the “OFF” position.
WARNING: The work detailed in this ITS involves working near 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 Appendix A – 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
4. Gain access to the rooftop ESS drains. Ensure that appropriate fall protection PPE is used and available for
the duration of the work.
Ensure appropriate safety procedures are followed for the duration of the work.
5. Gain access to the to both the front and rear drains of the rear ESS. Reference Figure 2 on the following page
for an exemplar ESS with rear drains visible.
INSTRUCTION TO SERVICE
ITS-60794
ITS-60794 Page 3 of 10 8/25/2023
Figure 2: Complete ESS Enclosure – Rear Drains Visible
6. Using a lint-free cloth, carefully clean the exterior of the drain and port assembly with isopropyl. Ensure a flash-off time of 1 minute is followed. This is to ensure that the pressure sensitive adhesive on the foam puck bonds sufficiently to the port.
7. A complete ESS enclosure will contain four drains. Carefully peel the white backing off of the insulation and apply a pre-formed foam puck (PN 1040861) over the ESS port and drain assembly. Repeat for all ESS drains on vehicle. Reference Figure 3 below for an installed foam-puck. WARNING: Avoid covering the piston when applying the foam puck!!!
Figure 3: Remove White Backing (L) and Adhere Foam Puck to the ESS Port and Drain Assembly (R) – Repeat for all Drains.
INSTRUCTION TO SERVICE
ITS-60794
ITS-60794 Page 4 of 10 8/25/2023
LABOUR – 5 STRINGS
Operation
Number of Technician(s)
Hours
Labor Time
T X HR
1
INSULATE 20 ESS DRAINS 5-STRING
1
1.0
1.0
PARTS
Item
Part Number
Description
Qty.
per Coach
Units
Notes
1
1040861
PUCK-FOAM, EMERG DRAIN
20
EA
SPECIAL TOOLS
Item
Part Number
Description
Qty.
Units
Notes
1
6487253
ALCOHOL-CRC ISOPROPYL 99%-16OZ
Source Locally
INSTRUCTION TO SERVICE
ITS-60794
ITS-60794 Page 5 of 10 8/25/2023
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.
INSTRUCTION TO SERVICE
ITS-60794
ITS-60794 Page 6 of 10 8/25/2023
Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000-volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000-volt Category III, 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
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.
INSTRUCTION TO SERVICE
ITS-60794
ITS-60794 Page 7 of 10 8/25/2023
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.)
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.
INSTRUCTION TO SERVICE
ITS-60794
ITS-60794 Page 8 of 10 8/25/2023
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.
INSTRUCTION TO SERVICE
ITS-60794
ITS-60794 Page 9 of 10 8/25/2023
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
INSTRUCTION TO SERVICE
ITS-60794
ITS-60794 Page 10 of 10 8/25/2023
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.

**************************************************************************************************************

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: 60730 5/30/2023
SECTION:
260-Battery Compartment
WRITTEN BY:
Michel d’Auteuil
SUBJECT:
Install 4 drains into each ESS compartment – 5 String ESS
ISSUE:
Should a leak occur, liquids can accumulate in the ESS compartment
SUMMARY:
Install 4 drains into each of the 5 ESS compartments
ITS60730
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
23V083000
2023-073
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 2 of 11 5/30/2023
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 Appendix A – 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
WARNING: ARC FLASH GLOVES MUST BE USED ANYTIME THE ESS HAS AN
UNCOVERED HOLE
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 3 of 11 5/30/2023
Section 2 – ESS Access
4. Gain access to the rooftop ESS enclosures. Ensure that appropriate fall protection PPE is used and available for the duration of the work. Reference Figure 2 below for the upper ESS layout. Ensure appropriate safety procedures are followed for the duration of the work.
Figure 2: Upper ESS Layout
5. Open the rear access door to expose the drain ports (some components removed for clarity). You will need special torque tools to access the ports on the rear ESS.
 NOTE: At this point access to the ESS compartments is available.
Figure 3: Rear ESS Layout and rear drain locations
ESS3 ESS4 ESS5
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 4 of 11 5/30/2023
Section 3 – Drain Installation
6. Remove plugs from the ESS and immediately install an ESS drain cartridge assembly PN 1025289. Torque to 40 ft-lbs. Repeat for all 20 drains.
Figure 4: Drain Locations (four per ESS) – USE ARC FLASH GLOVES
7. Add 3 supplied desiccant bags (PN 6492726) to the desiccant holder. The desiccant bags must not be left exposed to air longer than necessary. Reference Error! Reference source not found. for details.
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 5 of 11 5/30/2023
Figure 5: Desiccant Basket Location – USE ARC FLASH GLOVES
8. Clean workspace and return coach to revenue service condition. LABOUR – 5 STRINGS
Operation
Number of Technician(s)
Hours
Labor Time
T X HR
1
INSTALL 20 ESS DRAINS 5-STRING
1
2
2
PARTS KIT – 5 STRINGS
Item
Part Number
Description
Qty.
per Coach
Units
Notes
1
6492726
POUCH-DESICCANT SINGLE BAGGED
15
EA
ITS Parts
2
1025289
ASSY – DRAIN CARTRIDGE
20
EA
TOOL KIT
Item
Part Number
Description
Qty.
Units
Notes
1
6495077
TOOL-15 DEGREE OFFSET BOX END
1
EA
Part of Tool Kit
2
6495078
TOOL-1/4 DRIVE RATCHET
1
EA
3
6495079
TOOL-40FT LBS PRESET TORQUE WRENCH
1
EA
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 6 of 11 5/30/2023
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.
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 7 of 11 5/30/2023
Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000-volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000-volt Category III, 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
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.
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 8 of 11 5/30/2023
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.)
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.
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 9 of 11 5/30/2023
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.
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 10 of 11 5/30/2023
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
INSTRUCTION TO SERVICE
ITS-60730
ITS-60730 Page 11 of 11 5/30/2023
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.

**************************************************************************************************************

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: 60782 08/10/2023
SECTION:
260-Battery Compartment
WRITTEN BY:
Devin Draward
SUBJECT:
Add insulation to drain ports of each ESS compartment – 5 String ESS
ISSUE:
Environmental conditions may cause the ESS drain to activate inadvertently
SUMMARY:
Add insulation to drain ports of 5 ESS compartments
ITS60782
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
23V083000
2023-073
INSTRUCTION TO SERVICE
ITS-60782
ITS-60782B Page 2 of 10 8/10/2023
PROCEDURE:
1. Set the park brake and chock the wheels.
2. Turn the master run switch, the main battery disconnect and the HV interlock switch to the “OFF” position.
WARNING: The work detailed in this ITS involves working near 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 Appendix A – 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
4. Gain access to the rooftop ESS drains. Ensure that appropriate fall protection PPE is used and available for
the duration of the work.
Ensure appropriate safety procedures are followed for the duration of the work.
5. Gain access to the to both the front and rear drains of the rear ESS. Reference Figure 2 below for an
exemplar ESS with rear drains visible.
INSTRUCTION TO SERVICE
ITS-60782
ITS-60782B Page 3 of 10 8/10/2023
Figure 2: Complete ESS Enclosure – Rear Drains Visible
6. A complete ESS enclosure will contain four drains. Carefully wrap each ESS drain with pre-cut 8” segments of Armacell R-1 Foam Insulation Tape (2 in. x .125 in. x 30 ft. bulk roll), ensuring joints are sealed. Trim excess carefully with a razor blade. Repeat for all drains on vehicle. WARNING: Avoid covering the piston when applying the foam tape!!! Tape is difficult to adjust once bonded!!!
Figure 3: ESS Drains Insulated with 8” Strips of Armacell R-1 Foam Tape
INSTRUCTION TO SERVICE
ITS-60782
ITS-60782B Page 4 of 10 8/10/2023
LABOUR – 5 STRINGS
Operation
Number of Technician(s)
Hours
Labor Time
T X HR
1
INSULATE 20 ESS DRAINS 5-STRING
1
1.0
1.0
PARTS
Item
Part Number
Description
Qty.
per Coach
Units
Notes
1
N/A
Armacell R-1 Foam Insulation Tape (2 in. x .125 in. x 30 ft. bulk roll)
160
IN.
Source Locally
SPECIAL TOOLS
Item
Part Number
Description
Qty.
Units
Notes
1
N/A
Razor Blade or Utility Knife
Source Locally
INSTRUCTION TO SERVICE
ITS-60782
ITS-60782B Page 5 of 10 8/10/2023
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.
INSTRUCTION TO SERVICE
ITS-60782
ITS-60782B Page 6 of 10 8/10/2023
Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000-volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000-volt Category III, 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
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.
INSTRUCTION TO SERVICE
ITS-60782
ITS-60782B Page 7 of 10 8/10/2023
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.)
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.
INSTRUCTION TO SERVICE
ITS-60782
ITS-60782B Page 8 of 10 8/10/2023
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.
INSTRUCTION TO SERVICE
ITS-60782
ITS-60782B Page 9 of 10 8/10/2023
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
INSTRUCTION TO SERVICE
ITS-60782
ITS-60782B Page 10 of 10 8/10/2023
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.

**************************************************************************************************************

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: 60783 08/10/2023
SECTION:
260-Battery Compartment
WRITTEN BY:
Devin Draward
SUBJECT:
Add insulation to drain ports of each ESS compartment – 6 String ESS
ISSUE:
Environmental conditions may cause the ESS drain to activate inadvertently
SUMMARY:
Add insulation to drain ports of 6 ESS compartments
ITS60783
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
23V083000
2023-073
INSTRUCTION TO SERVICE
ITS-60783
ITS-60783B Page 2 of 10 8/10/2023
PROCEDURE:
1. Set the park brake and chock the wheels.
2. Turn the master run switch, the main battery disconnect and the HV interlock switch to the “OFF” position.
WARNING: The work detailed in this ITS involves working near 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 Appendix A – 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
4. Gain access to the rooftop ESS drains. Ensure that appropriate fall protection PPE is used and available for
the duration of the work.
Ensure appropriate safety procedures are followed for the duration of the work.
5. Gain access to the to both the front and rear drains of the rear ESS. Reference Figure 2 below for an
exemplar ESS with rear drains visible.
INSTRUCTION TO SERVICE
ITS-60783
ITS-60783B Page 3 of 10 8/10/2023
Figure 2: Complete ESS Enclosure – Rear Drains Visible
6. A complete ESS enclosure will contain four drains. Carefully wrap each ESS drain with pre-cut 8” segments of Armacell R-1 Foam Insulation Tape (2 in. x .125 in. x 30 ft. bulk roll), ensuring joints are sealed. Trim excess carefully with a razor blade. Repeat for all drains on vehicle. WARNING: Avoid covering the piston when applying the foam tape!!! Tape is difficult to adjust once bonded!!!
Figure 3: ESS Drains Insulated with 8” Strips of Armacell R-1 Foam Tape
INSTRUCTION TO SERVICE
ITS-60783
ITS-60783B Page 4 of 10 8/10/2023
LABOUR – 6 STRINGS
Operation
Number of Technician(s)
Hours
Labor Time
T X HR
1
INSULATE 24 ESS DRAINS 6-STRING
1
1.25
1.25
PARTS
Item
Part Number
Description
Qty.
per Coach
Units
Notes
1
N/A
Armacell R-1 Foam Insulation Tape (2 in. x .125 in. x 30 ft. bulk roll)
192
IN.
Source Locally
SPECIAL TOOLS
Item
Part Number
Description
Qty.
Units
Notes
1
N/A
Razor Blade or Utility Knife
Source Locally
INSTRUCTION TO SERVICE
ITS-60783
ITS-60783B Page 5 of 10 8/10/2023
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.
INSTRUCTION TO SERVICE
ITS-60783
ITS-60783B Page 6 of 10 8/10/2023
Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000-volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000-volt Category III, 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
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.
INSTRUCTION TO SERVICE
ITS-60783
ITS-60783B Page 7 of 10 8/10/2023
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.)
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.
INSTRUCTION TO SERVICE
ITS-60783
ITS-60783B Page 8 of 10 8/10/2023
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.
INSTRUCTION TO SERVICE
ITS-60783
ITS-60783B Page 9 of 10 8/10/2023
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
INSTRUCTION TO SERVICE
ITS-60783
ITS-60783B Page 10 of 10 8/10/2023
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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Page 1 of 3
IMPORTANT SAFETY RECALL
02-May-2023 VIA US First Class Mail and email
ATTN:
Subject: Motor Vehicle Safety Recall 23V-083 Energy Storage System (ESS) Liquid Accumulation
To whom it may concern:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety
Act. New Flyer of America Inc. (New Flyer) has decided that a defect which relates to motor vehicle safety exists
in certain 2021-2022 XE35, 2021-2023 XE40, and 2021-2022 XE60 battery electric vehicles. These vehicles are
outfitted with an Energy Storage System (ESS) that is a fiberglass enclosure. Note that previous ESS versions
were a different design and metallic enclosures are not included in this recall.
If a leak occurs inside of an ESS and is undetected, liquid can accumulate, leading to an electrical short,
increasing the risk of a fire.
Please note this is the “second notification letter” referenced in the interim notice, which was sent to you via
email on or about 24-February-2023 and shortly thereafter via US First Class mail. No further notices are
anticipated.
New Flyer has determined that the following vehicles, operated by the are affected by
this recall action:
Make: New Flyer Heavy Duty Urban Transit Bus
Model: 2022 XE40
VINs: 5FYB8FJ1XN , 5FYB8FJ11N , 5FYB8FJ13N
Proper Personal Protective Equipment (PPE) must be used, and all safety protocol must be followed when
working with and near/around high voltage (HV) components. Please refer to your Service Manual for
details.
What New Flyer will do, free of charge:
• Automatic drain valves will be installed (the Retrofit), after scheduling with customers. In the event liquid
accumulates, these drain valves will allow the accumulation to freely exit the ESS without the need of
electrical power. This will require New Flyer to:
o Provide 4 drainage holes in each ESS assembly and install a metallic port into the holes
o Install an automatic drain valve system in each of the 4 ports (per Figure 1)
o Please note this Retrofit may be performed in 2 phases – your RPSM and/or CPM can provide
details per customer
▪ Phase 1: Installing the ports with a simple plug, material is available to complete this
phase now, and
▪ Phase 2: Removing the previously installed plug and installing the drain valve. Drain
valves are expected to be available in June 2023
▪ Once the drain valve is installed (Phase 2), the Retrofit is considered complete
Page 2 of 3
What customers should do:
• Before the Retrofit is complete, continue performing the Interim Actions noted below in left column in
Table I from the original Interim Notice
• After the Retrofit is complete, perform the Final Actions noted below in the right column in Table I
• If you have performed the Retrofit, you can submit a claim(s) through the normal warranty process
Table I
Interim Actions, BEFORE the Retrofit is complete Final Actions, AFTER the Retrofit is complete
In the interim, in an abundance of caution, if buses
will be inoperable for more than 3 days, New Flyer
recommends either draining the coolant from the
Battery Thermal Management System (BTMS) or
inspecting for normal coolant levels through the
remote fill LEDs every 3 days the bus is parked, or
visually inspecting for liquid through the desiccant cap
every 3 days. Desiccant caps should not be left off if
ESS’s are dry
No special actions if a bus is out-of-service; continue typical
maintenance practices/procedures.
Customers must ensure their drivers and technicians
are aware of the risk associated with coolant leaks
inside the ESS. If an operator reports a yellow “LOW
COOLANT” or a red “CRITICALLY LOW COOLANT”
warning on the dash, all ESS’s must be inspected
immediately to be sure a leak is not accumulating in
the ESS. See NOTE below if liquid is noticed in an
ESS. Contact your New Flyer Regional Product
Support Manager (RPSM) to discuss next steps. If no
liquid is seen, continue with normal procedures to
address the cause of the dash warning per your
Service Manual. After correction, the bus can then be
operated as normal
If an operator reports a yellow “ESS LOW COOLANT”
or a red “ESS CRIT LOW COOLANT” light on the dash,
or if these lights illuminate at the maintenance panel
(rear curbside access panel), customers should take
appropriate actions to find the root-cause of the
warning/indicator, such as look for evidence of an
external leak, an automatic drain valve that has
opened, etc., prior to adding coolant.
Customers can contact their RPSM, CPM or refer to
maintenance manuals for any questions related to
these actions.
Customers must ensure their technicians and anyone
who fills / tops-up coolant understands that low levels
of coolant in the BTMS must be leak tested, root
caused, and repaired prior to any top-ups of coolant.
BTMS coolant top-ups cannot be performed without
positive repairs or accumulation in the ESS may occur
Customers must ensure their technicians and anyone who
fills / tops-up coolant understands that low levels of coolant
in the BTMS must be leak tested, root caused, and
repaired, in accordance with maintenance manuals, prior to
any top-ups of coolant. BTMS coolant top-ups cannot be
performed without positive repairs or accumulation in the
ESS may occur
We recommend that customers refresh their
personnel on the appropriate operating and
maintenance procedures for battery-electric vehicles.
We recommend that customers routinely refresh the
training of their personnel on the appropriate operating and
maintenance procedures for battery-electric vehicles.

**************************************************************************************************************

PARTS MANUAL BULLETIN
This Parts Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. Refer to details below.
PMB-052 1 of 3 The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
PMB-052
ISSUE DATE: Jun 23 2023
APPLICABILITY
VEHICLE LENGTH  30ft.  35ft.  40ft.  60ft.  ALL
VEHICLE TYPE
 Xcelsior®  MiDi®  Invero®
 ALL
 Low Floor  High Floor
FUEL TYPE
 Diesel  Diesel/Electric  CNG  LNG
 ALL
 Fuel Cell  Trolley/Electric  Battery/Electric
SUBJECT ESS Drain Valve and Coolant Decals
SECTION TITLE SECTION 04, SECTION 06
DETAILS This Bulletin provides new part numbers for the ESS Drain Valve and Coolant
Decals Installed on your New Flyer Vehicle.
Refer to SMB196 for Drain Valve Inspection and Installation Procedures.
This bulletin applies to all Xcelsior® Electric models fitted with Next Generation
ESS enclosures.
This information supersedes all prior information on this subject already provided
in your New Flyer Parts Manuals. Make this Parts Bulletin available to service
personnel to inform them of changed information.
PARTS MANUAL BULLETIN PMB-052
ESS DRAIN VALVE AND COOLANT DECALS
PI00115586A
2 of 3 PMB-052
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
ESS Drain
Valve and
Coolant
Decals
pi00115586A
pt00115586A
BATTERY COOLANT LEVEL
Risk of fire
Do not add coolant prior to inspecting battery
coolant circuit for leaks. See coolant fill
procedure decal for details.
LED COLOR OPERATION MODE FILL MODE
GREEN NORMAL FULL
AMBER LOW
RED CRITICAL LOW CRITICAL LOW
LOW
WARNING
Risk of fire
Do not add coolant prior to inspecting
batterycoolant circuit for leaks. See
coolant fill procedure decal for details.
WARNING
P/N 1013826 REV.A
ESS BATTERY
ENCLOSURE ASSEMBLY
2
4
4
4
4
1
3
FUSEBOX ACCESS
DOOR
ESS BATTERY
THERMAL MANAGEMENT
SYSTEM
ITEM QTY PART NUMBER DESCRIPTION
PARTS MANUAL BULLETIN PMB-052
ESS DRAIN VALVE AND COOLANT DECALS
PT00115586A
PMB-052 3 of 3
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
1 1 1013621 Decal, ESS Coolant Level
2 1 1013826 Decal, Warning Risk Of Fire
3 1 1013620 Decal, Battery Coolant Fill
4 4 1025289 Drain Valve, ESS Enclosure

**************************************************************************************************************

SMB-196 1 of 8
SERVICE MANUAL BULLETIN
This Service Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. Refer to details below.
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
ISSUE DATE: Jun 23 2023
SMB-196
APPLICABILITY
VEHICLE LENGTH  30ft.  35ft.  40ft.  60ft.  ALL
VEHICLE TYPE
 Xcelsior®  MiDi®  Invero®
 ALL
 Low Floor  High Floor
FUEL TYPE
 Diesel  Diesel/Electric  CNG  LNG
 ALL
 Fuel Cell  Trolley/Electric  Battery/Electric
SUBJECT ESS Battery Enclosure Drain Valve
SECTION TITLE SECTION 04, SECTION 06, SECTION 19 & PREVENTIVE MAINTENANCE
DETAILS This bulletin provides new inspection and replacement requirements for
the drain valve installed on the ESS Battery Enclosure as well as
changes to the Low Coolant indicators/messages.
This bulletin applies to all Xcelsior® Electric models fitted with Next Generation
ESS enclosures.
This information supersedes any prior information on this subject
already provided in your New Flyer Service Manual. Make this Service
Bulletin available to service personnel to inform them of changed information.
2 of 8 SMB-196
SERVICE MANUAL BULLETIN
SMB-196
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
1. ESS BATTERY ENCLOSURE
DRAIN VALVE
1.1. Description
Four drain valves are located on the lower
perimeter of the ESS enclosure near each
corner. See “Fig. 1: ESS Drain Valve” on
page 2. The drain valves are threaded into
the enclosures with an ORB (O-ring boss)
type connection. The drains are fully
mechanical consisting of a valve body,
spring, spring cup, pin, bobbin, piston, orings,
retention line and rivet in a contained
unit.
1.2. Operation
If liquid is present inside the ESS enclosure
a mechanism inside the drain valve
will be activated which allows the drain
valve piston to be expelled by spring force
which in turn allows liquid to flow through
the drain and out of the ESS enclosure.
The expelled drain valve components are
retained by a retention line and can be
used to identify that a drain valve has been
activated.
Fig. 1: ESS Drain Valve
DRAIN VALVE
(TYPICAL 4 PLACES)
s1339104a.svg
SMB-196 3 of 8
SERVICE MANUAL BULLETIN
SMB-196
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
2. PREVENTIVE
MAINTENANCE
2.1. Daily Preventive Maintenance
2.1.1. Exterior Check
❒ ESS battery coolant reservoir level is correct.
In case of a low coolant condition, DO
NOT add coolant prior to inspecting the
battery coolant circuit for leaks. Unaddressed
leaks may result in the risk of
fire.
☞NOTE:
The coolant level in the rooftop ESS coolant
reservoir can be monitored at the rear
curbside fusebox coolant maintenance
panel. The coolant level is indicated by the
LED color as described on the panel decal.
2.2. Quarterly Preventive
Maintenance
Maintenance of high voltage equipment
must be performed by qualified personnel
only. Refer to the high voltage safety
in your New Flyer Service Manual for
safety requirements. Ensure that the
High Voltage Interlock and Battery Disconnect
switches are set to the OFF
position.
ALWAYS wear appropriate Personal
Protection Equipment (PPE) and
remove all jewelry while servicing the
vehicle’s electrical components. Refer
to your New Flyer Service Manual for
PPE requirements.
Refer to the high voltage safety in your
New Flyer Service Manual and familiarize
yourself with the safety requirements
before performing any
maintenance or repair on the High Voltage
Equipment.
2.2.1. ESS Enclosure Drain Valve Inspection
Use work platforms or scaffolding
whenever working on roof-mounted
components. Ensure maintenance personnel
use an approved safety harness.
Inspect the ESS enclosure drain valves on
a quarterly basis as follows:
1. Set Battery Disconnect switch to the OFF
position.
2. Set the High Voltage Interlock switch to the
OFF position.
If any ESS drain valve is found to have
been activated, contact New Flyer for
assistance. DO NOT return the affected
ESS to service without addressing the
cause of the activation.
3. Gain access to all rooftop and rear ESS
enclosures and inspect the four (4) drain
valves on each ESS enclosure. Visually
inspect drain valve to ensure it is in the
unactivated condition, with the piston face
flush with the valve body and not protruding
beyond the valve body. See “Fig. 2:
ESS Enclosure Drain Valve Inspection” on
page 4.
Excessive external contamination on
the ESS enclosure drain valves could
potentially prevent the valves from
functioning properly.
4. Check the drain valves for any external
contamination (salt, mud, etc.) and clean
as necessary.
4 of 8 SMB-196
SERVICE MANUAL BULLETIN
SMB-196
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
Fig. 2: ESS Enclosure Drain Valve Inspection
2.3. Four Year Preventive
Maintenance
Maintenance of high voltage equipment
must be performed by qualified personnel
only. Refer to the high voltage safety
in your New Flyer Service Manual for
safety requirements. Ensure that the
High Voltage Interlock and Battery Disconnect
switches are set to the OFF
position.
ALWAYS wear appropriate Personal
Protection Equipment (PPE) and
remove all jewelry while servicing the
vehicle’s electrical components. Refer
to your New Flyer Service Manual for
PPE requirements.
Refer to the high voltage safety in your
New Flyer Service Manual and familiarize
yourself with the safety requirements
before performing any
maintenance or repair on the High Voltage
Equipment.
2.3.1. ESS Enclosure Drain Valve
Replacement
Use work platforms or scaffolding
whenever working on roof-mounted
components. Ensure maintenance personnel
use an approved safety harness.
Replace the ESS enclosure drain valves,
every four years as follows:
1. Set Battery Disconnect switch to the OFF
position.
2. Set the High Voltage Interlock switch to the
OFF position.
3. Gain access to all rooftop and rear ESS
enclosures and inspect the four (4) drain
valves on each ESS enclosure. See “Fig.
3: ESS Enclosure Drain Valve Replacement”
on page 5.
UNACTIVATED DRAIN VALVE ACTIVATED DRAIN VALVE
s0700821a.svg
SMB-196 5 of 8
SERVICE MANUAL BULLETIN
SMB-196
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
4. Visually inspect drain valve to ensure it is
in the unactivated condition. Refer to 2.2.1.
“ESS Enclosure Drain Valve Inspection” on
page 3 for procedure.
Leaving the drain valve ports open for
extended periods of time can lead to
entry of moisture and/or foreign debris.
Ensure replacement drain valves or
plugs are available at the time of drain
valve removal.
5. If no drain valves were found to be activated,
proceed to replace the valves as follows:
a. Clean area around drain valve.
b. Use a hex head wrench to remove the
drain valve.
c. Inspect threaded portion of port and
clean/repair threads as necessary.
d. Install new drain valve and torque to 40
ft-lb. (54 Nm).
Fig. 3: ESS Enclosure Drain Valve Replacement
DRAIN VALVE
(TYPICAL 4 PLACES)
s1339104a.svg
6 of 8 SMB-196
SERVICE MANUAL BULLETIN
SMB-196
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
3. ESS BATTERY THERMAL
MANAGEMENT SYSTEM
3.1. Filling & Deaeration
In case of a low coolant condition, DO
NOT add coolant prior to inspecting the
battery coolant circuit for leaks. Unaddressed
leaks may result in the risk of
fire.
Fill Pressure must not exceed 25 psi to
avoid injury or damage to components.
☞NOTE:
The following procedure is designed to fill
the ESS Battery Thermal Management
System following major service of the system.
New Flyer recommends using a maximum
flow rate of 2.5 gpm (9.5 l/min) when
filling this system.
1. Conduct visual internal inspection of each
ESS enclosure through the desiccant basket
to confirm no liquid is present inside,
and external inspection of drain valves to
confirm none have opened.
If liquid is detected or a drain valve is
found open, DO NOT PROCEED with
coolant fill. Immediately investigate and
correct root cause of the leak.
2. Perform a cooling system pressure test
prior to filling the system. Refer to Section
6 “Coolant System Pressure Test” in your
New Flyer Service Manual for procedure.
If leak is detected, DO NOT PROCEED
with coolant fill. Immediately investigate
and correct root cause of the leak.
Repeat leak test after performing
repairs.
3. Connect a battery charger to the 12/24V
batteries for the duration of the fill procedure
to prevent the batteries from draining
excessively.
4. Check the High Voltage Interlock switch is
OFF. If ON, set the Master Run switch to
OFF, then High Voltage Interlock switch to
OFF. See “Fig. 4: ESS Coolant Level Indicator
& Fill Mode Switch” on page 7.
5. Ensure all drain cocks are closed and all
drain plugs are installed.
6. Switch the 12/24V Battery Disconnect
switch to ON.
7. On the driver’s side console, set the Master
Run switch to DAY-RUN.
8. Open the fusebox access door.
9. Open the 1/4 turn vent valve attached to
the clear vent line, located in the propulsion
compartment beside the pressure fill
port.
10.Place a clean bucket under the ¼ turn vent
valve near the pressure fill location.
11.Connect pressure fill hose to the coupler
located at the bottom curbside rear corner.
12.Fill the system until the coolant level indicator
of the low voltage fusebox indicates
FULL or a steady stream of coolant comes
out the clear vent line into the bucket. Disconnect
the pressure fill hose.
13.Turn ON the ESS Coolant Fill Mode switch
on the low voltage fusebox.
14.Maintain the coolant level at FULL on the
coolant level indicator. Disconnect the
pressure fill hose when not filling to prevent
back-filling of the filling device.
15.The fill mode will run for 20 minutes after
the last CRITICAL LOW coolant indication
to deaerate the system. The fill mode will
turn itself off once the time has been
reached.
16.Verify the coolant level display is displaying
FULL.
17.Close the 1/4 turn vent valve located near
the pressure fill port.
18.Remove the pressure fill tool, battery charger,
and return the Master Run and 12/24V
Battery Disconnect switches to the OFF
position.
SMB-196 7 of 8
SERVICE MANUAL BULLETIN
SMB-196
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
3.2. ESS Maintenance Indicator
High cell temperature delta is an indication
of unequal flow distribution or
potential HV battery problems that
could lead to premature battery aging
and failure. Maintenance personnel
should service the ESS as soon as possible.
The ESS Maintenance indicator is located
on the low voltage fusebox panel and indicates
high battery cell temperature and/or
high battery cell temperature deviation
which could be an indication of a problem
with the battery thermal management system
or HV batteries.
Fig. 4: ESS Coolant Level Indicator & Fill Mode Switch
BATTERY COOLANT LEVEL
Risk of fire
LED COLOR OPERATION MODE FILL MODE
GREEN NORMAL FULL
AMBER LOW
RED CRITICAL LOW CRITICAL LOW
LOW
WARNING
ESS COOLANT
LEVEL INDICATOR
ESS MAINTENANCE
INDICATOR
HIGH VOLTAGE
INTERLOCK SWITCH
12V/24V BATTERY
DISCONNECT SWITCH
ESS COOLANT
FILL MODE
SWITCH
s03001251a.svg
8 of 8 SMB-196
SERVICE MANUAL BULLETIN
SMB-196
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2023 New Flyer Industries Canada ULC
4. INSTRUMENTATION &
CONTROLS
4.1. Instrument Panel
4.1.1.Low Coolant Indicator
(Amber)
The Low Coolant indicator illuminates
if an insufficient amount of coolant is
present in the cabin heating or traction
motor/inverter coolant reservoirs.
4.1.2. Operator Screen
4.1.2.1. Text Messages
DO NOT OPERATE THE VEHICLE if the
Critical Low Coolant indicator illuminates.
❒ CRITICAL LOW COOLANT (Red) – The
Critical Low Coolant message will appear
on the LCD screen and a buzzer will sound
to indicate that the coolant level in traction
motor/inverter cooling or cabin heating
system is too low for proper operation.
DO NOT OPERATE THE VEHICLE if the
ESS Critical Low Coolant indicator illuminates.
❒ ESS CRIT LOW COOLANT (Red) – The
ESS Critical Low Coolant message will
appear on the LCD screen and a buzzer
will sound to indicate that the coolant level
in ESS battery thermal management system
is too low for proper operation.
❒ ESS LOW COOLANT (Amber) – The ESS
Low Coolant message will appear on the
LCD screen if an insufficient amount of
coolant is present in the ESS battery thermal
management system reservoir.
☞NOTE:
DO NOT add coolant prior to inspecting
the ESS coolant circuit for leaks. Refer to
Section 6 of your New Flyer Service Manual
for pressure test and coolant fill procedures.
❒ ESS LOW ISO FAULT (Red) – The ESS
Low Isolation Fault message will appear on
the LCD screen and a buzzer will sound
shortly after the MRS is turned OFF or ON
if the battery system detects an isolation
fault within the disconnected strings. The
vehicle cannot be started while this fault is
active.
☞NOTE:
☞NOTE:
To resolve this fault the affected part of the
battery system must be repaired or
replaced in the affected string.
LOW
COOLANT
❒ ESS COOLANT LEAK (Amber)
☞NOTE:
This message has been removed from the text
messages.

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-083
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
New Flyer of America, Inc. FEB 15, 2023 NHTSA Recall No. : 23V-083 Manufacturer Recall No. : R23-002 Manufacturer Information :
Manufacturer Name : New Flyer of America, Inc.
Address : 711 Kernaghan Avenue
Winnipeg, MB 00 R2C3T4 Company phone : 204-224-6706
Population :
Number of potentially involved : 219 Estimated percentage with defect : NR
Vehicle Information : Vehicle 1 : 2021-2023 New Flyer XE35, XE40, XE60 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The recall population was determined based on the specific type of ESS used. Product difference will be determined when the remedy is defined.
Affected models and MY: 2021 XE35 – 8
2022 XE35 – 28
2021 XE40 – 71
2022 XE40 – 83
2023 XE40 – 3
2021 XE60 – 24
2022 XE60 – 2
Production Dates : MAR 31, 2021 – FEB 13, 2023 VIN Range 1 : Begin : NR End : NR Not sequential
Description of Defect :
Description of the Defect : Buses in the recall population may allow liquid accumulation in the ESS unit that may not be detected.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If a leak occurs inside of an ESS and is uncorrected, liquid can accumulate,
leading to an electrical short, increasing the risk of a fire.
Description of the Cause : Root-cause is unknown at this time. As inspections progress, New Flyer will
analyze any ESS with liquid present and address. Part 573 Safety Recall Report 23V-083 Page 2 Identification of Any Warning
that can Occur : If the bus is on, warning lights on the dash would indicate an issue with a high voltage isolation fault. Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
July, 2022, An electric bus at a customer’s site was reported with a no-start condition. Prior to arrival of our Service technician, the lower rear battery enclosure was reported to be smoking, and the bus was moved outside. Ultimately, a thermal event with runaway occurred on July 27, 2022. August through October, 2022: investigation continues while reviewing data from the bus, as well as from other electric buses. The event bus’s rear battery enclosures (upper and lower) were removed, quarantined, and scheduled for thorough teardown and review with multiple parties. The review of enclosure was inconclusive due to extent of damage, but internal markings indicated possible fluid collection inside the lower enclosure. November, 2022 through January, 2023: Testing and validation continued with our Service and Engineering teams. January 18, 2023, An electric bus at a customer’s site was reported with a no-start condition, and reported the lower, rear battery enclosure smoking, and the bus was moved outside. Upon our Service technician’s arrival, no smoke was evident, thermal imaging showed no measurable elevation in temperature of the suspect enclosure and remained steady throughout the day. Both rear enclosures were removed from the bus and placed in a secure location. The enclosure was reviewed at the customers site the following week. Physical inspection showed internal markings that indicated possible fluid collection inside the lower enclosure.
January 30th through February 8th, data analysis continues, and physical bus inspections occur. Two other enclosures were found among the buses on-site with liquid inside. As the symptoms indicate similarity between the events, and finding of liquid, these were deemed sufficient for The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-083
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
formal review on February 10th, and a special Safety Committee meeting was scheduled for February 13th. The latter meeting resulted in a recall determination.
Description of Remedy :
Description of Remedy Program : The remedy is currently being determined. In the interim, buses in the
recall population will be inspected for liquid in the ESS units and addressed accordingly. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
If customers have costs associated with this recall, reimbursement will occurr through New Flyer’s normal warranty process.
The remedy is currently being determined. The remedy is currently being determined. Shipments of affected buses were halted. Recall Schedule :
Description of Recall Schedule : Notifications will be issued soon after approval of the Interim Draft letter. A final customer notification letter will be drafted and sent once the remedy is defined and the letter is approved.
Planned Dealer Notification Date : FEB 20, 2023 – FEB 20, 2023
Planned Owner Notification Date : FEB 20, 2023 – FEB 20, 2023
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-083
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
New Flyer of America, Inc. APR 21, 2023 NHTSA Recall No. : 23V-083 Manufacturer Recall No. : R23-002 Manufacturer Information :
Manufacturer Name : New Flyer of America, Inc.
Address : 711 Kernaghan Avenue
Winnipeg, MB 00 R2C3T4 Company phone : 204-224-6706
Population :
Number of potentially involved : 219 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2021-2023 New Flyer XE35, XE40, XE60 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The recall population was determined based on the specific type of ESS used. Product difference will be determined when the remedy is defined.
Affected models and MY: 2021 XE35 – 8
2022 XE35 – 28
2021 XE40 – 71
2022 XE40 – 83
2023 XE40 – 3
2021 XE60 – 24
2022 XE60 – 2
Production Dates : MAR 31, 2021 – FEB 13, 2023 VIN Range 1 : Begin : NR End : NR Not sequential
Description of Defect :
Description of the Defect : Buses in the recall population may allow liquid accumulation in the ESS unit that may not be detected.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If a leak occurs inside of an ESS and is uncorrected, liquid can accumulate,
leading to an electrical short, increasing the risk of a fire.
Description of the Cause : Root-cause is unknown at this time. As inspections progress, New Flyer will
analyze any ESS with liquid present and address. Part 573 Safety Recall Report 23V-083 Page 2 Identification of Any Warning
that can Occur : If the bus is on, warning lights on the dash would indicate an issue with a high voltage isolation fault. Involved Components : Component Name 1 : ASSY-ENCLOSURE Component Description : ESS enclosure, fiberglass Component Part Number : 822311 Supplier Identification : Component Manufacturer
Name : New Flyer of America Address : 106 National Drive
Anniston Alabama 36201
Country : United States Chronology :
July, 2022, An electric bus at a customer’s site was reported with a no-start condition. Prior to arrival of our Service technician, the lower rear battery enclosure was reported to be smoking, and the bus was moved outside. Ultimately, a thermal event with runaway occurred on July 27, 2022. August through October, 2022: investigation continues while reviewing data from the bus, as well as from other electric buses. The event bus’s rear battery enclosures (upper and lower) were removed, quarantined, and scheduled for thorough teardown and review with multiple parties. The review of enclosure was inconclusive due to extent of damage, but internal markings indicated possible fluid collection inside the lower enclosure. November, 2022 through January, 2023: Testing and validation continued with our Service and Engineering teams. January 18, 2023, An electric bus at a customer’s site was reported with a no-start condition, and reported the lower, rear battery enclosure smoking, and the bus was moved outside. Upon our Service technician’s arrival, no smoke was evident, thermal imaging showed no measurable elevation in temperature of the suspect enclosure and remained steady throughout the day. Both rear enclosures were removed from the bus and placed in a secure location. The enclosure was reviewed at the customers site the following week. Physical inspection showed internal markings that indicated possible fluid collection inside the lower enclosure.
January 30th through February 8th, data analysis continues, and physical bus inspections occur. Two other enclosures were found among the buses on-site with liquid inside. As the symptoms indicate similarity between the events, and finding of liquid, these were deemed sufficient for The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-083
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
formal review on February 10th, and a special Safety Committee meeting was scheduled for February 13th. The latter meeting resulted in a recall determination.
Description of Remedy :
Description of Remedy Program : The remedy is currently being determined. In the interim, buses in the
recall population will be inspected for liquid in the ESS units and addressed accordingly.
New Flyer will add 4 automatic activating drain valves in each ESS assembly. This remedy may occur in 2 phases. 1) Apply appropriate holes in the ESS and install adhere a threaded port with a plug. 2) Install the automatic drain valves (expected to be available in June/July-2023). If customers have costs associated with this recall, reimbursement will occur through New Flyer’s normal warranty process.
How Remedy Component Differs from Recalled Component :
The remedy is currently being determined. Current ESS do not have drain valves – these will be noticeable by the additional ports in the ESS
Identify How/When Recall Condition was Corrected in Production :
The remedy is currently being determined. Shipments of affected buses were halted.
Buses in the production cycle will have the same remedy installed, prior to release/sale.
Recall Schedule : Description of Recall Schedule : Notifications will be issued soon after approval of the Interim Draft letter.
Letter with the remedy described will be uploaded for review/comment the week of 24-April-2023, and sent shortly after comments are received.
A final customer notification letter will be drafted and sent once the remedy is defined and the letter is approved.
Planned Dealer Notification Date : FEB 20, 2023 – FEB 20, 2023
Planned Owner Notification Date : FEB 20, 2023 – FEB 20, 2023
* NR – Not Reported

SEOCONTENT-END