R24-02 – Liquid in Battery Packs May Cause Fire – 2021-2023 New Flyer XE35, XE40, 2021-2024 XE60, & 2023-2024 XHE40

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-056
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
New Flyer of America, Inc. FEB 08, 2024 NHTSA Recall No. : 24V-056 Manufacturer Recall No. : R24-02 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 : 337 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2021-2023 New Flyer XE35
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : Recall population is determined by specific PNs which included a rubber washer as part of the ESS drain assembly. Those vehicles not included did not have the rubber washer applied to the drain.
Production Dates : JUL 29, 2021 – JAN 14, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2021-2023 New Flyer XE40 Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Recall population is determined by specific PNs which included a rubber washer as part of the ESS drain assembly. Those vehicles not included did not have the rubber washer applied to the drain.
Production Dates : APR 27, 2021 – DEC 29, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-056 Page 2 Vehicle 3 : 2021-2024 New Flyer XE60
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : Recall population is determined by specific PNs which included a rubber washer as part of the ESS drain assembly. Those vehicles not included did not have the rubber washer applied to the drain.
Production Dates : APR 02, 2021 – JAN 23, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 4 : 2023-2024 New Flyer XHE40 Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Recall population is determined by specific PNs which included a rubber washer as part of the ESS drain assembly. Those vehicles not included did not have the rubber washer applied to the drain.
Production Dates : SEP 05, 2023 – DEC 22, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : ESS (Energy Storage System) drain valve assemblies with a rubber washer included have a delayed activation, which could allow liquid to accumulate within the ESS assembly if a leak occurs.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Delayed activation of a drain valve could allow liquid accumulation to reach a level of causing isolation faults. If left unchecked electrical shorting may occur. Electrical shorting increases the risk of a fire.
Description of the Cause : NR Identification of Any Warning
that can Occur : For buses regularly in-service, warnings would be noticed with a low coolant warning on the instrument cluster or at the service/charging area indicating low coolant in the BTMS (Battery Thermal Management System). If a low coolant indication is noticed, operators must locate the cause of the condition before adding coolant. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-056 Page 3 Involved Components : Component Name 1 : ASSY-DRAIN CARTRIDGE Component Description : ESS drain valve assembly Component Part Number : 1044209 Component Name 2 : ASSY-DRAIN CARTRIDGE REWORKED
Component Description : ESS drain valve assembly Component Part Number : 1050112 Supplier Identification : Component Manufacturer
Name : New Flyer of America Address : 106 National Drive
Anniston Alabama 36201
Country : United States Chronology :
September 2023, a drain valve for the ESS assembly was released which had a washer added to the face of the “bobbin” (internal component which reacts to liquid exposure). This was added to inhibit nuisance activation of the drain valve during times of high humidity and temperature. December 2023, testing was being performed on an ESS assembly to validate liquid level calculations vs physical testing prior to drain valve activation. This testing indicated a less than optimal activation time of some of the drain valves. December 2023/January 2024 testing and analysis continued on the delayed activation experienced from the drain valve and was ultimately determined the washer added to inhibit nuisance activation was impeding the bobbin from full function within a reasonable timeframe. This issue was reviewed by the Vehicle Safety Committee during a special meeting on January 25, 2024, where the need for a recall was concurred, culminating in this 573 filing. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-056
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The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : New Flyer will remove the rubber washer from affected drain valves and
identify those corrected in the field with a specific mark on the drain valve housing, free of charge.
If a customer prefers to perform this work, New Flyer will provide the remedy instructions free of charge, and labor can be submitted for reimbursement through New Flyer’s warranty system. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : New Flyer has received no warranty claims, field reports or accident/ injury reports associated with this condition.
The remedied drain valves will not have the rubber washer installed. Production ceased shipment and started removing the rubber washer from affected buses. Any buses in the field awaiting delivery were also held by New Flyer until the remedy was applied. Recall Schedule :
Description of Recall Schedule : New Flyer does not use a dealer network; dates for dealer notification are
aligned with Owner Notification dates.
Planned Dealer Notification Date : MAR 15, 2024 – MAR 15, 2024
Planned Owner Notification Date : MAR 15, 2024 – MAR 15, 2024
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-056
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
New Flyer of America, Inc. JAN 31, 2024 NHTSA Recall No. : 24V-056 Manufacturer Recall No. : R24-02 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 : NR Estimated percentage with defect : NR
Vehicle Information :
Vehicle 1 : 2021-2023 New Flyer XE35
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : Recall population is determined by specific PNs which included a rubber washer as part of the ESS drain assembly. Those vehicles not included did not have the rubber washer applied to the drain.
Production Dates : JUL 29, 2021 – JAN 14, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2021-2023 New Flyer XE40 Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Recall population is determined by specific PNs which included a rubber washer as part of the ESS drain assembly. Those vehicles not included did not have the rubber washer applied to the drain.
Production Dates : APR 27, 2021 – DEC 29, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-056 Page 2 Vehicle 3 : 2021-2024 New Flyer XE60
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : Recall population is determined by specific PNs which included a rubber washer as part of the ESS drain assembly. Those vehicles not included did not have the rubber washer applied to the drain.
Production Dates : APR 02, 2021 – JAN 23, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 4 : 2023-2024 New Flyer XHE40 Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Recall population is determined by specific PNs which included a rubber washer as part of the ESS drain assembly. Those vehicles not included did not have the rubber washer applied to the drain.
Production Dates : SEP 05, 2023 – DEC 22, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : ESS drain valve assemblies with a rubber washer included have a delayed activation, which could allow liquid to accumulate within the ESS assembly if a leak occurs.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Delayed activation of a drain valve could allow liquid accumulation to reach a level of causing isolation faults. If left unchecked electrical shorting may occur. Electrical shorting increases the risk of a fire.
Description of the Cause : NR Identification of Any Warning
that can Occur : For buses regularly in-service, warnings would be noticed with a low coolant warning on the instrument cluster or at the service/charging area indicating low coolant in the BTMS. If a low coolant indication is noticed, operators must locate the cause of the condition before adding coolant. Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-056 Page 3 Component Name 1 : ASSY-DRAIN CARTRIDGE Component Description : ESS drain valve assembly Component Part Number : 1044209 Component Name 2 : ASSY-DRAIN CARTRIDGE REWORKED
Component Description : ESS drain valve assembly Component Part Number : 1050112 Supplier Identification : Component Manufacturer
Name : New Flyer of America Address : 106 National Drive
Anniston Alabama 36201
Country : United States Chronology :
September 2023, a drain valve for the ESS assembly was released which had a washer added to the face of the “bobbin” (internal component which reacts to liquid exposure). This was added to inhibit nuisance activation of the drain valve during times of high humidity and temperature. December 2023, testing was being performed on an ESS assembly to validate liquid level calculations vs physical testing prior to drain valve activation. This testing indicated a less than optimal activation time of some of the drain valves. December 2023/January 2024 testing and analysis continued on the delayed activation experienced from the drain valve and was ultimately determined the washer added to inhibit nuisance activation was impeding the bobbin from full function within a reasonable timeframe. This issue was reviewed by the Vehicle Safety Committee during a special meeting on January 25, 2024, where the need for a recall was concurred, culminating in this 573 filing. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-056
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : New Flyer will remove the rubber washer from affected drain valves and
identify those corrected in the field with a specific mark on the drain valve housing, free of charge.
If a customer prefers to perform this work, New Flyer will provide the remedy instructions free of charge, and labor can be submitted for reimbursement through New Flyer’s warranty system. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : New Flyer has received no warranty claims, field reports or accident/ injury reports associated with this condition.
The remedied drain valves will not have the rubber washer installed. Production ceased shipment and started removing the rubber washer from affected buses. Any buses in the field awaiting delivery were also held by New Flyer until the remedy was applied. Recall Schedule :
Description of Recall Schedule : New Flyer does not use a dealer network; dates for dealer notification are
aligned with Owner Notification dates.
Planned Dealer Notification Date : MAR 15, 2024 – MAR 15, 2024
Planned Owner Notification Date : MAR 15, 2024 – MAR 15, 2024
* NR – Not Reported

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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: 60913 January 25, 2024
SECTION:
260-Battery Compartment
WRITTEN BY:
Troy Stutsky
SUBJECT:
Version 2 drains in the ESS compartments will not deploy when required.
ISSUE:
The dissolving powder washer in the version 2 drains is not working correctly.
SUMMARY:
Inspect for version 2 drains and rework them to remove the washer and reinstall them. Mark the reworked drains with a green paint marker.
ITS60913
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
To be Determined
To be Determined
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
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.
Ensure appropriate safety procedures are followed for the duration of the work.
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.
INSTRUCTION TO SERVICE
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 NOTE: At this point access to the ESS compartments is available.
6. Inspect the part number that is on the top of the ESS drain cartridges.
Figure 2: Part Number Identification a. If the part number on the drain cartridge is 1025289 AND has a bobbin lot code of 402595, 402648 or 402656, replace the drain cartridge with a new one. Install the new ESS drain cartridges and torque to 40Ft/Lbs. Mark the top of the new ESS drain cartridge with a “green” paint marker to identify the drain has been replaced.
Figure 3: Mark with a Green Paint Marker
Part Number
Lot Number
Date
INSTRUCTION TO SERVICE
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b. If the part number on the drain cartridge is 1025289 and has any other bobbin lot code than the ones mentioned above, leave this drain installed and mark the top of the ESS drain cartridge with a “green” paint marker to identify the drain has been inspected and is good. c. If the part number on the drain cartridge is 1050112 WITH A REV C MARKED ON IT, leave this drain installed and mark the top of the ESS drain cartridge with a “green” paint marker to identify the drain has been inspected and is good.
d. If the part number on the drain cartridge starts with 1044209 or 1050112 they will need to be reworked. Remove the drain. Use a pick to loosen the black washer. Cut the black washer so it can be fully removed from the drain and discarded. Reinstall the reworked ESS drain cartridges and torque to 40Ft/Lbs. Mark the top of the reworked ESS drain cartridge with a “green” paint marker to identify the drain has been reworked.
Figure 3: Remove Black Washer from Drain Cartridge
Remove this black washer
INSTRUCTION TO SERVICE
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Figure 4: Torque ESS Drain Cartridges – USE ARC FLASH GLOVES
7. Clean workspace and return coach to revenue service condition.
INSTRUCTION TO SERVICE
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LABOUR ESTIMATE
Operation
Number of Technician(s)
Hours
Labor Time
T X HR
1
Inspect for version 2 drains and rework them as required per the instruction. Mark the reworked drains with a green paint marker.
1
1.25
1.25
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
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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
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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.

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