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NHTSA ID Number: 10169768
Manufacturer Communication Number: SMB189
Summary
Service Manual Bulletin – Update to high voltage safety procedures, specifically Lockout/Tagout, de-energizing and re-energizing procedures for both battery electric and fuel cell buses.
19 Affected Products
Vehicles
NEW FLYER | XE35 | 2019-2020 |
| NEW FLYER | XE40 | 2013-2020 |
| NEW FLYER | XE60 | 2017-2020 |
| NEW FLYER | XHE40 | 2018-2020 |
| NEW FLYER | XHE60 | 2015, 2020 |
SMB-189
ISSUE DATE: Dec 20 2019
High Voltage Safety – Lockout / Tagout & De-Energizing & Energizing Procedure
This bulletin provides revised lockout / tagout and de-energizing and energizing procedures on your New Flyer vehicles in Three Parts.
Make this Service Bulletin available to service personnel to inform them of changed information.
SEOCONTENT-START
SMB-189 1 of 12
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
ISSUE DATE: Dec 20 2019
SMB-189
APPLICABILITY
VEHICLE LENGTH ๏ฏ 30ft. ๏ฏ 35ft. ๏ฏ 40ft. ๏ฏ 60ft. ๏ฎ ALL
VEHICLE TYPE
๏ฎ Xcelsiorยฎ ๏ฏ MiDiยฎ ๏ฏ Inveroยฎ
๏ฏ ALL
๏ฏ Low Floor ๏ฏ High Floor
FUEL TYPE
๏ฏ Diesel ๏ฏ Diesel/Electric ๏ฏ CNG ๏ฏ LNG
๏ฏ ALL
๏ฎ Fuel Cell ๏ฏ Trolley/Electric ๏ฎ Battery/Electric
SUBJECT High Voltage Safety – Lockout / Tagout & De-Energizing & Energizing
Procedure
SECTION TITLE Lockout / Tagout & De-Energizing & Energizing Procedure
DETAILS This bulletin provides revised lockout / tagout and de-energizing and
energizing procedures on your New Flyer vehicles in Three Parts.
Make this Service Bulletin available to service personnel to inform them
of changed information.
2 of 12 SMB-189
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
PART ONE
1. Lockout / Tagout Procedure
for all Battery Electric
Vehicles
The following Lock Out / Tag Out procedure
should be followed when working on
or near the High Voltage components.
โNOTE:
Use commercially available lock out equipment
and tags and be sure to follow any
local laws or workplace procedures.
1.1. Locking / Tagging Out
1. Set the Master Run switch to the STOPSYSTEM
position.
2. Rotate the 12/24 volt Battery switch to the
OFF position.
3. Lock and tag the switch and retain key.
See โFig. 1: Locking / Tagging Outโ on
page 2.
4. Switch the High Voltage Interlock switch to
the HV OFF position.
5. Lock and tag the switch and retain key.
6. Verify the low voltage and high voltage systems
are de-energized. Refer to De-Energizing
& Energizing Procedures in this
bulletin.
1.1.1. Locks / Tags Removal
1. The locks and tags shall be removed by
the installer of the locks and tags or shall
be removed 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 is 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.
Fig. 1: Locking / Tagging Out
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s145303a.svg
SMB-189 3 of 12
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
PART TWO
2. De-Energizing & Energizing
Procedures for all Battery
Electric Vehicles equipped
with Manual Service
Disconnects (MSD)
NEVER try to connect or disconnect circuit
components such as cables, fuses,
or connectors while there is current
flowing in the circuit.
2.1. De-Energizing Procedure
1. Prepare the work area. Refer to โService
Preparationโ in your New Flyer Service
Manual for information on how to safely
prepare the work area.
2. Ensure the DC high voltage charging
cables are disconnected from the vehicle.
3. Lock Out and Tag Out the Battery Disconnect
and High Voltage Interlock switch.
Refer to 1. โLockout / Tagout Procedure for
all Battery Electric Vehiclesโ on page 2 in
this bulletin for procedure.
4. Wear High Voltage Personal Protection
Equipment (PPE). Refer to โPPE Requirementsโ
in your New Flyer Service Manual
for guidelines.
โNOTE:
Refer to โEquipment Requirementsโ in your
New Flyer Service Manual for information
on the type of multimeter required for the
following test.
5. Ensure there is no voltage on the 12/24
VDC battery bus bars. Measure in the
main fusebox between the 24V bus bar
and the ground bar. See โFig. 2: Low Voltage
Verificationโ on page 3.
Fig. 2: Low Voltage Verification
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s145301a.svg
4 of 12 SMB-189
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
6. Ensure there is no voltage on the High
Voltage System. Measure in the roofmounted
high voltage fuse box as follows:
a. Measure from the positive bus bar to
the negative bus bar. See โFig. 3: High
Voltage Verification – 1โ on page 4.
b. Measure from the positive bus bar to
the grounded enclosure or roof rack
structure. See โFig. 4: High Voltage Verification
– 2โ on page 5.
c. Measure from the ground bar to the
grounded enclosure or roof rack structure.
See โFig. 5: High Voltage Verification
– 3โ on page 5.
Fig. 3: High Voltage Verification – 1
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s145302a.svg
SMB-189 5 of 12
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
Fig. 4: High Voltage Verification – 2
Fig. 5: High Voltage Verification – 3
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s145304a.svg
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s145305a.svg
6 of 12 SMB-189
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
NEVER remove the ESS Manual Service
Disconnect plug while current is flowing
through it. The High Voltage may
create a long enough ionized gas path,
during circuit interruption, to bridge the
contacts of the switch base and therefore
continue the current flow. This ionized
gas is very hot and can cause
burns, fire and electrical shock.
Using a clamp-on current probe and
DMM, ensure that there is no current
flowing in the cables connecting to the
ESS Manual Service Disconnect plug.
7. Remove all the ESS Manual Service Disconnect
plugs as follows:
a. Press the locking tab and rotate the
MSD lever 45ยฐ. See โFig. 6: Manual
Service Disconnect – 1โ on page 6.
Fig. 6: Manual Service Disconnect – 1
b. Press the locking tab and rotate the
MSD lever to the 90ยฐ position. See โFig.
7: Manual Service Disconnect – 2โ on
page 7.
c. Remove the Manual Service Disconnects.
See โFig. 8: Manual Service Disconnect
– 3โ on page 7.
d. Install a yellow insulating cover, that is
open circuited in the Manual Service
Disconnect receptacle and lock it in
place.
โNOTE:
Removing the Manual Service Disconnects
reduces the ESS voltage but each
battery within the ESS remains a high voltage
hazard at 88 volts.
8. Ensure that insulating covers are installed
in all ESS Manual Service Disconnect
receptacle locations.
9. Stow the removed MSDs in a locked location
to which only you have access.
10.Disconnect the high voltage cables at the
HV Junction Box on the side of the ESS.
????????????????????
????????????????
s145311a.svg
SMB-189 7 of 12
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
Fig. 7: Manual Service Disconnect – 2
Fig. 8: Manual Service Disconnect – 3
2.2. Energizing Procedure
Perform a visual check to ensure that all
possible HV compartments are closed and
there is no debris, tools or test equipment
lying on HV terminations before energizing
the vehicle.
DO NOT touch cable terminations until
checking to ensure there is no voltage
between any of these cables and with
respect to vehicle chassis.
While connecting HV cables continuously
monitor, with the DMM, for the
inadvertent appearance of HV. If HV
appears troubleshoot why the HV
appeared and resolve before proceeding.
1. Using insulated tools, reconnect all high
voltage cables.
โNOTE:
For the following devices, use a phase
rotation meter to ensure correct cable
sequences:
โ Air Compressor
โ ESS Heat Exchanger
โ HVAC Unit
2. Reinstall high voltage junction box covers.
3. Install the ESS Manual Service Disconnect
plugs.
4. Close all HV access panels, doors, enclosures.
5. Remove the lockout / tagout from the 12/24
volt Battery Disconnect switch and turn the
switch to the ON position.
6. Remove the lock/tag from the High Voltage
Interlock switch and set the switch to the
HV ON position.
7. Set the Master Run switch to the DAY-RUN
or NIGHT-RUN position.
8. Remove โSafety Barricadeโ with warning
lights and โDanger High Voltageโ signs
around the vehicle perimeter.
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s145312a.svg
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s145313a.svg
8 of 12 SMB-189
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
PART THREE
3. De-Energizing & Energizing
Procedures for all Battery
Electric Vehicles without
Manual Service Disconnects
(MSD)
NEVER try to connect or disconnect circuit
components such as cables, fuses,
or connectors while there is current
flowing in the circuit.
3.1. De-Energizing Procedure
1. Prepare the work area. Refer to โService
Preparationโ in your New Flyer Service
Manual for information information on how
to safely prepare the work area.
2. Ensure the DC high voltage charging
cables are disconnected from the vehicle.
3. Lock out and Tag Out the Battery Disconnect
and High Voltage Interlock switch.
Refer to 1. โLockout / Tagout Procedure for
all Battery Electric Vehiclesโ on page 2 in
this bulletin for procedure.
4. Wear High Voltage Personal Protection
Equipment (PPE). Refer to โPPE Requirementsโ
in your New Flyer Service Manual
for guidelines.
โNOTE:
Refer to โEquipment Requirementsโ in your
New Flyer Service Manual for information
on the type of multimeter required for the
following test.
5. Ensure there is no voltage on the 12/24
VDC battery bus bars. Measure in the
main fusebox between the 24V bus bar
and the ground bar. See โFig. 9: Low Voltage
Verificationโ on page 8.
6. Ensure there is no voltage on the High
Voltage System. Measure in the roofmounted
high voltage fuse box.
a. Measure from the positive bus bar to
the negative bus bar. See โFig. 10: High
Voltage Verification – 1โ on page 9.
b. Measure from the positive bus bar to
the grounded enclosure or roof rack
structure. See โFig. 11: High Voltage
Verification – 2โ on page 9.
c. Measure from the ground bar to the
grounded enclosure or roof rack structure.
See โFig. 12: High Voltage Verification
– 3โ on page 10.
Fig. 9: Low Voltage Verification
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s145301a.svg
SMB-189 9 of 12
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
Fig. 10: High Voltage Verification – 1
Fig. 11: High Voltage Verification – 2
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s145304a.svg
10 of 12 SMB-189
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
Fig. 12: High Voltage Verification – 3
7. Using a clamp-on current probe and DMM,
ensure that there is no current flowing in
the mid-string cable or cables inside the
ESS enclosure.
โNOTE:
The battery strings inside the ESS have a
mid-string cable identified with a label.
Removing this cable as a service disconnect
will reduce the voltage approximately
in half. Each battery remains at a high voltage
of 88V so continued caution is
required.
8. Disconnect the mid-string cable for all battery
strings located inside the ESS compartment.
See โFig. 13: Mid-String Cableโ
on page 11.
9. Remove the cable connectors as follows:
a. Pull tab #1 up. See โFig. 14: Release
Connector Tab #1โ on page 11.
b. Using an insulated flat-bladed screw
driver, press on tab #2 and release tab.
See โFig. 15: Release Connector Tab
#2โ on page 11.
c. Pull the high voltage connector off the
battery pack.
10.Cover the connector on the cable with a
locking cover to prevent it from being reinstalled
until after the service work is complete.
See โFig. 16: Locking Cable Coverโ
on page 11.
Removing the mid-string cable will
reduce the high voltage risk but not
eliminate it. Continue to use caution
while disconnecting any other cables
from the batteries or while working on
any other components within the ESS.
11.Repeat this procedure to disconnect the
most positive and most negative cable in
the battery string (or strings) located in the
ESS.
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s145305a.svg
SMB-189 11 of 12
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
Fig. 13: Mid-String Cable
Fig. 14: Release Connector Tab #1
Fig. 15: Release Connector Tab #2
Fig. 16: Locking Cable Cover
s145307a.svg
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s145309a.svg
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s145308a.svg
s145410a.svg
12 of 12 SMB-189
SERVICE MANUAL BULLETIN
SMB-189
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 โVehicle Patent Informationโ in this manual.
Copyright ยฉ 2019 New Flyer Industries Canada ULC
3.2. Energizing Procedure
Perform a visual check to ensure that all
possible HV compartments are closed and
there is no debris, tools or test equipment
lying on HV terminations before energizing
the vehicle.
DO NOT touch cable terminations until
checking to ensure there is no voltage
between any of these cables and with
respect to vehicle chassis.
While connecting HV cables continuously
monitor, with the DMM, for the
inadvertent appearance of HV. If HV
appears troubleshoot why the HV
appeared and resolve before proceeding.
1. Using insulated tools, reconnect all high
voltage cables.
โNOTE:
For the following devices, use a phase
rotation meter to ensure correct cable
sequences:
โ Air Compressor
โ ESS Heat Exchanger
โ HVAC Unit
2. Reinstall high voltage junction box covers.
3. Close all HV access panels, doors, enclosures.
4. Remove the lockout/tagout from the 12/24
volt Battery Disconnect switch and turn the
switch to the ON position.
5. Remove the lock/tag from the High Voltage
Interlock switch and set the switch to the
HV ON position.
6. Set the Master Run switch to the DAY-RUN
or NIGHT-RUN position.
7. Remove โSafety Barricadeโ with warning
lights and โDanger High Voltageโ signs
around the vehicle perimeter.
SMB189
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| โThis site contains affiliate links for which OEMDTC may be compensatedโ |
- High Quality: Made of high-quality non-Conductive thermoplastic, the locks has great temperature resistance and wear resistance.
- Special Design: Compliance with "one employee, one lock, one key" directive, security and writable Label for marking
- Wide Application: The locks are designed for lockout tagout applications and features a cylinder which is reserved for safety padlocks.
- Package Content: Including 2 padlocks, each padlock is equipped with 2 keys.
- ใValue Pack ใThere are a total of 50 lockout tagout tags and 50 pieces of adjustable zip ties.The size of each tags is 5.51 x 3in/14 x 7.6cm,the zip ties size is 5.9inch/15cm.Easy to hang,sufficient quantity for your use and replacement.
- ใHigh Quality MaterialsใThese danger do not operate tags are made of PVC.Tear,weather,and chemical resistant,with a hole on the top for connecting the tag through a zip ties,suitable for both indoor and outdoor applications, capable of withstanding harsh weather conditions.
- ใEasy to UseใThe do not operate equipment tags is spacious and has enough space to write specific information about the lock process. Include the name of the authorized personnel,dept,expected completion and more.Permanent markings or wax/oil pens can be used to clearly record key locking label information.
- ใReliable and PracticalใOur lockout tagout tags provide clear danger warnings,clearly states that the device should not be operated during the lock period.With these tags,will give you a peace of mind of knowing that to ensure the safety of others is conveyed by this tag clearly.These tags have bold colors and large fonts that clearly warn others that a machine or equipment is under maintenance or out of service.
- ใOSHA CompliantใDanger tags developed and tested to ensure proper safety tagout compliance.
- Superior Durability - Lock out tagout locks keyed different made of industrial-grade non-conductive thermoplastic unibody, corrosion-resistant stainless steel shackle, exceptionally built to endure long term heavy industrial use
- Padlock Lock Out Key Engineered for Safety - Lock out tag out lock with high grade brass core cylinder designed to retain key until shackle is locked, ensures the lock will not be left unlocked
- Multilingual Labels - Each LOTO lock comes with 2 sets of labels in English, Spanish, and French; โDanger Locked Out Do Not Removeโ warning label for the front side and a spacious writable label for the back side
- Premium Lockout Tagout Lock Set - (10) Red safety lockout lock keyed different with 1-1/2 inch long stainless steel shackle, 1/4-inch shackle diameter, 2 keys per tagout lock; matching code engraved on keys and padlock body, each safety padlock in the pack has a unique code
- OSHA Compliant - Lock out tag out locks set meticulously designed to help businesses meet and exceed compliance with safety standards and requirements
- Specifications:This 12.24ร15.98ร1.73 inch lockout tagout storage station can hang four safety padlocks,and can also store other items,which is suitable for a wide range of functions
- Scope of application:The Loto Station generally used in chemical industry,electric power and machinery manufacturing enterprises.
- Industrial standard:This OSHA-compliant padlock station has excellent heat and shock resistance, and a sturdy hook design holds the padlock well
- Design:Clear yellow closable top keeps out dust and keeps the wall-mountable lockout tagout kit storage clean
- Good service:If you have any problems with receiving the goods,you can contact us in time and propose a solution to your satisfaction
- ELECTRICAL APPLICATION: Lockout tagout lock is best used for electrical lockout applications as part of a comprehensive OSHA compliant safety program
- RELIABLY DURABLE: Zenex thermoplastic safety lock body is durable, lightweight, and non-conductive and functions in temperatures from -70 to 350 degrees Fahrenheit
- SAFETY PADLOCK: Features a cylinder that is reserved for safety padlocks; key retaining feature ensures padlock is not left unlocked
- BRIGHT RED: Breaker box lock has a bright red finish that indicates potential danger, and the white label on the back allows for customization
- MEASUREMENTS: 1-1/2 in. (38 mm) Wide lock body with 1/4 in. (6 mm) diameter shackle, 1-1/2 in. (38 mm) shackle length and 25/32 in. (20 mm) width
- Keep your employees safe and your business compliant with these lockout/tagout tags from Harrier Hardware!
- These vinyl tags have brass grommets, clear warnings, and a writeup section that are all OSHA-compliant (1910.147)
- These tags are resistant to water, weather, and hot and cold conditions
- Each tag measures 3 inches wide by 5.5 inches tall (3" W x 5.5" T)
- Includes (40) lockout/tagout tags
- 42 Pcs Lockout Tagout Kit: This 42-piece lockout tagout set provides complete electrical safety management with 3 non-conductive stainless steel beam safety padlocks,2 steel hasps,1 insulated nylon hasp,15 lockout tagout tags,and 20 nylon cable ties,all organized in a portable storage bag.Ideal for securing fixed panels,transformers,and energy control systems
- OSHA Compliant Padlocks:Heavy-duty stainless steel beam safety locks feature corrosion-resistant construction with dual keys (primary and spare) and unique engraved matching codes for traceability.Tested to meet strict OSHA standards for hazardous energy isolation,ensuring workplace compliance and accident prevention
- Dual Material Lockout Hasps:Includes tamper-proof steel hasps with heat-resistant handles and a flexible insulated nylon hasp designed for explosive environments.Both types enable multi-person lockouts on equipment,preventing unauthorized activation while accommodating diverse industrial scenarios
- Durable Identification System:High-visibility tags with wipe-clean surfaces allow clear hazard messaging,paired with rustproof metal eyelets for longevity.Reinforced nylon ties secure warnings tightly to machinery,minimizing tag loss and enhancing worksite communication
- Multi-Industry Protection:Essential for electrical, mechanical, and pipeline maintenance, this kit reduces fire risks and equipment damage by blocking accidental energization. Safeguards circuit breakers, valve controls, and power switches across manufacturing, utilities, and repair facilities
- 64 pcs lockout tagout kit - 4 x safety padlocks, 1 x plastic lockout hasps, 2 x steel hasps, 20 x lockout tagout tags, 30 x nylon ties, 1 x carry bag, 5 x breaker lockouts, 1 x plug lockout.
- Application - Best used for electrical lockout applications, locking to prevent someone from wrong operation. Widely used in power switch, air source switch, pipeline valve, mechanical fixed moving parts etc.
- Safety Padlocks - Keyed-different lockout locks with a non-conductive thermoplastic unibody, lockout locks with a non-conductive thermoplastic unibody, 1-1/2 inch long stainless steel shackle, 2 keys per lock.
- Two Type Lockout Hasps - interior jaw diameter hasps with chrome-plated steel jaw & double-layered nylon-coated handle; polypropylene hasp with 3-inch shackle length.
- Plug Lockout - Made with durable polypropylene, this electric plug lock resists extreme impact and tampering. Secures most 110V up to 125V plugs, meet OSHA standards on proper control of hazardous energy and remain compliant.
- Safety Padlock: 4 red keyed different padlocks, 2 Keys per Lock. Made with a premium chrome-plated brass cylinder for outdoor durability of over 5 years
- 4 Lockout Haspใ: 2 lock out tag out hasp (1 in, 1.5 in) with sturdy chrome-plated steel jaw and Plastic-coated handle; 2 nylon lockout hasp resistant to explosions and insulating
- Plug Lock with Circuit Breaker Lockout : 1*plug lock, secures most 110V up to 125V plugs; 2 universal multi-pole breaker lock; 1* Large 480/600V, 2*medium 480/600V, 3*120/277V clamp-on circuit breaker lock
- Lockout Tagout Devices: 1 pocket bag, 15 lockout tags, 20 nylon ties
- OSHA Compliant LOTO Kit: Lockout tagout kit with 30 versatile lock out tag out devices stored in a vibrant,Stored in a waterproof,wear-resistant and portable nylon storage bag,developed and tested to ensure proper control of hazardous energy sources and ensure personnel safety
Last update on 2025-04-18 / Affiliate links / Images from Amazon Product Advertising API
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