NHTSA ID Number: 10210017
Manufacturer Communication Number: ITS60421
TSB/Document Date: 2022-04-06
Summary
This Instruction to Service (ITS) is a description of the inspections being recommedned by MCI due to the parts shortages which are impacting the repair instructions associated with NHTSA Recall 21V-748. These are the same instructions as outlined in the previously submitted Technical Service Information Bulletin TSIB 22-01.
INSTRUCTION TO SERVICE
ITS60421
DATE: March 17, 2022
SECTION:
292-Electrical Harnesses
WRITTEN BY:
Aditya Gadepalli
SUBJECT:
MCI
Main Distribution Panel Protection
This is to inform you that your vehicle may contain a defect that could affect the
safety of a person. The Main Distribution Panel (MDP) in the battery
compartment has experienced failures that may result in thermal events and/or
uncommanded vehicle shutdown.
ISSUE:
SUMMARY:
Due to the current global parts shortage, the components required to conduct
the related recall repair instructions are not currently available. This is specific
to repair instructions ITS60272 (J4500), ITS-60335 (J3500), ITS 60283 (D
Coach), and ITS60298 (D45CRT and D4520 coach).
In the interim period, prior to these repair instructions being incorporated on the
buses identified above, MCI recommends conducting an immediate inspection
of the MDP, MCI P/N: 07-08-7940, and regular interval inspections every three
months for signs of thermal stress or corrosion following this inspection
procedure
Due to the Main Distribution Panel failures resulting from supplier quality and
environmental issues, it is recommended the MDP be inspected and replaced
until the permanent solution of replacing the MDP with a circuit breaker
assembly is applied.
ITS60421
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
2021-595
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED TO FOR FUTURE MAINTENANCE UNTIL
THE 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
ITS60421
PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Follow steps 4 to 8 on J4500, J3500, D45CRTLE, and D4520 coach models.
4. Locate the Main Battery Disconnect Switch and ensure it is in the off position.
Turn off
MDS.
5. Disconnect GND, 12V, and 24V battery cables from the coach batteries. Ensure the battery cables do not
come in contact with each other or the coach.
Disconnect all
battery cables.
6. Locate the MDP compartment mounted on the rear wall in the battery compartment. Remove and save the 4
thumb screws to release the MDP cover.
Remove and save 4
thumb screws.
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INSTRUCTION TO SERVICE
ITS60421
7. Remove tyraps that secure BT-P162 to the Main Disconnect Switch cables.
Remove BT-P162 tyraps on
battery cables.
8. Disconnect connectors BT-P161 and BT-P162 from MDP.
Disconnect BT-P161
and BT-P162.
9. Follow steps 10 to 15 on D4000, D4500, D4005, D4005, and D4000 ISTV coach models.
10. Locate the Main Battery Disconnect Switch and ensure it is in the off position.
Turn off
MDS.
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INSTRUCTION TO SERVICE
ITS60421
11. Disconnect GND, 12V, and 24V battery cables from the coach batteries. Ensure the battery cables do not
come in contact with each other or the coach.
Disconnect
battery cables
12. Remove and save the two thumbscrews from the MDP cover.
Remove the thumb
screws
13. Remove and save 4 screws holding the MDP cut-out part to the MDP cover.
Remove and save the
screws
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INSTRUCTION TO SERVICE
ITS60421
14. Disconnect the two connectors, BT-P162 and BT-P161, from the main distribution panel.
Disconnect the wires
15. Slide out and save the battery compartment cover out of the bracket.
Slide the cover out
16. Inspect the front of the MDP for corrosion at all connectors and verify the retaining nuts for all the power
cables are properly torqued. If corrosion is found, consult your local MCI representative for more heavier duty
inspection and cleaning ITS-60422.
NOTE: Refer to the step 35 for power stud torque specifications of the MDP.
ITS60421
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INSTRUCTION TO SERVICE
ITS60421
17. If no corrosion is found, inspect for heat damage on the BT-P162 connector. If heat damage is observed,
perform steps 18 to 21. Otherwise, skip to step 22.
Bad
Good
Perform steps 18 to 21
Skip to step 22
18. Cut HVAC wires CT0021, CT0022, CT0026, and CT0027 4-5 inches from the 24V BT-P162 connector.
Cut wires 4-5 inches after
the connector
Schematic of J4500, J3500,
D45CRTLE and D4520 coach models
Schematic of D4000, D4500, D4005,
D4005, and D4000 ISTV coach models
NOTE: Heatshrink and tie back the wire attached to the pins to avoid corrosion.
ITS60421
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INSTRUCTION TO SERVICE
ITS60421
19. Crimp HHG in-line fuse holders, MCI P/N: T19-1168, to the HVAC wires using splice connector, MCI P/N: 1911-431, black heat shrink, MCI P/N: 19-11-1465, and a 1/2” ring terminal at the end, MCI P/N: 19-11-393.
Crimp inline fuse holder to
the HVAC wires
20. Remove 20A fuses from the MDP and install them in the in-line fuse holders.
Remove 20A fuses and
install in in-line fuse holders
21. Connect the modified HVAC wires to either 24V SW stud on the MDS as shown below for various coach
models. Torque the nut to 300 In-lbs.
Connect the modified HVAC
wires to 24V SW stud on MDS
J4500/J3500/D45CRTLe/D4520 coach models
ITS60421
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INSTRUCTION TO SERVICE
ITS60421
Connect the modified HVAC
wires to 24V SW stud on MDS
D4000, D4500, D4005, D4005,
and D4000 ISTV coach models
22. Cover all open connectors and fuse slots with masking tape.
Cover open
connectors and
fuse slots.
23. Using short sprays, apply the corrosion inhibitor, MCI P/N: 23-02-0119, on all power and fuse studs. Wipe off
any excessive corrosion inhibitor from the fuse windows using a dry rag.
Spray anticorrosive on
MDP studs.
ITS60421
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INSTRUCTION TO SERVICE
ITS60421
24. Follow steps 25 to 28 for J4500/J3500/D45CRT-Le/D4520 coach models.
25. Route through the MDP cover holes and secure connectors BT-P161 and BT-P162 to the MDP board.
Connect BT-P161 and
BT-P162.
26. Secure the MDP cover using the 4 thumb screws, MCI P/N: 07-08-9231.
Install 4 thumb
screws.
27. Secure the BT-P161/BT-P162 harnesses to the MDP cover using 5 tyraps, MCI P/N: 19-11-258, and existing
mounts.
Secure harness
using 5 tyraps.
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INSTRUCTION TO SERVICE
ITS60421
28. Loosely secure the BT-P162 branch to the MDS battery cables, allowing a smooth curve on the harness.
Ensure there is no side strain at the connector.
Loosely secure BT162 to MDS Cables.
29. Perform steps 30 to 34 on D4000, D4500, D4005, D4005, and D4000 ISTV coach models.
30. Slide in and discard the battery compartment cover out of the bracket.
Slide the cover in
31. Connect the two connectors, BT-P162 and BT-P161, to the main distribution panel.
Connect the wires
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INSTRUCTION TO SERVICE
ITS60421
32. Re-install the MDP cut-out part to the MDP cover using existing screws.
Re-install MDP cut-out
part
33. Secure the MDP cover using the existing two thumbscrews.
Re-install the MDP
cover
34. Secure the BT-P162 and BT-P161 connectors to the MDP cover using 2 tyraps, MCI P/N: 19-11-258. Ensure
the tyraps do not create tension at the pins or connectors.
Secure BT-P162/ BT-P161
to MDP cover.
ITS60421
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INSTRUCTION TO SERVICE
ITS60421
35. Following are the torque values for the MDP studs:
NOTE: Inspection and preventive maintenance are no longer required once the MDP is replaced
with circuit breakers as per ITS60272 (J4500), ITS-60335 (J3500), ITS 60283 (D Coach), and ITS60298
(D45CRT and D4520 coach).
ITS60421
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INSTRUCTION TO SERVICE
ITS60421
LABOUR ESTIMATE
Operation
1
Number of
Technician(s)
1
MDP Inspection and cleaning
Hours
2
Labor Time
T X HR
2
PARTS REQUIRED
Description
Qty.
per
Coach
4
Units
Item
Part Number
1
19-11-393
Ring Terminal, ½ IN 12AWG
2
T19-1168
Holder-Fuse, Inline, HHG, W/Cap
4
EA
3
19-11-431
Connector-Splice,Butt,12 10 AWG,
4
EA
4
19-11-1465
Heatshrink, 2”
4
EA
Notes
EA
SPECIAL TOOLS REQUIRED
Item
Part Number
Description
1
23-02-0119
Sealant-Corrosion Inhibitor
ITS60421
Page 13 of 13
Qty.
Units
1
EA
Notes
March 17, 2022
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TSB/Document ID: ITS60421
Replacement Service Bulletin Number:
MFR Communication Date: 2022-03-17
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
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