INSTRUCTION TO SERVICE
ITS: 60778

DATE 8/9/2023

SECTION:

549U – MCC Cable Installation

WRITTEN BY:

Daniel Tice

SUBJECT:

MCC Cable and Bracket Rework

ISSUE:

MCC Cable Rubs Bracket at Side Screens

SUMMARY:

Replace Bracket and Apply Self Fusing Tape to Damaged Cable Areas

ITS60778
Ref. NHTSA Recall No.
Not Applicable

Ref. Transport Canada Recall No.
Not Applicable

THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED TO FOR FUTURE MAINTENANCE UNTIL
THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A
RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND
MAINTENANCE STAFF GOING FORWARD.
This document and the contents discussed herein are the confidential and proprietary information of New Flyer Industries Canada
ULC and New Flyer of America Inc. and are disclosed by New Flyer in confidence. This document and the contents herein are not
to be disclosed by the intended recipient without the prior written authorization of New Flyer. Any unauthorized disclosure,
reproduction or other distribution of this document or information strictly prohibited and may result in action being taken against
the party making the unauthorized disclosure. This document and all copies hereof must be returned to New Flyer upon request.

INSTRUCTION TO SERVICE
ITS60778

PROCEDURE:
1. Ensure to apply the parking brake.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Ensure to wear the proper PPE and fall protection while work is performed.
4. Gain access to the roof MCC unit. See Figure 1.
5. Locate the existing MCC cable cover/bracket . See Figure 1.
6. Remove the exiting MCC cable cover/bracket hardware and set aside for re-installation. See Figure 1.
7. Discard existing bracket after removal.

MCC Bracket

Bracket Hardware
Figure 1: MCC cable cover bracket location reference.

ITS60778

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August 09, 2023

INSTRUCTION TO SERVICE
ITS60778

8. Inspect the upper cable for damage or chafing to the cable sheathing surface. See photos below to determine
if chafing is present and at what level. See Figure 2.
9. If no chafing or damage has occurred move to step 13 bracket replacement steps in this ITS.
10. If more than surface chafing is present as shown below report the bus number to your RPSM. See Figure 2.

Chafing
Inspection Area

Cable Sheathing
damage. Report bus
to RPSM.

Minor Cable Sheathing
Chafing. Clean and
Wrap with Item #2

Figure 2: MCC cable cover chafing inspection location reference.

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August 09, 2023

INSTRUCTION TO SERVICE
ITS60778

11. If minimal surface chafing is present clean the section of cable where surface chafing has occurred about four
inches on each side of the damaged area using electrical contact cleaner item #1 and a lint free dry cloth. See
Figure 3.
12. Starting four inches away from the area with chaffing wrap self-fusing tape item #2 over the area ending four
inches on the other side. See Figure 3.

1,2

Item

Part Number

Description

1

3824510-101

Contact cleaner

2

947924

Tape Self-Fusing 1”

Figure 3: MCC cable chafing repair location reference.
13. Install the MCC cable cover/bracket item #3 with the existing hardware. See Figure 4.
14. Remove all tools and debris.
15. Turn the main battery disconnect switch to the “ON” position and return to service.

Side Screen Brackets Removed for Clarity.
3

Re-use
Existing
Hardware

Re-use
Existing
Hardware

Item

Part Number

Description

3

1039881

Cover HV Cable

Figure 4: New MCC cable cover bracket location reference.

ITS60778

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August 09, 2023

INSTRUCTION TO SERVICE
ITS60778

LABOUR ESTIMATE
Operation
1

Replace MCC Bracket and Apply Self Fusing Tape

Number of
Technician(s)
1

Hours
.5

Labor Time
T X HR
.5

PARTS REQUIRED
Qty.
per
Coach

Item

Part Number

Description

1

3824510-101

Contact cleaner

2

947924

Tape Self-Fusing 1”

3

1039881

Cover HV Cable

0.010
3
1

Units

Notes

EA
FT
EA

SPECIAL TOOLS REQUIRED

Item

ITS60778

Part Number

Qty.

Description

Page 5 of 5

Units

Notes

August 09, 2023