NHTSA ID Number: 11012980
Manufacturer Communication Number: ITS61235
TSB/Document Date: 2025-01-21
Summary
This bulletin outlines steps to replace the existing harness with mini
fuses to a more robust design and heavier duty fuses.
INSTRUCTION TO SERVICE
ITS61235
January 6, 2025
SECTION:
292-Electrical Harnesses
SUBJECT:
Battery Compartment Fuse Rework- J45
The mini fuses in the battery compartment for the condenser may not be
ISSUE:
enough for certain load conditions and could damage the fuses
This bulletin outlines steps to replace the existing harness with mini fuses to a
SUMMARY:
more robust design and heavier duty fuses
ITS61235
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 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
ITS61235
PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Remove and discard the fuse layout decals, and VEC fuse bracket.
Remove and
discard the decal
and bracket
4. Cut the zip ties securing the ground cable.
Cut ground
cable tyraps
ITS61235
Page 2 of 11
January 6, 2025
INSTRUCTION TO SERVICE
ITS61235
5. Remove and save the five screws securing the circuit breaker assembly.
Remove and save screws
securing the CB assembly
6. Remove and discard the fuse block harnesses connected to 24V Hot and 12V Hot studs behind the MDS.
For coaches with DD13, retain the ACM connection with maxi fuse and leave it connected to 12V Hot stud.
Remove and discard 24V and
12V Hot fuse block harness
7. Install 24V Hot jumper harness, PN: 1108662, to the 24V Hot stud and torque the nut to 150 In-Lbs.
8. Install 12V Hot jumper harness, PN: 1108665, to the 12V Hot stud and torque the nut to 150 In-Lbs.
9. Remove and discard the 24V SW harness connected to the EC Power Busbar.
Remove and discard
24V SW harness
10. Install 24V SW jumper harness, PN: 1108652, to the EC power busbar and torque to 65 In-Lbs.
11. Identify and blind cut following wires from the fuse holder section, wires: 0011, 0083, 0084, 0034, 170, 0021,
0022, 0026, and 0027. If the coach is equipped with DD13 engine, also cut wire ID 0004.
ITS61235
Page 3 of 11
January 6, 2025
INSTRUCTION TO SERVICE
ITS61235
12. Using splice, solder and heat shrink, splice wire IDs as shown below between spliced wires and 24V HOT
jumper harness.
13. Using splice, solder and heat shrink, splice wire IDs as shown below between spliced wires and 24V SW
jumper harness.
ITS61235
Page 4 of 11
January 6, 2025
INSTRUCTION TO SERVICE
ITS61235
14. If the coach is equipped with DD13 engine, follow this step. Otherwise, skip to step 16. Using splice, solder
and heat shrink, splice wire IDs as shown below between spliced wires and 12V HOT jumper harness.
15. If the coach is equipped with X12 engine and line heater, follow this step. Otherwise, skip to step 17. Using
splice, solder and heat shrink, splice wire ID 0034 to the 24V SW jumper harness spare 0050G shown below.
16. Using top fuse mounting bracket, PN: 1107066, as template at the location shown below, drill 0.25” holes for
mounting and install the bracket using rivets, PN: 071992.
Install 1107066
using rivets 071992
8.25”
ITS61235
Page 5 of 11
January 6, 2025
INSTRUCTION TO SERVICE
ITS61235
17. Using bottom fuse mounting bracket, PN: 1107197, as template at the location shown below, drill 0.25” holes
for mounting and install the bracket using rivets, PN: 071992.
Install 1107197
using rivets 071992
4.25”
18. Clean the brackets with isopropyl alcohol and allow 5 min flash off time. Install decal 1108054 on the top
bracket and 1108125 on the bottom bracket.
Install decal
1108054
Install decal
1108125
ITS61235
Page 6 of 11
January 6, 2025
INSTRUCTION TO SERVICE
ITS61235
19. Follow the decals to install the fuse holders to the brackets and install fuses accordingly using screws, PN:
14S98006.
Install fuses
using screws
20. Install 20A fuse to the fuse holder with X12 option, wire 0034.
21. Install 30A fuse to the fuse holder with DD13 option wire 0004.
22. Use zip ties, MCI P/N: 5958112, to secure the harnesses to the existing harness in battery compartment.
Secure harness
using zip ties
23. Clean the surface of the battery compartment wall above the fuse holder brackets with isopropyl alcohol and
allow 5 min flash off time.
ITS61235
Page 7 of 11
January 6, 2025
INSTRUCTION TO SERVICE
ITS61235
24. Install circuit breaker panel decal, PN: 07-10-2255, above the fuse holder bracket.
Install decal
07-10-2255
25. Install battery compartment layout decal, PN: 07-10-2211, above the circuit breaker panel decal.
Install decal
07-10-2211
ITS61235
Page 8 of 11
January 6, 2025
INSTRUCTION TO SERVICE
ITS61235
26. Mount the circuit breaker assembly to the adapter plate using the saved capscrews. Torque capscrews to 9
FT-LBS.
Mount CB assembly
27. Using cable ties, MCI P/N: 5958112, secure the battery ground to the left side of the CB assembly.
Secure ground
cable using tyraps
ITS61235
Page 9 of 11
January 6, 2025
INSTRUCTION TO SERVICE
ITS61235
LABOUR ESTIMATE
Operation
1
Battery Compartment Fuse Rework- J45
Number of
Technician(s)
1
Hours
1
Labor Time
T X HR
1
PARTS REQUIRED
Item
Part Number
1
1108662
HRNS-BATT FH 24V HOT JMPR
Qty.
per
Coach
1
2
1108665
HRNS-BATT FH 12V HOT JMPR
1
EA
3
1108652
HRNS-BATT FH 24V SW JMPR
1
EA
4
1107066
ASSY-BRACKET FUSE HOLDER
1
EA
5
1107197
ASSY-BRACKET FUSE HOLDER
1
EA
6
071992
RIVET-1/4 SS .08-.575GP
4
EA
7
1108054
DECAL-BATT COMPT FUSES
1
EA
8
1108125
DECAL-BATT COMPT FUSES
1
EA
9
14S98006
SCREW MACHINE NO.8-32 3/8
12
EA
10
07-10-2255
DECAL-CIRCUIT BREAKER PANEL, J4500
1
EA
11
07-10-2211
DECAL-BATTERY COMPT. LAYOUT
1
EA
12
5958112
TYRAP-7.0 BLACK
10
EA
13
8112224
PLUG FUSE IN 10A
1
EA
14
8112225
FUSE PLUG IN 15A
1
EA
15
8112226
FUSE PLUG IN 20A
5
EA
16
8112227
FUSE PLUG IN 25A
2
EA
17
8112228
FUSE PLUG IN 30A
2
EA
18
19-11-1465
HEAT SHRINK-4-1
3
FT
19
19-11-431
SPLICE
12
EA
20
115540
FUSE HOLDER CAP
12
EA
Qty.
Units
Description
Units
Notes
EA
SPECIAL TOOLS REQUIRED
Item
Part Number
Description
1
23-05-0005
ALCOHOL - ISOPROPYL
2
1109772
ITS61235
Notes
Page 10 of 11
January 6, 2025
INSTRUCTION TO SERVICE
ITS61235
ITS61235
Page 11 of 11
January 6, 2025
- ALL SIZES YOU NEED - The fuses automotive kit covers 182pcs...
- HIGH QUALITY - The auto fuse is made of Premium zinc alloy...
- EASY TO IDENTIFY - The blade fuses of each current...
- WIDE APPLICATION - variety of sizes that are commonly used...
- FUSE PULLER - The fuses puller is included in the mini
fuses...
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TSB/Document ID: ITS61235
Replacement Service Bulletin Number:
MFR Communication Date: 2025-01-10
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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