NHTSA ID Number: 11025615
Manufacturer Communication Number: ITS61489
TSB/Document Date: 2025-11-19
Summary
Instructions to update V2 traction inverters with new bootloader.
INSTRUCTION TO SERVICE
ITS61489
November 6, 2025
SECTION:
260 – Battery Compartment
SUBJECT:
Update V2 traction inverters with new bootloader
ISSUE:
Programming V2 inverters at 24 V can result in bricking permanently
SUMMARY:
Connect to and program ELFA3 traction inverters
ITS61489
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
ITS61489
PROCEDURE:
1. Set park brake and chock wheels.
2. Ensure MRS is in the OFF position
WARNING: DO NOT TURN OFF BATTERY DISCONNECT SWITCH. INVERTERS CANNOT BE
PROGRAMMED WITH LV BATTERIES DISCONNECTED.
3. Ensure correct inverter program is available. Consult your New Flyer representative if program is not
available. If the bootloader has already been installed skip to Part 2 and consult the table for programming
inverters.
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Part 1: Installing new bootloader
NOTE: The new bootloader only needs to be installed once per inverter. After initial install, skip to
Part 2 to cover programming inverters.
NOTE: Installing the bootloader will delete any existing programming. DO NOT DRIVE THE VEHICLE
UNTIL ALL TRACTION INVERTERS HAVE BEEN REPROGRAMMED.
1.1 35/40 Foot Standard Grade
4. Enter the bus and gain access to the engine compartment by lifting the seats at the back of the vehicle.
5. Locate the X1 connector on the traction inverter (see figure 1) and remove it. Secure this connector nearby
using Tywraps to reconnect later. Be aware the locking tab is located on the bottom of the connector and
needs to be opened.
Figure 1: XE35/40 traction inverter X1 connector highlighted in light blue
6. Take the X1 connector included in PN 1144289 ASSY-12V INVERTER PROG BOX and attach it to the
traction inverter.
7. Ensuring the ignition switch on 1144289 is in the OFF position, connect the ground (black) plug to ground in
the rear panel using alligator clips.
8. Ensuring the ignition switch on 1144289 is in the OFF position, connect the supply voltage (red) plug to the
12V bus bar in the rear panel using alligator clips.
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INSTRUCTION TO SERVICE
ITS61489
9. Connect USB end of PCAN tool to laptop USB port 1.
10. Connect male DB9 end of PCAN tool to female DB9 connector on 1144289.
11. Open supplied CANFlash program on laptop.
12. Once CANFlash is open select P-CAN under the Vendor drop-down menu. Select PCAN_USBBUS1 under
the Port drop-down menu (see figure 2). It’s important to ensure the physical connection to the laptop
matches the same port as dictated by the CANFlash setup. Click Next when complete.
Figure 2: CANFlash PCAN settings
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13. Click Load zip file. Select SS1000214_Official Release Bootloader 5.11.zip (see figure 3). Ensure the knob
on top of 1144289 is set to inverter ID 1. Click Next when complete.
Figure 3: Load zip file in CANFlash
NOTE: DO NOT UNZIP THE FILES. CANFlash will handle all the required processes.
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INSTRUCTION TO SERVICE
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14. Click the Enable advanced mode button. Change the Delay start of flash process box to 30000. Change
the repeat CAN messages box to 5 (see figure 4). Click Next when complete.
Figure 4: Advanced settings for CANFlash
15. Flip the ignition switch on 1144289 ON when CANFlash says Switch IGN on! (see figure 5). In part 1 you do
not need to turn the Master Run switch ON.
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Figure 5: Flip switch on 1144289 when CANFlash shows Switch IGN on!
16. The flashing process will start automatically. When the process is complete CANFlash will show 100% and a
message saying All tasks finished will appear. Pressing Finish will close CANFlash.
17. Disconnect the 1144289 X1 connector from the traction inverter. Reconnect the bus-side X1 connector
removed in step 5 to the inverter.
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1.2 60 Foot Rear Inverter
18. Enter the bus and gain access to the engine compartment by lifting the seats at the back of the vehicle.
19. Locate the X1 connector on the traction inverter (see figure 6) and remove it. Secure this connector nearby
using Tywraps to reconnect later. Be aware the locking tab is located on the bottom of the connector and
needs to be opened.
Figure 6: XE60 rear traction inverter X1 connector highlighted in light blue
20. Take the X1 connector included in PN 1144289 and attach it to the traction inverter.
21. Ensuring the ignition switch on 1144289 is in the OFF position, connect the ground (black) plug to ground in
the rear panel using alligator clips.
22. Ensuring the ignition switch on 1144289 is in the OFF position, connect the supply voltage (red) plug to the
12V bus bar in the rear panel using alligator clips.
23. Connect USB end of PCAN tool to laptop USB port 1.
24. Connect male DB9 end of PCAN tool to female DB9 connector on 1144289.
25. Open supplied CANFlash program on laptop.
26. Once CANFlash is open select P-CAN under the Vendor drop-down menu. Select PCAN_USBBUS1 under
the Port drop-down menu (see figure 7). It’s important to ensure the physical connection to the laptop
matches the same port as dictated by the CANFlash setup. Click Next when complete.
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Figure 7: CANFlash PCAN settings
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27. Click Load zip file. Select SS1000214_Official Release Bootloader 5.11.zip (see figure 8). Ensure the knob
on top of 1144289 is set to inverter ID 3. Click Next when complete.
Figure 8: Load zip file in CANFlash
NOTE: DO NOT UNZIP THE FILES. CANFlash will handle all the required processes.
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INSTRUCTION TO SERVICE
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28. Click the Enable advanced mode button. Change the Delay start of flash process box to 30000. Change
the repeat CAN messages box to 5 (see figure 9). Click Next when complete.
Figure 9: Advanced settings for CANFlash
29. Flip the ignition switch on 1144289 ON when CANFlash says Switch IGN on! (see figure 10). In part 1 you do
not need to turn the Master Run switch ON.
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Figure 10: Flip switch on 1144289 when CANFlash shows Switch IGN on!
30. The flashing process will start automatically. When the process is complete CANFlash will show 100% and a
message saying All tasks finished will appear. Pressing Finish will close CANFlash.
31. Disconnect the 1144289 X1 connector from the traction inverter. Reconnect the bus-side X1 connector
removed in step 5 to the inverter.
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INSTRUCTION TO SERVICE
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1.3 35/40 Foot High Grade
32. Enter the bus and gain access to the engine compartment by lifting the seats at the back of the vehicle.
33. Locate the X1 connector on the streetside traction inverter (see figure 11) and remove it. Secure this
connector nearby using Tywraps to reconnect later. Be aware the locking tab is located on the bottom of the
connector and needs to be opened.
Figure 11: XE35/40 high grade streetside traction inverter X1 connector highlighted in light blue
34. Take the X1 connector included in PN 1144289 and attach it to the streetside traction inverter.
35. Ensuring the ignition switch on 1144289 is in the OFF position, connect the ground (black) plug to ground in
the rear panel using alligator clips.
36. Ensuring the ignition switch on 1144289 is in the OFF position, connect the supply voltage (red) plug to the 12
V bus bar in the rear panel using alligator clips.
37. Connect USB end of PCAN tool to laptop USB port 1.
38. Connect male DB9 end of PCAN tool to female DB9 connector on 1144289.
39. Open supplied CANFlash program on laptop.
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40. Once CANFlash is open select P-CAN under the Vendor drop-down menu. Select PCAN_USBBUS1 under
the Port drop-down menu (see figure 12). It’s important to ensure the physical connection to the laptop
matches the same port as dictated by the CANFlash setup. Click Next when complete.
Figure 12: CANFlash PCAN settings
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41. Click Load zip file. Select SS1000214_Official Release Bootloader 5.11.zip (see figure 13). Ensure the
knob on top of 1144289 is set to inverter ID 1. Click Next when complete.
Figure 13: Load zip file in CANFlash
NOTE: DO NOT UNZIP THE FILES. CANFlash will handle all the required processes.
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INSTRUCTION TO SERVICE
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42. Click the Enable advanced mode button. Change the Delay start of flash process box to 30000. Change
the repeat CAN messages box to 5 (see figure 14). Click Next when complete.
Figure 14: Advanced settings for CANFlash
43. Flip the ignition switch on 1144289 ON when CANFlash says Switch IGN on! (see figure 15). In part 1 you do
not need to turn the Master Run switch ON.
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Figure 15: Flip switch on 1144289 when CANFlash shows Switch IGN on!
44. The flashing process will start automatically. When the process is complete CANFlash will show 100% and a
message saying All tasks finished will appear. Pressing Finish will close CANFlash.
45. Disconnect the 1144289 X1 connector from the streetside traction inverter. Reconnect the bus-side X1
connector removed in step 5 to the streetside inverter.
46. Locate the X1 connector on the curbside traction inverter (see figure 16) and remove it. Secure this connector
nearby using Tywraps to reconnect later. Be aware the locking tab is located on the bottom of the connector
and needs to be opened.
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Figure 16: XE35/40 high grade curbside traction inverter X1 connector highlighted in light blue
47. Take the X1 connector included in PN 1144289 and attach it to the curbside traction inverter.
48. Ensuring the ignition switch on 1144289 is in the OFF position, connect the ground (black) plug to ground in
the rear panel using alligator clips.
49. Ensuring the ignition switch on 1144289 is in the OFF position, connect the supply voltage (red) plug to the 12
V bus bar in the rear panel using alligator clips.
50. Connect USB end of PCAN tool to laptop USB port 1.
51. Connect male DB9 end of PCAN tool to female DB9 connector on 1144289.
52. Open supplied CANFlash program on laptop.
53. Once CANFlash is open select P-CAN under the Vendor drop-down menu. Select PCAN_USBBUS1 under
the Port drop-down menu (see figure 17). It’s important to ensure the physical connection to the laptop
matches the same port as dictated by the CANFlash setup. Click Next when complete.
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Figure 17: CANFlash PCAN settings
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54. Click Load zip file. Select SS1000214_Official Release Bootloader 5.11.zip (see figure 18). Ensure the
knob on top of 1144289 is set to inverter ID 2. Click Next when complete.
Figure 18: Load zip file in CANFlash
NOTE: DO NOT UNZIP THE FILES. CANFlash will handle all the required processes.
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55. Click the Enable advanced mode button. Change the Delay start of flash process box to 30000. Change
the repeat CAN messages box to 5 (see figure 19). Click Next when complete.
Figure 19: Advanced settings for CANFlash
56. Flip the ignition switch on 1144289 ON when CANFlash says Switch IGN on! (see figure 20). In part 1 you do
not need to turn the Master Run switch ON.
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Figure 20: Flip switch on 1144289 when CANFlash shows Switch IGN on!
57. The flashing process will start automatically. When the process is complete CANFlash will show 100% and a
message saying All tasks finished will appear. Pressing Finish will close CANFlash.
58. Disconnect the 1144289 X1 connector from the curbside traction inverter. Reconnect the bus-side X1
connector removed in step 5 to the curbside inverter.
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1.4 60 Foot Centre Axle
59. Gain access to the centre axle inverter rack on the roof of the vehicle. Ensure requisite safety precautions are
taken.
60. Locate the X1 connector on the curbside traction inverter (see figure 21) and remove it. Secure this connector
nearby using Tywraps to reconnect later. Be aware the locking tab is located on the bottom of the connector
and needs to be opened.
Figure 21: XE60 centre axle curbside traction inverter X1 connector highlighted in light blue
61. Take the X1 connector included in PN 1144289 and attach it to the curbside centre axle traction inverter.
62. Ensuring the ignition switch on 1144289 is in the OFF position, connect the ground (black) plug to ground in
the centre door panel using alligator clips.
63. Ensuring the ignition switch on 1144289 is in the OFF position, connect the supply voltage (red) plug to the 12
V bus bar in the centre door panel using alligator clips.
64. Connect USB end of PCAN tool to laptop USB port 1.
65. Connect male DB9 end of PCAN tool to female DB9 connector on 1144289.
66. Open supplied CANFlash program on laptop.
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67. Once CANFlash is open select P-CAN under the Vendor drop-down menu. Select PCAN_USBBUS1 under
the Port drop-down menu (see figure 22). It’s important to ensure the physical connection to the laptop
matches the same port as dictated by the CANFlash setup. Click Next when complete.
Figure 22: CANFlash PCAN settings
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68. Click Load zip file. Select SS1000214_Official Release Bootloader 5.11.zip (see figure 23). Ensure the
knob on top of 1144289 is set to inverter ID 1. Click Next when complete.
Figure 23: Load zip file in CANFlash
NOTE: DO NOT UNZIP THE FILES. CANFlash will handle all the required processes.
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69. Click the Enable advanced mode button. Change the Delay start of flash process box to 30000. Change
the repeat CAN messages box to 5 (see figure 24). Click Next when complete.
Figure 24: Advanced settings for CANFlash
70. Flip the ignition switch on 1144289 ON when CANFlash says Switch IGN on! (see figure 25). In part 1 you do
not need to turn the Master Run switch ON.
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Figure 25: Flip switch on 1144289 when CANFlash shows Switch IGN on!
71. The flashing process will start automatically. When the process is complete CANFlash will show 100% and a
message saying All tasks finished will appear. Pressing Finish will close CANFlash.
72. Disconnect the 1144289 X1 connector from the curbside centre axle traction inverter. Reconnect the bus-side
X1 connector removed in step 5 to the curbside inverter.
73. Locate the X1 connector on the streetside centre axle traction inverter (see figure 26) and remove it. Secure
this connector nearby using Tywraps to reconnect later. Be aware the locking tab is located on the bottom of
the connector and needs to be opened.
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Figure 26: XE60 centre axle streetside traction inverter X1 connector highlighted in light blue
74. Take the X1 connector included in PN 1144289 and attach it to the streetside centre axle traction inverter.
75. Ensuring the ignition switch on 1144289 is in the OFF position, connect the ground (black) plug to ground in
the centre door panel using alligator clips.
76. Ensuring the ignition switch on 1144289 is in the OFF position, connect the supply voltage (red) plug to the 12
V bus bar in the centre door panel using alligator clips.
77. Connect USB end of PCAN tool to laptop USB port 1.
78. Connect male DB9 end of PCAN tool to female DB9 connector on 1144289.
79. Open supplied CANFlash program on laptop.
80. Once CANFlash is open select P-CAN under the Vendor drop-down menu. Select PCAN_USBBUS1 under
the Port drop-down menu (see figure 27). It’s important to ensure the physical connection to the laptop
matches the same port as dictated by the CANFlash setup. Click Next when complete.
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Figure 27: CANFlash PCAN settings
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81. Click Load zip file. Select SS1000214_Official Release Bootloader 5.11.zip (see figure 28). Ensure the
knob on top of 1144289 is set to inverter ID 2. Click Next when complete.
Figure 28: Load zip file in CANFlash
NOTE: DO NOT UNZIP THE FILES. CANFlash will handle all the required processes.
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INSTRUCTION TO SERVICE
ITS61489
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TSB/Document ID: ITS61489
Replacement Service Bulletin Number:
MFR Communication Date: 2025-11-19
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL/PROPULSION SYSTEM
MFR Component System:
MFR Component Subsystem:
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