INSTRUCTION TO SERVICE
ITS: 60830

September 26, 2024

SECTION:

260-Hybrid - incl Batteries/Power cables

WRITTEN BY:

New Flyer Service Engineering

SUBJECT:

Repair ECP & MCP pump conncetors to prevent water intrusion

ISSUE:

Water intrusion through ECP & MCP pump connectors causing pumps to fail

SUMMARY:

R&R ECP and MCP pump connectors. Add heatshrink to the ECP & MCP
pump harness connections and ensure the conections are secured horizontally.

ITS60830
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
ITS60830

PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.

3. On the roof of the bus, locate the ECP coolant pump. See Figure 1.

Figure 1: ECP & MCP Coolant Pump Locations

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4. Locate the existing connectors on the ECP coolant pump. See Figure 2.

Figure 2: ECP Pump Connectors
5. Disconnect the two connectors from the ECP coolant pump to the bus side harness. Inspect the connector
pins for corrosion. If corrosion is found replace the connector pins as required. and follow the Figure 3 for the
Pins P/Ns. Please use the Inspection sheet in Appendix A to record any buses that showed signs of corrosion
in the connectors. (NOTE: Please reuse the pin locks)

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Figure 3: ECP Pump Connector Pins Part Numbers
6. Carefully de-pin connector “ECP PUMP – 4CCT” (Power Connector) in Figure 2, discard connector along with
the rubber boot. Retain the cavity plug from the unused cavity.
7. Slide a 2” piece of adhesive heatshrink (NF PN 136366) over the back of the connector and wires then re-pin
the wires into the new connector kit (NF PN 1048120). Plug the unused cavity with the exiting cavity plug
retained from the original connector.
8. Shrink the heatshrink, extending over the back of the connector and wire bundle. Use sealant (NF PN
5959336) or equivalent to fill gaps in wire bundle to ensure complete seal. See Figure 4.

Figure 4: Apply Heatshrink and Sealant
9. Carefully depin connector “ECP PUMP – 6CCT” (CAN Connector) in Figure 2, discard connector along with
the rubber boot. Retain the cavity plug from the unused cavity.

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INSTRUCTION TO SERVICE
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10. Slide a 2” piece of heatshrink (NF PN 136365) over top of the wires and then re-pin the wires into the new
connector kit (NF PN 484006). Plug the unused cavity with the exiting cavity plug retained from the original
connector.
11. Shrink the heatshrink, extending over the back of the connector and wire bundle. Use sealant (NF PN
5959336) or equivalent to fill gaps in wire bundle to ensure complete seal. See Figure 4.
12. Secure the connectors horizontally using clamps (NF 731400) & (NF 608614). See Figure 5.

Figure 5: Connector Locations for Heat Shrink Application
13. At the rear of the bus, locate the MCP coolant pump. See Figure 1.
14. Locate the existing connectors on the MCP coolant pump. See Figure 6.

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INSTRUCTION TO SERVICE
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Figure 6: MCP Pump Connectors
15. Disconnect the two connectors from the MCP coolant pump to the bus side harness. Inspect the connector
pins for corrosion. If corrosion is found replace the connector pins as required and follow the Figure 7 for the
Pins P/N. Please use the Inspection sheet in Appendix A to record any buses that showed signs of corrosion
in the connectors. (NOTE: Please reuse the pin locks)

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Figure 7: MCP Pump Connector Pins Part Numbers
16. Carefully de-pin connector “MCP PUMP – P25” (Power Connector) in Figure 5, discard connector along with
the rubber boot. Retain the cavity plug from the unused cavity.
17. Slide a 2” piece of adhesive heatshrink (NF PN 136366) over the back of the connector and wires then re-pin
the wires into the new connector kit (NF PN 1048120). Plug the unused cavity with the exiting cavity plug
retained from the original connector.
18. Shrink the heatshrink, extending over the back of the connector and wire bundle. Use sealant (NF PN
5959336) or equivalent to fill gaps in wire bundle to ensure complete seal. See Figure 4.
19. Carefully depin connector “MCP PUMP – P26” (CAN Connector) in Figure 5, discard connector along with the
rubber boot. Retain the cavity plug from the unused cavity.
20. Slide a 2” piece of heatshrink (NF PN 136365) over top of the wires and then re-pin the wires into the new
connector kit (NF PN 484006). Plug the unused cavity with the exiting cavity plug retained from the original
connector.
21. Shrink the heatshrink, extending over the back of the connector and wire bundle. Use sealant (NF PN
5959336) or equivalent to fill gaps in wire bundle to ensure complete seal. See Figure 4.
22. Secure the connectors horizontally using clamps (NF 731400) & (NF 608614). See Figure 5.
23. Clean up all tools and debris and return the bus to service condition.
24. Turn the main battery switch to the “ON” position.
25. Verify proper function of the ECP & MCP coolant pumps.



NOTE: If ECP or MCP Pump is compromised is should be replaced under warranty (Separate Work

Order).

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LABOUR ESTIMATE
Operation
1

Repair ECP & MCP pump conncetors to prevent water

Number of
Technician(s)
1

Hours

Labor Time
T X HR
3.0

3.0

intrusion

PARTS REQUIRED

Item

Part Number

1

136366

TUBE-HEATSHRINK .75 SS

Qty.
per
Coach
1

2

136365

TUBE-HEATSHRINK 1.0 SS

1

FT

3

1048120

KIT-4CCT TWR DTP BK W/BOOT ADPTR

2

EA

4

5959336

GE SCS1203 BLACK 1200

0.01

EA

2

EA

Description

Units

Notes

FT

CONSTRUCTION SILICONE SEALANT
5

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484006

KIT-CONN 6CCT TWR DTM

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Appendix A
Connector Inspection Document

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