INSTRUCTION TO SERVICE
ITS: 61518

DATE 2025-12-15

SECTION:

260U – Battery System

SUBJECT:

Rework - OVHD charge cable rework to prevent water intrusion

ISSUE:

Low isolation faults present due to water entering the cable

SUMMARY:

Rework OVHD - Apply Scotchkote OVHD charge box HV cables

ITS61518
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
ITS61518

The intent of ITS-61518 is to inspect each cable and quick disconnect
receptacle validating they are good for use based on NO corrosion being
present and or water intrusion and apply Scotchkote to good cables and reinstall.

Inspection log is to log the condition of the cables and provide
documentation back to the RPSM for cables and receptacles that need
replacement.
Note: All cables replaced with new cables will still require the Scotchkote
application applied in Part 2 of this ITS before installing on the bus.
ITS-61518 contains:
• Part 1 Instruction for cable inspection, documentation and temporary
resealing of cables that will require replacement.
• Part 2 Scotchkote application, receptacle replacement and cable reinstallation.
• Cable inspection log.

ITS61518

Page 2 of 16

December 15, 2025

INSTRUCTION TO SERVICE
ITS61518

Part 1 PROCEDURE: POS and NEG HV Cable Inspection
WARNING: Only trained personnel shall supervise and perform High Voltage system testing,
checkout and troubleshooting. Two personnel (one called the Checker & the other called
Monitor/Recorder) shall perform Checkout Procedures, together, to ensure safety of themselves, others
nearby & for the protection of vehicle & property. Refresher training shall be provided to these personnel
on a regular basis and when new systems are to be checked by them.
1.
2.
3.
4.
5.
6.

Turn the master run switch to the off position and wait 5 minutes before proceeding.
Turn the 12/24V battery disconnect and HV Interlock switch to the “OFF” position.
Lock and tag the electrical system of the bus out and retain the key. See Figure 1.
Use commercially available lockout equipment and tags being sure to follow local regulations.
Install a Lockout/Tagout Steering wheel cover as require.
Ensure to use proper PPE and fall protection.



NOTE: Refer to the Lockout/Tagout Procedure in section 1 of your Preventive Maintenance
Manual or section 9 of your Service manual for additional information.



NOTE: Use commercially available lock out equipment and tags being sure to follow any local
laws or workplace procedures.



NOTE: Refer to New Flyer High Voltage Safety Guidelines and Procedures Document 532295
(Appendix A) when completing installation or service work on high voltage power cables.

Figure 1: Lockout tagout location reference.

ITS61518

Page 3 of 16

December 15, 2025

INSTRUCTION TO SERVICE
ITS61518

7.

Ensure no voltage is present before work begins.

8.

Gain access to the DC rail switch box and disconnect the quick disconnect connectors from the overhead
charge rail box for the NEG cables item #9. See Figure 2.

9.

Inspect the negative cable (items #9) for water and corrosion and note your findings on the attached
inspection document. See Figure 2.

10. Inspect the cable receptacle item #12 for the NEG cables items #8 and #9 for water and corrosion and
note your findings on the attached inspection document. See Figure 2.



NOTE: Cables with corrosion and or water intrusion will require replacement and new cables will
require part 2 of this ITS scotchkote application before installing. Provide inspection documentation
to RPSM for parts ordering.

9

12

Corrosion
Corrosion

Item

Part Number

Description

9

903121

EP90HV10-RAIL NEG TO DC RLSW NEG

12

748646

ASSY-HV NEG RECEPTACLE

Figure 2 - OVHD HV HV NEG cable quick disconnect location reference.

ITS61518

Page 4 of 16

December 15, 2025

INSTRUCTION TO SERVICE
ITS61518

11. Disconnect the quick disconnect connectors from the overhead charge rail box for the POS cables item
#10. See Figure 3.
12. Inspect each cable items #10 for water and corrosion and note your findings on the attached inspection
document. See Figure 3.
13. Inspect the cable receptacle item #13 for the POS cables for water and corrosion and note your findings
on the attached inspection document. See Figure 3.



NOTE: Cables with corrosion and or water intrusion will require replacement and new cables will
require part 2 of this ITS scotchkote application before installing. Provide inspection documentation to
RPSM for parts ordering.

10

13

Water

Corrosion
Corrosion

Item

Part Number

Description

10

904896

EP90HV8-RAIL POS TO DC RL SW POS

13

748644

ASSY-HV POS RECEPTACLE

Figure 3 - OVHD HV POS cable quick disconnect location reference.

ITS61518

Page 5 of 16

December 15, 2025

INSTRUCTION TO SERVICE
ITS61518

14. Gain access to the DC charge rail and remove the cable rail mounting hardware from both the NEG and
POS cables items #10 and #11 and set aside for re-installation. See Figure 4.
15. Remove each cable dust boot and set aside for re-installation. See Figure 4.
16. Carefully remove the adhesive heat shrink from each cable and discard. See Figure 4.
17. Inspect each cable items #10 and #11 for signs of water or corrosion on the cable lugs and conductors
and note your findings on the attached inspection document. See Figure 4.



NOTE: Cables with corrosion and or water intrusion will require replacement and new cables will
require part 2 of this ITS scotchkote application before installing. Provide inspection documentation to
RPSM for parts ordering.
10

11

Water Residue
Corrosion

Corrosion

Remove
Adhesive Heat
Shrink

Remove
Cable Dust
Boot

Figure 4 - OVHD HV POS and NEG cable lug location reference.

ITS61518

Page 6 of 16

December 15, 2025

INSTRUCTION TO SERVICE
ITS61518



NOTE: Cables found to have NO corrosion and or replacement cable are present at time of inspection
move to Part 2 PROCEDURE: POS and NEG Scotchkote Application and Cable Replacement.



NOTE: Cables found to have corrosion move to the following steps to apply temporary sealing and reinstall until replacement cables can be sourced. Provide inspection document to RPSM for parts ordering.
18. Cables found to have water intrusion or corrosion present will require replacement. If replacement cables
are not present at the time of inspection without removing the compromised cables from the bus place a
shop rag or plastic underneath the cable. See Figure 5.
19. Apply heat shrink item #1 to the cable lug ends and over the cable sheathing. See Figure 5.
20. Install a final piece of heat shrink item #2 over the heat shrink applied in step 19 and over the loom and
install dust cap removed in previous steps. See Figure 5.

1

2

Re-install Dust Cover

Item

Part Number

Description

1

251215

TUBE-HEAT SHRINK 1.0” BK

2

028247

TUBE-HEAT SHRINK 1.7” BK

Figure 5 - OVHD HV cable lug temporary lug repair location reference.

ITS61518

Page 7 of 16

December 15, 2025

INSTRUCTION TO SERVICE
ITS61518

21. Re-connect the cable quick disconnect connectors to their respective connection points.
22. Re-connect the cable ring terminals to their respective connection points on the charge rail using the
existing hardware and torque cable lug hardware to torque to 22 FT-LBS. See Figure 6.

Torque to 22 FT-LBS.

Re-connect Quick Disconnect Cables

Figure 6 – Cable connections and torque value location references.

ITS61518

Page 8 of 16

December 15, 2025

INSTRUCTION TO SERVICE
ITS61518

Part 2 PROCEDURE: POS and NEG HV Cable Scotchkote Application and
Cable Replacement.
WARNING: Only trained personnel shall supervise and perform High Voltage system testing,
checkout and troubleshooting. Two personnel (one called the Checker & the other called
Monitor/Recorder) shall perform Checkout Procedures, together, to ensure safety of themselves, others
nearby & for the protection of vehicle & property. Refresher training shall be provided to these personnel
on a regular basis and when new systems are to be checked by them.
1.
2.
3.
4.
5.
6.

Turn the master run switch to the off position and wait 5 minutes before proceeding.
Turn the 12/24V battery disconnect and HV Interlock switch to the “OFF” position.
Lock and tag the electrical system of the bus out and retain the key. See Figure 1.
Use commercially available lockout equipment and tags being sure to follow local regulations.
Install a Lockout/Tagout Steering wheel cover as require.
Ensure to use proper PPE and fall protection.



NOTE: Refer to the Lockout/Tagout Procedure in section 1 of your Preventive Maintenance
Manual or section 9 of your Service manual for additional information.



NOTE: Use commercially available lock out equipment and tags being sure to follow any local
laws or workplace procedures.



NOTE: Refer to New Flyer High Voltage Safety Guidelines and Procedures Document 532295
(Appendix A) when completing installation or service work on high voltage power cables.

Figure 1: Lockout tagout location reference.

ITS61518

Page 9 of 16

December 15, 2025

INSTRUCTION TO SERVICE
ITS61518

7.

Ensure no voltage is present before work begins.

8.

Gain access to the DC rail switch box and disconnect the quick disconnect connectors from the overhead
charge rail box for the NEG and POS cables item #9 and #10. See Figure 2.

9.

Gain access to the DC charge rail and remove the cable mounting hardware to the rail for the NEG and
POS cables and set aside for re-installation. See Figure 2.



NOTE: Cables with corrosion and or water intrusion will require replacement and new cables will
require scotchkote application before installing.
10

9

10

11

Remove Cable
Mounting Hdw.

Figure 2 - OVHD HV HV NEG cable quick disconnect location reference.

ITS61518

Page 10 of 16

December 15, 2025

INSTRUCTION TO SERVICE
ITS61518

10. Remove any clamps and hardware securing the cables in place and set aside for re-installation. See