INSTRUCTION TO SERVICE
ITS61557

FEBRUARY 6, 2026

SECTION:

290-PLC Programs

SUBJECT:

#PLC# - Saucon addition to MCI coach

ISSUE:

Customer request to have PLC transmit specified signals to Saucon.

SUMMARY:

Flash Latest Released PLC Program to the Vehicle

ITS61557
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
ITS61557

Section

Field Name

Input / Example

1. EXECUTIVE
SUMMARY

Document Type

Customer Request

Year and Model
Affected

Select 2025-2026 J4500 vehicles

Triggering Event

Condition is primarily triggered when the vehicle
performs an event monitored by Saucon.

2. SAFETY RISK

Safety Risk
Statement

Not Applicable

3. CORRECTIVE
ACTION

Corrective
Measure

Flash Latest Released PLC Program to the Vehicle

Issue Resolution
Statement

Issue resolved by updating logic groups as requested by
customer.

Validation Criteria

The program works as expected if the customer can see
the transmitted message via the Saucon system.

ITS61557

Page 2 of 4

FEBRUARY 6, 2026

INSTRUCTION TO SERVICE
ITS61557

PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “ON” position.
3. Turn the MRS Switch to the “DAY RUN” position to turn on the bus.
4. Turn the HAZARD SWITCH to “ON”.
5. Connect the USB interface of your NEXIQ to your laptop.
6. Connect the CAN interface of your NEXIQ to Channel 1 (Pins C and D) of the Rear Vehicle Diag port.
7. Open the PLC program in the VMM software.
8. Select Tools and Query VMMs.

Figure 1: Query VMMs Option
9. Ensure you are communicating with all the nodes in the query screen prior to downloading.
10. Select download logic.
11. Ensure the correct file name and revision appear in the file window.

Figure 2: File Selection and Flashing Start

ITS61557

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FEBRUARY 6, 2026

INSTRUCTION TO SERVICE
ITS61557
12. The software will verify the correct number of VMMs are found. Do not download program if all VMMs are
not located. If the correct number of VMMs were found, select Yes.
13. Flashing will happen in two parts; the main logic and the J1939 Table data will be 2 separate progress
screens. Make sure not to close anything after the first progress screen reaches 100% as another one will
appear after that also needs to complete before flashing is completed.
14. Once flashing has truly finished, allow the bus to stay awake for 15 minutes without knifing the bus or turning
off the hazards. This ensures that the VMMs stay awake long enough to load the program into the dash with
the new PLC program. This is an important step as the dash may get stuck rebooting repeatedly if interrupted
while it is being programmed by the other VMMs. This needs to happen as the DPS70 has a slave VMM
inside of it that is not programmed as a part of the above outlined VMM flashing process.
NOTE – For a non-touchscreen bus, there is no requirement to wait 15 minutes. The bus can be turned
off immediately after a flash.
15. Remove all tools and debris from work area to return coach to service.
16. Turn the main battery disconnect switch to the “OFF” position.

LABOUR ESTIMATE
Number of
Technician(s)
1

Operation
1

Flash VMM Program

Hours

Labor Time
T X HR
0.5

0.5

SPECIAL TOOLS REQUIRED
Item

Part Number

Description

Qty.

Units

1

Laptop with Vansco VMM Software

1

EA

2

NEXIQ DLA Adaptor

1

EA

ITS61557

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Notes

FEBRUARY 6, 2026