ITS60421

INSTRUCTION TO SERVICE
ITS60422
March 17, 2022
SECTION:
292-Electrical Harnesses
WRITTEN BY:
Aditya Gadepalli
SUBJECT:
ISSUE:
SUMMARY:
MCI Main Distribution Panel Inspection and Cleaning for Harsh/Corrosive
Environment
This is to inform you that your vehicle may contain a defect that could affect the
safety of a person. The Main Distribution Panel (MDP) in the battery
compartment has experienced failures that may result in thermal events and/or
uncommanded vehicle shutdown.
Due to the current global parts shortage, the components required to conduct
the related recall repair instructions are not currently available. This is specific
to repair instructions ITS60272 (J4500), ITS-60335 (J3500), ITS 60283 (D
Coach), and ITS60298 (D45CRT and D4520 coach).
In the interim period, prior to these repair instructions being incorporated on the
buses identified above, MCI recommends conducting an immediate inspection
of the MDP, MCI P/N: 07-08-7940, and regular interval inspections every three
months for signs of thermal stress or corrosion following this inspection
procedure
Due to the Main Distribution Panel failures resulting from supplier quality and
environmental issues, it is recommended the MDP be inspected and replaced
until the permanent solution of replacing the MDP with a circuit breaker
assembly is applied.
ITS60422
Ref. NHTSA Recall No.
21V-748
Ref. Transport Canada Recall No.
2021-595
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
ITS60422
PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Follow steps 4 to 8 on J4500, J3500, D45CRTLE, and D4520 coach models.
4. Locate the Main Battery Disconnect Switch and ensure it is in the off position.
Turn off
MDS.
5. Disconnect GND, 12V, and 24V battery cables from the coach batteries. Ensure the battery cables do not
come in contact with each other or the coach.
Disconnect all
battery cables.
6. Locate the MDP compartment mounted on the rear wall in the battery compartment. Remove and save the 4
thumb screws to release the MDP cover.
Remove and save 4
thumb screws.
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7. Remove tyraps that secure BT-P162 to the Main Disconnect Switch cables.
Remove BT-P162 tyraps on
battery cables.
8. Disconnect connectors BT-P161 and BT-P162 from MDP.
Disconnect BT-P161
and BT-P162.
9. Follow steps 10 to 15 on D4000, D4500, D4005, D4005, and D4000 ISTV coach models.
10. Locate the Main Battery Disconnect Switch and ensure it is in the off position.
Turn off
MDS.
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INSTRUCTION TO SERVICE
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11. Disconnect GND, 12V, and 24V battery cables from the coach batteries. Ensure the battery cables do not
come in contact with each other or the coach.
Disconnect
battery cables
12. Remove and save the two thumbscrews from the MDP cover.
Remove the thumb
screws
13. Remove and save 4 screws holding the MDP cut-out part to the MDP cover.
Remove and save the
screws
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14. Disconnect the two connectors, BT-P162 and BT-P161, from the main distribution panel.
Disconnect the wires
15. Slide out and save the battery compartment cover out of the bracket.
Slide the cover out
16. Remove all cables from MDP. Make a note of where each cable is connected on the board. Place nuts and
lock washers back on studs after the cables are removed.
Remove all cables
from MDP.
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INSTRUCTION TO SERVICE
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17. Remove & save 8 MDP mounting screws and washers to remove the MDP from the coach.
Remove mounting
screws.
18. Blast the MDP board with air and clean the board with hard nylon wire brush by spraying cleaning spray
lightly to eliminate the dirt.
Clean the board with cleaning
spray using nylon wire brush

NOTE: Maintain caution to spray the cleaner lightly as it could remove the existing conformal coating and
also maintain caution not to damage the pins on the MDP.

NOTE: If the board is found damaged/corroded beyond repair, please contact your local MCI
representative for the replacement board.
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INSTRUCTION TO SERVICE
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19. Using short sprays, apply the corrosion inhibitor, MCI P/N: 23-02-0119, on back of the board and allow 510min for it to dry.
Spray corrosion inhibitor, MCI
P/N: 23-02-0119
20. Using RTV silicon, place a bead of silicone around fuse checker connectors K1 and J7.
Apply RTV around K1
and J7 connectors.
21. Using RTV silicon, seal the top of fuse checker connectors K1 and J7. Let the silicon dry (approximately 30
minutes).
Apply RTV on top of K1 and
J7 connectors.
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INSTRUCTION TO SERVICE
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22. Re-install the MDP to the wall using existing screws and torque the screws to 75 In-Lbs. Re-install the cables
referencing the torques specified in step 39.
Re-install the board
using existing screws
23. Cover all open connectors and fuse slots with masking tape.
Cover open
connectors and
fuse slots.
24. Using short sprays, apply the corrosion inhibitor, MCI P/N: 23-02-0119, on all power and fuse studs. Wipe off
any excessive corrosion inhibitor from the fuse windows using a dry rag.
Spray anticorrosive on
MDP studs.
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INSTRUCTION TO SERVICE
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25. Cut HVAC wires CT0021, CT0022, CT0026, and CT0027 4-5 inches from the 24V BT-P162 connector.
Cut wires 4-5 inches after
the connector
Schematic of J4500, J3500,
D45CRTLE and D4520 coach models

Schematic of D4000, D4500, D4005,
D4005, and D4000 ISTV coach models
NOTE: Heatshrink and tie back the wire attached to the pins to avoid corrosion.
26. Crimp HHG in-line fuse holders, MCI P/N: T19-1168, to the HVAC wires using splice connector, MCI P/N: 1911-431, black heat shrink, MCI P/N: 19-11-1465, and a 1/2” ring terminal at the end, MCI P/N: 19-11-393.
Crimp inline fuse holder to
the HVAC wires
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27. Remove 20A fuses from the MDP and install them in the in-line fuse holders.
Remove 20A fuses and
install in in-line fuse holders
28. Connect the modified HVAC wires to either 24V SW stud on the MDS as shown below for various coach
models. Torque the nut to 300 In-lbs.
Connect the modified HVAC
wires to 24V SW stud on MDS
J4500, J3500, D45CRTLE
and D4520 coach models
Connect the modified HVAC
wires to 24V SW stud on MDS
D4000, D4500, D4005, D4005,
and D4000 ISTV coach models
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29. Follow steps 31 to 33 for J4500/J3500/D45CRT-Le/D4520 coach models.
30. Secure the MDP cover using the 4 thumb screws, MCI P/N: 07-08-9231.
Install 4 thumb
screws.
31. Seal the opening on MDP cover for BT-P161 and BT-P162 connectors over the wires with duct tape.
Cover the openings
with duct tape

NOTE: Ensure smooth routing of cables and ensure no rubbing on the remaining wires.
32. Re-install the battery cables and torque the studs following the maintenance manual.
Reconnect all
battery cables.
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34. Perform steps 35 to 37 on D4000, D4500, D4005, D4005, and D4000 ISTV coach models.
35. Prior to installing the MDP cover, re-install the MDP cut-out part to the MDP cover using existing screws. Duct
tape over the BT-P161 and BT-P162 connectors around the wires to seal the area.
Re-install MDP cut-out
part
Install duct tape

NOTE: Ensure smooth routing of cables and ensure no rubbing on the remaining wires.
36. Slide in and re-install the MDP cover using the existing two thumbscrews.
Re-install the MDP
cover
Slide the cover in
37. Re-install the battery cables and torque the studs following the maintenance manual.
Re-connect
battery cables
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INSTRUCTION TO SERVICE
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38. Following are the torque values for the MDP studs:

NOTE: Inspection and preventive maintenance are no longer required once the MDP is replaced
with circuit breakers as per ITS60272 (J4500), ITS-60335 (J3500), ITS 60283 (D Coach), and ITS60298
(D45CRT and D4520 coach).
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INSTRUCTION TO SERVICE
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LABOUR ESTIMATE
Operation
1
MDP Inspection and cleaning for harsh/corrosive
Number of
Technician(s)
1
Hours
3
Labor Time
T X HR
3
environment
PARTS REQUIRED
Description
Qty.
per
Coach
4
Units
Item
Part Number
1
19-11-393
Ring Terminal, ½ IN 12AWG
2
T19-1168
Holder-Fuse, Inline, HHG, W/Cap
4
EA
3
19-11-431
Connector-Splice,Butt,12 10 AWG,
4
EA
4
19-11-1465
Heatshrink, 2”
4
EA
Notes
EA
SPECIAL TOOLS REQUIRED
Qty.
Units
Sealant-Corrosion Inhibitor
1
EA
N/A
Duct tape
1
EA
3
N/A
Nylon brush
1
EA
4
N/A
Electrical cleaning spray (vendor: CRC, VPN:
1
EA
1
EA
Item
Part Number
Description
1
23-02-0119
2
Notes
5102)
5
ITS60422
N/A
Ultra Grey RTV Silicone (Vendor: Imperial,
VPN: 9166)
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