2017-2021 MCI Motorcoach R21-010 Circuit Board in Battery Compartment May Fail

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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 ITS60272 October 18, 2021 SECTION: 292-Electrical Harnesses WRITTEN BY: Hugo Freire SUBJECT: MCI J Coach MDP Replacement with Circuit Breaker Assembly ISSUE: 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. SUMMARY: Due to the Main Distribution Panel failures resulting from supplier quality and environmental issues, it is recommended the MDP be replaced with a circuit breaker assembly. ITS60272 Ref. NHTSA Recall No. Ref. Transport Canada Recall No. 21V-748 2021-595 MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 2 of 18 October 18, 2021 PROCEDURE: 1. Set park brake and chock wheels. 2. Turn the Main Battery Disconnect Switch to the “OFF” position. 3. 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. 4. Locate the MDP compartment mounted on the rear wall in the battery compartment. Remove and discard the 4 thumb screws to release the MDP cover. Remove and discard thumb screws. Turn off MDS. Disconnect all battery cables. MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 3 of 18 October 18, 2021 5. Remove 5 tyraps located at the bottom of the plastic MDP cover to remove the cover. 6. Remove tyraps that secure BT-P162 to the Main Disconnect Switch cables. 7. Disconnect connectors BT-P161 and BT-P162 from MDP. Remove 5 tyraps & remove cover. Remove BT-P162 tyraps on battery cables. Disconnect BT-P161 and BT-P162. MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 4 of 18 October 18, 2021 8. 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. 9. Remove & discard 8 MDP mounting screws and washers to remove the MDP from the coach. 10. Remove & discard the hex bolts used to seal the cables on the top and bottom of the MDP enclosure. Remove all cables from MDP. Remove mounting screws. Remove cable seal bolts MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 5 of 18 October 18, 2021 11. Remove & save Main Disconnect Switch mounting bolts. Disconnect battery cables from MDS and feed-through stud, saving hardware. Remove and save trim lock from the MDS. 12. Remove & save the MDP box mounting bolts. Discard MDP box with cables connected to studs J1-J4. 13. Remove the 3 tyrap mounts from the left battery compartment wall. Remove 3 tyrap mounts. Remove & save mounting bolts. Remove & save mounting bolts. MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 6 of 18 October 18, 2021 14. Using a step-up drill bit and the table below, carefully increase the stud size on 9 ring terminals removed for the MDP from ¼” to 5/16”. 15. Cut the wires from BT-P162 and BT-P161 12 inches from the connector. 16. Tie back all spare wires from BT-P161 and BT-P162 using heat shrink, MCI P/N: 19-11-1465. Also, tie back Alt 55SI sense wire CT 0012D. Source (MDP) Source Wire ID Description J36 07-09-1814 EVAP 24V SW J38 07-09-1803 RJB 24V SW J39 07-09-1805 FJB 24V SW J40 07-09-1807 RJB 24V HOT J41 07-09-1809 FJB 24V HOT J42 07-09-1804 RJB 12V SW J43 07-09-1806 FJB 12V SW J44 07-09-1808 RJB 12V HOT J45 07-09-1810 FJB 12V HOT Enlarge hole. Cut Wire 12” from connector Tie back 20 unused wires MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 7 of 18 October 18, 2021 17. Using butt splices, MCI P/N: 19-11-431, and black heat shrink, MCI P/N: 19-11-1465, attach the ECM, Spheros, and booster pump power wires to BT-FBA part of fuse holder jumper, MCI P/N: 929287, as shown below. 18. Using butt splices, MCI P/N: 19-11-431, and black heat shrink, MCI P/N: 19-11-1465, attach the HVAC condenser wires to BT-FBB part of fuse holder jumper, MCI P/N: 929287, as shown below. 19. Using butt splices, MCI P/N: 19-11-431, and black heat shrink, MCI P/N: 19-11-1465, attach the MCM, TCM, and line heater power wires to BT-FBC part of fuse holder jumper, MCI P/N: 929287, as shown below. 20. If coach has a DD13 engine, use butt splices, MCI P/N: 19-11-431, and black heat shrink, MCI P/N: 19-11-1465, attach the ACM power wire (Wire ID 0006) to fuse holder A (FHA), part of the jumper harness, MCI P/N: 929287. Otherwise, tie back the inline fuse holder. Splice into fuse block A, BT-FBA Splice into fuse block B, BT-FBB Splice into fuse block C, BT-FBC MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 8 of 18 October 18, 2021 21. Cut 18.5” from 12 SW EQ cable, MCI P/N: 07-09-1812. Place a 2” piece of adhesive heat shrink, MCI P/N: 19-11-67, and 2” blue heat shrink, MCI P/N: 117202, and crimp ring terminal, MCI P/N: 19-11-3763 to the cable. Use a heat gun on heat shrink, the blue heat shrink should be on top. 22. Cut 16.5” from 24 SW EQ cable, MCI P/N: 07-09-1811. Place a 2” piece of red heat shrink, MCI P/N: 19-11-2371, and crimp ring terminal, MCI P/N: 19-11-3763 to the cable. Use a heat gun on adhesive heat shrink. 23. Loosely mount the adapter plate, MCI P/N: 929386, on the left wall using the 2 saved cap screws, MCI P/N: 19-01-1532, at the highlighted locations. Mark the 3 remaining mounting locations of the CB assembly. Add new ring terminal. Add new ring terminal. Loosely mount CB adapter plate using saved capscrews Mark new hole locations MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 9 of 18 October 18, 2021 24. Remove adapter plate, MCI P/N: 929386. Using a drill stop, drill three 35/64” holes at the marked circuit breaker assembly locations. Pay close attention to not to puncture the fuel tank on the other side of the wall.  NOTE: Ensure extreme caution while drilling on the left battery compartment wall to avoid puncturing the fuel tank on the other side of the wall. 25. Cover 10 unused holes on the left battery compartment wall with RTV silicone. 26. Place a ¼” bead of RTV silicone around 1” inside edge of the back side of the adapter plate, MCI P/N: 929386, before mounting. Drill 3 35/64” holes on the marked hole locations. Cover unused holes with RTV silicone Place a ¼” bead of RTV silicone around edges of plate. MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 10 of 18 October 18, 2021 27. Mount adapter plate, MCI P/N: 929386. Install 3 rivet nuts, MCI P/N: 6485136, to the newly drilled holes. 28. Remove MDP decal from the back wall. Use the fuse holder bracket assembly, MCI P/N: 07-10-2254, as a template to mark 3 mounting holes 10.5” from the top of the Evap filter door and 1” from the HVAC duct. 29. Use a 13/64” drill bit to drill the 3 marked holes. Mount the FH bracket assembly using 3 rivets, MCI P/N: 19-13-137. 30. Install fuse holder decal, MCI P/N: 929387, and CB panel decal, MCI P/N: 07-10-2283 above the fuse holder bracket. Attach 3 rivet nuts to mount adapter plate Mark 3 holes to mount the fuse holder bracket Install 3 rivets to mount fuse holder bracket 1” 10.5” MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 11 of 18 October 18, 2021 31. Install cables and fuse holder jumper ring terminals, MCI P/N: 929287, to the CB assembly. Add adhesive Loctite, MCI P/N: 21-7212-18, to threads before tightening. Torque studs using the reference connection chart below. Source Source Wire ID Description Target Description Torque Rating J25 07-09-1812 12 SW EQ BT-T125 BT-F25 36-40 IN-LBS J26 07-09-1811 24 SW EQ BT-T126 BT-F26 36-40 IN-LBS J27 07-09-1815 24 HOT INV (OPTION) BT-T516 CB6 70-75 IN-LBS J27 07-08-2627 BATT CHARGER BT-T516A CB6 70-75 IN-LBS J27 – AMEREX (INLINE Fuse) BT-T516 CB6 70-75 IN-LBS J36 07-09-1814 EVAP 24V SW BT-T513 CB3 70-75 IN-LBS J38 07-09-1803 RJB 24V SW BT-T512 CB2 70-75 IN-LBS J39 07-09-1805 FJB 24V SW BT-T511 CB1 70-75 IN-LBS J40 07-09-1807 RJB 24V HOT BT-T515 CB5 70-75 IN-LBS J41 07-09-1809 FJB 24V HOT BT-T514 CB4 70-75 IN-LBS J42 07-09-1804 RJB 12V SW BT-T518 CB8 70-75 IN-LBS J43 07-09-1806 FJB 12V SW BT-T517 CB7 70-75 IN-LBS J44 07-09-1808 RJB 12V HOT BT-T520 CB10 70-75 IN-LBS J45 07-09-1810 FJB 12V HOT BT-T519 CB9 70-75 IN-LBS – 0045 FUSE BLOCK A BT-T3B 24V HOT MDS 150 IN-LBS – 0050 FUSE BLOCK B BT-T4B EC PWR BUSBAR 65 IN-LBS – 0048 FUSE BLOCK C1 BT-T1B 12V HOT MDS 150 IN-LBS – 0047 FUSE BLOCK C2 BT-T4C EC PWR BUSBAR 65 IN-LBS – 07-09-1819 12V BATTERY BT-T1C 12V HOT MDS 150 IN-LBS – 07-09-1818 24V BATTERY BT-T3A 24V HOT MDS 150 IN-LBS BT-T4 07-09-2208 EC PWR STUD BT-T4 EC PWR STUD 300 IN-LBS MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 12 of 18 October 18, 2021 32. Using tyraps included in the switch assembly, secure cables connected to the MDS and circuit breakers. Ensure smooth curves and routing on all cables. 33. Apply torque seal, MCI P/N: 5023844, to each stud after being torqued. 34. Spray back of circuit breaker assembly (bus bars and studs), MCI P/N: 07-09-3366, with anti-corrosive spray, MCI P/N: 23-02-0119. Use tyraps to secure cables Apply torque seal on CB nuts Spray anti-corrosive spray in the back of the CB assembly MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 13 of 18 October 18, 2021 35. Mount the circuit breaker assembly, MCI P/N: 07-09-3366, to the adapter plate using 5 saved capscrews, MCI P/N: 19-01-1532. Torque capscrews to 9 FT-LBS. 36. Using tie cable with mount, MCI P/N: 19-11-3472, and tyraps to secure the battery ground to the left side of the CB assembly. 37. Secure battery cables to the 3 bottom tyrap mounts using tyraps, MCI P/N: 5958112. Mount CB assembly Secure ground cable using tyraps Secure cables using tyraps MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 14 of 18 October 18, 2021 38. Connect the fuse block B ring terminal (Wire ID 0050) to the 24V SW stud (BT-T4B) on the circuit breaker busbar, MCI P/N: 7L-8-5055, using lock washer, MCI P/N:19-2-37, and nut, MCI P/N: 19-3-32. Torque nut to 65 IN-LBS. Torque main power feeder to 20-25 FT-LBS. 39. Connect the fuse block C ring terminal (Wire ID 0047) to the 24V SW stud (BT-T4C) on the circuit breaker busbar, MCI P/N: 7L-8-5055, using lock washer, MCI P/N:19-2-37, and nut, MCI P/N: 19-3-32. Torque stud to 65 IN-LBS. Spray 3 studs with anti-corrosive spray, MCI P/N: 23-02-0119. 40. Attached reworked equalizer cables to fuse holder BT-125/BT-126. Ensure a smooth curve from the equalizer to the fuse holders. Torque studs to 40 IN-LBS. Connect to BT-T4B stud. Connect to BT-T4C stud. Apply corrosion inhibitor spray Attach 12/24V EQ cables to CB assembly MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 15 of 18 October 18, 2021 41. From the kit, locate the VEC fuse holder cover, MCI P/N: 07-08-5651, bracket, MCI P/N: 07-08-5652, and assemble them as shown below. 42. Attach 3 VEC fuse holder cap brackets, MCI P/N: 07-08-5652, using 6 screws, MCI P/N:19-1-386, 6 lock washer, MCI P/N:19-2-37, and 6 flat washers, MCI P/N:19-2-23. 43. Add 20A/30A/15A fuses according to the fuse layout decal, MCI P/N: 929387, to the fuse holder jumper harness, MCI P/N: 929287. Connect the fuse holder jumper harness to the bracket assembly. 44. Use tyraps, MCI P/N: 5958112, to secures fuse cables to the harness bundle behind the batteries. VEC fuse holder bracket VEC fuse holder cover Mount 3 fuse holder covers to wall bracket Use tyraps to secure cable bundles MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 16 of 18 October 18, 2021 45. Use tyraps, MCI P/N: 5958112, to secure cables behind the batteries circuit breaker assembly. 46. Remove a piece of the trim lock from MDS and install it at the bottom left corner of the circuit breaker assembly. 47. Reconnect the battery cables, torque nuts to 54-60 IN-LBS. Turn on MDS and turn on coach ignition to verify rework. Use tyraps to secure cable bundles Install trim lock to the bottom left corner of the CB assembly Reinstall battery terminals MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 17 of 18 October 18, 2021 LABOUR ESTIMATE Operation Number of Technician(s) Hours Labor Time T X HR 1 MDP replacement with circuit breaker assembly 1 7.5 7.5 PARTS REQUIRED Item Part Number Description Qty. per Coach Units Notes 1 117202 HEATSHRINK – 3/4IN, BLUE 1 AR 2 6485136 NUT, RIVET 5/16″ – 18 UNC OPEN END ZINC PLATED 3 EA 3 07-08-1059 FUSE – MINI, 15A 1 EA 4 07-08-1061 FUSE – MINI, 20A 5 EA 5 07-08-1429 FUSE – MINI, 30A 2 EA 6 07-08-3954 FUSE – MINI 25A 2 EA 7 07-08-5651 VEC FUSE HOLDER COVER 3 EA 8 07-08-5652 VEC FUSE HOLDER BRACKET 3 EA 9 07-09-3366 SWITCH ASSY-MAIN DISCONNECT & BREAKERS 1 EA 10 07-10-2254 ASSY-BRKT, 4 FUSE HOLDER 1 EA 11 19-11-2371 HEATSHRINK – 3/4IN, RED 1 EA 12 19-11-3472 TIE CABLE – WITH MOUNT 2 EA 13 19-11-3763 #10 RING TERMINAL 2 EA 14 19-11-431 CONNECTOR-SPLICE, BUTT,12 10 AWG 11 EA 15 19-11-67 HEATSHRINK – DUAL WALL, 3/4IN, BLK 1 EA 16 19-13-137 RIVET-.187 3 EA 17 19-1-386 SCREW-CAP, HEX,1/4-20UNC X 1/2 SST 18-8 6 EA 18 19-2-23 WASHER-FLAT,1/4 ID, SST 6 EA 19 19-2-37 WASHER – LOCK, SST, 1/4 ID 8 EA 20 19-3-32 NUT-1/4-20, SST 2 EA 21 5958112 TYRAP-7.31” LONG 15 EA 22 19-11-1465 HEAT SHRINK- 4FT, BLACK 2 FT 23 7L-8-5055 BAR ASSY-BUS 1 EA 24 929386 PLATE – ADAPTER CIRCUIT BREAKER BT COMP J45 1 EA 25 929287 HARNESS – FUSE HOLDER JUMPER 1 EA 26 929387 DECAL – FUSE LAYOUT BATT COMPT J45 1 EA 27 07-10-2283 DECAL-CIRCUIT BREAKER PANEL, D45 CRT 1 EA MDP Replacement with Circuit Breaker Assembly ITS60272 ITS60272 Page 18 of 18 October 18, 2021 SPECIAL TOOLS REQUIRED Item Part Number Description Qty. Units Notes 1 IMP9166-1 Ultra Grey RTV Silicone 1 EA 2 23-02-0119 CRC SP-400 Corrosive Inhibitor 1 EA 3 21-7212-18 Adhesive – Loctite 242, Thread Locking 1 EA 4 5023844 TORQUE SEAL, ORANGE,5 OZ. 1 EA 5 NA Step-Up Drill Bit 1 EA 6 NA 35/64” Drill Stop 1 EA 7 NA Rivet Nut Gun 1 EA 8 NA 13/64” Drill Bit 1 EA 9 NA Heat Gun 1 EA 10 NA IN-LBS Torque Wrench 1 EA 11 NA FT-LBS Torque Wrench 1 EA 12 NA Heavy Duty Terminal Crimp tool 1 EA CABLE REPLACEMENT PART NUMBERS MDP Circuit Breakers SOURCE TARGET CABLE DESCRIPTION SOURCE TARGET CABLE J1 BT-T4 07-09-1799 24V SW – – – J2 BT-T3B 07-09-1800 24V HOT – – – J3 BT-T1B 07-09-1802 12V HOT – – – J4 BT-T2 07-09-1801 12V SW – – – J25 BT-T5 07-09-1812 12 SW EQ BT-T125 BT-T5 07-09-3352 J26 BT-T6 07-09-1811 24 SW EQ BT-T126 BT-T6 07-09-3351 J27 – 07-08-2627 BATT CHARGER BT-T516 – 07-10-2198 J27 INV 24V 07-09-1815 24 HOT INV BT-T516A INV 24V 07-09-3354 J36 EVAP-J2 07-09-1814 EVAP 24V SW BT-T513 EVAP-J2 07-09-3353 J38 RJDP-J3 07-09-1803 RJB 24V SW BT-T512 RJDP-J3 07-09-3342 J39 FJDP-J3 07-09-1805 FJB 24V SW BT-T511 FJDP-J3 07-09-3344 J40 RJDP-J4 07-09-1807 RJB 24V HOT BT-T515 RJDP-J4 07-09-3346 J41 FJDP-J4 07-09-1809 FJB 24V HOT BT-T514 FJDP-J4 07-09-3348 J42 RJDP-J1 07-09-1804 RJB 12V SW BT-T518 RJDP-J1 07-09-3343 J43 FJDP-J1 07-09-1806 FJB 12V SW BT-T517 FJDP-J1 07-09-3345 J44 RJDP-J2 07-09-1808 RJB 12V HOT BT-T520 RJDP-J2 07-09-3349 J45 FJDP-J2 07-09-1810 FJB 12V HOT BT-T519 FJDP-J2 07-09-3347 BT-T4 EC-STUD24 07-09-2208 MAIN FEEDER BT-T4 EC-STUD24 07-09-2208 BATT 12V BT-T1A 07-18-1819 BATT 12V HOT BATT 12V BT-T1A 07-18-1819 BATT 24V BT-T3A 07-18-1818 BATT 24V HOT BATT 24V BT-T3A 07-18-1818 BATTGND BT-T8A 07-09-1820 BATT GND BATT GND BT-T8A 07-09-1820

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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 ITS60283 November 3, 2021 SECTION: 294-Power Cables WRITTEN BY: Hugo Freire SUBJECT: MCI D-Legacy MDP Replacement with Fuse Holders ISSUE: 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. SUMMARY: Due to the Main Distribution Panel failures resulting from supplier quality and environmental issues, it is recommended the MDP be replaced with a fuse holders. ITS60283 Ref. NHTSA Recall No. Ref. Transport Canada Recall No. 21V-748 2021-595 D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 2 of 30 November 3, 2021 PROCEDURE: 1. Set park brake and chock wheels. 2. Turn the main battery disconnect switch to the “OFF” position. 3. Disconnect all the studs from the battery and take the batteries off the tray and save them for later use. 4. Remove and discard the two thumbscrews from the MDP cover. 5. Remove and discard 4 screws holding the MDP cut-out part to the MDP cover. Remove the thumb screws Remove and discard the screws D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 3 of 30 November 3, 2021 6. Disconnect the two connectors, BT-P162 and BT-P161, from the main distribution panel. 7. Slide out and discard the battery compartment cover out of the bracket. 8. Disconnect all the cables connected to the studs on the MDP and pull them out of the bracket. Discard the nuts and washers.  NOTE: Labeling cable MDP stud locations will make it easier to connect cables to the fuse holders. Slide the cover out Remove the cables Disconnect the wires D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 4 of 30 November 3, 2021 9. Remove & discard the four bolts on the bracket and discard the bracket. 10. Remove and discard the 8 screws holding the MDP to the divider panel. Retain the MDP for the next step. 11. Remove all 50A fuses from the MDP and install two each on the three 2AMI fuse holders, MCI P/N: T07-3274, as shown below, and torque the nuts to 13 In-Lbs. Remove and discard the bolts Remove and discard the screws D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 5 of 30 November 3, 2021 12. Remove all 80A fuses from the MDP and install them on the 4AMI fuse holder, MCI P/N: T07-3723, at the locations shown below. Torque the nuts to 13 In-Lbs.  NOTE: Install a 200A fuse, MCI P/N: 19-11-4046, on the third fuse holder position, BT-PDM4-F3, for coaches with evaporator AMI fuse holders in the HVAC compartment. 13. Remove two 100A and 150A fuses (if an inverter is installed, MCI P/N: 19-11-4011) from the MDP and install the fuses on the fuse blocks, MCI P/N: T07-3726. Torque the nuts to 39.8 In-Lbs. 14. Using 1/4-20 bolts, MCI P/N: 19-1-387, 1/4” washers, MCI P/N: 19-2-23, install two 2AMI fuse holders, MCI P/N: T07-3724, to the fuse block mounting bracket, MCI P/N: 935529. Torque the bolts to 75 In-Lbs. 1/4” bolt Washer 2AMI fuse holder D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 6 of 30 November 3, 2021 15. Install the 3 populated fuse blocks, MCI P/N: T07-3726, as shown below using #8-32 bolt, MCI P/N: 6460364. Torque the bolts to 24 In-Lbs.  NOTE: Install the fuse block with the 150A inverter fuse in the 1st position on the left. 16. Install 9 tie bases, MCI P/N: 19-11-3472, at the locations shown below. 17. Using 1/4-20 bolts, MCI P/N: 19-1-387, 1/4” washers, MCI P/N: 19-2-23, install one 2AMI fuse holder, MCI P/N: T07-3724, and one 4AMI fuse holder, MCI P/N: T07-3723, to the fuse block mounting bracket, MCI P/N: T07-3720. Torque the bolts to 75 In-Lbs. #8-32 bolt Tie bases MCI P/N: 19-11-3472 1/4” bolt Washer Fuse holder Fuse block Inverter fuse block D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 7 of 30 November 3, 2021 18. Install 8 tie bases, MCI P/N: 19-11-3472, at the locations shown below. 19. Reworking power cables involve the following steps: 20. Apply colored heat shrink on top of the black heat shrink if the existing colored heat shrink was removed during the rework of the cable. Red heat shrink, MCI P/N: 19-11-2371, blue heat shrink, MCI P/N: 21-7406-50. 21. Carry out the above-mentioned steps on the following cables with respective ring terminals: Cable P/N MDP Location Ring terminal P/N Description Heat Shrink Color 07-09-1822 J2 19-11-3999 Term-ring, non-insulated, 5/16in,1/0 AWG Red 07-09-1823 J4 19-11-2328 Term – ring, non-insulated, 5/16in, 2 AWG Blue 07-09-1824 J3 19-11-41 Term-ring, non-insulated,5/16in, 4 AWG Blue 07-09-1862 J42 19-11-41 Term-ring, non-insulated,5/16in, 4 AWG Blue 07-09-1863 J43 19-11-41 Term-ring, non-insulated,5/16in, 4 AWG Blue 07-09-1864 J44 5944917 Term-ring, non-insulated,5/16in, 6 AWG Blue 07-09-1865 J45 5944917 Term-ring, non-insulated,5/16in, 6 AWG Blue Cut Strip Apply adhesive black 3/4:” dia heat shrink, MCI P/N: 19-11-67 Crimp and solder Install tie bases D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 8 of 30 November 3, 2021 22. Identify the 12V equalizer cable, MCI P/N: 07-09-2012, and cut the cable 7” from the center of the ring terminal. 23. Identify the 24V equalizer cable, MCI P/N: 07-09-2011, and cut the cable 3” from the center of the ring terminal. 24. Perform the following steps on the 12V equalizer and 24V equalizer cables: 25. Apply colored heat shrink on top of the black heat shrink if the existing colored heat shrink is removed during the rework of the cable. Cable P/N MDP Location Ring terminal P/N Description Heat Shrink Color 07-09-2011 J26 19-11-3763 Term -ring, non-insulated, #10,4 AWG Red 07-09-2012 J25 19-11-3763 Term -ring, non-insulated, #10,4 AWG Blue 26. If the coach is equipped with an inverter, remove and replace the inverter power cable ring terminal, MCI P/N:19-11-4539, and add red heat shrink, MCI P/N: 19-11-2371. Cut the cable 7” from the center of ring terminal Cut the cable 3” from the center of ring terminal Apply black 3/4:” dia heat shrink MCI P/N: 19-11-67 Crimp and solder Strip Apply black 3/4:” dia heat shrink MCI P/N: 19-11-67 Crimp and solder Strip D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 9 of 30 November 3, 2021 27. Identify the wires CT0002 and CT0012 in the battery compartment. Cut and discard the ring terminal and apply 2.3” black heat shrink, MCI P/N: 19-11-1465, to the wires. 28. Identify CT 0011, ISX ECM, wire in the battery compartment. Cut and discard the ring terminal. 29. Perform the following steps on the ISX ECM wire, CT 0011, using 12 AWG 1/4″ ring terminal, MCI P/N: 19-11-46, 10-12 AWG butt splice connector, MCI P/N: 19-11-431, HHG inline fuse holder, MCI P/N: T19-1168, and 2.3” black heat shrink, MCI P/N: 19-11-1465. Cut the ring terminal and apply black heat shrink MCI P/N: 19-11-1465 Crimp Crimp, solder and heat shrink Crimp and solder Strip Black adhesive heat shrink Ring terminal HHG inline fuse holder D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 10 of 30 November 3, 2021 30. Remove 30A fuse from the MDP and install it in the HHG inline fuse. 31. If farebox is installed, perform the steps 31-33, otherwise skip to step 34. Identify wire 9502 in the battery compartment, previously connected to J29 of the MDP, and cut the ring terminal. 32. Rework farebox wire 9502, using ring terminal, MCI P/N: 19-11-46, butt splice connector, MCI P/N: T19-1166, HHG inline fuse holder, MCI P/N: T19-1168, and 2.3” black heat shrink, MCI P/N: 19-11-1465. Wire 9502, old destination: MDP-J29 Crimp Crimp, solder and heat shrink Crimp and solder Strip Black adhesive Heat shrink Ring terminal HHG inline fuse holder D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 11 of 30 November 3, 2021 33. Remove 30A fuse from the MDP and install it in the HHG inline fuse. 34. Identify the MDP 12V BT-P161 connector in the battery compartment. Cut and discard the connector and apply 2.3” black heat shrink, MCI P/N: 19-11-1465, to all spare wire PWR SPARE 9 through PWR SPARE 20. 35. Identify the MDP 24V PWR BT-P162 connector in the battery compartment. Cut and discard the connector and apply 2.3” black heat shrink, MCI P/N: 19-11-1465, to CT0057C, CT0057D, PWR SPARE 2 through PWR SPARE 8 wires. Cut the BT-P162 connector & Tie back wires Cut the BT-P161 connector & Tie back spare wires D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 12 of 30 November 3, 2021 36. Identify CT170 wire in the BT-162 center tunnel harness. 37. Perform the following steps on the TCM wire, CT 170, using ring terminal, MCI P/N: 19-11-46, butt splice connector, MCI P/N: T19-1166, HHG inline fuse holder, MCI P/N: T19-1168, and 2.3” black heat shrink, MCI P/N: 19-11-1465. 38. Remove 15A fuse from the MDP and install it in the HHG inline fuse. Crimp Crimp, solder and heat shrink Crimp and solder Strip Black adhesive heat shrink Ring terminal HHG inline fuse holder D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 13 of 30 November 3, 2021 39. Connect HVAC condenser wires of the coach, part of BT-P162, to jumper harness, MCI P/N: T07-3722, using 12-14 AWG butt splice connector, MCI P/N: T19-1167, 2.3” black heat shrink, MCI P/N: 19-11-1465, and performing following steps: 40. Install four 20A mini fuses in the BT-FB connector, part of the jumper harness, MCI P/N: T07-3722. 41. Connect 12V Hot jumper harness, MCI P/N: 933856, to CNG power wires using 12-14 AWG butt splice connector, MCI P/N: T19-1167, 2.3” black heat shrink, MCI P/N: 19-11-1465. Also, install 20A and a 30A fuse on the BT-FB3 connector as shown below. CT harness, BT-P161 12-14 AWG Butt splice connector MCI P/N: T19-1167 Jumper harness, T07-3722 Crimp butt splice Crimp and solder Strip wire on the coach Black adhesive heat shrink D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 14 of 30 November 3, 2021 42. Push all the power cables away from the divider panel and place a 16”x24” plywood in the battery compartment between all the cables and the divider panel. 43. Using a chisel remove the weld nuts and tie bases on the divider panel. 44. Place the plate, MCI P/N: T03-3050, on the divider panel such that the holes shown below align with the divider panel. Align these holes of plate with holes on divider panel 16”x24” plywood D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 15 of 30 November 3, 2021 45. Secure the plate to the divider panel at the four holes shown in the previous picture using 5/16-18 bolt, MCI P/N: T19-1164, 5/16 washer, MCI P/N: T19-1162, and 5/16-18 nut, MCI P/N: 19-3-314. Torque the bolt to 132 In-Lbs. 46. Match drill the holes shown below in the divider panel using a 5/16 drill bit. Divider panel Plate 5/16-18 bolt Washer Match drill the holes using 5/16 drill bit 5/16-18 nut D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 16 of 30 November 3, 2021 47. Secure the plate to the divider panel at the below-shown holes using 5/16-18 bolt, MCI P/N: T19-1164, 5/16 washer, MCI P/N: T19-1162, and 5/16-18 nut, MCI P/N: 19-3-314. Torque the bolt to 132 In-Lbs. 48. Match drill the holes shown below in the divider panel using a 13/64 drill bit. Match drill the holes using 13/64 drill bit Install 5/16-18 bolt, washer, nut Divider panel 5/16-18 bolt Washer 5/16-18 nut D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 17 of 30 November 3, 2021 49. Match drill the holes shown below in the divider panel using a 25/64 drill bit. 50. Match drill the remaining 13 holes in the divider panel using a 1/4 drill bit. 51. Match drill the below-shown holes in the divider panel using a 1-5/8” hole saw. Match drill the holes using 25/64 drill bit Match drill the holes using 1-5/8” hole saw Match drill the holes using 1/4 drill bit D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 18 of 30 November 3, 2021 52. Install 10-24 bolt, MCI P/N: T19-1160, washer, MCI P/N: 19-02-6047, and nut, MCI P/N: T19-1159, in the two 13/64 holes. Torque the bolt to 23 In-Lbs. 53. Install two 1/4-20 rivnuts, MCI P/N: T19-1161, in the 25/64 holes shown below. 54. Install grommets, MCI P/N: T19-1165, in the big holes of the plate. 10-24 bolt Washer ¼-20 rivnut Install grommets MCI P/N: T19-1165 10-24 nut D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 19 of 30 November 3, 2021 55. Identify the switch power cables by following the table below and separate them from the rest of the cables and route them into the filter side compartment through the respective grommet. Cable P/N Old Destination Heat Shrink Color Grommet 07-09-1866 MDP-J36 Red Top 07-09-1871 MDP-J37 Red Top 07-09-1858 MDP-J38 Red Middle 07-09-1859 MDP-J39 Red Middle 07-09-1821 MDP-J1 Red Middle 07-09-1823 MDP-J4 Blue Bottom 07-09-1863 MDP-J43 Blue Bottom 07-09-1862 MDP-J42 Blue Bottom 56. Install the air filter side fuse block assembly in the position shown below using 1/4-20 nut, MCI P/N: 19-3-32, 1/4-20 bolt, MCI P/N: 19-1-387, 1/4″ washer, MCI P/N: 19-2-23. Torque the nuts to 75 In-Lbs. 57. Install battery side fuse holder bracket in the battery compartment using 1/4-20 nut, MCI P/N: 19-3-32, 1/4-20 bolt, MCI P/N: 19-1-387, 1/4” washer, MCI P/N: 19-2-23. Torque the nuts to 75 In-Lbs. Fuse holder bracket 1/4-20 bolt Washer Fuse holder bracket 1/4-20 bolt Washer D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 20 of 30 November 3, 2021 58. Install 4 tie bases, MCI P/N: 19-11-3472, in the holes below the bracket. 59. Connect the free ends of the 07-09-1823, 07-09-1863, and 07-09-1862 cables to the small fuse block on the AC filter side as shown below. 60. Connect the free ends of the 07-09-1871, 07-09-1866, 07-09-1821, 07-09-1858, and 07-09-1859 cables to the big small fuse holder studs from the top respectively on the big fuse block behind the divider panel. 07-09-1823, old destination: MDP-J4 07-09-1863, old destination: MDP-J43 07-09-1862, old destination: MDP-J42 07-09-1821, old destination: MDP-J1 07-09-1859, old destination: MDP-J39 07-09-1858, old destination: MDP-J38 07-09-1871, old destination: MDP-J37 07-09-1866, old destination: MDP-J36 19-11-3472 Tie bases Torque all the nuts to 50 In-Lbs. Torque all the nuts to 50 In-Lbs. D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 21 of 30 November 3, 2021 61. Using the zip ties, part of the tie bases, MCI P/N: 19-11-3472, tie the cables to the mount bases. 62. Spray the corrosion inhibitor, CRC SP400 or similar, on all the studs and close the caps of the fuse blocks. 63. In the battery compartment side tie all the five 24V SW cables using tryraps, MCI P/N: 19-11-3472, and three 12V SW cables using a tyraps. 64. Tie the 24V SW cables and 12V cables together using a double loop zip tie, P/N: 19-11-3078. Double loop zip tie, 19-11-3078 D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 22 of 30 November 3, 2021 65. Identify the below-mentioned cables and separate them from the rest: Cable P/N Old destination Heat Shrink color 07-09-1824 MDP-J3 Blue 07-09-1865 MDP-J45 Blue 07-09-1864 MDP-J44 Blue 07-09-1822 MDP-J2 Red 07-09-1861 MDP-J41 Red 07-09-1860 MDP-J40 Red 66. Install the free ends of the 07-09-1865, 07-09-1864, and 07-09-1824 cables to the innermost fuse block in the battery compartment as shown below. 67. Install the free ends of the 07-09-1861, 07-09-1860, and 07-09-1822 cables to the outer fuse block in the battery compartment as shown below. 07-09-1865, old destination: MDP-J45 07-09-1864, old destination: MDP-J44 07-09-1824, old destination: MDP-J3 07-09-1861, old destination: MDP-J41 07-09-1860, old destination: MDP-J40 07-09-1822, old destination: MDP-J2 Torque all the nuts to 50 In-Lbs. Torque all the nuts to 50 In-Lbs. D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 23 of 30 November 3, 2021 68. Spray corrosion inhibitor, CRC SP400 or similar, on the fuse block and close the lid. 69. Tie the cables to the existing tie mounts using zip ties. 70. Tie the three 12V cables using a zip tie to the tie base. 71. Tie the three 24V cables using a zip tie to the tie base. 72. Pull all the cables up and tie the 12V hot and 24V hot cables using a double-loop zip tie, MCI P/N:19-11-3078. Try to keep the cables as high as possible from the battery tray. 73. Tie the SW cables and HOT cables using a double-loop zip tie. 74. Install free end of the 24V equalizer cable, MCI P/N:07-09-2011, to the top stud of the center LMI fuse block and torque the nut to 39.8 In-Lbs. 07-09-2011, old destination: MDP-J26 Double loop zip tie D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 24 of 30 November 3, 2021 75. Install free end of the 12V equalizer cable, MCI P/N: 07-09-2012, to the top stud of the outer LMI fuse block and torque the nut to 39.8 In-Lbs. 76. Route the equalizer cables, MCI P/N: T07-3721, and connect them to the equalizer fuse holders and MDS switch side as shown below. 77. Torque the nuts on the equalizer fuse block to 39.8 In-Lbs and nuts on the MDS to 300 In-Lbs. 78. Connect the reworked inverter cable to the top stud of the left fuse block and torque the nut to 39.8 In-Lbs. 07-09-2012, old destination: MDP-J25 12V equalizer cable of T07-3721 24V equalizer cable of T07-3721 07-09-1839, old destination: MDP-J27 D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 25 of 30 November 3, 2021 79. Connect the MDS 24V HOT to inverter cable, MCI P/N: 920456, to the bottom stud of the left LMI fuse block and torque the nut to 39.8 In-Lbs. Connect the other end to 24V Hot MDS stud. 80. Tie the equalizer and inverter cables to the tie bases using zip ties. 81. Tie the 12V and 24V equalizer cables using a double loop zip tie, MCI P/N: 19-11-3078. Double loop zip tie Zip tie Install cable 920456 D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 26 of 30 November 3, 2021 82. Tie the equalizer harness, ground together using zip ties, and route it as shown below. 83. Install the guard, MCI P/N: T07-3725, as shown below using two 10-24 nuts, MCI P/N: T19-1159, and torque to 23 In-Lbs. 84. Apply torque seal to all the newly installed nuts and bolts. Guard 10-24 nut Equalizer harness and ground Apply torque seal D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 27 of 30 November 3, 2021 85. From the kit, locate the 2 VEC fuse holder covers, MCI P/N: 07-08-5651, 2 brackets, MCI P/N: 07-08-5652, and assemble them as shown below. 86. Position brackets, MCI P/N: 07-08-5652, in the top right of the battery compartment. Drill four 0.391” holes using the brackets as templates. Install ¼” rivet nut, MCI P/N: 19-13-156, on the drilled holes. Secure the bracket using ¼” screw, MCI P/N: 19-1-386, and washer, MCI P/N: 19-2-23. 87. Secure the connector from the jumper harness to the VEC fuse holder cover. 88. Using washer, MCI P/N:19-2-23, and nut, MCI P/N: 19-3-32, connect the ring terminals of the HVAC jumper harness to the 24V switch busbar, on the MDS as shown below. Torque stud to 65 IN-LBS. VEC fuse holder bracket VEC fuse holder cover Install rivet nuts to mount cap assemblies. Connect ring terminal of the HVAC jumper D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 28 of 30 November 3, 2021 89. Using washer, MCI P/N:19-2-23, and nut, MCI P/N: 19-3-32, Connect the ring terminal of the TCM (wire CT170) inline fuse to the 24V switch busbar on the MDS as shown below and Torque stud to 65 IN-LBS. 90. Using washer, MCI P/N:19-2-23, and nut, MCI P/N: 19-3-32, connect the ring terminals of the ECM (wire CT 0011) and farebox (wire 9502) to the 24V Hot busbar, MCI P/N: 7L-8-5055, on the MDS as shown below. Torque stud to 65 IN-LBS. 91. Clean the battery compartment and allow 5min flash off time after applying isopropyl alcohol. Install the decal, MCI P/N: 920762, on the battery compartment door.  NOTE: If a coach has evaporator AMI fuse holders in the HVAC compartment, install decal 933516 instead of decal 920762. Connect ring terminal of wire 0011 Decal 920762 Connect ring terminal of wire 170 D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 29 of 30 November 3, 2021 92. Clean the battery compartment for all dirt and debris. Install the steam-washed battery tray using the existing hardware. 93. Put the batteries back on the battery tray and install the cables as shown below. 94. Completed battery compartment rework for reference. GND cable 24V cable 12V cable Install the tray using the bolts, lock washers, flat washers. D Legacy MDP Replacement with Fuse Holders ITS60283 ITS60283 Page 30 of 30 November 3, 2021 LABOUR ESTIMATE Operation Number of Technician(s) Hours Labor Time T X HR 1 MDP Replacement with Fuse Holders 1 11 11 PARTS REQUIRED Item Part Number Description Qty. per Coach Units Notes 1 6490291 KIT – D-LEGACY MDP REPLACEMENT 1 EA SPECIAL TOOLS REQUIRED Item Part Number Description Qty. Units Notes 1 NA Flat air chisel with 1” wide bit 1 EA 2 23-02-0119 CRC SP-400 Corrosive Inhibitor 1 EA 3 5023844 TORQUE SEAL, ORANGE,5 OZ. 1 EA 4 NA Metal hole saw 1-5/8” 1 EA 5 NA Wire Crimp tool 1 EA 6 NA Heavy Duty Terminal Crimp tool 1 EA 7 NA Rivet Nut Gun 1 EA 8 NA Various Drill Bit Sizes 1 EA 9 NA Heat Gun 1 EA 10 NA IN-LBS Torque Wrench 1 EA 11 NA FT-LBS Torque Wrench 1 EA

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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 ITS60298 October 22, 2021 SECTION: 292-Electrical Harnesses WRITTEN BY: Hugo Freire SUBJECT: MCI D45CRT/D4520 Coach MDP Replacement with Circuit Breaker Assembly ISSUE: 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. SUMMARY: Due to the Main Distribution Panel failures resulting from supplier quality and environmental issues, it is recommended the MDP be replaced with a circuit breaker assembly. ITS60298 Ref. NHTSA Recall No. Ref. Transport Canada Recall No. 21V-748 2021-595 MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 2 of 19 October 22, 2021 PROCEDURE: 1. Set park brake and chock wheels. 2. Turn the Main Battery Disconnect Switch to the “OFF” position. 3. 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. 4. Locate the MDP compartment mounted on the rear wall in the battery compartment. Remove and discard the 4 thumb screws to release the MDP cover. Remove and discard thumb screws. Turn off MDS. Disconnect all battery cables. MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 3 of 19 October 22, 2021 5. Remove 5 tyraps located at the bottom of the plastic MDP cover to remove the cover. 6. Remove tyraps that secure BT-P162 to the Main Disconnect Switch cables. 7. Disconnect connectors BT-P161 and BT-P162 from MDP. Remove 5 tyraps & remove cover. Remove BT-P162 tyraps on battery cables. Disconnect BT-P161 and BT-P162. MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 4 of 19 October 22, 2021 8. 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. 9. Remove & discard 8 MDP mounting screws and washers to remove the MDP from the coach. 10. Remove & discard the hex bolts used to seal the cables on the top and bottom of the MDP enclosure. Remove all cables from MDP. Remove mounting screws. Remove cable seal bolts MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 5 of 19 October 22, 2021 11. Remove & save Main Disconnect Switch mounting bolts. Disconnect battery cables from MDS and feed-through stud, saving hardware. Remove and save trim lock from the MDS. 12. Remove & save the MDP box mounting bolts. Discard MDP box with cables connected to studs J1-J4. 13. Remove the 3 tyrap mounts from the left battery compartment wall. Remove 3 tyrap mounts. Remove & save mounting bolts. Remove & save mounting bolts. MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 6 of 19 October 22, 2021 14. Using a step-up drill bit and the table below, carefully increase the stud size on 9 ring terminals removed for the MDP from ¼ to 5/16”. 15. Cut the wires from BT-P162 and BT-P161 12 inches from the connector. 16. Tie back all spare wires from BT-P161 and BT-P162 using heat shrink, MCI P/N: 19-11-1465. Also, tie back Alt 55SI sense wire CT 0012D. Source (MDP) Source Wire ID Description J36 07-09-1814 EVAP 24V SW J38 07-09-2013 RJB 24V SW J39 07-09-2015 FJB 24V SW J40 07-09-2017 RJB 24V HOT J41 07-09-2019 FJB 24V HOT J42 07-09-2014 RJB 12V SW J43 07-09-2016 FJB 12V SW J44 07-09-2018 RJB 12V HOT J45 07-09-2020 FJB 12V HOT Enlarge hole. Cut Wire 12” from connector Tie back 20 unused wires MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 7 of 19 October 22, 2021 17. Using butt splices, MCI P/N: 19-11-431, and black heat shrink, MCI P/N: 19-11-1465, attach the ECM, Spheros, and booster pump power wires to BT-FBA part of fuse holder jumper, MCI P/N: 933736, as shown below.  NOTE: PRVEST1 is an optional wire part of harness 07-12-9149, splice into cavity H if present, otherwise tieback. 18. Using butt splices, MCI P/N: 19-11-431, and black heat shrink, MCI P/N: 19-11-1465, attach the HVAC condenser wires to BT-FBB part of fuse holder jumper, MCI P/N: 933736, as shown below. 19. Using butt splices, MCI P/N: 19-11-431, and black heat shrink, MCI P/N: 19-11-1465, attach the MCM, TCM, and line heater power wires to BT-FBC part of fuse holder jumper, MCI P/N: 933736, as shown below.  NOTE: If PR VEST 24V SW wire is present splice into cavity D of jumper, otherwise splice in wire 0034 Splice into fuse block A, BT-FBA Splice into fuse block B, BT-FBB Splice into fuse block C, BT-FBC MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 8 of 19 October 22, 2021 20. Cut 18.5” from 12 SW EQ cable, MCI P/N: 07-09-1812. Place a 2” piece of adhesive heat shrink, MCI P/N: 19-11-67, and 2” blue heat shrink, MCI P/N: 117202, and crimp ring terminal, MCI P/N: 19-11-3763 to the cable. Use a heat gun on heat shrink, the blue heat shrink should be on top. 21. Cut 16.5” from 24 SW EQ cable, MCI P/N: 07-09-1811. Place a 2” piece of red heat shrink, MCI P/N: 19-11-2371, and crimp ring terminal, MCI P/N: 19-11-3763 to the cable. Use a heat gun on adhesive heat shrink. 22. Add #10 ring terminal, MCI P/N: 19-11-3417, to ramp power wire RMP 0041 previously on J53 of the MDP. 23. Loosely mount the adapter plate, MCI P/N: 935087, on the left wall using the 3 saved cap screws, MCI P/N: 19-01-1532, at the highlighted locations. Mark the 5 mounting locations for the CB assembly. Add new ring terminal. Add new ring terminal. Loosely mount CB adapter plate using saved capscrews Mark new hole locations MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 9 of 19 October 22, 2021 24. Remove adapter plate, MCI P/N: 935087. Using a drill stop, drill three 35/64” holes at the marked circuit breaker assembly locations. Pay close attention to not to puncture the fuel tank on the other side of the wall.  NOTE: Ensure extreme caution while drilling on the left battery compartment wall to avoid puncturing the fuel tank on the other side of the wall. 25. Cover 10 unused holes on the left battery compartment wall with RTV silicone. 26. Place a ¼” bead of RTV silicone around 1” inside edge of the back side of the adapter plate, MCI P/N: 935087, before mounting. Drill 3 35/64” holes on the marked hole locations. Cover unused holes with RTV silicone Place a ¼” bead of RTV silicone around edges of plate. MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 10 of 19 October 22, 2021 27. Mount adapter plate, MCI P/N: 935087. Install 5 rivet nuts, MCI P/N: 6485136, to the newly drilled holes. 28. Remove MDP decal from the back wall. Use the fuse holder bracket assembly, MCI P/N: 07-10-2254, as a template to mark 3 mounting holes 10.5” from the top of the Evap filter door and 1” from the HVAC duct. 29. Use a 13/64” drill bit to drill the 3 marked holes. Mount the FH bracket assembly using 3 rivets, MCI P/N: 19-13-137. 30. Install fuse holder decal, MCI P/N: 934008, and CB panel decal, MCI P/N: 07-10-2283 above the fuse holder bracket. Attach 5 rivet nuts to mount adapter plate Mark 3 holes to mount the fuse holder bracket Install 3 rivets to mount fuse holder bracket 1” 10.5” MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 11 of 19 October 22, 2021 31. Install cables and fuse holder jumper ring terminals, MCI P/N: 933736, to the CB assembly. Add adhesive Loctite, MCI P/N: 21-7212-18, to threads before tightening. Torque studs using the reference connection chart below. Source Source Wire ID Description Target Description Torque Rating J25 07-09-1812 12 SW EQ BT-T125 BT-F25 36-40 IN-LBS J26 07-09-1811 24 SW EQ BT-T126 BT-F26 36-40 IN-LBS J27 07-09-1815 24 HOT INV (OPTION) BT-T516 CB6 70-75 IN-LBS J27 07-08-2627 BATT CHARGER BT-T516A CB6 70-75 IN-LBS J27 – AMEREX (INLINE Fuse) BT-T516 CB6 70-75 IN-LBS J36 07-09-1814 EVAP 24V SW BT-T513 CB3 70-75 IN-LBS J38 07-09-2013 RJB 24V SW BT-T512 CB2 70-75 IN-LBS J39 07-09-2015 FJB 24V SW BT-T511 CB1 70-75 IN-LBS J40 07-09-2017 RJB 24V HOT BT-T515 CB5 70-75 IN-LBS J41 07-09-2019 FJB 24V HOT BT-T514 CB4 70-75 IN-LBS J42 07-09-2014 RJB 12V SW BT-T518 CB8 70-75 IN-LBS J43 07-09-2016 FJB 12V SW BT-T517 CB7 70-75 IN-LBS J44 07-09-2018 RJB 12V HOT BT-T520 CB10 70-75 IN-LBS J45 07-09-2020 FJB 12V HOT BT-T519 CB9 70-75 IN-LBS J53 RMP 0041 LE RAMP PWR BT-T33 BT-F33 36-40 IN-LBS – 0045 FUSE BLOCK A BT-T3B 24V HOT MDS 150 IN-LBS – 0050 FUSE BLOCK B BT-T4B EC PWR BUSBAR 65 IN-LBS – 0047 FUSE BLOCK C BT-T4C EC PWR BUSBAR 150 IN-LBS – 07-09-1819 12V BATTERY BT-T1C 12V HOT MDS 150 IN-LBS – 07-09-1818 24V BATTERY BT-T3A 24V HOT MDS 150 IN-LBS BT-T4 07-09-1600 EC PWR STUD BT-T4 EC PWR STUD 300 IN-LBS MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 12 of 19 October 22, 2021 32. Install 30A fuse block, MCI P/N: 07-10-2419, on the front right section of the CB using existing CB assembly hardware. Connect the WCL power cable, MCI P/N: 07-09-3396, to the 24V SW MDS stud and BT-F33 on the top of the 30A fuse block. 33. Using tyraps included in the switch assembly, secure cables connected to the MDS and circuit breakers. Ensure smooth curves and routing on all cables. 34. Apply torque seal, MCI P/N: 5023844, to each stud after being torqued. Use tyraps to secure cables Apply torque seal on CB nuts Mount 30A fuse block Install cable 07-09-3396 MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 13 of 19 October 22, 2021 35. Spray back of circuit breaker assembly (bus bars and studs), MCI P/N: 07-09-3366, with anti-corrosive spray, MCI P/N: 23-02-0119. 36. Mount the circuit breaker assembly, MCI P/N: 07-09-3366, to the adapter plate using 5 saved capscrews, MCI P/N: 19-01-1532. Torque capscrews to 9 FT-LBS. 37. Using tie cable with mount, MCI P/N: 19-11-3472, and tyraps to secure the battery ground to the left side of the CB assembly. Spray anti-corrosive spray in the back of the CB assembly Mount CB assembly Secure ground cable using tyraps MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 14 of 19 October 22, 2021 38. Secure battery cables to the 3 bottom tyrap mounts using tyraps, MCI P/N: 5958112. 39. Connect the fuse block B ring terminal (Wire ID 0050) to the 24V SW stud (BT-T4B) on the circuit breaker busbar, MCI P/N: 7L-8-5055, using lock washer, MCI P/N:19-2-37, and nut, MCI P/N: 19-3-32. Torque nut to 65 IN-LBS. Torque main power feeder to 20-25 FT-LBS. 40. Connect the fuse block C ring terminal (Wire ID 0047) to the 24V SW stud (BT-T4C) on the circuit breaker busbar, MCI P/N: 7L-8-5055, using lock washer, MCI P/N:19-2-37, and nut, MCI P/N: 19-3-32. Torque stud to 65 IN-LBS. Spray 3 studs with anti-corrosive spray, MCI P/N: 23-02-0119. Secure cables using tyraps Connect to BT-T4B stud. Connect to BT-T4C stud. Apply corrosion inhibitor spray MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 15 of 19 October 22, 2021 41. Attached reworked equalizer cables to fuse holder BT-125/BT-126. Ensure a smooth curve from the equalizer to the fuse holders. Torque studs to 40 IN-LBS. 42. From the kit, locate the VEC fuse holder cover, MCI P/N: 07-08-5651, bracket, MCI P/N: 07-08-5652, and assemble them as shown below. 43. Attach 3 VEC fuse holder cap brackets, MCI P/N: 07-08-5652, using 6 screws, MCI P/N:19-1-386, 6 lock washer, MCI P/N:19-2-37, and 6 flat washers, MCI P/N:19-2-23. 44. Add 20A/30A/15A fuses according to the fuse layout decal, MCI P/N: 934008, to the fuse holder jumper harness, MCI P/N: 933736. Connect the fuse holder jumper harness to the bracket assembly. Attach 12/24V EQ cables to CB assembly VEC fuse holder bracket VEC fuse holder cover Mount 3 fuse holder covers to wall bracket MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 16 of 19 October 22, 2021 45. Use tyraps, MCI P/N: 5958112, to secures fuse cables to the harness bundle behind the batteries. 46. Use tyraps, MCI P/N: 5958112, to secure cables behind the batteries circuit breaker assembly. 47. Remove a piece of the trim lock from MDS and install it at the bottom left corner of the circuit breaker assembly. Use tyraps to secure cable bundles Use tyraps to secure cable bundles Install trim lock to the bottom left corner of the CB assembly MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 17 of 19 October 22, 2021 48. Reconnect the battery cables, torque nuts to 54-60 IN-LBS. Turn on MDS and turn on coach ignition to verify rework. Reinstall battery terminals MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 18 of 19 October 22, 2021 LABOUR ESTIMATE Operation Number of Technician(s) Hours Labor Time T X HR 1 MDP replacement with circuit breaker assembly 1 7.5 7.5 PARTS REQUIRED Item Part Number Description Qty. per Coach Units Notes 1 117202 HEATSHRINK – 3/4IN, BLUE 1 AR 2 6485136 NUT, RIVET 5/16″ – 18 UNC OPEN END ZINC PLATED 5 EA 3 07-08-1059 FUSE – MINI, 15A 1 EA 4 07-08-1061 FUSE – MINI, 20A 5 EA 5 07-08-1429 FUSE – MINI, 30A 4 EA 6 07-08-3954 FUSE – MINI 25A 2 EA 7 07-08-5651 VEC FUSE HOLDER COVER 3 EA 8 07-08-5652 VEC FUSE HOLDER BRACKET 3 EA 9 07-09-3366 SWITCH ASSY-MAIN DISCONNECT & BREAKERS 1 EA 10 07-10-2254 ASSY-BRKT, 4 FUSE HOLDER 1 EA 11 19-11-2371 HEATSHRINK – 3/4IN, RED 1 EA 12 19-11-3472 TIE CABLE – WITH MOUNT 2 EA 13 19-11-3763 #10 RING TERMINAL 2 EA 14 19-11-431 CONNECTOR-SPLICE, BUTT,12 10 AWG 12 EA 15 19-11-67 HEATSHRINK – DUAL WALL, 3/4IN, BLK 1 EA 16 19-13-137 RIVET-.187 3 EA 17 19-1-386 SCREW-CAP, HEX,1/4-20UNC X 1/2 SST 18-8 6 EA 18 19-2-23 WASHER-FLAT,1/4 ID, SST 6 EA 19 19-2-37 WASHER – LOCK, SST, 1/4 ID 8 EA 20 19-3-32 NUT-1/4-20, SST 2 EA 21 5958112 TYRAP-7.31” LONG 10 EA 22 19-11-1465 HEAT SHRINK- 4FT, BLACK 2 FT 23 7L-8-5055 BAR ASSY-BUS 1 EA 24 935087 PLATE – ADAPTER CB BT COMPT CRTLE/D4520 1 EA 25 933736 HARNESS – FUSE HOLDER JUMPER D45CRT 1 EA 26 934008 DECAL-FUSE LAYOUT BATT COMPT D45CRT 1 EA 27 07-10-2283 DECAL-CIRCUIT BREAKER PANEL, D45 CRT 1 EA MDP Replacement with Circuit Breaker Assembly ITS60298 ITS60298 Page 19 of 19 October 22, 2021 28 07-09-3396 CABLE – MDS TO BT-F33, 24V SW 1 EA 29 07-10-2419 FUSE BLOCK -LMI, BOLT IN, 30A 1 EA 30 19-11-3417 RING TERM_SOLISTRAND #10_12-10 AWG 1 EA SPECIAL TOOLS REQUIRED Item Part Number Description Qty. Units Notes 1 IMP9166-1 Ultra Grey RTV Silicone 1 EA 2 23-02-0119 CRC SP-400 1 EA 3 21-7212-18 Adhesive – Loctite 242, Thread Locking 1 EA 4 NA TORQUE SEAL, ORANGE,5 OZ. 1 EA 5 NA Step-up Drill Bit 1 EA 6 NA 35/64” Drill Stop 1 EA 7 NA Rivet Nut Gun 1 EA 8 NA 13/64” Drill Bit 1 EA 9 NA Heat Gun 1 EA 10 NA IN-LBS Torque Wrench 1 EA 11 NA FT-LBS Torque Wrench 1 EA 12 NA Heavy Duty Terminal Crimp Tool 1 EA

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NEW FLYER. Wltii IMPORTANT SAFETY RECALL NOTICE 24 November 2021 Subject: Motor Vehicle Safety Recall 21V- 748 – Main Distribution Panel Circuit Boards To Whom it May Concern: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Motor Coach Industries Inc. (MCI) has decided, that a defect which relates to motor vehicle safety, exists on specific MCI vehicles e ui ed Main Distribution Panel Circuit Boards, MCI PN 07-08-7940. MCI has determined is the Owner/Operator of the vehicles listed below which are a ec e y Make: Model: VIN: MCI D4500 1 M8PDMBA3HP , 1 M8PDMBA2JP , 1 M8PDMBA4JP , 1 M8PDMBA6JP , 1 M8PDMBA8JP , 1 M8PDMBAXJP , 1M8PDMBA6JP , 1M8PDMBA8JP , 1M8PDMBAXJP , 1M8PDMBA1JP , 1M8PDMBA3JP , 1M8PDMBA5JP , 1M8PDMBA7JP , 1M8PDMBA9JP , 1M8PDMBA0JP , 1M8PDMBA2JP , 1 M8PDMBA9JP , 1 M8PDMBA0JP , 1 M8PDMBA2JP , 1 M8PDMBA4JP , 1 M8PDMBA6JP , 1M8PDMBA8JP , 1M8PDMBAXJP , 1M8PDMBA1JP , 1 M8PDMBA3JP 1 M8PDMBA5JP , 1 M8PDMBA1JP 1 M8PDMBA3JP , 1 M8PDMBA5JP 1 M8PDMBA7 JP 1 M8PDMBA9JP 1 M8PDMBA0JP 1 M8PDMBA2JP 1 M8PDMBA4JP 1 M8PDMBA8JP 1 M8PDMBA4JP 1 M8PDMBA6JP 1 M8PDMBA8JP 1 M8PDMBAXJP , 1M8PDMBA1JP 1M8PDMBA3JP 1M8PDMBA7JP , 1 M8PDMBA9JP 1 M8PDMBA7JP 1 M8PDMBA4JP , 1 M8PDMBAXJP , 1 M8PDMBA0JP 1 M8PDMBA2JP , 1 M8PDMBA4JP , 1 M8PDMBA6JP 1 M8PDMBA8JP 1M8PDMBAXJP , 1M8PDMBA1JP 1M8PDMBA3JP , 1 M8PDMBA5JP 1 M8PDMBA7JP 1 M8PDMBA3JP 1M8PDMBA5JP , 1M8PDMBA7JP 1M8PDMBA9JP 1M8PDMBA0JP 1M8PDMBA2JP 1M8PDMBA4JP 1 M8PDMBA8JP 1 M8PDMBAXJP 1 M8PDMBA6JP 1 M8PDMBA8JP 1 M8PDMBAXJP 1 M8PDMBA 1 JP 1 M8PDMBA3JP 1 M8PDMBA5JP 1 M8PDMBA7 JP 1 M8PDMBA9JP , 1 M8PDMBA0JP 1 M8PDMBA2JP 1 M8PDMBA9JP , 1 M8PDMBA0JP 1 M8PDMBA2JP 1M8PDMBA4JP 1M8PDMBA6JP 1M8PDMBA8JP , 1M8PDMBAXJP 1M8PDMBA3JP 1M8PDMBA5JP , 1M8PDMBA7JP 1M8PDMBA9JP 1M8PDMBA0JP , 1M8PDMBA2JP 1M8PDMBA4JP 1M8PDMBA6JP 1M8PDMBA8JP 1M8PDMBAXJP 1M8PDMBA6JP , 1M8PDMBA8JP 1M8PDMBAXJP 1M8PDMBA1JP , 1M8PDMBA3JP 1M8PDMBA5JP 1M8PDMBA7JP 1M8PDMBA9JP 1M8PDMBA4KP 1M8PDMBA6KP , 1M8PDMBA8KP 1M8PDMBAXKP , 1M8PDMBA1KP , 1M8PDMBA3KP 1M8PDMBA5KP 1M8PDMBA1KP 1M8PDMBA3KP 1M8PDMBA5KP 1M8PDMBA7KP 1M8PDMBA9KP 1M8PDMBA0KP 1M8PDMBA2KP 1M8PDMBA4KP 1M8PDMBA6KP 1M8PDMBA8KP 1M8PDMBA0KP 1M8PDMBA2KP 1M8PDMBA4KP 1M8PDMBA6KP 1M8PDMBA8KP 1M8PDMBAXKP 1M8PDMBA1KP 1M8PDMBA3KP 1M8PDMBA5KP 1M8PDMBA7KP 1M8PDMBA3KP 1M8PDMBA5KP 1M8PDMBA7KP 1M8PDMBA9KP 1M8PDMBA0KP 1M8PDMBA2KP 1M8PDMBA4KP 1M8PDMBA6KP 1M8PDMBA8KP 1M8PDMBAXKP 1M8PDMBA6KP 1M8PDMBA8KP 1M8PDMBAXKP 1M8PDMBA1KP 1M8PDMBA3KP 1M8PDMBA5KP 1M8PDMBA7KP 1M8PDMBA9KP 1M8PDMBA0KP 1M8PDMBA2KP 1M8PDMBA9KP 1M8PDMBA0KP 1M8PDMNA5LP 1M8PDMNA7LP 1M8PDMNA9LP 1M8PDMNA0LP 1M8PDMNA2LP 1M8PDMNA9LP 1M8PDMNA0LP 1M8PDMNA2LP , 1M8PDMNA4LP 1M8PDMNA6LP MCI is recalling all buses equipped with the Main Distribution Panel (MDP) Circuit Boards, MCI part number 07-08-7940. The circuit boards within the MDP may fail resulting in uncommanded vehicle shutdown or thermal events which may result in fire. Fire and/or uncommanded vehicle shutdown increases the risk for collision and the potential for personal injury. Parts and labor required to accomplish the recall will be provided by MCI at no cost. MCI will remove the existing Main Distribution Panel and install a new Main Disconnect and Circuit Breaker Panel. Please contact the MCI Customer Service Line at 1-800-241-2947 and arrange for the corrective action to be incorporated at your nearest MCI Service Center. Alternately, you can request a parts and instructions necessary to conduct this retrofit and charge the labor time back to MCI through the normal warranty process. MCI estimates the repair time to be approximately 5 hours, excluding vehicle and shop logistics. Due to the current global supply shortages, the necessary parts required to conduct this corrective action may not be available in sufficient quantities until February 2022. Until the corrective action can be incorporated on the above vehicles, MCI recommends conducting regular visual inspections of the MDP circuit board every 6000 miles for signs of thermal stress or corrosion during the normal battery maintenance inspections. Please refer to Technical Service Information Bulletin TSIB 21-10 to conduct this inspection. TSIB 21-10 is available at https://www.mcicoach.com/. If you are a lessor of vehicles which are affected, it is required that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. If you have sold or otherwise transferred the vehicle(s) identified above, please contact the MCI Customer Service Line at 1-800-241-2947 with all of the information you have regarding the current owner/operator of the vehicle(s). If you had this corrective action performed before you received this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall. If MCI is unable to correct this defect within a reasonable time, you may submit a written complaint to the: Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE, Washington, DC, 20590, Or call 1-888-327-4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov. We regret any inconvenience which this action may cause you. However, we are concerned about the safety of your passengers and employees. Thank you for your attention to this important matter. Sincerely, MOTOR COACH INDUSTRIES INC. By: Kerry Legg Vehicle Safety & Regulatory Compliance Manager (204) 224-6706 cc: Scott Halbesma –Vice President, Customer Care

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