SB-10057538-5927

INSTRUCTION TO SERVICE
ITS: 5808
SECTION:

290

WRITTEN BY:

Tyler Omichinski

SUBJECT:

Revise rear panel wiring and programming for Allison ESS A/C command

Electrical Schematics

ITS5808

THIS DOCUMENT AND THE CONTENTS DISCUSSED HEREIN ARE THE CONFIDENTIAL AND
PROPRIETARY INFORMATION OF NEW FLYER INDUSTRIES CANADA ULC AND NEW FLYER OF
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THIS DOCUMENT AND ALL COPIES HEREOF MUST BE RETURNED TO NEW FLYER UPON REQUEST.

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Locate the rear electrical panel above the rear bench. Access the inside of the panel to add wiring.
3. Terminate one end of the 18 GA yellow HP10W wire (NF P/N 129444) with a pin terminal PIN 18 16 AWG
DEUTSCH (NF P/N 034795). Connect the terminated end of the wire with XRR11-8. The wiring diagram for
this connection is shown in Fig. 1.

Figure 1: Wiring diagram for HP10W connection
4. Run the HP10W wire from XRR11-8 to the J1-2 connector of the 2820 module (Node 5). Cut the wire to
length and terminate the end with CONT-SOCKET 20-16GA AMP (NF P/N 158564).
5. Remove the J1 connector from the 2820 module (Node 5) and pry the red secondary lock forward. Insert the
free end of the HP10W wire into cavity 2 of connector J1. Reseat the secondary lock and plug J1 back into
Node 5. Secure the HP10W wire using tyraps (NF P/N 5958112). Figure 2 shows the J1 connector.

Figure 2: Diagram of J1 connector

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6. Terminate one end of the 16 GA tan CC66BC wire (NF P/N 129422) with the terminal TERMINAL 150
SERIES PAC (NF P/N 010741). Connect the terminated end to cavity 3F of connector J1 in Node 9. Figure 3
shows the wiring diagram for the CC66BC wire.

Figure 3: Wiring diagram for CC66BC connection
7. Find a suitable location to tyrap the XBCC1 connector; use this location to cut the CC66BC wire to length.
Terminate the free end of the CC66BC wire with SOCKET 18 16AWG DEUTSCH (NF P/N 034794). Insert
this end into cavity 1 of the XBBCC1 connector from KIT- BUSBAR 4X1 DEUTSCH (NF P/N 169346).
8. Terminate one end of both the 16 GA tan CC66B and CC66C wires (NF P/N 129422) with terminal SOCKET
18 16AWG DEUTSCH (NF P/N 034794). Insert wire CC66B into cavity 3 of the XBBCC1 connector and
insert wire CC66C into cavity 2 of the XBBCC1 connector. Plug the open cavity 4 with PLUG SEAL 16-12GA
(NF P/N 8110650).
9. Insert the wedge from the XBBCC1 connector kit into the connector. Place the cover cap on the connector.
Figure 4 shows the XBBCC1 connector assembly. Secure the connector using a tyrap (NF P/N 5958112).

Figure 4: XBBCC1 connector assembly
10. Run the CC66B and CC66C wires to the XRR40 connector and cut them to length. Terminate the free end of
both the CC66B and CC66C wires with terminal PIN-16-14GA W/PACK (NF P/N 102878) and SEAL
CONNECTOR (NF P/N 102877). Connect wire CC66B to cavity B of XRR40. Connect wire CC66C to cavity C
of XRR40. Secure the CC66 wires with tyraps (NF P/N 5958112).
11. Turn the main battery disconnect switch to the “ON” position.
12. Install the latest version of the PLC program for your SR, available from your Regional Product Support
Manager. Use VMMS software and the DLA Kit (NF P/N 6351820). Refer to Table I when selecting the
appropriate PLC program.

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NOTE:

Use the appropriate program according to which SR you are servicing. Reference Table I.

Table I: PLC PROGRAM BASED ON SR

NOTE:

SR

Program NF P/N

1216

180392

1235

185115

1299

184451

1419

190302

The Allison program must also be updated at this point. Contact your Allison representative.

13. Replace the rear panel wiring diagram decal. Refer to Table II to select the appropriate part number for the
SR you are servicing; each SR has a unique decal. Apply adhesive (NF P/N 170962) to the back of the decal
before installation.
NOTE:

Use the appropriate decal according to which SR you are servicing. Reference Table II.

Table II: WIRING DIAGRAM DECAL BASED ON SR
SR

Decal NF P/N

1216

180709

1235

184854

1299

186138

1419

191543

14. Close the rear electronic equipment access door and return the bus to service condition.

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LABOUR ESTIMATE
Operation
1

Wiring and program changes for Hybrid Battery Cooling

Men

Hours

1

2.0

Labour Time
M X HR
2.0

Request

PARTS REQUIRED
Item

Part Number

1

6447775

KIT-ESS COOLING REQUEST SR-1216

Qty.
per
Coach
1

2

6447776

KIT-ESS COOLING REQUEST SR-1235

1

EA

For SR-1235

3

6447777

KIT-ESS COOLING REQUEST SR-1299

1

EA

For SR-1299

4

6447778

KIT-ESS COOLING REQUEST SR-1419

1

EA

For SR-1419

Description

Units

Notes

EA

For SR-1216

KIT-ESS COOLING REQUEST SR-1216 PARTS LIST (P/N 6447775)
Item

Part Number

1

129444

WIRE-18GA YELLOW GXL

Qty.
per
Coach
6

2

034795

PIN 18 16 AWG DEUTSCH

1

EA

3

158564

CONT-SOCKET 20-16GA AMP

1

EA

4

5958112

TYRAP-7.0 BLACK

20

EA

5

129422

WIRE-16GA TAN GXL

18

FT

Description

Notes
Units
FT

Label HP10W

Label
6 ft “CC66BC”
6 ft “CC66B”
6 ft “CC66C”

6

010741

TERMINAL 150 SERIES PAC

1

EA

7

034794

SOCKET 18 16AWG DEUTSCH

3

EA

8

8110650

PLUG SEAL 16-12GA

1

EA

9

102878

PIN MALE TERM

2

EA

10

102877

SEAL-CONN 14 16 AWG

2

EA

11

180709

DECAL-REAR PANEL

1

EA

12

170962

ADHESIVE-SPRAY 77

0.05

EA

13

169346

KIT-4CCT TWR DT

1

EA

SR-1216 Only

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KIT-ESS COOLING REQUEST SR-1235 PARTS LIST (P/N 6447776)
Item

Part Number

1

129444

WIRE-18GA YELLOW GXL

Qty.
per
Coach
6

2

034795

PIN 18 16 AWG DEUTSCH

1

EA

3

158564

CONT-SOCKET 20-16GA AMP

1

EA

4

5958112

TYRAP-7.0 BLACK