INSTRUCTION TO SERVICE
ITS: 58774
SECTION:

292

Electrical Harnesses

WRITTEN BY:

Kristian Melo

SUBJECT:

Rewire TRW steering column to provide a memory power circuit

ITS58774
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERED 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 UNAUTHOIZED DISCLOSURE, REPRODUCTION OR OTHER
DISTRIBUTION OF THIS DOCUMENT OR INFORMATION IS 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.

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Locate the fuse box assembly.
3. Drill a hole 0.5” in diameter into the front door of the fuse box for the new emergency power switch. Exact
location shown in Figure 1 below.

Switch 117047

Seal 400073
Guard 8111605
Decal
535764
Decal
670903

Figure 1: Emergency Power Switch Location
4. Install the provided emergency power switch (PN: 117047), seal (PN: 400073), switch guard (PN: 8111605)
and decals (PN: 535764 and 670903). For stack up of switch install see Figure 2 below.

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Nut
Panel

Seal

Guard

Figure 2: Emergency Power Switch Stack Up

5. Drill and tap 10-24UNC hole on the interior left side of the fuse box. Location shown in Figure 3 below.
Interior Left Wall of Fuse Box

Screw and
Washer

2A Fuse
Figure 3: Location of 10-24UNC Hole for Fuse
6. Secure the provided 2A fuse (PN: 198196) to the inside of the fuse box using the hole drilled in step 5 and the
provided screw (PN: 14S00006) and washer (PN: 659000).
7. Locate the XEFB9 connector on the side of the fuse box as well as the XBHR3 connector on the rear curbside
bulkhead. See Figure 4 below for locations.

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8. Using the provided ESS RH RR COMPT jumper harness (PN: 814838), connect the appropriate end of the
jumper to XEFB9-A.
9. Route harness to the XBHR3 connector and insert this end of the harness into XBHR3-8.
10. Secure wiring neatly along routing paths using tyraps (PN: 5958112).

XBHR3-SHR

Routing

Engine Compartment

XEFB9

Curb Side
Figure 4: Routing ESS RH RR COMPT Jumper Harness

11. Locate the provided fuse box jumper harness (PN: 813086). This will be installed inside the fuse box. Refer to
Figure 5 below for the locations the wires will be installed in.
a.

Identify wire 99PS99A. Terminate the appropriate end to terminal A of fuse F99PS and the opposite end
to wire cavity A of XBAT12.

b.

Identify wire 99PS99B. Terminate the appropriate end to terminal B of fuse F99PS and the opposite end
to terminal 3 of the new emergency power switch “EMER PWR SW”.

c.

Identify wire 99PS99C. Terminate the appropriate end to terminal 2 of the new emergency power switch
“EMER PWR SW” and the opposite end of the wire to cavity A of connector XEFB9-SHR.

12. Secure wiring neatly along routing paths inside panel using tyraps (PN: 5958112).

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Figure 5: Fuse Box Jumper Wiring

13. Gain access to the side console and locate wire 20SPR20F terminated with an end cap. Cut and trim the
wire, discarding the end cap. Re-terminate with provided socket (PN: 102879).
14. Insert this newly terminated wire into cavity A of connector XSC50-TWR, shown on Figure 6, on the underside
of the side console.
15. Identify wire 51AF92 that is installed at position 2 of breaker F35AF, see Figure 6 for location. Cut and trim
the wire, re-terminate with provided ring terminal (PN: 8110713).
16. Connect this newly terminated wire to position 3 of the terminal strip XSC4, shown in Figure 6.
17. Secure wiring neatly along routing paths inside panel using tyraps (PN: 5958112).

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Figure 6: Side Console New Wiring Locations

18. Locate the provided power relay (PN: 133915) and attach it to the provided connector (PN: 133916).
19. Install this new relay assembly using the provided screw (PN: 14S00006) and washer (PN: 659000). This
relay will be installed in the next position above the 24V relays on the right side of the panel, refer to Figure 7.
20. Locate the provided power resistor (PN: 627976). Using the provided screw and washers, (same parts as
above) install below node 9. See Figure 7 below.

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Screw and
Washer
Power Relay

Screw and
Washer

Power
Resistor

Figure 7: Power Relay and Resistor Install Locations

21. Locate the side console jumper (PN: 813084) to be installed.
a.

Identify wire 99AF99G. Insert the appropriate end to cavity A of the previously installed power resister.
Insert the opposite end to cavity A of connector XSC50-SHR.

b.

Identify wire 99AF99H. Insert the appropriate end to cavity B of the previously installed power resister.
Insert the opposite end to position 3 of terminal strip XSC4.

c.

Identify wire 99AF99J. Connect the appropriate end to position 87 of the new power relay. Connect the
opposite end to position 3 of terminal strip XSC4.

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d.

Identify wire 99AF99N. Connect the appropriate end to position 85 of the new power relay. Connect the
opposite end to position 12 of the ground bar GNDBSC.

e.

Identify wire 99AF99M. Connect the appropriate end to position 86 of the new power relay. Connect the
opposite end to terminal 2 of breaker F35AF.

f.

Identify wire 99AF99K. Connect the appropriate end to terminal 30 of the new power relay. Connect the
opposite end to terminal 2 of breaker F35AF.

22. Ensure wiring is secured neatly along routing paths using tyraps (PN: 5958112).
23. Install the provided DECAL-SIDE CONSOLE PNL (PN: 759631) and DECAL-FUSE BOX (PN: 759635).
24. Remove all tools and debris and return the bus to service condition.
25. Turn the main battery disconnect switch to the “ON” position.
26. After installation of the ITS is complete, the Straight Ahead position of the steering column will need to be
reset. To do this, you will need the adapter to communicate with the steering column. The column
communicates at a 250k baud rate.

Figure 7: Adapter harness

27. The figure below shows the screen you will see after you open the TRW ReAx Diagnostic Tool, select the
adapter that you are using from the drop-down menu. Then connect to the column by clicking the “Connect”
button. The bus must be running to communicate with the column, not just key on. (Note how the Position Index
Valid is “False”, this is normal.)

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Figure 8: TRW Software
28. Once you have set the wheels straight ahead by looking at the tires, you will then click the “Reset Straight
Ahead” button. (Note how the Position Index Valid is now “True”, this is because the steering wheel was turned
past straight ahead when making sure the wheels were facing straight ahead.)

Figure 9: TRW Software Calibration Setup

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29. After clicking the “Reset Straight Ahead” button this is the screen you will see. Follow the instructions on the
screen. (NOTE: The bus must be running, not just key on, to communicate with the steering column.)

Figure 10: TRW Software Calibration Setup
30. After you have waited 30 seconds and restarted the bus, you will need to reconnect to the column as you did
initially. Once you are connected the “Absolute Steering Angle” should be 0.0 degrees if you have not turned
the steering wheel after performing the procedure. Also, the “Position Index Valid” will be red and FALSE,
until the steering wheel is turned past straight ahead. At this point the ITS is complete.

Figure 11: TRW Software Calibration Setup

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LABOUR ESTIMATE
Operation

Men

Hours

Labour Time
M X HR

1

Rewire TRW steering column to provide a memory power

1

3.5

3.5

circuit

PARTS REQUIRED
Qty.
Item

Part Number

Description

per

Units

Notes

Coach
1

8111605

GUARD KNEELING SW

1

EA

2

814838

HRNS-JMPR ESS RH RR COMP

1

EA

3

813086

HRNS-JMPR FUSE BOX

1

EA

4

813084

HRNS-JMPR SIDE CONSOLE PNL

1

EA

5

670903

DECAL-EMERG POWER

1

EA

6

659000

WASHER FLAT SST 10

3

EA

7

627976

ASSY-RESISTOR PACK 1K OHMS/.5W

1

EA

8

535764

DECAL-ON OFF TOGGLE

1

EA

9

400073

SEAL-SWITCH RING

1

EA

10

198196

ASSY-2A FUSE M/PACK CAP

1

EA

11

14S00006

SCREW MACHINE NO 10 PN HD

3

EA

12

133916

CONN-POTTER&BRUMFIELD

1

EA

13

133915

RELAY-12V, 70A

1

EA

14

117047

SWITCH SPST WP MAINTAIN

1

EA

15

8110713

TERM-R #10 8AWG IN

1

EA

16

102879

SOCKET-FEM TERM

1

EA

17

5958112

TYRAP-7.0 BLACK

20

EA

18

759631

DECAL-SIDE CONSOLE PNL

1

EA

19

759635

DECAL-FUSE BOX

1

EA

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SPECIAL TOOLS REQUIRED
Qty.
Item

Part Number

Description

per

Notes
Units

Coach
1

Laptop with TRW ReAx Diagnostic Tool

1

EA

2

TRW adapter harness

1

EA

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