INSTRUCTION TO SERVICE
ITS: 58777
SECTION:

292

Electrical Harnesses

WRITTEN BY:

Kristian Melo

SUBJECT:

Rewire TRW steering column to provide a memory power circuit

ITS58777
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 of the fuse box. Details shown in Figure 3 and 4 (different per SR).
Interior 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 wire 36SPR36G in the engine fuse box.
8. Apply provided socket (PN: 102879) to 36SPR36G and load 36SPR36G into cavity A of XEFB9 (PN: 104043),
location shown in Figure 4, using the provided connector seal (PN: 102877) to seal open cavities.

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F99PS
A: PS99A
B: PS99B

XEFB9
A: 36SPR36G
B:
C:

MAIN PWR SW

2: PS99B
3: PS99C

EMER PWR SW
a) SR-2293,2294

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F99PS

XEFB9

MAIN PWR SW

EMER PWR SW
b) SR-2218,2285

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F99PS

XEFB9

MAIN PWR SW

EMER PWR SW

c) SR-2274
Figure 4: Fuse Box Connection Locations
9. Secure wiring neatly along routing paths using tyraps (PN: 5958112).
10. Locate HRNS-JMPR FUSE BOX (PN: 813086)
a.

Identify wire 99PS99A. Terminate the appropriate end to terminal A of fuse F99PS (see Figure 4) and
connect the other end of the wire to position 2 of MAIN PWR SW (see Figure 4).

b.

Identify wire 99PS99B. Terminate the appropriate end of the wire to terminal B of fuse F99PS and connect
the other end of the wire to terminal 3 of EMER PWR SW (indicated in Figure 4).

c.

Identify wire 99PS99C. Connect the appropriate end of the wire to terminal 2 of EMER PWR SW and insert
the other end of the wire to cavity A of the connector XEFB9-SHR (see Figure 4).

11. Secure wiring neatly along the paths inside the paths with tyraps (PN: 5958112).
12. In the side console, identify the spare wire terminated with an end cap indicated by Table 1 below. Cut and trim
the wire and re-terminate with the provided socket (PN: 102879).
Table 1: Side Console Spare Wire
SR
Wire Label

2293, 2294, 2218, 2274

2285

20SPR20F

20SPRE20J

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13. Insert the wire into cavity A of the connector XSC50-TWR on the underside of the side console panel.
For SR-2293, SR-2294, SR-2218 or SR-2274 SKIP TO STEP 21
14. Locate connector XJ20 at the joint bulkhead.
15. Load the other end of 20SPR20J into cavity 3 of XJ20.
16. Secure wires neatly along the routing paths.
17. Locate XJ21 at the joint bulkhead.
18. Identify the end of wire 21SPR21C terminated with an end cap at the joint. Cut and trim the wire and then reterminate with the provided socket (PN: 102879).
19. Insert the wire into cavity 3 of the connector XJ21 at the joint bulkhead.
20. Secure wiring neatly along routing paths using tyraps (PN: 5958112).
21. Locate XBHR3 at the rear curbside bulkhead shown below in Figure 5.

Figure 5: Rear bulkhead with connector XBHR3 indicated.
22. In connector XBHR3, locate wires “A” and “B” shown in Table 2 below. Swap these wires with each other.

Table 2: XBHR3 Wires Swap
SR

2293, 2294, 2218, 2274

2285

Wire A Label

20SPR20F

21SPR21C

Wire A Location

XBHR3-16

XBHR3-16

Wire B Label

20SPR20G

21SPR21D

Wire B Location

XBHR3-14

XBHR3-14

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23. Secure wiring neatly along the paths inside the paths with tyraps (PN: 5958112).
24. Identify end of wire 51AF92A terminated within the side console panel at position 2 of breaker F20AF. Cut and
trim the wire. Re-terminate the wire with the provided ring terminal (PN: 8110713) and connect it to terminal
strip XSC4 at the position indicated in Table 3 below.

Table 3: XSC4 Position for Wire 51AF92A
SR
XSC4 Position

2293, 2294

2218, 2274, 2285

XSC4-1

XSC4- 7

25. Secure wiring neatly along the paths inside the paths with tyraps (PN: 5958112).
26. Locate the provided power relay (PN: 133915) and attach it to the provided connector (PN: 133916).
27. 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 6.

SCREW AND
WASHER
TRW
POWER
RELAY

SCREW AND
WASHER

POWER
RESISTOR

Figure 6: Side Console Panel Locations

28. Locate the provided power resistor (PN: 627976). Using the provided screw and washers, (same parts as
above) install below node 9. See Figure 6.
29. Locate the HRNS-JMPR SIDE CONSOLE PNL (PN: 813084) to be installed. Locations indicated in Figure 7.
a.

Identify wire 99AF99G. Insert the appropriate end to cavity A of TRW PWR RESISTOR-SHR. Insert the
opposite end to cavity A of connector XSC38-SHR.

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b.

Identify wire 99AF99H. Insert the appropriate end to cavity B of TRW PWR RESISTOR-SHR. Connect
the opposite end to terminal strip XSC4.

c.

SR-2293 or SR-2294

SR-2218 or SR-2274 or SR-2285

Position 1

Position 7

Identify wire 99AF99J. Connect the appropriate end to position 87 of TRW PWR RELAY. Connect the
opposite end to terminal strip XSC4.

d.

SR-2293 or SR-2294

SR-2218 or SR-2274 or SR-2285

Position 1

Position 7

Identify wire 99AF99N. Connect the appropriate end to position 85 of TRW PWR RELAY. Connect the
opposite end to GNDBSC.

e.

Identify wire 99AF99M. Terminate the appropriate end to position 86 of TRW PWR RELAY. Terminate
the opposite end to terminal 2 of breaker F20AF.

f.

Identify wire 99AF99K. Terminate the appropriate end to terminal 30 of TRW PWR RELAY. Terminate
the opposite end to terminal 2 of breaker F20AF.

30. Secure wiring neatly along the paths inside the paths with tyraps (PN: 5958112).

a) SR-2293, 2294, 2218, 2285

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b) SR-2274
Figure 7: Side Console Connection Locations
31. Install the provided decals.
SR

SR-2293, SR-2294

SR-2218

SR-2274

SR-2285

DECAL-SIDE CONSOLE PNL

753029

740484

734734

748217

DECAL-FUSE BOX

753033

740477

734730

748221

32. Remove all tools and debris and return the bus to service condition.
33. Turn the main battery disconnect switch to the “ON” position.
34. 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 8: Adapter harness

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35. 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.)

Figure 9: TRW Software
36. 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.)

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