INSTRUCTION TO SERVICE
ITS: 58779
SECTION:

292

Electrical Harnesses

WRITTEN BY:

Kristian Melo

SUBJECT:

Rewire TRW steering column to provide a memory power circuit

ITS58779
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.

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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.
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),
shown below in Figure 4, using the provided connector seal (PN: 102877) to seal open cavities.

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XEFB9

F99PS
A: PS99A
B: PS99B

A: 36SPR36G
B:
C:

EMER PWR SW

XBAT12

A: PS99A

MAIN PWR SW

a) SR-2177

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XEFB9

EMER PWR SW

MAIN PWR SW

F99PS

b) SR-1767, 2027, 2063
Figure 4: Fuse Box Connection Locations

9) Secure wiring neatly along routing paths using tyraps (PN: 5958112).
10) Locate and install HRNS-JMPR FUSE BOX (PN: 813086).
a) Identify wire 99PS99A. Terminate the appropriate end to terminal A of breaker F99PS (indicated in Figure
4) and connect the other end of the wire as indicated in Table 1.

Table 1: Install Location of Wire 99PS99A
SR
Location

SR-2177

SR-1767, SR-2027, SR-2063

Position A of XBAT12

Position 2 of MAIN PWR SW

b) Identify wire 99PS99B. Terminate the appropriate end of the wire to terminal B of breaker 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.
11) Secure wiring neatly along the paths inside the paths with tyraps (PN: 5958112).
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12) In the side console, identify the end of wire 20SPR20J terminated with an end cap. Cut and trim the wire and
re-terminate with the provided socket (PN: 102879).
13) Insert the wire into cavity A of the connector indicated in Table 2. This connector is locatedon the underside of
the side console panel.
Table 2: Wire 20SPR20J Install location
SR
Location

SR-2177, SR-1767

SR-2027, SR-2063

XSC50-TWR

XSC38-TWR

For SR-2027 and SR-2063 SKIP TO STEP 16
14) Locate XJ20 connector in the curbside joint bulkhead.
15) Load 20SPR20J into cavity 3 of XJ20.
16) Identify end of wire 51AF92A terminated within the side console panel at position 2 of breaker F35AF. Cut and
trim the wire. Re-terminate the wire with the provided ring terminal (PN: 8110713) and connect it at position 6
of terminal XSC4.
17) Secure wiring neatly along the paths inside the paths with tyraps (PN: 5958112).
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 5.
20) Locate the provided power resistor (PN: 627976). Using the provided screw and washers, (same parts as
above) install below node 9. See Figure 5 below.

SCREW AND
WASHER
TRW
POWER
RELAY
SCREW AND
WASHER

POWER
RESISTOR

Figure 5: Side console panel with power relay and power resistor locations indicated.

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21) Locate the HRNS-JMPR SIDE CONSOLE PNL (PN: 813084) to be installed. Details shown in Figure 6.
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.
b) Locate wires PS80A, EN48G, and EN48C. Remove the wires from XSC4-6, remove terminals, and reterminate with provided socket (PN: 034794). Insert wires into splice bus (PN: 169346).
i)

PS80A to cavity 3

ii)

EN48C to cavity 1

iii) EN48G to cavity 2
c) Identify wire 99AF99H. Insert the appropriate end to cavity B of TRW PWR RESISTOR-SHR. Connect the
opposite end to position 6 of terminal strip XSC4.
d) Identify wire 99AF99J. Connect the appropriate end to position 87 of TRW PWR RELAY. Connect the
opposite end to position 6 of terminal strip XSC4.
e) Identify wire 99AF99N. Connect the appropriate end to position 85 of TRW PWR RELAY. Connect the
opposite end to GNDBSC.
f)

Identify wire 99AF99M. Terminate the appropriate end to position 86 of TRW PWR RELAY. Terminate the
opposite end to terminal 2 of breaker F35AF.

g) Identify wire 99AF99K. Terminate the appropriate end to terminal 30 of TRW PWR RELAY. Terminate the
opposite end to terminal 2 of breaker F35AF.
22) Secure wiring neatly along the paths inside the paths with tyraps (PN: 5958112).

Figure 6. Side console with XSC4, XSC38, GNDBSC, and F20AF indicated.

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For SR-2027 and SR-2063 SKIP TO STEP 29
23) Locate XJ21 at the joint.
24) Identify wire 21SPR21C terminated with an end cap at the joint. Cut and trim the wire and then re-terminate
with the provided socket (PN: 102879). Insert the wire into cavity 3 of the connector XJ21 at the joint bulkhead.
25) Locate XBHR3 at the rear curbside bulkhead shown below in Figure 7.

Figure 7. Rear bulkhead with connector XBHR3 indicated.

26) In connector XBHR3, locate 21SPR21C and 21SPR21D.
27) Swap 21SPR21C in XBHR3-16 with 21SPR21D in XBHR3-14.
28) Secure wiring neatly along routing paths using tyraps (PN: 5958112).
29) Install provided side console and fuse box decals.
SR-2177

SR-1767

SR-2027

SR-2063

DECAL-SIDE CONSOLE PNL

729856

551751

633051

641828

DECAL-FUSE BOX

729860

551754

633055

633055

30) Remove all tools and debris and return the bus to service condition.
31) Turn the main battery disconnect switch to the “ON” position.
32) 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.

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Figure 8: Adapter harness

33) 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
34) 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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Figure 10: TRW Software Calibration Setup
35) 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 11: TRW Software Calibration Setup
36) 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.

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Figure 12: 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