INSTRUCTION TO SERVICE
ITS: 60428

May 19, 2022

SECTION:

284-ELECTRICAL PANELS (SC, RR, ED)

WRITTEN BY:

Curtis Matthews / Filipe Matias

SUBJECT:

Install ultracapacitor delay relay

ISSUE:

Ring gear damage causing stalling and inhibiting the bus from starting

SUMMARY:

Ring gears are being damaged from excessive torque upon startup. Excessive
torque occurs when low voltage batteries are fully charged and Ultracap
engages upon startup. To remedy this issue, this ITS will add a delay to the
Ultracap to lower the impulse when battery charge is greater than 24V.

ITS60428
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED 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 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
ITS60428

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Gain access to the rear facing SDS compartment and find the location of the New Flyer Connect module,
Node 21 connector J3, and the upper ground bar GNDBSDS. Gain access to the SC towers in the side
console See figure 1. Gain access to the exterior street side SDS cabinet as seen in figure 2.

GNDBSDS

UCAP
Delay
Relay

SDS
Panel

XSDS53B

Node 21

New Flyer
Connect module

SC Tower
Connectors

Figure 1: SDS compartment and side console access view

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May 19, 2022

INSTRUCTION TO SERVICE
ITS60428

Figure 2: Exterior street side work area access inside SDS cabinet

NOTE: See figure 2 for exterior street side access to the SDS cabinet for easy access to spare wires located at
the bottom of the SDS cabinet.

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May 19, 2022

INSTRUCTION TO SERVICE
ITS60428

3. Mount the new relay UCAP DELAY RLY on the relay mounting bracket in SDS cabinet as shown in figure 1
and figure 3. The installation should use the parts listed below as shown in figure 3. Torque screw to 22 INLBS (DRY). Apply torque stripe along screw and relay mounting bracket.
a.

Screw PN: 14S00006

b.

Washer PN: 659000

c.

UCAP DELAY RLY PN: 106614

d.

Base – Locking Relay Socket PN: 685168

e.

Lock – Relay Base PN: 685169
Washer
Screw

UCAP Delay
Rly
Base – Locking
Relay Socket
and Lock –
Relay Base

Relay mounting
bracket
Figure 3: New relay install inside SDS cabinet

4. Using the supplied jumper harness PN: 908517, route the harness to the respective locations according to the
table 1 below, figure 4 figure 5 and figure 6. Secure harness with tyrap PN: (5958112) every 18 inches of wire
length and 6 inches from connection points. For further reference, you can also view the schematic in figure
13.

Table 1: Jumper harness PN: 908517 pinouts

99PS99AA

X end terminal
positions
XSDS53B-SHR-N

UCAP terminal
positions
UCAP DELAY RLY-30

X end
terminals
034795

UCAP
terminals
682919

99PS99AB

NODE 21-J3-6

UCAP DELAY RLY-86

034794

682919

Tan

99PS99AC

GNDBSDS-9-2

UCAP DELAY RLY-85

170794

682919

White

99PS99AD

XSDS53B-SHR-P

UCAP DELAY RLY-87a

034795

682919

Tan

Wire Code

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Page 4 of 13

Wire color
Tan

May 19, 2022

INSTRUCTION TO SERVICE
ITS60428

NOTE: X end terminal positions are an arbitrary name given to denote the connecting point on the other end of
the wire, opposite the ultracapacitor. I.e.: X end terminal “034795” terminates one end of wire “99PS99AA” and
inserted into X end terminal position “XSDS53B-N”, see figure 1 for location of the XSD53B connector. The other
end of wire “99PS99AA” is terminated with UCAP terminal “682919” and inserted into UCAP terminal position
“UCAP DELAY RLY-30”.

Upper Ground Bar
GNDBSDS-9-2,
(Torque to 30 in-lbs)
(DRY)
Wire 99PS99AC
(WHITE)
Secure jumper
harness with tyrap
PN: (5958112) every
18 inches of wire
length and 6 inches
from connection
points

Wire 99PS99AB
(TAN)
Wires 99PS99AA
(TAN) and 99PS99AD
(TAN)

Route 99PS99AD and
99PS99AA wires and
terminate into
connector XSDS53B
(See Figure 1), in
positions P and N,
respectively.

Node 21

Wire 99PS99AB
(TAN)
Connect to J3 pin 6
Figure 4: SDS compartment view facing rear of bus

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INSTRUCTION TO SERVICE
ITS60428

GNDBSDS-9-2

XSDS53B-SHR-N

XSDS53B-SHR-P
Rly

NODE 21-J3-6

Figure 5: Relay pinout diagram (bottom view)

Node 21
J3-6

Node 21 in
SDS cabinet
for reference
Figure 6: Module Node 21

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May 19, 2022

INSTRUCTION TO SERVICE
ITS60428

5. In SC Tower (shown in figure 1), find location of connector XSC67 and XSC68 inside the side console panel.
See figure 7 for XSC67 and XSC68 location and figure 9 and 10 for spare harness location/routing.
a.

Identify the wire 11PS22VB currently inserted into terminal C of XSC68-SHR and inserted at the other
end into terminal 4 of the front start push button. De-pin wire 11PS22VB at both ends. See figure 8 for
connection locations. For further reference, you can also view the schematic in figure 13.

b.

Using the supplied jumper harness PN: 908525, follow original routing of wire 11PS22VB and insert the
wires in their respective locations per Table 2 below.

Table 2: Jumper harness PN: 908525 pinouts

99PS99AE

X end terminal
positions
FRT START PB-TWR-4

Y end terminal
positions
XSC67-SHR-A

X end
terminals
477408

Y end
terminals
102878

99PS99AF

XSC67-SHR-C

XSC68-SHR-C

102878

102878

Wire Code

c.

Wire color
Red
Tan

Identify the spare wire 53SPR53J, locate the end by the side console panel, terminate that end with
socket PN: 102879, and insert the wire into terminal A of XSC67-TWR. Wrap wire with 1/8” loom PN:
666993.

d.

Identify the spare wire 53SPR53K, locate the end by the side console panel, terminate that end with
socket PN: 102879, and insert the wire into terminal C of XSC67-TWR. Wrap wire with 1/8” loom PN:
666993.

e.

Secure wires with tyraps PN: (5958112) every 18 inches of wire length and 6 inches from connection
points.

XSC67