NHTSA ID Number: 10215530
Manufacturer Communication Number: ITS60428
TSB/Document Date: 2022-07-07
Summary
Technical Instruction describing how to install an ultracapacitor delay relay.
XSC68
Figure 7: XSC Connectors in the side console panel
ITS60428
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INSTRUCTION TO SERVICE
ITS60428
Front start
push button
XSC67
XSC68
Figure 8: Side console panel
Figure 9: Exterior side console view (spare harness location/routing)
ITS60428
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INSTRUCTION TO SERVICE
ITS60428
Spare wires
(orange)
Figure 10: Exterior side console view spare harness (loom removed)
6. Identify the other end of spare wire 53SPR53J at the base of the SDS panel, see figure 11. Terminate the
wire with socket PN: 034793 and insert the wire into terminal N of the XSDS53B-TWR which the location can
be seen in figure 1.
7. Identify the other end of spare wire 53SPR53K at the base of the SDS panel, see figure 11. Terminate the
wire with socket PN: 034793 and insert the wire into terminal P of the XSDS53B-TWR which the location can
be seen in figure 1.
ITS60428
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May 19, 2022
INSTRUCTION TO SERVICE
ITS60428
Spare wires
53SPR53J and
53SPR53K
Figure 11: Exterior, street side work area access, inside bottom of SDS cabinet
ITS60428
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INSTRUCTION TO SERVICE
ITS60428
8. Wrap up spare wires with original loom and with cable ties PN: 351161, as necessary. See figure 12.
Spare wires
harness cable ties
Figure 12: Spare wires wrapped and secured in exterior side console
Figure 13: UCAP delay relay schematic
ITS60428
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May 19, 2022
INSTRUCTION TO SERVICE
ITS60428
9. Ensure all connectors are connected. Remove all tools and debris and return the bus to service condition.
10. Turn the main battery disconnect switch to the “ON” position.
11. Turn 4way flashers on, then download the latest released PLC program “765061C.vmm” onto the bus. Then
turn 4way flashers off once PLC program has finished downloading.
12. Test bus after ITS procedure is complete:
a.
Assure that the main battery disconnect switch has been in the “ON” position for at least 15 seconds for
ultracapacitor to charge.
b.
To test the ultracapacitor delay relay, the bus batteries will need to be below 24V. Use a multimeter to
check voltage of the 24V system on the 24VBATSDS in the SDS cabinet and assure the battery voltage
is below 24V. Turn on bus lights to drain battery below 24V if necessary. See location of 24VBATSDS in
figure 14.
c.
Once the voltage is under 24V, with a multimeter connected to pins 30 and 87a of Ultracap delay relay,
there should be continuity across. See schematic in figure 13 and figure 5.
d.
With the multimeter still connected, press the Front Start push button, wait at least 1 second and check
continuity across pins 30 and 87a of Ultracap delay relay, again. There should be no continuity across
pins 30 and 87a at this point. If there is continuity, then please contact New Flyer
service.
PS61PC
24VBATSDS
Figure 14: SDS compartment view facing front of bus
ITS60428
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May 19, 2022
INSTRUCTION TO SERVICE
ITS60428
LABOUR ESTIMATE
Operation
1
Number of
Technician(s)
1
Install ultracapacitor delay relay
Hours
3.5
Labor Time
T X HR
3.5
PARTS REQUIRED
Qty.
per Coach
1
Units
EA
HRNS-JUMPER SC PANEL
1
EA
SCREW MACHINE NO 10 PN HD
1
EA
659000
WASHER FLAT SST 10
1
EA
5
106614
RELAY 24V SPDT
1
EA
6
685168
1
EA
7
685169
LOCK- RELAY BASE
1
EA
8
034793
2
EA
9
5962614
TYRAP MIN 4" BLACK
20
EA
Use as necessary
10
5958112
TYRAP-7.0 BLACK
20
EA
Use as necessary
11
5955945
TYRAP-HVY 14" BLACK
20
EA
Use as necessary
12
351161
CABLETIE-WIDE HEAVY-DUTY
4
EA
Use as necessary
13
102879
SOCKET-FEM TERM
2
EA
14
666994
SPLIT LOOM - 1/4"
10
FT
15
666993
SPLIT LOOM - 1/8"
4
FT
Qty.
per Coach
1
Units
EA
1
EA
Item
1
Part Number
908517
2
908525
3
14S00006
4
Description
HRNS-JUMPER SDS PANEL
Notes
SPECIAL TOOLS REQUIRED
Item
1
Part Number
NPN
2
NPN
ITS60428
Description
DELPHI CRIMPER
MULTIMETER
Page 13 of 13
Notes
May 19, 2022
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TSB/Document ID: ITS60428
Replacement Service Bulletin Number:
MFR Communication Date: 2022-05-19
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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