INSTRUCTION TO SERVICE
ITS60429

May 26,2022

SECTION:

284-ELECTRICAL PANELS (SC, RP)

WRITTEN BY:

Filipe Matias

SUBJECT:

Install ultracapacitor delay relay

ISSUE:

Ring gear damage causing stalling and inhibiting the bus from starting
(Only for SR-2276)

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.

ITS60429
Ref. NHTSA Recall No.
Not Applicable

Ref. Transport Canada Recall No.
Not Applicable

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
ITS60429

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Gain access to the Side Console in the Driver’s area as shown in Figure 1.

Side Console Panel

Figure 1 - Location of Side Console Panel

3. Locate the wire 11PS22VB, connected from the Start Push to Start Switch on Term 4 (see Figure 2), to
connector XSC68 (Pin C) as shown in Figure 7.
4. De-pin/disconnect both ends of the wire and discard.

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INSTRUCTION TO SERVICE
ITS60429

11PS22VB

Figure 2– Location and removal of wire 11PS22VB

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INSTRUCTION TO SERVICE
ITS60429

Relay

Figure 3 – Relay Location

5. Mount the new relay UCAP DELAY RLY on the right side of the Side Console Panel as shown in Figure 3.
Use the following parts:



a.
b.

Screw P/N: 14S00006
Washer P/N: 659000

c.

UCAP DELAY RLY P/N: 106614

d.

Base – Locking Relay Socket P/N: 685168

e.

Lock – Relay Base P/N: 685169

ITS60429

NOTE: Torque to 22 IN-LBS (DRY)

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May 26,2022

INSTRUCTION TO SERVICE
ITS60429

Washer

Relay

Screw
Torque to 22 IN-LBS
(DRY)

Base &
Lock

Figure 4 – Relay Installation Detail
6. Using the supplied harness P/N: 908557, route the wires to the respective locations according to the table 1
below and Figure 4. For further reference, you can also view the schematic in Figure 14.

Table 1: Jumper harness P/N: 908517 pinouts
UCAP terminal
positions
UCAP DELAY RLY-87a

X end
terminals
034795

UCAP
terminals
682919

UCAP DELAY RLY-30

034794

682919

Tan

99PS99AB

X end terminal
positions
XSC68-SHR-C
FRONT START PBTWR-4
XSC21-SHR-C

UCAP DELAY RLY-86

034795

682919

Tan

99PS99AC

GNDBSDS-13-2

UCAP DELAY RLY-85

170794

682919

White

Wire Code
99PS22VB
99PS99AA

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Wire color
Tan

May 26,2022

INSTRUCTION TO SERVICE
ITS60429

99PS99AA
99PS22VB
Rly
99PS99AC

99PS99AB

Figure 5 – Relay Connections

99PS99AC

99PS99AA

P/N: 908517

99PS99AB
99PS99VB

Figure 6– Harness Routing
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INSTRUCTION TO SERVICE
ITS60429

7. Connect the wires:
a.

99PS22VB to XSC68, Pin C

b.

99PS99AA to Push to Start Button, Term 4

c.

99PS99AB to XSC21, Pin C

d.

99PS99AC to Ground stud

XSC68
XSC21

Figure 7– Connections (Bottom of Side Console)

Figure 8 – Front Left side panel

8. Gain access to the Front Left side panel as shown in Figure 8.
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INSTRUCTION TO SERVICE
ITS60429

Spare wires
(Orange)

Figure 9 - Exterior side console view spare harness (Loom removed)

9. Cut the Plastic Ties and remove the Loom as shown in Figure 9.
10. Locate spare wire 53SPR53E 14OR. Strip the insulation from the end of the wire and crimp terminal P/N:
102879; connect to Connector XSC21, pin C.

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INSTRUCTION TO SERVICE
ITS60429

Spare wires
harness cable ties

Figure 10 – Harness Detail

11. Install the Loom over the harness and secure using plastic ties P/N 5958112, 5955945 or 351161, according
to the bundle diameter.

12. Gain access to the Rear Panel
13. Locate Spare wire 53SPR53E in Harness P/N 728214 (Right Hand Options) inside the Rear Panel.
14. Strip the insulation from the end of the wire and crimp terminal P/N 034793; Insert in connector XRR53_SHR,
location 3 as shown in Figure 11& Figure 12.
15. Route wire 99PS99AD from Module Node 14 to connector XRR53_SHR as shown in Figure 11.
16. Insert one end of wire 99PS99AD to connector XRR53_SHR and the other to J3-6 on Node 14 (Figure 13).

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May 26,2022

INSTRUCTION TO SERVICE
ITS60429

Connect to
J3 pin 6

Spare Wire
53SPR53

NODE 14

99PS99AD
P/N 908564
Insert terminal in
cavity 3

A
Connector
XRR53

Figure 11 – Rear Panel

Connector
XRR53

Figure 12 – View A - Connector XRR53 Location

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May 26,2022

INSTRUCTION TO SERVICE
ITS60429

99PS99AD
J3-6

Figure 13 – Node 14 (J3-6 detail)

Figure 14 – Schematic
17. Secure all the wires to the existing harness bundles using the plastic ties P/N 5958112 or 5955945, according
to the diameter of the bundle.

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INSTRUCTION TO SERVICE
ITS60429

18. Ensure all connectors are connected. Remove all tools and debris from work area to return coach to service.
19. Turn the main battery disconnect switch to the “ON” position.
20. 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.

21. 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 to
allow the 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 24VBAT Bus Bar in the Side Console and assure the battery
voltage is below 24V. Turn on bus lights to drain battery below 24V, if necessary. See location of
24VBAT in Figure 15.

24V Bus Bar

Figure 15 – Side Console (24VBAT)
c.

Once the battery voltage is under 24V, check if there is continuity across pins 30 and 87a of ultracap
delay relay. See schematic in Figure 14. The relay is normally closed.

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May 26,2022

INSTRUCTION TO SERVICE
ITS60429

d.

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.

22. Rework is complete.

ITS60429

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May 26,2022

INSTRUCTION TO SERVICE
ITS60429

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

Description

Qty.
per
Coach
1

Units

Item

Part Number

Notes

1

102879

SOCKET-FEM TERM

2

034793

SOCKET DEUTSCH 16-14AWG

1

EA

3

659000

WASHER FLAT SST 10

1

EA

4

14S00006

SCREW MACHINE NO 10 PN HD

1

EA

5

685169

LOCK- RELAY BASE

1

EA

6

685168

BASE- LOCKING RELAY SOCKET

1

EA

7

106614

RELAY 24V SPDT

1

EA

8

5962614

TYRAP MIN 4" BLACK

20

EA

Use as necessary

9

5958112

TYRAP-7.0 BLACK

20

EA

Use as necessary

10

5955945

TYRAP-HVY 14" BLACK

20

EA

Use as necessary

11

351161

CABLETIE-WIDE HEAVY-DUTY

4

EA

Use as necessary

Qty.

Units

Notes

EA

SPECIAL TOOLS REQUIRED

Item

Part Number

1

NPN

DELPHI CRIMPER

1

EA

2

NPN

MULTIMETER

1

EA

ITS60429

Description

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May 26,2022