NHTSA ID Number: 10057607
Manufacturer Communication Number: L3-FSV-295
TSB/Document Date: 2015-06-12
Summary
NABI: ON SOME BUSES, THE OVERHEAD HANDRAIL ARE NOT CONTINUOUS AND NEED TO INSTALL THE LONGER HANDRAILS. *PE
NJT Suburban Handrail Installation
SB-10057607-4615
Prepared by:
Dave Hancock
Senior Field Service Representative
862-241-8959
Approved By:
Dan Allen
Chief Engineer of Mfg. and Svc. Support
Property and TopBus Number: NJT 164200 Suburban – 5200-5423.
Issue:
Suburban Handrails
Reason/ cause:
Overhead Handrail must be Continuous
Solution:
Install Longer Handrails
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
NJT Suburban Handrail Installation
Number of affected buses:
223
Estimate repair hours/bus:
3 Hours
Necessary parts:
Item
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
Description
Grab rail Road Side
Grab rail Curb Side
Bracket Stanchion Luggage Rack
Bolt 5/16-18 x 5/8
Nut 5/16-18 x 5/8 Hex Stover
Washer Flat 5/16 SS
Screw / Sleeve Nut SS
Pivot Cup
Grab rail Ceiling Hangar Assy 7-1/2
Loctite
TSC ¼-20 x 1” PHCR Type F
Nut ¼-20 Hex Head SS
Washer Flat ¼” SS
Rail Support 57” LG
Spacer ½”
Spacer ¾”
Spacer 1”
SS 5/16-18 x 1 1/4” Bolt
SS 5/16-18 x 1 1/2” Bolt
SS 5/16-18 x 1 3/4” Bolt
PN
10B-1710-001
10B-1710-002
10B-1710-003
22051805855
21051888
5001210
5027840
5016391
10A-1710-003
5014201
5015841
200420SS
2604SS
556-1710-004M
McMaster Carr PN: 92825A201
McMaster Carr PN: 92825A203
McMaster Carr PN: 92825A205
McMaster Carr PN: 92240A585
McMaster Carr PN: 92240A587
McMaster Carr PN: 92240A589
Qty
1
1
2
2
2
2
2
2
2
.20
2
2
2
AR
AR
AR
AR
AR
AR
AR
Necessary Tools / Supplies:
Phillips Screwdriver & Impact Driver
Chop Saw
Drill
#6 Drill Bit
3/8” Drill Bit
¼” Pilot Bit
7/16” Wrench
Ratchet with 7/16” Socket
Clamp
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
NJT Suburban Handrail Installation
SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY
STANDARDS AND LOCAL/PROPERTY REQUIREMENTS
1. Park the bus on level surface and apply parking brake. Turn engine off.
2. Locate the curbside front handrail (see below).
Note
Location of
Hand
Straps
Before
Removal.
3. Remove components noted in the below picture in order to remove the existing handrail (see
below). Save the removed hardware for installation of the new handrail.
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
NJT Suburban Handrail Installation
Discard
Existing
Handrail
(save
hardware).
Discard
Ceiling
Mounting
Cup (save
hardware).
4. Install new ceiling mounting hangar (see below) using the hardware removed from step 3.
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
NJT Suburban Handrail Installation
5. Install new mounting bracket to the luggage rack utilizing one existing mounting screw (see
below).
6. Drill hole using #6 drill bit & install self-tapping screw to second hole in bracket (see below).
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
NJT Suburban Handrail Installation
7. Install new grab rail in end clamping bracket and line up to be cut. Place end cap on grab rail
and line up with bracket installed in step 6 & 7 to determine how much of the grab rail needs to
be cut (see below). Return grab rail back to bus & install to the end clamping bracket.
8. Drill a 3/8” hole in end cap (see below). If necessary, drill a ¼” pilot hole before drilling the 3/8”.
Drill 3/8”
hole
through the
pole.
9. Before installing the end cap to the mounting bracket on the luggage rack make sure the
original/additional parts are slid on to the new grab rail (straps, mounting clamps).
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
NJT Suburban Handrail Installation
10. Install provided barrel bolts to previously drilled hole in step 8 & tighten securely (coat threads
with Loctite 242 Threadlocker before installing).
11. Mount end cap to mounting bracket installed in step 5 & 6 using the hardware provided (see
below).
NOTE: If there is a gap between the mounting bracket & the end cap, a spacer must be used.
Use the appropriate spacer for the gap (1/2”, ¾” or 1”) & the appropriate bolt (1 1/4”, 1/1/2” or 1
1 3/4”). See below.
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
NJT Suburban Handrail Installation
If there is a gap between the
end & mounting bracket a
spacer & longer bolt must
be used.
12. Install provided ceiling hangar clamp to the new grab rail using the provided hardware (see
below). Coat threads with Loctite 242 Threadlocker before installing.
13. Reinstall vertical stanchion to the new grab rail using the removed clamp from step 3 (see
below). Drill a 3/8” hole in the new grab rail for the top hole. Using the removed hardware from
step 3, install & tighten securely (coat threads with Loctite 242 Threadlocker before installing).
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
NJT Suburban Handrail Installation
NOTE: If existing stanchion pole does not reach, a new pole must be used. Cut pole to fit.
14. Install forward ceiling hangar removed in step 3 using the hardware removed in step 3 (see
below). Tighten hardware securely (coat threads with Loctite 242 Threadlocker before
installing).
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
NJT Suburban Handrail Installation
15. Apply Loctite 242 Threadlocker to the clamping bracket screw threads, reinstall hardware &
tighten securely (see below).
16. Repeat same process for street side handrail replacement.
17. Inspect and file down any sharp edges caused from performing this retrofit.
18. Clean up any debris caused by performing this retrofit.
19. Record bus number, mileage and date of completion; return form to Field Service Manager
Work Instruction Number: L3/FSV-295
L4/QUA-003
Revision: Initial
Date: 10/21/2014
Revision: Initial
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TSB/Document ID: L3-FSV-295
Replacement Service Bulletin Number:
MFR Communication Date: 2014-10-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT ADAPTIVE/MOBILITY
MFR Component System:
MFR Component Subsystem:
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