SB-10057796-2168

INSTRUCTION TO SERVICE
ITS: 5927
SECTION:

284

WRITTEN BY:

Troy Stutsky

SUBJECT:

Add two bonded and riveted brackets the front and rear of the side console

Electrical Panels

ITS5927

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. Open the side console from the interior of the bus and inspect it to find out what revision number the console
is by reading the revision letter sticker.
3. If the console is revision level “G” or higher, only the cup holder hardware will need to be changed.
4. To change the cup holder hardware, follow these steps:
a. Remove and discard the cup holder hardware. Retain the cup holder for re-installation.
b. Re-install the cup holder using the four new screws (NF PN 14S00010BK) and four new acorn nuts
(NF PN 60N00000BK). Please install hardware as shown in Figure 8 below.
c.
5.

Skip to Step 11 of this ITS.

If the revision level is “F” or under, please continue with the instruction steps below.

6. To install the new front bracket (NF PN 571812) on the front end of the side console, follow these steps:
a. Locate the front bracket (NF PN 571812) and hold it in place in the location shown in Figure 1.

Remove paint from area where
bracket will bond to the side
console

Figure 1: Front Bracket Location
b. With the front bracket held in place, mark the location of the bracket on the side console box and on the
underside of the side console top panel to indicate the area the bracket will be bonded to.

_________________________________________________________________________________________________________________
ITS: 5927
Page 2 of 9

c.

Remove the bracket and with a sanding tool or equivalent tool, remove the paint from the inside of the
marked out area on these surfaces. See Figure 1.

d. Clean the two bonding surfaces with Isopropyl Alcohol (NF PN 134336) and allow alcohol the flash off
until dry to the touch.
e. Bond the bracket (NF PN 571812) in place. Follow the Plexus bonding instructions in Appendix A.
Please ensure that there is plenty of Plexus squeeze out in order to provide a complete surface bond.



NOTE:

Ensure the Plexus does not come into contact with the side console box sliders and the

captive screw retainer.
f.

Using a drill and a #10 drill bit, drill four through holes in the front bracket in the four locations shown in
Figure 2. Rivets will go through the side console top panel and through the side of the side console box.



NOTE:

Please ensure wires are not damaged when drilling the through holes.

Figure 2: Rivet Hole Locations and Rivet Orientation Instructions
g. Install two black rivets (NF PN 8410642) in the side console top panel in the correct orientation as shown
in Figure 2.
h. Install two black rivets (NF PN 8410642) in the side of the side console box in location shown in Figure 2.
i.

Apply a bead of black Sika (NF PN 055700) around the perimeter of the park brake riser box on the top
of the side console panel and tool to a smooth finish. See Figure 3.

_________________________________________________________________________________________________________________
ITS: 5927
Page 3 of 9

Figure 3: Apply Black Sika to Seal the Outside of the Brake Valve Box
j.

Apply a bead of white Sika (NF PN 055701) around the welded edges on the inside of the park brake
valve riser box to seal any gaps and apply a bead of white Sika (NF PN 055701) on the underside of the
park brake valve edges too. See Figure 4.

Seal around brake
valve with white
Sika from the
inside of the brake
valve box

Seal welded edges
with white Sika on
the inside of the
brake valve box

Figure 4: Seal the Brake Valve Box with White Sika
7. Inspect the rear end of the side console closest to the rear of the bus. If there is not a crack present, please
follow these steps:

_________________________________________________________________________________________________________________
ITS: 5927
Page 4 of 9

a. Remove and discard the cup holder hardware. Retain the cup holder for re-installation.
b. Re-install the cup holder using the four new screws (NF PN 14S00010BK) and four new acorn nuts (NF
PN 60N00000BK). Please install hardware as shown in Figure 8 below.
c.

Skip to Step 11 of this ITS.

8. If there is a crack found while inspecting the rear end of the side console closest to the rear of the bus,
please install the new rear bracket (NF PN 578711) on the rear end of the side console. Follow these steps:
a.

Remove and discard the cup holder hardware. Retain the cup holder for re-installation later.

b.

Locate the rear bracket (NF PN 578711) and hold it in place in the location shown in Figure 5.

Bracket PN 578711 to be butted
up against switch panel

Remove paint from area where
bracket will bond to the side
console
Figure 5: Rear Bracket Location
c.

With the rear bracket held in place, mark an outline around the bracket on the side console box and on
the underside of the side console top panel to indicate the area the bracket will be bonded to.

d.

Remove the bracket and with a sanding tool or equivalent tool, remove the paint from the inside of the
marked out area on these surfaces. See Figure 5.

e.

Clean the two bonding surfaces with Isopropyl Alcohol (NF PN 134336) and allow alcohol the flash off
until dry to the touch.

f.

Bond the bracket (NF PN 578711) in place. Follow the Plexus bonding instructions in Appendix A.
Please ensure that there is plenty of Plexus squeeze out in order to provide a complete surface bond.



NOTE:

Ensure the Plexus does not come into contact with the side console box sliders and the

captive screw retainer.
g.

Using a drill and a #10 drill bit, drill four through holes in the rear bracket in the four locations shown in
Figure 6. Rivets will go through the side console top panel and through the side of the side console box.



NOTE:

Please ensure wires are not damaged when drilling the through holes.

_________________________________________________________________________________________________________________
ITS: 5927
Page 5 of 9

Figure 6: Rear Bracket Hole Locations
h.

Install two black rivets (NF PN 8410642) in the side console top panel in location shown in Figure 6.

i.

Install two black rivets (NF PN 8410642) in the side of the side console box in location shown in Figure 6.

9. Using the cup holder mounting hole as a template, drill a 0.201” diameter hole through the rear bracket that is
covering the original cup holder mounting hole. See Figure 7.

_________________________________________________________________________________________________________________
ITS: 5927
Page 6 of 9

Drill a 0.201” dia hole through the
rear bracket using the cup holder
mounting hole as a template

Figure 7: Cup Holder Mounting Hole Location
10. Re-install the cup holder using the four new screws (NF PN 14S00010BK) and four new acorn nuts (NF PN
60N00000BK). Please install hardware as shown in Figure 8.

Figure 8: Re-install Cup Holder with New Hardware
11. Clean up all tools and debris and return the bus to service condition.
12. Turn the main battery disconnect switch to the “ON” position.

_________________________________________________________________________________________________________________
ITS: 5927
Page 7 of 9

Appendix A
Plexus Bonding Procedure
1. CHECK THE EXPIRY DATE ON THE CONTAINER OF PRIMER AND ADHESIVE TO ENSURE
THE PRODUCTS ARE NOT PAST SHELF LIFE.
2. APPLY THIN LAYER OF PLEXUS PC120 PRIMER (NF PN 067196) ALONG ALL SURFACES
THAT ARE TO BE BONDED USING CLEAN CLOTH.
3. WHILE THE PRIMER IS STILL WET, WIPE DOWN ALL PRIMED SURFACES WITH CLEAN LINT
FREE DRY CLOTH TO REMOVE ANY SURFACE CONTAMINANTS LIFTED OFF BY PRIMER
PC120, AND LEAVE ONLY A THIN, QUICK DRYING FILM.
4. WHEN THE PRIMER PC120 IS COMPLETELY DRIED, APPLY PLEXUS MA1020 ADHESIVE (NF
PN 526515) TO INDICATED SURFACES.
5. DISPENSE ADHESIVE LENGTH OF MIX NOZZLE (NF PN 6351374) WHEN USING A NEW
NOZZLE BEFORE APPLYING TO PRIMED SURFACE.
6. PLACE BONDING SURFACES TOGETHER, PRESS THE SURFACES FIRMLY TOGETHER AND
APPLY CLAMPS OR WEIGHTS.
7. REMOVE ANY EXCESS SQUEEZED-OUT ADHESIVE AND ALLOW TO DRY FOR 20 MINUTES
BEFORE REMOVING CLAMPS.

_________________________________________________________________________________________________________________
ITS: 5927
Page 8 of 9

LABOUR ESTIMATE
Operation
1

Add two bonded and riveted brackets the front and rear of the

Men

Hours

1

1.5

Labour Time
M X HR
1.5

side console.

PARTS REQUIRED
Item

Part Number

1

6449248

Description
KIT- SIDE CONSOLE BRACKET

Qty.
per
Coach
1

Units

Notes

EA

INSTALLATION KIT
2

067196

PRIMER-PLEXUS PC120

0.01

QT

3

526515

ADHESIVE-PLEXUS MA1020

0.1

EA

4

134336

ISOPROPYL-ALCOHOL

0.01

EA

5

055701

(OBS) SIKA 221 WHITE

0.1

EA

6

055700

ADHESIVE SIKA 221 BLACK

0.1

EA

Units

PARTS KIT – P/N 6449248
Item

Part Number

1

6361396

APPLICATOR TIPS

Qty.
per
Coach
1

2

571812

BRACKET-SC BOX

1

EA

3

8410642

RIVET BLIND BLACK PAINTED 3/16" X

8

EA

BRACKET-SC BOX

1

EA

Description

Notes

EA

.187/.437
4

578711

5

14S00010BK

SCREW-PH CR BLK #10 24

4

EA

6

60N00000BK

NUT-CRN #10UNC BLK

4

EA

SPECIAL TOOLS REQUIRED
Item

Part Number

1

6341339

Description
APPLICATOR GUN

Qty.
per
Coach
1

Notes
Units
EA

1 only per
property

_________________________________________________________________________________________________________________
ITS: 5927
Page 9 of 9