INSTRUCTION TO SERVICE
ITS: 6234
SECTION:

420

WRITTEN BY:

T Stutsky

SUBJECT:

Inspect front mask support bracket bond and repair if necessary

Body Appearance Exterior

ITS 6234

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. Using the inspection sheet in Appendix A, inspect the front mask support bracket to see if it is bonded to the
front mask.
3. If the front mask support bracket is bonded in place there is no need to continue to step 4.
4. If the front mask support bracket is not bonded to the front mask do the following:
a. Open the destination sign door and locate the destination sign closeout panel brackets and remove
streetside and curbside rivets. See Figure 1 and 2.

Remove rivets

Figure 1: SS closeout bracket rivets

Remove rivets

Figure 2: CS closeout bracket rivets

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b.

Lay the destination sign close out panel bracket on the bottom of the destination sign closeout so it is
out of the way. See Figure 3.

Figure 3: Move the bracket out of the way
c.

Unplug the marker light harnesses and remove the pass-through grommets. See Figure 4.

Figure 4: Unplug the marker light harnesses

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d. Tape cable ties or something equivalent to the marker light connectors to help make it easier to pull
them through the pass-through holes when assembling later. See Figure 5.

Figure 5: Cable ties taped to the connectors
e. Remove and retain the bolts from the front mask support bracket and remove the bracket. See Figure
6.

Figure 6: Remove the front mask support bracket

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f.

Use a lint free cloth dampened with Sika Aktivator/Cleaner (NF PN 055702) and apply it on the bonding
surfaces of the bracket and the front mask. Let it flash off for 10-15 minutes or until completely dry. See
Figure 7 and 8.

Figure 7: Apply Sika Aktivator/Cleaner on the bonding surface of the bracket

Figure 8: Apply Sika Aktivator/Cleaner on the bonding surface of the mask

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g. Using a brush or equivalent tool, apply Sika 206 primer (NF PN 6358899) to the bonding surface of the
bracket and let it flash off for 10-15 minutes or until completely dry. See Figure 9.

Figure 9: Apply Sika primer to the bracket
h. Apply a continuous bead of Sika 252 adhesive (NF PN 055698) to the bonding surface of the bracket
as shown in Figure 10 and 11.

Figure 10: Sika adhesive application

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Sika to be applied where red lines are

Figure 11: Sika adhesive application
i.

Install the front mask support bracket and pull marker light wires through it. See Figure 12.

Figure 12: Re-install front mask support bracket

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j.

Push the bracket up against front mask making sure to line up the bracket mounting holes and hold the
bracket in place with the existing hardware. Allow the Sika adhesive to adhere to the front mask for 40
mins. See Figure 13 and 14.

Figure 13: Front mask support bracket placement

Figure 14: Fasten the front mask support bracket in place to allow adhesive to bond

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k.

Once the Sika adhesive has been allowed to bond for 40 mins, remove and retain the hardware from
the front mask support bracket.

l.

While installing the destination sign closeout bracket, pull the marker light wires through the destination
sign closeout bracket and hold the bracket in place. See Figure 15.

Figure 15: Place the destination sign closeout bracket in place
m. Fasten the destination sign closeout bracket back in place with six 3/16” rivets (NF PN 8410642). See
figure 16 and 17.

Install rivets

Figure 16: Install SS closeout bracket rivets

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Install rivets

Figure 17: Install CS closeout bracket rivets
n. Apply Loctite 243 (NF PN 081034) to front mask support bracket bolts. See Figure 18.

Figure 18: Apply Loctite to the bracket bolts
o. Fasten the front mask support bracket and destination sign closeout bracket back in place to the
structure tubes using the existing hardware that has Loctite 243 applied to the bolts. See Figure 19.

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Fasten the front mask support
bracket and destination sign
closeout bracket back in place to
the structure tubes using the
existing hardware

Figure 19: Fasten the brackets to the structure tubes
p. Re-install the grommets and re-connect the marker lights. See Figure 20.

Figure 20: Re-connect the marker lights
q. Clean up all tools and debris and return the bus to service condition.
r.

Turn the main battery disconnect switch to the “ON” position.

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LABOUR ESTIMATE
Operation

Men

Hours

1

Inspect the front mask support bracket bonding

1

0.25

Labour Time
M X HR
0.25

2

Re-bond the front mask support bracket

2

1.25

2.5

PARTS REQUIRED
Description

Qty.
per
Coach
0.01

Units

Item

Part Number

1

055702

AKTIVATOR-SIKA 205

2

6358899

SIKA 206 PRIMER (250 ML)

0.01

EA

3

055698

ADHESIVE 252 BLK

0.5

EA

4

081034

LOCTITE-243 MEDIUM 10ML

0.01

EA

5

8410642

RIVET BLIND BLACK PAINTED 3/16" X

6

EA

Notes

EA

Source Locally

.187/.437

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Appendix A
Front Mask Inspection
Date__________ SR#___________

Bus#___________ Inspector Name_____________

Front Mask Support Bracket

1. From inside the destination sign access door, reach up to where the front mask and front mask support bracket
bonded joint is (highlighted in the picture above). Push out on the front mask next to the bonded area.
Does the front mask and front mask support bracket separate?
Please circle -

YES

NO

Is there Sika adhesive present?
Please circle -

YES

NO

1. Inspect to see that the front mask support bracket hardware is installed and is tight.
Is the hardware installed?
Please circle -

YES

NO

If yes, is the hardware tight?
Please circle -

YES

NO

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