L3-FSV-295 Service Bulletin/Repair Instructions

NJT Suburban Handrail Installation
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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