INSTRUCTION TO SERVICE
ITS: 58518
SECTION:

422 Internal Applied Parts

WRITTEN BY:

James Ashdown

SUBJECT:

Install lanyards on stop request sign access door

ITS58518
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERED 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 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.

PROBLEM DESCRIPTION: Buses received without lanyards on stop request sign access door.
SOLUTION: Install lanyards on all applicable field buses.

PROCEDURE:
1. Enter bus and turn the battery disconnect switch to the “OFF” position.

2. Locate/open both stop request sign and HVAC center cover access doors. Refer to Figure 1.

HVAC center cover
access door

Stop request sign
access door

Figure 1 – Locate/open stop request sign and HVAC center cover access doors

3. Position HVAC C/O Brackets (P/N 363132 x2, P/N 496420 x2) on the insides of stop request access sign door
panel and HVAC center cover panel in accordance with Figures 2 and 3. Lightly trace around brackets to later
assist in positioning during Plexus application.

_________________________________________________________________________________________________________________
ITS: 58818
Page 2 of 7

Stop request sign
access door

HVAC C/O Brackets (P/N 496420)

Figure 2 – View above stop request sign and HVAC center cover access doors (doors shown in closed
position)
HVAC C/O Bracket
(P/N 363132)

HVAC C/O Bracket
(P/N 363132)

Center cover
panel

Figure 3 – View inside stop request sign compartment looking aft

_________________________________________________________________________________________________________________
ITS: 58818
Page 3 of 7

4. Wipe down the bonding surfaces of HVAC C/O Brackets (P/N 363132 x2, P/N 496420 x2), stop request access
sign door panel and center cover panel with a lint free cloth and Isopropyl Alcohol (P/N 134336). Let flash dry
for a minimum of 5 minutes to a maximum of 60 minutes. Refer to Figures 2 and 3.
Note: Ensure that all bonding surfaces are free of grease and debris. Refer to Appendix A – Plexus Application
Procedure for Steps 4 - 7.

5. Apply a thin layer of Plexus PC120 Primer (P/N 067196) to bonding surfaces of HVAC C/O Brackets (P/N
363132 x2, P/N 496420 x2) and let dry for one minute.

6. Apply Plexus Adhesive MA920 (P/N 067197) to bonding surfaces of HVAC C/O Brackets (P/N 363132 x2,
P/N 496420 x2) within one hour of applying Plexus PC120 Primer (P/N 067196).

7. Clamp and secure HVAC C/O Brackets (P/N 363132 x2, P/N 496420 x2) in position on approximately 20
minutes. Ensure to wipe off excess Plexus squeeze out before curing. Refer to Figures 2 and 3.
Note: Adhesive must come out of bond holes in brackets to ensure a proper bond.

8. Secure Lanyards (P/N 444987) x2 to HVAC C/O Brackets (P/N 363132) x2 on center cover panel using
Screws (P/N 14S00010) x2, Washers (P/N 10W00000) x4, and Locknuts (P/N 40N00000) x2. Refer to Figure
4.

Secure with Screw (P/N 14S00010),
Washers (P/N 10W00000) x2, and
Locknut (P/N 40N00000)

Lanyard (P/N 444987)
Center cover panel

Figure 4 – Secure lanyards to HVAC C/O Brackets (Door in closed position - one lanyard location shown)

_________________________________________________________________________________________________________________
ITS: 58818
Page 4 of 7

9. Close and secure both stop request sign and HVAC center cover access doors.

10. Remove all tools and debris and return the bus to service condition.
11. Turn the main battery disconnect switch to the “ON” position.

_________________________________________________________________________________________________________________
ITS: 58818
Page 5 of 7

LABOUR ESTIMATE
Operation
1

Install lanyards on stop request sign access door

Men

Hours

1

0.75

Labor Time
M X HR
0.75

PARTS REQUIRED
Description

Qty.
per
Coach
.01

Units

.01

EA

2

EA

4

EA

0.01

EA

Item

Part Number

1

067196

PRIMER-PLEXUS PC120

2

067197

ADHESIVE-PLEXUS MA920

3

14S00010

4

10W00000

5

134336

ISOPROPYL-ALCOHOL

6

444987

LANYARD-11.5 LG, TYPE 3 DTCHBL

2

EA

7

40N00000

NUT LOCK NYLON #10 24 UNC

2

EA

8

496420

BRACKET-HVAC C/O TETHER

2

EA

9

363132

BRACKET-HVAC C/O TEATHER

2

EA

SCREW PH CROSS RECESS SS #10 24
UNC X 5/8" LG.
WASHER-FLAT #10 NOM

Notes

QT

SPECIAL TOOLS REQUIRED
Item

Part Number

Description

1

6470988

MIXING NOZZLE 490ML

2

6472958

PLEXUS MANUAL APPLICATOR 490ML

Qty.
per
Coach
1

Notes
Units

1

EA

EA

_________________________________________________________________________________________________________________
ITS: 58818
Page 6 of 7

Appendix A – Plexus Application Procedure
1. Wipe down all contact surfaces with clean lint free cloth, ensure that surface area
is free of grease and debris.
2. Apply Plexus PC120 Primer along all surfaces which are to be bonded using a clean cloth. Let flash off until
completely dry.
3. Apply Plexus MA920 Adhesive to indicated surface. Dispense adhesive length of mix nozzle when using a
new nozzle before applying to primed surface.
4. Place bonding surfaces together, pressing bonding surfaces firmly together and apply clamps.
5. Remove any excess squeezed-out adhesive and allow drying for 20 minutes before removing clamps.

** SAFETY:
Applicator shall use rubber gloves and approved respirator when using Plexus Primer and
Adhesive.

_________________________________________________________________________________________________________________
ITS: 58818
Page 7 of 7