INSTRUCTION TO SERVICE
ITS: 59076
SECTION:

273

Exterior Lights

WRITTEN BY:

Mike Pearson

SUBJECT:

Replace specified street and curbside front headlamps

ITS59076
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.

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Locate and open the exterior wiper motor access door, interior LH lower dash panel access door and interior RH
lower dash panel access door.
3. Inspect the date stamp on the existing curbside and street side headlamps, an inspection mirror may be needed to
view the date stamp location, see Figure 1 for date stamp location.
4. If the headlamp date stamp is between 26-June-2019 and 14-October-2020 the headlamp will need to be replaced
as per Steps 5 thru 8, document and discard the headlamp as per Step 12. If the headlamp date stamp is not
between 26-June-2019 and 14-October-2020 the headlamp is not to be replaced.
5. Disconnect tie back the harness from the headlamp being replaced.
6. Remove and save the existing headlamp mounting hardware.
7. Remove the existing headlamp and install the new curbside headlamp p/n 621840 and/or street side headlamp p/n
621841 depending on date stamp using the existing hardware from Step 6, torque hardware to 40-50 in*lbs.
Headlamp modules are to be centered in the pockets in the front mask to ensure that there is no contact between
the headlamp and the panel.
8. Reconnect the harnesses to the corresponding headlamps.
9. Remove all tools and debris and return the bus to service condition
10. Close the exterior wiper motor access door, interior LH lower dash panel access door and interior RH lower dash
panel access door.

11. Turn the main battery disconnect switch to the “ON” position.
12. Removed headlamps, failed or not must have the headlamp date code documented for each claim (headlamp) to
be accepted, as well as an approx. 1/4” dia hole is to be drilled thru the rear of the headlamp to an approx. depth
of ½”. The date code and hole can be located as shown;

Street and
curbside front
headlamps

Drill an approx. 0.25 dia hole thru the rear of the
headlamp at the center of this approx. area

Headlamp
date code

Figure 1: Headlamp Date Code and Hole Locations, Typ for CS & SS

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ITS:59076
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LABOUR ESTIMATE
Operation

1

Replace existing street and curbside front headlamps

Men

Hours

Labour Time
M X HR

1

0.50

0.50

PARTS REQUIRED
Item

Part Number

1

621840

Assembly-Headlamp LED CS

Qty.
per
Coach
1

2

621841

Assembly-Headlamp LED SS

1

Description

Units

Notes

EA

As required

EA

As required

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ITS:59076
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