INSTRUCTION TO SERVICE
ITS: 60401

06/20/2022

SECTION:

526

Seating

WRITTEN BY:

Kalman Takacs

SUBJECT:

Tighten hardware / Replace rivets on upper deck cantilever seats if required

ISSUE:

Cantilever seats on upper deck may move

SUMMARY:

Repair seat securement per this ITS.

ITS60401
Ref. NHTSA Recall No.
Not Applicable

Ref. Transport Canada Recall No.
Not Applicable

THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED 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 unauthorized disclosure,
reproduction or other distribution of this document or information 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.

INSTRUCTION TO SERVICE
ITS60401

SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY STANDARDS
AND LOCAL/PROPERTY REQUIREMENTS.
PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. On the cantilever mounted seats located at the upper deck, check the seats for tightness according to the
followings:
a.

Attach the bracket # XC-MT-3120 to the bottom seat frame. Refer to Figures 1 and 2 below.

Figure 1: Bracket to attach force gauge
b.

Attach force gauge to the end of the bracket. Refer to Figure 2.

Figure 2: Force gauge is attached
c.

ITS60401

Push down the gauge until it shows 50 lbs. Then pull up gauge until it shows 50 lbs. Refer to Figure 2.

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INSTRUCTION TO SERVICE
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d.

Less than 3/8” of movement at the aisle end allowed at 50 lbs. push and 50 lbs. pull force. Use a helper to
measure the movement with a tape measure. Refer to Figure 3.

Figure 3: Measure movement (if any)
3. If the seat is tight (less than 3/8” of movement at the aisle end) move on to the next seat / bus.
4. If the seat is loose:

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INSTRUCTION TO SERVICE
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a.

Check the mounting hardware of the seat and make sure it is tight and torqued to spec. Locations of the
hardware to check with torque specs are shown in Figure 4 and 5. If the hardware is not torqued to spec,
add 1-2 drops of Loctite 243 (NF PN 081034) and torque hardware to spec and check the seat for tightness
again.
Please note: This is
for SS cantilever
seat forward of the
wheel well

Please note: This is
common to CS & SS
cantilever seats rear of
the wheel well

Add 1-2 drops of Loctite
243 and torque to 30 – 35
ft/Lbs.

Figure 4: Check Mounting Hardware & Torque to Spec if Required
There are four bolts on the rear and four
on the front of the diagonal seat support
beam for a total of 8 bolts. Do not torque
these bolts. They are set by the seat
supplier. If they are loose then contact
to the seat supplier.

Figure 5: Diagonal support beam joint-bolts

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INSTRUCTION TO SERVICE
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5. After torqueing the mounting and seat hardware check the seat for tightness again (less than 3/8” of movement
at the aisle end) by using the bracket and force gauge as described at Step 2.
6. If the seat is tight (less than 3/8” of movement at the aisle end) move on to the next seat / bus.
Lower seat track rivet inspection:
7. If seat is still moving more than 3/8” then inspect the lower seat track for tightness. This seat track should have
no excessive movement between itself and the wall. A slight flexing is normal when a helper is pulling the aisle
end of the seat upward. This pull up load doesn’t happen in service; the load (the weight of the seat and
passengers on seats) is pushing the seat track against the side wall structure. If the lower seat track is noticeably
loose, inspect rivets for tightness. Refer to Figure 6 for affected rivets and to Figure 7 for example issues need
to verify on rivets.

Lower seat track rivets. Typical both CS
& SS

Figure 6: Lower Seat Track Rivets (Typical CS & SS – Seat Removed from Picture for Clarity)

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INSTRUCTION TO SERVICE
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Mandrel is pushed in- incorrect
Head of rivet
marked with X10
- correct

Gap between the seat track
and the head of the rivet
(rivet is loose)

Figure 7: Rivet inspection

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Additional rivet installation
8. If lower seat track is loose then drill new hole by using a 17/64” DIA size drill bit ¾” or 1” from any existing
nonconforming rivets according to the drawings below.
Note: do not remove seats to add rivets to the lower seat track. The weight of the seat is helping to push the
lower seat track against the side wall structure.

Figure 8: Installing additional rivets (as many as required) to the street side seat track

Figure 9: Installing additional rivets (as many as required) to the curb side seat track

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INSTRUCTION TO SERVICE
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9. Install new rivets (NF PN 336379). Make sure the lower seat rail is tight against the wall and the new rivets are
fully seated into the mounting hole with force before pulling the rivet tight. Ensure this is done the same way on
each new rivet that is installed. Best practice is to begin installing rivets in the middle of the track and work out
towards the ends of the seat track. This provides an even and tight seal up against the structure.
10. If the seat is tight (less than 3/8” of movement at the aisle end) move on to the next seat / bus. If the seat is still
loose, continue to inspect the seat for any sources of movement and address as required. Once the seat is
tight, add note on the work order what action was taken to fix the seat and move on to the next seat / bus.

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If seat track has to be removed
11. If the lower seat track has to be removed for any reasons, then remove seats and carefully drill out the rivets in
the lower seat track according to the followings:
12. Use a pointy center-punch and hit the center of the mandrel out of the rivet. Refer to Figures 10 and 11.
Mandrel is pushed in half way.
Push it more until it fell off
Head of rivet

Figure 10: Rivet mandrel

Larger punch to push mandrel
into the side wall.

Smaller punch to remove
remaining shank of the rivet
after the head drilled off.

Figure 11: Tools to remove rivets (drill bit is not shown)

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13. Drill the head off by using a 17/64” size drill bit with a dept limiter adjusted to 3/16”. It is very important not to
drill into the seat track or the structure.
14. Punch the remaining shank of the rivet into the structure by using a 3/16” diameter punch. Do not enlarge the
existing hole: no larger diameter punch nor drill bits are approved for rivet removal!
15. After seat track is removed inspect mounting surface (side wall structure) for flatness. Ensure no foreign objects
or flooring are present along the mounting surface. Replace seat track if required. Install seat track with new
rivets (NF PN 336379). If existing holes are damaged (larger than .275”, then install rivets to seal the enlarged
holes but also must install new rivets ¾” from the compromised hole per Paragraph “Additional rivet
installation”. Make sure the lower seat rail is tight against the wall and the new rivets are fully seated into the
mounting hole with force before pulling the rivet tight. Ensure this is done the same way on each new rivet that
is installed. Best practice is to begin installing rivets in the middle of the track and work out towards the ends of
the seat track. This provides an even and tight seal up against the structure.
16. Reinstall seats and torque mounting hardware per Figure 4. Ensure the diagonal support is pushed all the way
up per engineering drawing. Refer to Figure 12 below.

Figure 12: Push diagonal support beam all the way up
17. Remove all tools and debris and return the bus to service condition.
18. Turn the main battery disconnect switch to the “ON” position.

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LABOUR ESTIMATE
Operation

People

Hours

Labor Time

1

Check Three Upper Deck Cantilever Seats for Tightness

2

0.25

0.5

2

Tighten Upper Deck Foremost SS Cantilever Seat Hardware

1

0.5

0.5

1

0.5

0.5

1

0.5

0.5

1

1.25

1.25

1

1.25

1.25

1

1.25

1.25

2

3

6

- If Required
3

Tighten Upper Deck Rearmost SS Cantilever Seat Hardware
- If Required

4

Tighten Upper Deck CS Cantilever Seats Hardware - If
Required

5

Add rivets to the Upper Deck Foremost SS Lower Seat Track
– If required

6

Add rivets to the Upper Deck Rearmost SS Lower Seat Track
– If required

7

Add rivets to the Upper Deck CS Lower Seat Track - If
required

8

Replace lower seat track – If required

PARTS REQUIRED

Item

Part Number

Description

1

081034

LOCTITE-243 MEDIUM 10ML

2

336379

RIVET-HUCKLOK 1/4" .187-.437

Qty.
per
Coach
0.01

Units

Notes

EA

Source Locally

20

EA

If Required

Qty.
per
Coach
1

Units

Notes

EA

Only 1

SPECIAL TOOLS REQUIRED

Item

Part Number

Description

1

XC-MT-3120

Bracket to test seat movement

Required Total
2

NPN

Hucklok Rivet Installation Tool with Custom
Nose Piece

1

EA

Only 1
Required Total
Source Locally



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