NHTSA ID Number: 10215533
Manufacturer Communication Number: ITS60452
TSB/Document Date: 2022-07-07
Summary
Technical Instruction describing how to rework and adjust the stop request pull cord cover.
INSTRUCTION TO SERVICE
ITS: 60452
DATE 6/22/2022
SECTION:
280C – Passenger Signal
WRITTEN BY:
Daniel Tice
SUBJECT:
Pull Cord Cover Rework and Adjustment
ISSUE:
Some current pull cord covers installed have minimal clearance causing the
pullcord switch to stick
SUMMARY:
Rework switch by adding additional mounting spacers, add Loctite and torque
mounting hardware.
ITS60452
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
ITS60452
PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Locate items #1 and #2 pull cord covers.
2
1
1
Item
Part Number
Description
1
544140-1016
Cover Chime Switch, Steel Grey
2
544142-1016
Cover Chime Switch, Steel Grey
Figure 1: Pull cord cover location reference.
ITS60452
Page 2 of 9
June 22, 2022
INSTRUCTION TO SERVICE
ITS60452
3. Loosen the two retaining screws in the Tiller line clamp (NF PN 444322) releasing the cable from the pull cord
switch. Set the clamp and pull cord aside for re-installation. See Figure 2.
4. Remove the pull cord cover mounting screws item #3 from the cover and set aside for re-installation. See
Figure 2.
5. Place the removed cover aside for re-installation.
1,2
Remove
Pull Cord
Cover
Screws
3
Remove
Pull Cord
Cover
Bushing.
Loosen Clamp
and Remove
Pull Cord from
Switch.
Item
Part Number
Description
1
544140-1016
Cover Chime Switch, Steel Grey
2
544142-1016
Cover Chime Switch, Steel Grey
3
852504
Screw Torx TR 10-24 .75 Thd Lock
Figure 2: Pull cord cover removal location reference.
ITS60452
Page 3 of 9
June 22, 2022
INSTRUCTION TO SERVICE
ITS60452
6. Remove the pull cord cover bracket mounting screws item #3 from the cover and set aside for re-installation.
See Figure 3.
7. Remove the existing pull cord switch mounting screws and washers. Set cover bracket, switch square spacer
and washers aside for re-installation. Discard mounting screws. See Figure 3.
8. Secure pull cord switch and wiring out of the way and enlarge the two holes in the Pier Panel only to .375” at
the two switch mounting screw locations only in preparation to install spacers under the switch. See Figure 3.
Note: Only drill the Pier panel, do not drill the structure.
3
Remove Pull Cord
Switch Mounting
Screws and Discard
Remove
Pull Cord
Cover
Bracket
Mounting
Screws
Drill Pier Panel only
out to .375 or 3/8”
DO NOT DRILL
STRUCTURE
3
Item
Part Number
Description
3
852504
Screw Torx TR 10-24 .75 Thd Lock
Figure 3: Pull cord switch cover bracket removal location reference.
ITS60452
Page 4 of 9
June 22, 2022
INSTRUCTION TO SERVICE
ITS60452
9. Place item #10 pull cord switch spacers in the .375” holes in the pier panel. See Figure 4.
10. Install the pull cord cover bracket over the spacers reinstalling the square pull cord switch spacer and switch
with the existing washer’s item #8, new item #7 Screws applying one or two drops of Loctite item #6 to their
threads. Do not fully tighten screws. Screws to be secured in following steps. See Figure 4.
11. Re-install switch cover bracket screws item #3 Screws applying one or two drops of Loctite item 6 to their
threads. See Figure 4.
3,6
6,7,8
Install
Pull Cord
Switch
Bracket
Spacers
#10
Re-install
Pull Cord
Cover
Bracket
Mounting
Screws
10
3
Rear View of Switch/Pier Panel Removed
Item
Part Number
Description
3
852504
Screw Trox TR 10-24 .75 Thd Lock
6
081034
Loctite
7
14S00016
Screw PH 10-24 x 1.00
8
50W00000
Washer SST Flat #10
10
968305
Spacer - .192 ID x .375 OD x .25 LG
Figure 4: Pull cord switch spacer location reference.
ITS60452
Page 5 of 9
June 22, 2022
INSTRUCTION TO SERVICE
ITS60452
12. Place the pull cord cover item #1 or #2 on the pull cord cover bracket and ensure the mounting screw holes
line up. See Figure 5.
13. Adjust the pull cord switch as needed to center the plunger in the cover opening and torque the switch
mounting screws item #7 to 30 IN-LBS. See Figure 5.
14. Install the original pull cord cover screws item #3. See Figure 5.
15. Re-install the pull cord with the original tiller line clamp (NP PN 444322) applying one or two drops of Loctite
item #6. See Figure 5.
Ensure
Mounting
Holes
Line up
1,2
3
Re-install
pull cord
applying
Loctite
Item #6 to
clamp
screws
Torque to 30 IN-LBS
7
Item
Part Number
Description
1
544140-1016
Cover Chime Switch, Steel Grey
2
544142-1016
Cover Chime Switch, Steel Grey
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TSB/Document ID: ITS60452
Replacement Service Bulletin Number:
MFR Communication Date: 2022-06-22
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
MFR Component Subsystem:
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