INSTRUCTION TO SERVICE
ITS: 60597

12/22/2022

SECTION:

201-Bumpers

WRITTEN BY:

Kalman Takacs

SUBJECT:

Inspect welds around the mounting bracket of pulleys inside front bumper and
reweld if required

ISSUE:

Quality of weld may not meet our standards.

SUMMARY:

Inspect weld and if required repair per this ITS.

ITS60597
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
ITS60597

SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY STANDARDS
AND LOCAL/PROPERTY REQUIREMENTS.
PROCEDURE:

1. Park bus on a leveled surface and apply parking brake. Place wheel chocks underneath the front wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
Inspection
3. Locate the front bumper-door. Refer to Figure 1.

Figure 1: Front bumper-door
4. Open the left side front access door. Refer to Figure 2.

Figure 2: Left side forward access door

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5. Unlock front bumper-door by pulling the handle located inside the left side compartment. Refer to Figure 3

Figure 3: Unlock front bumper-door
6. Locate the pulleys bracket at the left side of the door. Refer to Figure 4.

Figure 4: Pulleys bracket

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7. Visually inspect the welds around the bracket. look for missing welds, inconsistent bead-size, holes on weld
bead, asymmetrical weld penetration (weld is attached to one component only). Use magnifying glass, flash
light or take photos then zoom in the picture to find flaws if any. Document the condition of the welds (whatever
their condition is) by taking photos. Refer to Figures 5a and 5b.

Figure 5a: Location of the welds that need to be inspected

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Figure 5b: Location of the welds that need to be inspected
8. If the visual inspection reveals questionable weld quality, then use a prybar and see if there is any movement
between the bracket and the base of the bumper along the welds that would indicate a weld separation or
incomplete weld.
9. If welds pass the inspection, then no further action is required. Close and lock front bumper-door, lock the left
side forward access door, remove wheel chocks and turn battery disconnect switch to the “ON” position.
10. If welds failed the inspection, then proceed with the repair as detailed below.

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Weld Repair (only if required)
11. Close the front bumper-door and ensure it is locked.
12. Disconnect the spring cable from the bus frame by accessing to its mounting bolt through the left side
compartment while the bumper-door is closed and locked. Refer to Figure 6a.
Warning: the spring is stretched (under tension) when the front bumper-door is open and relaxed (less
tension) when the door is closed. Do not attempt to unhook the cable while the door is open! If cable is still
tight while the bumper-door is closed, then open door, remove liner (refer to Figure 9) to gain access to the
spring, then loosen the nut on the spring tensioner bolt to release tension. Refer to Figure 6b and
Maintenance Manual for more details. Close the door, ensure it is locked then remove mounting bolt of the
cable.

Mounting bolt of the cable

Spring-loaded cable

Figure 6a: Attachment of the spring-loaded cable (door is open just to show the cable and bolt)

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Figure 6b: Releasing tension of spring
13. With the helper is holding the front bumper-door, unlock its latch by pulling the handle located inside the left
side compartment. Refer to Figure 4.
14. Carefully open bumper-door.
15. Place support underneath the bumper-door ensuring not to damage the paint on the exterior surfaces.

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16. Remove link bar assembly from the right side of the bumper-door by removing the pin at the bumper-door side.
Refer to Figure 7.

Figure 7: Remove pin from link bar assembly
17. Disconnect electrical connector at the left side (if equipped). Refer to Figure 8.

Figure 8: Disconnect electrical harness
18. Remove RH and LH hinge-pins then place the door on a suitable work bench.

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19. Remove liner by removing the 15 ea. ratchet type fasteners (PN 19-05-0261). Refer to Figure 9.

Figure 9: Remove fasteners and liner
20. Drill out rivet heads on both sides of the bumper by using a 0.25” drill bit, then use a punch to remove the rivets.
Refer to Figure 10.

Figure 10: Remove rivets from the inner frame of the bumper

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21. Lift up and set aside the inner frame. Refer to Figure 11.

Figure 11: Remove inner frame
22. Remove cable pulleys if required to get better access to the affected welds.
23. Remove paint from the affected welds and 1”-1” along both sides of the welds that need to be repaired by using
wire wheel. Ensure to wear appropriate safety glasses, shield, respirator and gloves.
24. Carefully grind existing weld along the defect so it can be re-welded.
25. Degrease affected weld and surrounding area with sporophyll alcohol. Flash off 10 minutes.
26. Weld affected weld per the attached Welding Procedure Data Sheet (WPDS) 1-FFa GMAW 045. Refer to Figure
12 and Appendix. Wear appropriate welding helmet and gloves. Place wet clothes underneath the
bumper to protect / cool the painted exterior surface. Weld only one leg of the bracket at a time and
keep checking the temperature of the painted surface. Stop welding and let surface cool down as
required before continue welding.
27. Clean new welds and surrounding area with wire wheels.
28. Inspect new welds and reweld as required.
29. Degrease surfaces with sporophyll alcohol. Flash off 10 minutes.
30. Apply industrial primer then black paint over the repaired area. Follow instructions on the cans.

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Figure 12: Example photos of rewelded bracket

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Final Operation

31. Reinstall inner frame piece with new rivets (PN 19-13-0338). Refer to Figure 10.
32. Reinstall pulleys if they were removed. Apply Loctite thread locker adhesive (PN 21-7212-18) onto the threads
of the shoulder bolts. Ensure Loctite does not contaminae the shoulder area of the bolt.
33. Reinstall bumper-door assembly to the bus: reinstall hinge pins, reattach link by using a new cutter pin,
reconnect electric harness. Refer to Figures 7, 8 and 13.

PN 19-7-24 CLEVIS PIN 1/2 X 1 27/64
PN 19-7-8 PIN-COTTER,1/8 DIA X 1.00

Figure 13: Reinstall link with new cutter pin
34. Route spring-cable through pulleys. Refer to Figure 5a.
35. Close the bumper-door and reattach spring cable to the frame with the original shoulder screw. Refer to
Figure 6.
36. Adjust spring tension as required. Refer to Figure 6b and Maintenance Manual for more details.
37. Reinstall liner. Replace fasteners (PN 19-05-0261) as required. Refer to Figure 9.
38. Remove all tools and debris and return the bus to service condition.
39. Turn the main battery disconnect switch to the “ON” position.

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LABOUR ESTIMATE
Operation

People

Hours

Labor Time

1

Inspect bracket attachment

1

0.5

0.5

2

Repair welds per this ITS

1

3.0

3.0

PARTS REQUIRED
Qty.
per
Coach
16

Units

Item

Part Number

Description

Notes

1

19-13-0338

PLASTIC-RIVET .197 DIA

2

19-7-8

PIN-COTTER,1/8 DIA X 1.00

1

EA

3

19-05-0261

FASTENER-RATCHET TYPE

15

EA

4

21-7212-18

ADHESIVE-LOCTITE, BLUE

0.001

EA

5

134336

ISOPROPYL-ALCOHOL

0.02

EA

6

NA

Industrial primer, 16 oz can

0.5

EA

Purchased locally

7

NA

Black paint, flat, 16 oz can

0.5

EA

Purchased locally

Qty.
per
Coach
1

Units

Notes

EA

Only as required

SPECIAL TOOLS REQUIRED

Item

Part Number

Description

1

NA

MIG welding equipment

2

NA

Grinding tools

1

3

NA

Wire wheel, deburr bits

1




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Appendix – WPDS

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