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Title

FSC 22-18-2897 - 5 Tank Fairing Close out Bracket
URL Name

FSC-22-18-2897
Last Published Date

12/22/2022 1:18 PM
Publication Status

Published
Sharing Public URL

https://gillig.lightning.force.com/lightning/articles/Knowledge/FSC-22-18-2897
(https://gillig.lightning.force.com/lightning/articles/Knowledge/FSC-22-18-2897)

Field Service Campaign
Issue Description (Rich Text)

The CNG Pontoon Closeout Brackets may experience a fatigue failure and should be removed and replaced.
Rework Instructions for CNG Closeout Brackets 20-68822-007 & 20-68822-011 & Closeout Plate 20-68891-010
This knowledge article outlines the proper procedure to replace brackets 20-68822-007 and 20-68822-011 and modify closeout plate 20-68891010.
Symptoms (Rich Text)

Tools Required (Rich Text)

ü1/2” hex socket (qty 1)
ü3/8” or 1/2” square drive ratchet (compatible w/ the hex socket above) (qty 1)
üTorque wrench (compatible w/ the hex socket above) capable of 17 ft-lbs (qty 1)
ü1/2” crescent wrench (qty 1)
ü15/32” drill bit (must be suitable for drilling sheet metal) (qty 1)
üPower drill (qty 1)
üTape measure (qty 1)

Categories (0)

Expand All

üSafety harness & fall protection
Parts Required:

üBracket - 20-68822-024P (qty 2)
üBracket - 20-68822-025P (qty 1)
ü5/16-18 UNC x 1.25” cap screw - (P/N 54-11318-004) (qty 2)
ü5/16-18 UNC x 1.00” cap screw - (P/N 54-11318-003) (qty 5)
ü3/8” SAE washer - (P/N 54-12600-008) (qty 7)
ü5/16” fender washer - (P/N 54-12605-003) (qty 7)
ü5/16-18 lock nut - (P/N 54-12540-006) (qty 7)
Diagnostic Steps

Repair Steps

STEP 1: Disconnect forward gas spring from closeout bracket
WARNING: Be sure to wear a safety harness or other fall protection safety devices when working on the roof of the bus.
WARNING: The gas spring is under a compression load. Exercise caution when removing or re-attaching the gas spring.
1. Fully open both fairing doors.
2. Disconnect the street side forward gas spring (P/N 53-20347-012 or -013) from the ball stud (P/N 54-33553-001) on the closeout bracket (P/N 2068822-011).
3. Use 1/2” hex sockets or wrenches to remove the ball stud (P/N 54-33553-001) from the closeout bracket (P/N 20-68822-011). The ball stud will be
reused later.

STEP 2: Remove the closeout panel and two closeout brackets from the CNG frame.
1. Use the 1/2” hex socket and crescent wrench to remove the 5/16-18 hardware that secures the closeout panel (P/N 20-68891-010) to the brackets
(P/N 20-68822-007 & 20-68822-011).
2. Remove the closeout panel (P/N 20-68891-010) from the bus. This panel will need to be reworked on a work bench or other stable surface.
3. Remove the 5/16-18 hardware that secures the brackets (P/N 20-68822-007 & 20-68822-011) to the CNG frame.
4. Remove the brackets (P/N 20-68822-007 & 20-68822-011) from the bus. These brackets can be discarded.

STEP 3: Modify closeout panel 20-68991-010.
1. Place the closeout panel on a hard surface in the orientation shown in the lower left picture. Support the closeout as necessary to prevent
deformation during the rework process.
2. Use a 15/32” drill bit to drill new upper mounting holes as shown in the picture on sheet 5
3. Use a 15/32” drill bit and enlarge the existing lower mounting holes. Drill new lower mounting holes (as shown on sheet 6) and then trim the
material around the holes to make vertical slots.

STEP 4: Install new brackets.
1. Install new two new brackets (P/N 20-68822-024P) in the same location as brackets 20-68822-007 and 20-68822-011 using 5/16-18 UNC x
1.25 cap screws (P/N 54-11318-004) and 5/16” SAE washers (P/N 54-12600-007).

2. Hand-tighten the screws only (to allow for adjustments during the closeout plate installation).

STEP 5: Install closeout plate.
1. Place the modified closeout plate (P/N 20-68891-010) against the upper face of the new 20-68822-024P brackets.
2. Install the curb side upper mounting hardware into the large upper mounting holes that were drilled during the closeout plate modification.
The curb side bracket uses 5/16-18 UNC x 1.00 cap screws (P/N 54-11318-003), 3/8 SAE washers (P/N 54-12600-008), 5/16 fender washers
(P/N 54-12605-003), and 5/16-18 UNC lock nuts (P/N 54-12540-006).

STEP 5: Install closeout plate (continued)
3. Adjust the position of the street side 20-68822-024P bracket as necessary to align all of the closeout plate mounting holes and slots.
4. Install new gas spring bracket 20-68822-025P on the street side 20-68822-024P bracket.
5. Install the street side upper mounting hardware into the large upper mounting holes that were drilled during the closeout plate modification.
The street side bracket uses 5/16-18 UNC x 1.25 cap screws (P/N 54-11318-004), 3/8 SAE washers (P/N 54-12600-008), 5/16 fender washers

(P/N 54-12605-003), and 5/16-18 UNC lock nuts (P/N 54-12540-006).

Labor Information

Warranty Claims

Repair is reimbursable through GILLIG Warranty. Include the Repair Plan bulletin number in the “Describe Specific Repairs Section” (3C’s) of GILLIG
Application for Warranty Form.
Parts Return Disposition

Dispose locally
Vendor Article

Visibility
Visible In Internal App

Visible
to Customer
STEP
5: Install closeout plate (continued)
Visible In Public Knowledge Base

6. Tighten the upper mounting hardware to 17 ft-lbs torque (typical 4 places).
7. If required, loosen the lower bracket hardware and adjust the lower brackets as needed to align with the lower slots on the closeout plate.
8. Install the mounting hardware for the lower closeout mounting slots (typical 3 places). The lower mounting hardware consists of 5/16-18 UNC x
1.00 cap screws (P/N 54-11318-003), 3/8 SAE washers (P/N 54-12600-008), 5/16 fender washers (P/N 54-12605-003), and 5/16-18 UNC lock
nuts (P/N 54-12540-006).
9. Tighten the lower bracket mounting hardware and the closeout lower mounting hardware to 17 ft-lbs.

STEP 6: Install gas spring.
1. Install the ball stud (P/N 54-33553-001) onto the street side gas spring bracket (P/N 20-68822-025P). Include the 5/16 SAE washer (P/N 5412600-007) and 5/16-18 UNC lock nut (P/N 54-12540-006).
2. Tighten the ball stud hardware to 17 ft-lbs.
3. Connect the forward gas spring (P/N 53-20347-XXX) to the ball stud.

4. Close and lock the fairing doors.

Knowledge

Edit as Draft

FSC 22-18-2897 - 5 Tank Fairing Close out Bracket
Article Record Type

Article Number

Publication Status

Last Modified Date

Version Number

Field Service Campaign

000001136

Published

12/22/2022 1:18 PM

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Archive

Knowledge

Edit as Draft

FSC 22-18-2897 - 5 Tank Fairing Close out Bracket
Article Record Type

Article Number

Publication Status

Last Modified Date

Version Number

Field Service Campaign

000001136

Published

12/22/2022 1:18 PM

1

Archive