INSTRUCTION TO SERVICE
ITS60634

02/10/2023

SECTION:

490-Entrance Door

WRITTEN BY:

Mark Reitz

SUBJECT:

D45CRT Single Leaf Masats Entrance Door

ISSUE:

Entrance Door Adjustment

SUMMARY:

Performing this procedure will ensure the entrance door is adjusted and
operating properly.

ITS-60634
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 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
ITS60634

PROCEDURE:
1. Set park brake and chock wheels.
2. Start the coach and turn on the HVAC system. From outside the coach operate the door switch to open and
close the door. Observe if the door is closing properly. Note if the door bounces off of the door frame as it
attempts to close. Note if the door is not fully seated with the door frame when in the closed position.

Door not fully
seated

ITS-60634

Page 2 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634
3. With the door closed note the gaps on the rear edge and the front edge of the door at the locations indicated
in the photo below. The door gaps must be within 3mm forward side and rear side.

Gap check
rear side
these 2
places

Gap check
forward side
here

4. If the gap needs adjustment open the door then pull the manual door release handle.

Door release
handle

ITS-60634

Page 3 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634
5. Locate the 6 fasteners on the inside of the door leaf that attach the door leaf to the upper and lower linkage
arms. Completely loosen, but do not remove, 2 of the three bolts on the upper and lower mounting bracket.
Slightly loosen the remaining screws just enough to be able to slide the door fore or aft in the door mtg slots.
Have someone from the outside of the coach push the door closed and adjust the gaps evenly. Once the
gaps are set, tighten all six bolts to 14-16 ft-lbs.

3 top bolts

3 bottom bolts

ITS-60634

Page 4 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634
6. While closing the door note if the front side of the door closes before the rear side. The front side of the door
must engage the door frame first.

Steering shaft

7. If adjustment is needed slide the cover from the steering arm rod-end and loosen the two jam nuts on the
steering arm shaft.
Loosen jam nut

Length adjuster

Loosen jam nut

Cover

8. Turn the adjuster in ½ turn increments until the front of the door frame is 1/2” from the seal and the rear door
frame is 1-1/8” from the seal. Once the gaps are achieved do not yet tighten the jam nuts.

ITS-60634

Page 5 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634
9. Manually close the door slowly and observe the stepwell light going off and note how close the front edge of
the door is to the door frame. The door should be 1” from the door frame when the step light goes out. If not,
proceed to the next step.

10. To adjust the switch, open the door, remove the two screws holding the motor cover and locate the switch
adjustment cam.

Cover screws

Motor cover

Microswitch

Switch cam

ITS-60634

Page 6 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634
11. Check that there is 1mm of gap between the bottom of the door shaft and the adjustment cam. If not, raise or
lower the cam to the desired gap after slightly loosening the 3mm set screw only enough to rotate the cam.

Cam

1mm Gap

Bottom of shaft

12. Mark the adjustment starting point with a piece of tape and cut around the shaft as shown. Only make slight
rotations to the cam(approx. 1deg) then check where the stepwell light goes out. Continue adjusting the cam
until the door is about 1” from the frame when the stepwell light goes out (ref. Step 9 diagram). When
complete tighten the set screw to 30-32 in-lbs.

Reference tape

Cam set screw

ITS-60634

Page 7 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634
13. From outside the coach manually close the door slowly and observe the gap between all 4 lock wedge pairs.
Lock wedge gap should be even at all 4 pair locations. Ideal gap should be between 2-4mm. First attempt to
adjust the gap by loosening the bolts on the door side wedge and sliding the wedge. If more adjustment is
needed, then loosening the frame side wedge bolt and continue adjusting the gap. Be careful not to remove
the frame side bolt letting the T-nut slide down. Tighten wedge bolts to 5 ft-lbs and go to the next step.

Lock wedge
locations door
frame side

Note gap at all
four wedge lock
pair locations

Wedge bolt

ITS-60634

Page 8 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634
14. Check the wedge pair alignment and note if any of the lock wedge pairs do not overlap fully. See figure.

15. If wedge pair alignment needs to be adjusted then add washers under the door side wedge or subtract
washers under the frame side wedge as needed for proper overlap. On the frame side wedge be careful not
to let the T-nut slide down the track. Tighten all the wedge bolts to 17-19 ft-lbs.
16. Fully open the door and re-engage the door release handle to lock the door to the gear motor. With the coach
running and the HVAC system ON (voltage and cabin air pressure have an influence on how the door closes).
Using the door switch, open and close the door. At this time there may need to be fine tuning with the
steering adjuster to ensure all 4 lock wedge pairs are engaging properly.
17. From inside the coach push on the door at the wedge lock pair locations. If one of the wedges has not
engaged properly, you will hear a rattle of the wedges contacting each other. Reduce the wedge gap slightly
at that location.

Push at these
locations and
listen for any
rattle

ITS-60634

Page 9 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634

18. Put the coach into “High Ride”. Then using the air dump valves remove the air in the front and rear
suspension on the RH side of the coach so the coach is leaning to curbside.
Rear dump
valve

19. Open and close the door with the door switch 3-4 times. Observe function. If the door closes properly no
further adjustment is needed. If the door bounces off the frame or does not engage the lock wedge pairs then
adjustment of the door tension spring is necessary.
20. Fully open the door by using the manual release lever. Locate the top adjustment rod. Remove the rubber
boot and note the location of the spline bushing above or below the tube edge.

Adjustment rod

Spline bushing

Rubber boot

ITS-60634

Page 10 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634
21. If the spline bushing is below the top of the tube edge, loosen the jam nut and turn the adjustment rod until
the spline bushing is at the tube edge. See figure. Tighten jam nut to 92 ft-lbs. Re-engage manual door
release lever and test door open-close operation 3-4 times for proper closing. If more adjustment is
necessary, repeat this step by raising the spline bushing above the tube edge 1mm at a time and repeating
the open-close test until the door closes on the lean. Replace the rubber boot.

22. Once the door closes and locks well, carefully tighten the steering arm jam nuts 37 ft-lbs. During tightening it
is possible to change the adjustment. Replace the cover on the rod-end.
Torque jam nut

Torque jam nut

Replace cover

23. Perform door operational inspections every 6 months or 50,000 miles.

ITS-60634

Page 11 of 12

February 10, 2023

INSTRUCTION TO SERVICE
ITS60634

LABOUR ESTIMATE
Operation
1

Perform door operation inspection and adjustments

Number of
Technician(s)
1

Hours

Labor Time
T X HR
1

1

PARTS REQUIRED
Item

Part Number

Description

1

Qty.
per
Coach
1

Units

Qty.

Units

Notes

EA

SPECIAL TOOLS REQUIRED
Item

Part Number

Description

Notes

1

ITS-60634

Page 12 of 12

February 10, 2023