INSTRUCTION TO SERVICE
ITS61012

07/15/2024

SECTION:

490-Entrance Door

SUBJECT:

Front Plug Door Updates

ISSUE:

Update front plug door to improve reliability and reduce wind noise

SUMMARY:

Rework front plug doors per this ITS

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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
ITS61012

PROCEDURE:
1. Apply parking brake and place wheel chocks underneath the front wheels.
2. Operate the front door from outside by using the door control switch.

3. Ensure the coach has the latest door controller software. It must be the 426110B4v0413.s19 or newer version. If the
door software needs to be updated, then:
a.
Remove cover from the LH parcel rack to gain access to the door controller.
Note: refer to your maintenance manual for the exact location of the door controller.
b.
c.

Connect the cable with USB A and USB B ends to the controller and laptop.
Use the Masats door software to upload the new program. Refer to photos below.
Door controller

USB A to the
controller

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INSTRUCTION TO SERVICE
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Cable connected to
the door controller

Click Open Test
& Diagnosis

d.

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Start Masats software, chose language

Click Network &
Serial Tools

Select latest program then click
Program Switchboard then Accept

After new program has been uploaded, operate the door couple times to ensure it works properly.

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Hardware Updates:
4. Ensure door operates and aligned as designed:
a.

Check the gaps in front of and behind the door, between the door and the portal frame: gaps should be equal, in
other words, the door must be positioned centered inside the portal frame.

b.

When door is raised up and locked the gap between the top of the door and the portal frame must be ½”. At this
time the bottom of the glass should aligned with the body lines.

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INSTRUCTION TO SERVICE
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c.

Ensure the curvature of the door is matching the curvature of the portal frame. If not, contact your local MCI
representative for further inspection and corrective action.

5. If the door alignment doesn’t meet the above requirements, then adjust door per the Maintenance Manual. Also see
some door adjustment notes at paragraph 14 of this document.
6. Pull the emergency release arm so the door can be opened and closed manually.

 NOTE:

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Open clear cover and pull arm down to move door freely. Push red button on side to
reconnect door with the motor.

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INSTRUCTION TO SERVICE
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7. Apply foam “shim tape” (P/N 1079179, total qty 15’) to both leading edge and trailing edge of portalextrusion to shift and rotate the outer seal for a better engagement with the door.

8. Use rivet (P/N 19-13-170, qty 2) and washer (P/N 19-2-165, qty 2) to secure the seal to the step.
9. Wipe the joint of the step and seal with a cloth lightly soaked with denatured alcohol. Allow 2 minutes of flash off time,
then apply black Sika 221 sealer (PN 055700) between the leading and trailing inner door seals and the stepwell to
prevent gaps that result in road noise.

Black Sika 221

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INSTRUCTION TO SERVICE
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10. If bulb seal is not already present, then wipe the inside surface of the door with denatured alcohol along the leading
edge just rearward of the sensitive edge rubber molding. Allow 2 minutes flash off time, then add a D-seal (P/N
6819301, QTY 88.3”) to the inside surface of the door as shown on the photos below.

11. Close the door and check for gaps at the forward and rearward edges at the bottom. Add foam block (P/N 1081184,
QTY 2) to the lower seal section of the door if required to close gaps. Use black Sika 221 to secure foam blocks to the
door.

12. Slide lower door seal forward or rearward as required to close gaps. If required, trim seal to prevent interference with
the portal.

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INSTRUCTION TO SERVICE
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13. Replace existing upper door-side wedges (PN 03-32-2714, qty 2) with new wedges (P/N 1078171, qty 2) to enhance
wedge engagement. All other wedges can remain as is.
Old door-side wedge

New door-side wedges

14. Follow normal door adjustment procedure. Pay specific attention to:
a. Ensure wedges are well aligned with each other (fore-after) to prevent missing or sliding off one another.

Pull inner seal back and watch how the
wedges engaging while door is closing

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b.

Ensure good overlap between the wedges when door closes -before door starts vertical travel (for reliable
latching in all conditions). Latch must always “catch” in hot, cold, windy, slope, etc.)

c.

Ensure good wedge engagement when closed (to ensure reliable door retention in operation).

d.

Ensure door does not bounce when closing (to ensure wedges engage).

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INSTRUCTION TO SERVICE
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e.

Ensure upper hinge spring setting is correct.

f.

Remove door motor cover (refer to photo at Paragraph 27 of this document) to gain access to the switches and
cam. Ensure rotational cam is positioned correctly (should actuate microswitch when door is about ¾”-1” from
closed position

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INSTRUCTION TO SERVICE
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15. Confirm adequate seal engagement with paper test (close door on a piece of paper at leading and trailing edges of
the door to confirm seal pressure is adequate to prevent wind noise).

Paper

16. Remove the existing pin of the cam switch sensor and replace it with a longer pin (P/N 1079979, qty 1) to prevent
microswitch ring coming off the pin.

Longer pin installed

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INSTRUCTION TO SERVICE
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Add Interior Accessible Manual Slide Bolt:
Note:

These updated latches now can be used to lock the door from inside in closed position in case of a door motor
failure.

17. Remove the lock cover and the interior door panel from the door.

Interior door panel

Lock cover

18. Remove original pawl (PN 03-32-2871) then the original keylock tumbler (PN 03-08-7140) and discard both.

New keylock tumbler
PN 1056413

Existing door
latch assembly
PN 1080997

New lever (pawl),
PN 1088175

19. Install new keylock tumbler (PN 1056413), new lever (pawl) (PN 1088175) with a larger clip (PN 3j-29-73, qty 1).
Refer to photo above and below.

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INSTRUCTION TO SERVICE
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20. Replace clip with a larger size clip (P/N 3j-29-73, qty 1).

OLD

NEW

5”

21. Add an additional slide bolt assembly (without a key lock) to the leading edge of the door. Drill a 0.1935” (4.92 mm)
dia. holes per photos below, then install the slide bolt kit PN 03-32-3049 by using 10-24 thread size inserts (P/N
515277, qty 2), #10-24 screws (P/N 19-1-542, qty 2) and washers (P/N 19-02-6035, qty 2). Refer to photos below.

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22. Cut the door panel for the new forward slide bolt assembly then reinstall interior door panel.

23. Replace the screws of both the front and rear slide bolts with longer screws (P/N 19-01-1775, qty 2) and install rubber
caps (P/N 03-32-1580, qty 2) onto the head of the screws.

Slide bolt

Rubber cap

Longer screw

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24. Reinstall the interior door panel by applying toluene to the edge of the panel and the cutout on the door to reactivate
the glue. Install covers and decals to the front and rear lock cutouts. Front cover (P/N 1077141, qty 1), front decal
(P/N 1075644, qty 1), rear cover (P/N 1077133, qty 1), rear decal (P/N 03-15-1180, qty 1), screws (P/N 19-01-2074,
qty 4) for the front cover only.

Front cover and decal

Rear cover and decal

25. Add pull-handle along the window: drill a 25/64” (0.39”) diameter hole for the rear rivnut 7.5” from the rear edge of the
door. Use the handle to mark the hole location of the forward mounting screw. Install ¼-20 thread size rivnut (P/N 193-469, qty 2) then install handle (P/N 17K-3-178) with ¼-20 screws (P/N 19-1-645, qty 2).

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INSTRUCTION TO SERVICE
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26. Retrofit new slide bolt striker plate (P/N 1075166, qty 2) to both leading and trailing sides of the portal using screws
(P/N 19-1-492, qty 4) and inserts (P/N 1079976, qty 4).

27. Reinstall the cover of the door motor.
Cover

28. Double check that all door related hardware (jam nuts of the lower control arm, bolts of the upper and lower door
arms, bolts of all wedges, etc.) are torqued. Apply torque seal onto this hardware and take photos when it is done.
29. Check for completeness of the work. Remove debris, unused parts and tools from work area. Return coach to service
condition.

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INSTRUCTION TO SERVICE
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LABOUR ESTIMATE
Operation
1

Number of
Technician(s)
1

Update door per this ITS

Hours
10

Labor Time
T X HR
10

PARTS REQUIRED

Description

Qty.
per