NHTSA ID Number: 11007428
Manufacturer Communication Number: ITS61127
TSB/Document Date: 2024-09-07
Summary
Instruction to Service to rework end fairings and add support brackets for XHE40 buses.
INSTRUCTION TO SERVICE
ITS61127
08/16/2024
SECTION:
260
Battery Compartment
SUBJECT:
Rework end fairings to add support brackets (both curbside and streetside).
ISSUE:
XHE side screen end fairings do not have sufficient outboard support.
SUMMARY:
Rework end fairings to add support brackets.
ITS61127
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
ITS61127
PROCEDURE:
1. Set park brake and chock wheels.
2.
WARNING:
Please follow all New Flyer safety procedures, as shown in the New Flyer Service
Manual, when working on the roof of the bus and when working on or around high voltage cables.
Please follow all local service facility’s safety procedures when working on the roof of the bus and
when working on or around high voltage cables.
3. Turn the main battery disconnect switch to the “OFF” position.
4. On the roof top of the bus, remove the rear fairings (PN: 1048248 & 1048237) from the bus. See Figure 1.
FIGURE 1: REMOVE THE ENTIRE CLOSEOUT AND CAP ON BOTH SIDES
5. Bond Item 10 – PN: 1047445 (S/S) and Item 11 – PN: 1048068 (C/S) bond to the fairings as per the Plexus
procedure (Appendix A) as per the dimensions shown in view A & B. For steps 5 - 9, see Figure 2 - 4.
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FIGURE 2: SHOWN REWORK APPLICATION OF THE END CLOSEOUTS
6. If the rear curbside roof rail doesn’t already have inserts installed in the location shown in section C-C, drill
25/64” diameter holes at the dimensions shown in section C-C. Drill 25/64” diameter holes at the dimensions
shown in section C-C. Install insert – ¼ - 20 UNC SST (PN: 614488).
7. Mount assy – XHE Rear SS Fairing Mount, lower (PN: 1048399) – Item 12 to the inserts in the roof rail. Open
the rear streetside screen panel (if not already opened), re-install the end fairing with the added bracket.
8. Drill 25/64” diameter holes at the dimensions shown in view E and install Item 5 (PN: 514877).
9. Mount item 9 (PN: 1046158) to the inserts in the roof panel. Open the rear curbside screen panel (if not
already opened), re-install the end fairing with the added bracket.
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Shown View of the streetside with new bracket bonded in place.
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New bracket with
mounting hardware.
Items 1,2,4,8,10,12 & 13.
See Detail D.
FIGURE 3: REWORK TO ADD SUPPORT BRACKET ON S/S REAR CLOSEOUT PANEL.
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New bracket with mounting
hardware. Items 1,2,3,4,8,9,11 &13.
See View F.
FIGURE 4: REWORK TO ADD SUPPORT BRACKET ON C/S REAR CLOSEOUT PANEL.
10. Remove all tools and debris from work area to return coach to service.
11. Turn the main battery disconnect switch to the “ON” position.
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ITS61127
Appendix A
Plexus Application
Plexus Application Procedure
1. Wipe down all contact surfaces with clean lint free cloth, ensure that surface area
is free of grease and debris.
2. Apply Plexus PC120 Primer along all surfaces which are to be bonded using clean
cloth. Let flash off until completely dry.
3. Apply Plexus MA920 Adhesive to indicated surface. Dispense adhesive length of mix
nozzle when using a new nozzle before applying to primed surface.
4. Place bonding surfaces together, pressing bonding surfaces firmly together and apply
clamps.
5. Remove any excess squeezed-out adhesive and allow drying for 20 minutes before
removing clamps.
** SAFETY:
Applicator shall use rubber gloves and approved respirator when using Plexus
Primer and Adhesive.
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LABOUR ESTIMATE
Operation
1
Rework end fairings to add support brackets (both
Number of
Technician(s)
1
Hours
2.5
Labor Time
T X HR
2.5
curbside and streetside).
PARTS REQUIRED
Description
Qty.
per
Coach
4
Units
Item
Part Number
1
20B04016
BOLT HX SS 1/4X1.00
2
42N04000
NUT-NYLON LOCK 1/4-20 UNC SST
4
EA
3
50W04000
WASHER-FLAT 1/4 NOM
2
EA
4
081034
LOCTITE-243 MEDIUM 10ML
0.01
EA
5
514877
INSERT-1/4-20 UNC SST
2
EA
6
522558
INSERT-1/4-20 UNC SST
2
EA
7
067197
ADHESIVE – PLEXUS MA920
1
EA
8
614488
WASHER-SPL 1/4X1.125X.12 SST
6
EA
9
1046158
ASSY-XHE REAR CS FAIRING MOUNT,
1
EA
1
EA
1
EA
1
EA
0.01
EA
Notes
EA
Order 1 for entire SR
LOWER
10
1047445
BRACKET-XHE REAR SS FAIRING
MOUNT, UPPER
11
1048068
BRACKET-XHE REAR CS FAIRING
MOUNT, UPPER
12
1048399
ASSY-XHE REAR SS FAIRING MOUNT,
LOWER
13
5928660
NEVER SEIZE
14
067196
PRIMER-PLEXUS PC120
1
EA
Order 1 for entire SR
15
6472958
PLEXUS MANUAL APPLICATOR GUN FOR
1
EA
Order 1 for entire SR
1
EA
490 ML
16
ITS61061
6470588
MIXING NOZZLES
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TSB/Document ID: ITS61127
Replacement Service Bulletin Number:
MFR Communication Date: 2024-08-29
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE:BODY
MFR Component System:
MFR Component Subsystem:
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