INSTRUCTION TO SERVICE
ITS61120

August 9, 2024

SECTION:

420 – Shell Exterior

WRITTEN BY:

New Flyer Service Engineering

SUBJECT:

R&R Lock Handles on Baggage Doors, WCL Door & Rear Side Service Door.
Install Handle Lever Arm Stopper Brackets on WCL & Rear Side Service
Doors.

ISSUE:

Existing paddle latches are failing

SUMMARY:

Remove the faulty lock handles and replace them with an upgraded lock
handles on the Baggage, WCL & Rear Side Service doors. Install stopper
brackets on the WCL & Rear Side Service doors.

ITS61120
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
ITS61120

PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Locate the six baggage doors, the wheelchair lift door, and the rear side service door as shown in Figure 1.

Rear Side
Service Door

WCL Door

Baggage Doors

Figure 1: Lock Handle Locations
4. Remove and discard all the eight lock handles shown in Figure 1. Retain the lock cylinders for reassembly.
5. Install the existing lock cylinders into the new lock handles (PN 1056412). Ensure the linkages are connected
properly. Apply Blue Loctite (PN 21-7212-18) to the threads of the lock cylinder prior to tightening it. Ensure
not to apply the Loctite to the plastic handle.
6. Install the assembled lock handles back into the baggage doors. Use four new washers (PN 19-2-23), four
new screws (PN 19-1-386) to fasten them in place. Apply 1-2 drops of Loctite 243 (PN 23-02-0088) to the
threads of the hardware and torque to 9-11 Ft/Lbs. Use a paint marker and apply a torque stripe. Ensure the
lock handle linkages are re-connected properly and test doors for proper operation. Adjust as required.
7. Install the assembled lock handles back into the rear side service and the wheelchair lift doors. Use three new
washers (PN 19-2-23), three new screws (PN 19-1-386) to fasten them in place in the three holes shown in
Figure 2. Apply 1-2 drops of Loctite 243 (PN 23-02-0088) to the threads of the hardware and torque to 9-11
Ft/Lbs. Use a paint marker and apply a torque stripe.

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August 9, 2024

INSTRUCTION TO SERVICE
ITS61120

Figure 2: First Three Locations to Fasten
8. Locate the new handle lever arm stopper bracket (PN 1093572). Apply friction gasket (PN 1093498) to the
left-hand side of the stopper bracket. See Figure 3. Cut friction gasket to size as needed.

Figure 3: Apply Friction Gasket to Stopper Bracket
9. In the fourth screw location, install the new handle lever arm stopper bracket (PN 1093572) then fasten in
place using one new washer (PN 19-2-23), one new screw (PN 19-1-386). Make sure the position of the link
is at closed position so that the position of the stopper could be adjusted, and it is not interfering with the link
while locking the door. See Figure 4. Apply 1-2 drops of Loctite 243 (PN 23-02-0088) to the threads of the
hardware and torque to 9-11 Ft/Lbs. Use a paint marker and apply a torque stripe.

ITS61120

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August 9, 2024

INSTRUCTION TO SERVICE
ITS61120

Rear Side
Service Door

WCL Door

Figure 4: Adjusted Stopper Bracket with Link in Closed Position
10. Ensure the lock handle linkages are re-connected properly and test doors for proper operation. Adjust as
required.
11. Clean up all tools and debris and return the coach to service condition.
12. Turn the main battery disconnect switch to the “ON” position.

ITS61120

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August 9, 2024

INSTRUCTION TO SERVICE
ITS61120

LABOUR ESTIMATE
Operation
1

R&R Lock Handles on Baggage Doors, WCL Door &

Number of
Technician(s)
1

Hours
4.0

Labor Time
T X HR
4.0

Rear Side Service Door. Install Handle Lever Arm
Stopper Brackets on WCL & Rear Side Service Doors.

PARTS REQUIRED

Description

Qty.
per
Coach
8

Units
EA

Parts Ordered PPSO

Item

Part Number

1

1056412

2

21-7212-18

ADHESIVE-LOCKTITE THRD-LOCKING

0.01

EA

Source Locally

3

23-02-0088

ADHESIVE-LOCTITE 243

0.01

EA

Source Locally

4

1093572

BRKT-STOPPER HANDLE LEVER ARM

2

EA

Parts Ordered PPSO

5

1093498

GASKET-FRICTION,HANDLE

1

EA

Parts Ordered PPSO

6

19-2-23

WASHER-FLAT,1/4 ID,STAINLESS

32

EA

Parts Ordered PPSO

7

19-1-386

SCREW-CAP,HEX,1/4-20UNC X 1/2"

32

EA

Parts Ordered PPSO

HANDLE-CODEABLE LOCK

Notes

STAINLESS

ITS61120

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August 9, 2024