LI3753E

SAV.1E.2012MA
LI3753E
INFORMATION LETTER
REFERENCE:
Nova Bus Manuals
SECTION:
01: Structure
RS NO:
MQR 7621-1030
EFFECTIVE IN PROD.:
L961 (2016MA)
SUBJECT:
Right wall structure with 1:6 ramp
JUSTIFICATION:
Vertical beam might crack above front door, second post capping.
LEVEL
APPLICATION DEADLINE:N/A
DIRECT CHARGES
DESCRIPTION
1
Weld stiffening plates.
2
–
TIME
LABOUR
MATERIAL
Client
Client
8h
–
–
–
MATERIAL
QTY
PART NO
REV.
DESCRIPTION
REPLACES PART N°
1
N24104
–
BOLT M6 X 20 SS
–
1
N71118
–
PLATE FRONT DOOR (90°)
ST STL UNS304 ASTM A240 3/16" (4.8mm) THK
–
1
N71119
–
PLATE FRONT DOOR
ST STL UNS304 ASTM A240 3/16" (4.8mm) THK
–
1
N71120
–
BRACKET BETWEEN TUBES
ST STL UNS304 ASTM A240 12GA (2.8mm) THK.
–
2
N30702
–
POP RIVET 3/16 X 0.440 X 0.125
–
–
–
–
–
LEVEL 1
LEVEL 2
–
Materials will be available within 14 days. To order, please contact Prevost Parts by phone at 1‑800‑771‑6682, by fax at
1‑888‑668‑2555 or by email at [email protected]. Specify document number, quantity of parts required
and shipping address.
DISPOSAL OF PARTS
REMOVED PARTS ARE:
DISCARDED *
RETAINED
–
––
* Dispose of the unused parts and the defective parts in
accordance with local environmental standards in effect.
REVISION HISTORY
REV.
DATE
NR
2017MR10
CHANGE DESCRIPTION
Initial release
APPROVED BY: Daniel Theriault
WRITTEN BY
André Pelletier
Digitally signed by Daniel Theriault
DN: cn=Daniel Theriault, o=Nova Bus, ou, [email protected], c=CA
Date: 2017.03.15 11:31:44 -04'00'
PAGE 1 OF 16
INFORMATION LETTER
CLIENT
ORDER
ROAD NUMBER
FROM
TO
SAV.1E.2012MA
LI3753E
VIN (2NVY/4RKY...)
FROM
TO
QTY
Airdrie Transit - Alberta
L664
—
—
L82U2B3000507
L82U2B3000507
1
Ames Transportation Agency - Iowa
L707
660
661
S92U5C4500159
S92U1C4500160
2
Austin - CMTA - Texas
L635
5001
5001
S92U7C4500163
S92U7C4500163
1
Austin - CMTA - Texas
L636
5002
5022
S92U1D4500306
S92U0D4500328
21
Austin - CMTA - Texas
L704
5051
5068
L82J7E4500471
L82J2E4500488
18
Barrie - Ontario
L878
1501
1504
L82JXF3001691
L82J6F3001719
4
BC Transit - BCT - British Columbia
L604
9434
9434
L82U5C3000597
L82U5C3000597
1
BC Transit - BCT - British Columbia
L735
9435
9440
L82U4C3000848
L82U8C3000853
6
BC Transit - BCT - British Columbia
L736
9441
9446
L82U8D3000854
L82U7D3000859
6
BC Transit - BCT - British Columbia
L858
9447
9481
L82JXE3001401
L82J5F3001436
35
BC Transit - BCT - British Columbia
L891
—
—
L82J5F3001565
L82J2F3001569
5
Belleville Transit - Ontario
L655
—
—
L82U3B3000385
L82U3B3000385
1
Belleville Transit - Ontario
L702
—
—
L82U4D3000706
L82U4D3000706
1
Bow Valley Transit - Alberta
L712
5
6
L82U6C3000804
L82U8C3000805
2
Brampton - Ontario
L789
—
—
L82J4E3001216
L82J1E3001223
8
Brampton - Ontario
L816
—
—
L82J3E3001224
L82J9E3001230
7
Brampton - Ontario
L864
1501
1510
L82JXF3001500
L82J6F3001509
10
Brampton - Ontario
L865
1511
1519
L82JXF3001514
L82J9F3001522
9
Brantford - Ontario
L663
10121
10121
L82U1B3000532
L82U1B3000532
1
Brantford - Ontario
L718
10123
10125
L82U5C3000826
L82U9C3000828
3
Brantford - Ontario
L775
10131
10132
L82U1D3000999
L82U2D3001000
2
Brantford - Ontario
L928
10151
10153
L82J7F3001793
L82J0F3001795
3
Burlington - Ontario
L887
7017-15
7025-15
L82J7F3001681
L82J8F3001723
9
Calgary Transit - Alberta
L637
8161
8180
L82U7B3000356
L82U2B3000376
20
Calgary Transit - Alberta
L709
8181
8200
L82UXC3000806
L82U3C3000825
20
Calgary Transit - Alberta
L733
8201
8202
L82AXD3000926
L82A1D3000927
2
Central Oklahoma Transportation Authority
L619
—
—
L82X7C3000367
L82X7C3000367
1
Chicago Transit Authority - CTA - Illinois
L773
—
—
L82JXD4500429
L82J6D4500430
2
Chicago Transit Authority - CTA - Illinois
L811
7902
7949
L82J6E4500509
L82J4E4500556
48
Chicago Transit Authority - CTA - Illinois
L837
7950
7999
L82J6E4500655
L82J1E4500708
50
Chicago Transit Authority - CTA - Illinois
L847
8000
8049
L82J1E4500773
L82JXE4500822
50
Chicago Transit Authority - CTA - Illinois
L848
8050
8099
L82JXF4500823
L82J1F4500872
50
Chicago Transit Authority - CTA - Illinois
L849
8100
8149
L82J5F4500874
L82J3F4500923
50
Chicago Transit Authority - CTA - Illinois
L850
8150
8199
L82J5F4500924
L82J6G9775013
28
Clemson Area Transit - South Carolina
L617
—
—
S92U5C4500002
S92U5C4500002
1
Clemson Area Transit - South Carolina
L769
—
—
S92U1D4500418
S92U1D4500418
1
CT Transit - Connecticut
L554
1041
1065
S92U1A4000139
S92U0A4000164
25
CT Transit - Connecticut
L571
1101
1110
S92YXB4000144
S92Y4B4000169
10
CT Transit - Connecticut
L815
1426
1429
S92L0E4500709
S92L0E4500712
4
CT Transit - Connecticut
L814
1462
1473
S92LXE4500717
S92L4E4500728
12
Demo CNG
L716
—
—
L82A5D3000896
L82A5D3000896
1
PAGE 2 OF 16
INFORMATION LETTER
CLIENT
ORDER
ROAD NUMBER
SAV.1E.2012MA
LI3753E
VIN (2NVY/4RKY...)
FROM
TO
FROM
TO
QTY
Duke University - North Carolina
L651
—
—
S92Y1B4000145
S92Y3B4000146
2
Duke University - North Carolina (ref. L703)
L641
—
—
L82U9C4500012
L82U1C4500022
8
Durham Region Transit - Ontario
L872
8551
8553
L82J0F3001523
L82J4F3001525
3
Durham Region Transit - Ontario
L888
8554
8559
L82J2F3001703
L82J1F3001708
6
Fredericton - New Brunswick
L672
8111
8112
L82U0B3000540
L82U2B3000541
2
Fredericton - New Brunswick
L688
8113
8113
L82U8C3000643
L82U8C3000643
1
Fredericton - New Brunswick
L774
8131
8131
L82U7D3000960
L82U7D3000960
1
Fredericton - New Brunswick
L812
—
—
L82J4E3001202
L82J4E3001202
1
Fredericton - New Brunswick
L836
8143
8143
L82J9E3001390
L82J9E3001390
1
Fredericton - New Brunswick
L901
8151
8151
L82J7F3001602
L82J7F3001602
1
Grand River Transit - GRT - Ontario
L633
21101
21115
L82U7B3000289
L82U8B3000303
15
Grand River Transit - GRT - Ontario
L599
21116
21118
L82X9B3000465
L82X2B3000467
3
Grand River Transit - GRT - Ontario
L631
21119
21121
L82X4B3000468
L82X2B3000470
3
Grand River Transit - GRT - Ontario
L668
21201
21220
L82U6C3000737
L82UXC3000756
20
Grande Prairie Alberta
L834
—
—
L82J7E3001386
L82J2E3001389
4
Greater Toronto Airports Authority - GTAA - Ontario
L616
—
—
L82U4C4500001
L82U4C4500001
1
Guelph - Ontario
L669
225
228
L82U9B3000536
L82U4B3000539
4
Guelph - Ontario
L767
237
239
L82UXD3000967
L82U3D3000969
3
Guelph - Ontario
L835
240
243
L82J0E3001391
L82J6E3001394
4
Guelph - Ontario
L927
244
247
L82J1F3001756
L82J9F3001763
4
Halifax - Nova Scotia
L693
526
534
L82U8C3000657
L82U7C3000665
9
Halifax - Nova Scotia
L710
1160
1161
L82U7C3000780
L82U9C3000781
2
Halifax - Nova Scotia
L708
742
761
S92UXC3000782
S92U3C3000803
20
Hamilton - Ontario
L885
1501
1524
L82K3F4501093
L82K0F4501214
24
Honolulu - Hawaii
L559
201
224
L82U6A4000113
L82U7A4000136
24
Houston - Texas
L737
1510
1510
S92U4D4500297
S92U4D4500297
1
Houston - Texas
L755
1511
1579
S92U4D4500333
S92U8D4500402
69
Kingston Ontario
L880
1502
1502
L82JXF3001786
L82JXF3001786
1
Kingston Ontario
L925
1504
1510
L82J5F3001808
L82J5F3001811
4
Krapf's Coaches - Pennsylvania (ref. L833)
L754
—
—
L82U4D4500405
L82U4D4500405
1
Lethbridge - Alberta
L868
—
—
L82J2F3001510
L82J2F3001510
1
LYNX - Florida
L725
—
—
S92Y9D4500329
S92Y5D4500330
2
LYNX - Florida
L764
—
—
S92Y7D4500331
S92Y9D4500332
2
LYNX - Florida
L785
—
—
S92L6E4500505
S92L8E4500506
2
Marketing Sales Demo - MSD 6 Houston
L628
—
—
L82U8C4500003
L82UXC4500004
2
Moncton (Codiac) - New Brunswick
L569
—
—
L82U4B4000001
L82U4B4000001
1
Moncton (Codiac) - New Brunswick
L570
—
—
L82U6B4000002
L82U6B4000002
1
MTD - Santa Barbara, California
L730
—
—
S92J8E4500567
S92J1E4500569
3
NFTA - Buffalo, New York
L877
1501
1501
L82K0F4500984
L82K0F4500984
1
NFTA - Buffalo, New York
L897
1502
1520
L82K1F4501223
L82K1G9775008
1
Niagara Falls - Ontario
L652
—
—
S92U3C3000607
S92U6C3000617
11
PAGE 3 OF 16
INFORMATION LETTER
CLIENT
ORDER
ROAD NUMBER
FROM
SAV.1E.2012MA
LI3753E
VIN (2NVY/4RKY...)
TO
FROM
TO
QTY
Niagara Falls - Ontario
L653
—
—
L82U9C3000618
L82U9C3000621
5
Niagara Falls - Ontario
L771
1396
1397
L82U9D3000958
L82U0D3000959
2
Niagara Parks Commission - Ontario
L685
—
—
S92U9C3000644
S92U8C3000652
9
Niagara Parks Commission - Ontario
L656
—
—
L82U0C3000653
L82U2C3000654
2
North Bay - Ontario
L895
784
785
L82J7F3001678
L82J9F3001679
2
Oakville - Ontario
L874
—
—
L82J6F3001526
L82JXF3001531
6
Oakville - Ontario
L881
—
—
L82J2F3001717
L82J8F3001740
5
Peterborough - Ontario
L770
55
60
L82U0D3000993
L82UXD3000998
6
Peterborough - Ontario
L870
61
63
L82JXF3001612
L82J3F3001614
3
Peterborough - Ontario
L919
64
66
L82J6F3001767
L82JXF3001769
3
Red Deer - Alberta
L726
—
—
L82UXC3000840
L82U1C3000841
2
Red Deer - Alberta
L766
1104
1105
L82U7D3001025
L82U9D3001026
2
Red Deer - Alberta
L772
1106
1108
L82J2E3001120
L82J6E3001122
3
Red Deer - Alberta
L813
10008
10009
L82J2E3001361
L82J4E3001362
2
Red Deer - Alberta
L869
—
—
L82J9F3001570
L82J0F3001571
2
Red Deer - Alberta
L926
L82J2F3001796
L82J4F3001797
2
Regina - Saskatchewan
L639
645
654
L82U1B3000336
L82U2B3000345
10
Regina - Saskatchewan
L748
655
662
L82U3D3000874
L82U0D3000881
8
Regina - Saskatchewan
L776
663
669
L82U4D3001001
L82U5D3001007
7
Regina - Saskatchewan
L807
671
685
L82J8E3001137
L82J2E3001151
15
Regina - Saskatchewan
L892
686
691
L82J5F3001484
L82J4F3001489
6
San Joaquin County - California
L768
—
—
S92L4D4500422
S92L3D4500427
6
Sarnia Ontario
L873
151
152
L82J0F3001599
L82J0F3001600
2
Saskatoon - Saskatchewan
L568
—
—
S92U9B3000013
S92U9B3000013
1
Saskatoon - Saskatchewan
L618
—
—
S92U1C3000377
S92U1C3000377
1
Saskatoon - Saskatchewan
L690
1201
1204
L82U6C3000690
L82U1C3000693
4
Saskatoon - Saskatchewan
L831
1401
1405
L82J7E3001307
L82J9E3001311
5
Saskatoon - Saskatchewan
L894
1501
1510
L82J0F3001490
L82J7F3001499
10
Sault Ste-Marie Transit Services - Ontario (ref. L686)
L641
135
139
L82U7C4500008
L82U6C4500016
5
Sault Ste-Marie Transit Services - Ontario (ref. L751)
L754
—
—
L82U7D4500284
L82U7D4500284
1
SEPTA - Pennsylvania
L724
7300
7301
S92Y1D4500275
S92Y3D4500276
2
SEPTA - Pennsylvania
L728
L82W7D4500335
L82W7D4500335
1
SEPTA - Pennsylvania
L749
7302
7354
S92Y7D4500409
S92L2E4500470
53
SEPTA - Pennsylvania
L743
—
—
S92L1E4500489
S92L2E4500503
15
SEPTA - Pennsylvania
L741
—
—
S92L4E4500504
S92L4E4500504
1
SEPTA - Pennsylvania
L744
—
—
L82L7E4500570
L82LXE4500661
89
SEPTA - Pennsylvania
L742
7371
7414
S92L6E4500729
S92L7E4500772
44
SEPTA - Pennsylvania
L745
7415
7415
S92L0F4500873
S92L0F4500873
1
SEPTA - Pennsylvania
L746
7416
7454
S92L7F4500952
S92L8F4501012
39
St. Catharines Ontario
L879
1501
1504
L82J4F3001587
L82J4F3001590
4
St. Catharines Ontario
L898
1560
1560
S92J4F3001663
S92J4F3001663
1
PAGE 4 OF 16
INFORMATION LETTER
CLIENT
ORDER
ROAD NUMBER
FROM
TO
SAV.1E.2012MA
LI3753E
VIN (2NVY/4RKY...)
FROM
TO
QTY
St. John - New Brunswick
L871
40585
40586
L82J8F3001592
L82JXF3001593
2
St. John’s - Newfoundland
L687
1201
1209
L82U7C3000598
L82U2C3000606
9
St. John’s - Newfoundland
L731
1310
1314
L82U3C3000842
L82U2C3000847
5
St. John’s - Newfoundland
L808
1415
1419
L82J4E3001152
L82J1E3001156
5
St. John’s - Newfoundland
L875
1520
1525
L82JXF3001478
L82J3F3001483
6
Stratford - Ontario
L634
—
—
L82UXB3000352
L82UXB3000352
1
Stratford - Ontario
L752
—
—
L82U9D3000863
L82U9D3000863
1
Stratford - Ontario
L893
—
—
L82J9F3001584
L82J0F3001585
2
Strathcona County Transit - Alberta
L659
2024
2028
L82U7B3000440
L82U4B3000444
5
Sudbury - Ontario
L632
811
817
L82U9B3000326
L82U4B3000332
7
Sudbury - Ontario
L740
831
833
L82U1D3000887
L82U5D3000889
3
Sudbury - Ontario
L890
851
855
L82JXF3001609
L82J6F3001641
5
Thunder Bay - Ontario
L662
20168
20168
L82U3B3000533
L82U7B3000535
3
Thunder Bay - Ontario
L739
—
—
L82U3D3000860
L82U7D3000862
3
Thunder Bay - Ontario
L806
—
—
L82J6E3001170
L82J8E3001171
2
Thunder Bay - Ontario
L863
—
—
L82J8F3001558
L82J6F3001560
3
Timmins - Ontario
L661
—
—
L82U9B3000486
L82U9B3000486
1
Timmins - Ontario
L720
12-98
12-98
L82U0C3000829
L82U0C3000829
1
Timmins - Ontario
L783
—
—
L82U8D3001017
L82UXD3001018
2
Timmins - Ontario
L839
—
—
L82J8E3001395
L82J8E3001395
1
Toronto Transit Commission - TTC - Ontario
L729
9000
9000
S92U9D3000905
S92U9D3000905
1
Toronto Transit Commission - TTC - Ontario
L738
9001
9026
S92J6D3001094
S92J7D3001119
26
Toronto Transit Commission - TTC - Ontario
L777
9027
9152
S92J7E3001123
S92J6E3001372
126
Toronto Transit Commission - TTC - Ontario
L859
8400
8400
L82J5F3001405
L82J5F3001405
1
Toronto Transit Commission - TTC - Ontario
L860
8401
8504
L82J0F3001554
L82JXF3001805
104
University of Alabama - Alabama
L671
7024
7025
L82U5C4500119
L82U1C4500120
2
University of Alabama - Alabama
L727
7026
7027
L82U4D4500310
L82U6D4500311
2
University of Alabama - Alabama
L787
7028
7029
L82J2E4500507
L82J4E4500508
2
University of Alabama - Alabama
L902
7030
7031
L82J2F4500993
L82J4F4500994
2
University of Colorado - Colorado
L627
—
—
S92UXB4000139
S92U6B4000140
2
Walt Disney World - Florida
L763
—
—
S92U0D3001019
S92U4D3001024
6
Welland Ontario
L866
L82J9F3001648
L82J9F3001648
1
Whitehorse - Yukon
L784
43
43
L82U9D3001057
L82U9D3001057
1
Woodstock - Ontario
L778
—
—
L82U2D3001014
L82U2D3001014
1
Woodstock - Ontario
L832
—
—
L82J9E3001342
L82J9E3001342
1
Woodstock - Ontario
L923
15-16
15-16
L82J9F3001746
L82J9F3001746
1
York Regional Transit - Ontario
L654
1370
1390
S92U1D3000946
S92U2D3000986
21
York Regional Transit - Ontario
L761
1391
1396
S92U6D3001008
S92UXD3001013
6
York Regional Transit - Ontario
L896
1501
1517
L82J2F3001619
L82JXF3001741
17
PAGE 5 OF 16
INFORMATION LETTER
SAV.1E.2012MA
LI3753E
PROCEDURE
WARNING
Follow your internal safety procedures. Before performing any welding operation on the vehicle, sensitive
electronic components must be disconnected. Ask a qualified electrician to place the main battery
cut-off switch in the off position and disconnect the affected components per maintenance manual
section 01: Structure.
Figure 1 - Possible Crack Location
PAGE 6 OF 16
INFORMATION LETTER
SAV.1E.2012MA
LI3753E
NOTE
Some of the parts shown in the document may not be applicable to your vehicle configuration.
Retain hardware removed during the procedure for later reinstallation.
1.1.
Remove the access panel above the first curbside window. See Figure 2.
Access Panel
Baselight
Emergency
Valve
Side Sign
Upper Handrail
Door Capping
Wall Handrails
Front Door Rear
Panel
Figure 2 - Parts Identification
PAGE 7 OF 16
INFORMATION LETTER
SAV.1E.2012MA
LI3753E
1.2.
Remove the front door, rear panel only.
1.3.
Remove the upper handrail and wall hand rails.
1.4.
Mark the height position of the door second capping for later reinstallation. Remove door capping (2 pieces).
1.5.
Remove the door operator connecting rod on top of the door shaft.
1.6.
To remove the door shaft, remove the three bolts under the operator support plate. See Figure 3.
Figure 3 - Remove Door Shaft
1.7.
Remove the emergency valve capping.
1.8.
Disconnect the two chime cord wires and remove chime cord assembly. See Figure 4.
Figure 4 - Remove Chime Cord Assembly
PAGE 8 OF 16
INFORMATION LETTER
SAV.1E.2012MA
LI3753E
1.9.
Purge the air system, then disconnect the two pneumatic hoses and the connector at the emergency valve.
1.10.
Remove the emergency valve assembly.
1.11.
Disconnect the harness and remove the side sign with the help of an assistant.
1.12.
Remove the window frame screws from the upper horizontal and the front vertical frame portions in order to
facilitate the baselight and melamine removal.
1.13.
To remove the first baselight, start by drilling out the two rivets at the joint of the second baselight. See Figure 5.
Rivet
Locations
Upper Horizontal
Window Frame
Screws
Front Vertical
Window Frame
Screws
Melamine
Figure 5 - Drill Out the Two Rivets and Remove Window Frame Screws
1.14.
Disconnect the harness and remove the baselight.
1.15.
Remove the melamine using a utility knife to cut the double face tape between the wall and the melamine.
The melamine will be reinstalled after the repair, be careful to not damage it. See Figure 6.
Melamine
Figure 6 - Remove Melamine
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INFORMATION LETTER
1.16.
SAV.1E.2012MA
LI3753E
Remove the wires and the pneumatic hoses from the wall structure, including the pneumatic drain hose into
the vertical tube (see Figure 7) and attach them temporarily away from the area to be reworked. Remove
and keep the u-channel edge protector.
Drain Hose
Rework Area
Original
Stiffener Plate
Figure 7 - Secure All Hoses and Wires Away From the Rework Area
1.17.
Inspect the area shown in Figure 1. If a crack is found, make 1/8 in. stop holes at one or both ends if possible.
NOTE
All components and surfaces must be protected from cutting or grinding during the repair process.
1.18.
With a cut-off wheel, remove the original stiffener plate between the two vertical tubes, see Figure 7. This
plate will be replaced by N71120, see Figure 8.
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INFORMATION LETTER
1.19.
SAV.1E.2012MA
LI3753E
Surface preparation is very important. Grind as required to get smooth flat surfaces without wobbles. Remove
existing welding spatters. The area to prepare has to be approximetly 2 in. wider than the area covered by
the new stiffening plates. See shaded area in Figure 8 for preparation area to be covered.
N71119
N71120
N71118
Figure 8 - Surface Preparation Area
1.20.
If there is a ground stud in the area, cut it. See Figure 9.
Figure 9 - Cut the Stud
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SAV.1E.2012MA
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INFORMATION LETTER
1.21.
If there are existing protruding bumps greater than 1/16 in. from the existing weld beads, grind them flush
with the weld bead. The weld on the existing structure should not be more than 1/2 inch, if it is, it should be
ground down to insure that the maximum of 1/2 inch is respected. The minimum weld size to respect shall
remain equivalent to the thickness of the plate being welded and respecting a maximum weld size of a 1/4
inch. See Figures 10 and 11
Figure 10 - Examples of Weld Beads that May Need to be Ground (Not Limited to These)
1/16 in. or more
Figure 11 - Grind Protruding Bumps of More Than 1/16 in.
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INFORMATION LETTER
1.22.
SAV.1E.2012MA
LI3753E
Verify the plates position prior to welding. See Figure 12. It may be required to grind or modify the parts.
Wall
Wall
Flush with the tubes
2 3/8''
Structure
Structure
N71119 is Centered on the Tube
Figure 12 - Plates Position
1.23.
A 1/8 in. gap is required between N71119 and the existing weld on the structure, grind if necessary. Press fit
is not acceptable. See Figures 10 and 13.
Figure 13 - 1/8 in. Gap Required on Each Side of N71119
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SAV.1E.2012MA
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INFORMATION LETTER
CAUTION
All components must be protected from heat, spatter and flame during the welding process. Refer to
maintenance manual section 01: Structure for welding procedure. Given the heat transfer to the wall, take
care not to damage the parts in the surrounding area, such as the outside fiberglass panel.
1.24.
Plate N71119 must be centered with the vertical tube. N71118 and N71120 must be flush with the inside
face of the tubes. Make a full weld on every edge, represented by the dashed lines in Figure 14. Weld to the
structure tubes only, not to the wall.
Spot type weld, continuous bead, vertical up direction
1/4 in. weld (see the dashed lines)
Welding Process : GMAW
Wire
		
: 309LSI .045
Gas
		
: 98% Argon and 2% Oxygen
Welding Parameter : 23V, 350 IPM
Structure Tube
: 1 1/2 in. x 3 in. 12 GA SST
Wall : 14 gauge SST sheet
Structure Tubing
Wall
N71120
Flush With the
Tube Inside Face
N71118
Flush With the
Tube Inside Face
N71119
Structure Tubing
Figure 14 - Weld the Parts in Place
1.25.
Fill the corner gap between the structure and N71118. See Figure 15.
Figure 15 - Fill the Gap for N71118
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INFORMATION LETTER
1.26.
SAV.1E.2012MA
LI3753E
Make tack welds on the head of bolt N24104 to replace the previously cut ground stud. See Figures 16 and
17. The position shall be approximetly 1 in. above the plate N71119 and centered on the tube. The tack welds
should be on alternate corners of head bolt. This gives a total of 3 tack welds. During the tack weld operation
the dimension from opposite corners should not be reduced by more than 20%.
1 in.
Centered on the Tube
Figure 16 - New Ground Location
1.27.
If the tack welds are higher than the head of the bolt, grind them flush to allow for a proper ground contact.
See Figure 17.
Tack Welds
The Weld Must be
Lower or Flush to the
Head of the Bolt
Figure 17 - Tack Weld the Bolt
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INFORMATION LETTER
SAV.1E.2012MA
LI3753E
1.28.
Install the door shaft and apply a torque of 4.4 lb-ft to the three bolts. Use thread locker 9985283 or equivalent
and anti-tamper seal. See Figure 18.
1.29.
Install the door mechanism rod to the top of the shaft, torque to 13.3 lb-ft and apply thread locker 9985283
or equivalent and anti-tamper seal. We recommend applying grease N24412 or equivalent to the pivot, if
needed. See Figure 9.
13.3 lb-ft
Grease
4.4 lb-ft
Figure 18 - Torque Door Shaft
1.30.
Check that there is enough space between the new plate N71119 and the door mecanism. Grind the plate
if necessary.
1.31.
Put the drain hose back in place in the vertical tube and the wires on the structure like they were before.
1.32.
Install the original U-channel edge protector on plate N71120.
1.33.
Install the melamine and route the chime wires throug the hole.
1.34.
Install the door shaft capping at its original height.
1.35.
Install the baselight and two new N30702 rivets. Connect the baselight harness.
1.36.
Install the window frame screws.
1.37.
With an assistant, connect and install the side sign. Torque the six bolts to 6.3 lb-ft.
1.38.
Install the emergency handle assembly. Connect the hoses and harness.
1.39.
Install the chime cord assembly. Connect the two wires.
1.40.
Install the emergency handle capping.
1.41.
Install the wall and upper hand rails.
1.42.
Install the acess panel.
1.43.
Ask a qualified electrician to connect the components that were disconnected as per maintenance manual
section 01: Structure. Place the main battery cut-off switch in the ON position.
1.44.
Prior to returning the vehicle to service, validate the proper functionning of:
1.44.1. The door
1.44.2. Chime cord
1.44.3. Destination sign
1.44.4. The baselight
1.44.5. The emergency valve 
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