NABI -NJT: Radiator Support Crossmember Rework

SB-10057907-4756
Prepared by:

Kalman Takacs
Sr. Field Service Engineer

Approved by:

Dan Allen
Chief Engineer of Manufacturing and Service Support

Property name and Top bus number: NJT 416.15 164200, 164400, 279000, 279500,
289000, 308000

Issue:

Structural issues of the radiator support crossmember were reported.

Reason:

Structural upgrades are required to enhance durability.

Solution:

Remove old radiator support crossmember and install new crossbeam per this work
instruction.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

1

NABI -NJT: Radiator Support Crossmember Rework

Effected buses: 1299 buses
Estimated repair hours/bus: 35 hours/bus.
Engineering documentation: V01-6055-901 (4 pages)
Necessary parts:
Cross Beam Kit, Fan Support,
Frame plug for cavity protection holes, 10 mm,
Foam Tape, double sided, 1/2" Wide,
FOAM TAPE, 1/8x1-1/2, DBL, VHB,
SCREW, #10-32x3/4, PH, SS, F410,
#10 x 11/16 OD washer, flat,
WASHER, LOCK, #10, SS,
BOLT, 1/4-20x1, HEX, ZN, GR8,
NUT, 1/4-20, HEX, NYLOCK, ZP, GR 8,
WASHER, FLAT, 1/4, ZN, GR 8,
WASHER, LOCK, 1/4, ZN,
BOLT, 5/16-18x1, HEX, ZN, GR8,
WASHER, FLAT, 5/16, ZN, GR 8, USS,
WASHER, LOCK, 5/16 ZN,
CLAMP, HOSE, SILICONE/SS, 7/8"ID,
CLAMP, HOSE, SILICONE/SS, 1"ID,
For radiator with CAT and Cummins engines:
CLAMP, PWR GRIP SB, 2.5",
CLAMP, PWR GRIP, SB67, 2.50-2.75
HO$, SILICONE, RDCR, 2.5"ID-2.25",
HOSE, SILICONE, 2.5"IDx8",
CENTER BONDED MOUNT,
For CAC with CAT engine:
HUMP HOSE, 90, 3.5", HI TEMP,
CLAMP, T-BOLT, 4.3125"-4.625",
For CAC with Cummins engine:
HUMP HOSE, 3.5"IDx6",
CLAMP, T-BOLT, 3.5"-3.812",
LOCTITE 246, 1.69 FL OZ/50mL,
LUBRICANT, ANTI-SEIZE, 16 FL OZ,
Welding wire, ER308LSi, dia. 0.035”,
Acetone,
Industrial primer,

Work instruction number: L3/FSV-311
L4/QUA-003

Part #: V01-6055-901,
Part #: NABI1874,
Part #: 700-0001-200E,
Part #: 5021746,
Part #: 270140,
Part #: 2603SS,
Part #: 250010SS,
Part #: 220420088,
Part #: 5015581,
Part #: 2604,
Part #: 2504,
Part #: 220518088,
Part #: 2605,
Part #: 2505,
Part #: 5002523,
Part #: 5002524,

1 / bus,
5 / bus,
up to 2 feet / bus,
1 20’ roll / bus,
20 / bus,
20 / bus,
10 / bus,
10 / bus,
6 / bus,
10 / bus,
6 / bus
2 / bus,
2 / bus,
2 / bus,
as required,
as required,

Part #: 101-1375-001,
Part #: 101-1375-275,
Part #: 806-1310-004,
Part #: 500-1310-011,
Part #: 10A-1301-005,

2/bus,
2/bus,
1/bus
1/bus,
as required (4 / bus),

Part #: 511-1420-002,
Part #: 5013660,

as required (1 / bus),
as required (1 / bus),

Part #: 416.00.1060.974,
Part #: 416.06.1530.908,
Part #: 5033332,
Part #: 5024582,
Part #: NPN,
Part #: NPN,
Part #: NPN,

as required (1 / bus),
as required (2 / bus),
as required (1 / 40 buses),
as required (1 / 40 buses),
as required,
as required,
3 cans / bus,

Revision: A

Date: 04/13/2015
Revision: Initial

2

NABI -NJT: Radiator Support Crossmember Rework

Necessary tools:
Usual hand tools (wrenches, screwdrivers, hammer, chisel, etc.), angle grinder, GTAW (MIG) Welding
machine, 1/8” and 5/16” diameter drill bits, drill, wire wheel, 36G and 60G abrasive discs, de-burr bits,
partition/welding curtains, dust collector, chain and fork lift fork extension to remove radiator/CAC assembly,
coolant pump, drain pan, 5/16-18 plusnut gun, 10/32, ¼-20 and 5/16-16 tread taps, fire proof blankets,
Amerex fire suppression system probe.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

3

NABI -NJT: Radiator Support Crossmember Rework

SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY
STANDARDS AND LOCAL/PROPERTY REQUIREMENTS.
Stop welding 45 minutes before planning to leave the bus.
Ensure that partitions/welding curtains are placed around the work area.

General Information:






Read and understand this work instruction before starting the repair.
Study and familiarize yourself with the work area before starting the repair.
Before starting the work, make sure that all tools, protective equipment and parts are
available.
Any deviation from this work instruction should be discussed prior to performing any work
that does not conform to this work instruction.
Record bus number, mileage and date of completion and report weekly to Kalman Takacs.

General Preparation before Welding is Performed
1. Start bus and check driver’s dash for warning lights. Record and report any warning lights
(for example check engine light) to the garage foreman.

Driver’s dash with no issue-lights

2. Inspect rear marker lights, engine compartment lights, back up alarm for proper operation.
These components will be disconnected and they must work exactly as they were before.
Report any issues to the garage foreman before you start disassembling the bus.
3. The charge air cooler (CAC) and coolant radiators will be disconnected and removed from
the bus. Inspect them for any visible damage, leak, etc. and report findings (if any) to the
garage foreman before start disassembling the bus.
Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

4

NABI -NJT: Radiator Support Crossmember Rework

4. Take photos of bus number and the issue (dash warning light, leaks, etc.) that was found
during the inspection.
5. Turn off engine.
6. Turn off the main battery disconnect switch.

7. Tag and disconnect the battery cables.
8. Disconnect the ECU of engine, transmission and ABS. Disconnect the destination signs.
Disconnect the Clever device. Open the light panels and disconnect all the IO modules. See
some example pictures on the next page.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

5

NABI -NJT: Radiator Support Crossmember Rework

Disconnect A1, A2, A3 and MBC
modules underneath the driver’s window

Disconnect the clever device
behind the front SS seats

Disconnect C modules
behind the CS light panels

Disconnect E modules
behind the SS light panels

Disconnect transmission ECU behind the SS
rear light panel (or above the transmission)

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

6

NABI -NJT: Radiator Support Crossmember Rework

9. Disconnect the 2-way weather pack connector at the fire suppression bottle, located at the
street side compartment in front of the rear axle.

10. Protect repaired area from damage, grinding spark and welding splatter by using fire proof
blanket(s).

General Welding Instruction:
1. Remove coating material and primer from surfaces subject to be welded by using grinding
tools and wire wheels. Primary condition of good quality weld is a perfectly clean metal
surface.
2. Remove dust and degrease cleaned areas with acetone.
3. Weld only a completely clean surface! Grind surfaces with grinding disk suitable for stainless
steel material.
4. To prevent gas defects of the weld joints welding should be performed only in closed
production area protected from currents of air. Ensure adequate ventilation.
5. Welding parameters must be in accordance with attached Welding Procedure Specification
(WPS) NABI-2014-001 SS sheets.
6. Weld joints should be 100% visually inspected.
7. Protect repaired area from damage during welding.
Make sure that no cracks are present at the side wall structure. If crack was found, then follow the
steps below:



Find the end of the crack (it is recommended to use magnifier or dye penetrate),
Drill a 1/8” size hole at the end of the crack,

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

7

NABI -NJT: Radiator Support Crossmember Rework








Bevel the crack profile 2x30° for single “V” butt (groove) weld,
Clean the surface at the welding area with abrasive disc and/or wire wheel.
Degrease surface at the welding area by using acetone or denatured alcohol.
Weld the cracked and bevelled line with continuous weld per WPS NABI-2014-001
SS.
Grind the weld surface until the same height as the parent metal.
Check the welds by Visual Test and/or Dye Penetrate Test.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

8

NABI -NJT: Radiator Support Crossmember Rework

Disassembly
1. Disconnect electrical harnesses of the rear engine compartment doors then remove both
doors from their hinges. Do not remove or disassemble hinges!

2. Open the attic compartment door and unhook the door limiter cables so the attic door can be
opened all the way up.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

9

NABI -NJT: Radiator Support Crossmember Rework

3. Remove belt guard (see red circles below).

4. Disconnect electrical cables behind the rear engine control box then remove the control box.
If connectors are seized up then leave them connected: place the control box to the top of
the AC compressor and cover it with a fireproof blanket.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

10

NABI -NJT: Radiator Support Crossmember Rework

5. Remove fan belts and tensioners.

6. Remove cooling fan assembly and shrouds.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

11

NABI -NJT: Radiator Support Crossmember Rework

7. Remove fire suppression nozzles.

8. Remove gauges, harnesses, clamps, interior lights that attached to the radiator support
crossmember.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

12

NABI -NJT: Radiator Support Crossmember Rework

9. Remove side grills.

10. Remove closeout panels from the bottom and the sides of the radiator and CAC.
11. Remove air filter housing. Cover air intake hose to prevent contamination.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

13

NABI -NJT: Radiator Support Crossmember Rework

12. Remove brackets/clamps attached to the street side of the radiator.

13. Turn off the two ¼-turn coolant valves in front of the engine and in front of the B-axle.

14. Drain coolant into a suitable coolant pan by removing hose at the top of the engine. Only the
radiator needs to be drained. Stop draining coolant when it goes below the bottom of the
radiator. Follow safety instructions detailed in NABI Maintenance Manual when draining
coolant.
15. Disconnect hoses from radiator and CAC. Use extra care not to damage coolant hoses
when cutting the shrink-type plastic clamps off. Cover all open pipes to prevent
contamination.
16. Remove radiator and CAC mounting nuts at the bottom mounts.
Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

14

NABI -NJT: Radiator Support Crossmember Rework

17. Remove upper closeout panels from above the radiator/CAC assembly.

18. Place the forks of a forklift underneath the radiator/CAC assembly.
19. Disconnect the top mounts of the radiator/CAC assembly.

Work instruction number: L3/FSV-311
L4/QUA-003

Revision: A

Date: 04/13/2015
Revision: Initial

15

NABI -NJT: Radiator Support Crossmember Rework

20. Carefully remove radiator/CAC assembly from the bus. Secure radiators to the fork lift with
ratchet straps or similar. Place the radiator/CAC assembly on woodblocks and secure them
so they don’t fall.

Radiator/CAC assembly removal by using chain and fork extension:

Work instruction number: L3/FSV-311
L4/QUA-003