NHTSA ID Number: 10057907
Manufacturer Communication Number: SB-L3-FSV-311
TSB/Document Date: 2015-07-11
Summary
NEW FLYER
: INFORMATION REGARDING THE ENHANCEMENT DURABILITY OF STRUCTURAL UPGRADES THAT ARE REQUIRED FOR CROSSMEMBER RADIATOR SUPPORT BY REMOVING OLD RADIATOR SUPPORT CROSSBEAM AND INSTALLING NEW CROSSBEAM. *PE
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
21. Cover all ports of the radiator/CAC assembly to prevent contamination.
22. Remove air intake box.
23. Remove closeout panel from the radiator support crossbeam.
24. Cover the engine and surrounding components with a fireproof blanket(s).
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
Radiator Support Crossmember Removal
1. Cut Radiator Support Crossmember through beside the side walls. Four beams need to be
cut. If using plasma cutter keep ½” distance from the side wall structure.
2. Remove original Radiator Support Crossmember and discard it.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
3. Cut off the upper and lower aft legs of the air filter bracket and save them. These pieces will
be reused later. See photos below.
4. Grind remaining pieces off from the side wall structure. Cut mounting studs of the backup
alarm from the curb side wall. Grind the side wall smooth.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
5. Inspect the side wall structure. Repair cracks (if any) as described at the general welding
instruction section. If side wall structure has missing piece then repair it as photos shown
below.
Step 1: grind damaged area with a 36G abrasive
wheel
Step 3: drill ¼” holes for plug welds
Work instruction number: L3/FSV-311
L4/QUA-003
Step 2: cut damaged area
Step 4: insert a 1/8” thick 304 stainless steel
plate into the structure and hold it in place
with a welding wire
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
Step 5: plug weld fish plate to the structure
Step 6: Insert a patch plate over the fish plate
and weld them to the structure
6. Grind side wall smooth after welding was performed.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
New Support Crossmember Installation
1. Place the Side Plates (P/N V01-6055-101 for street side and -101T for the curb side) to the
side wall structure and align their horizontal legs with the horizontal tubes of the side wall
structure. Use clamps to hold plates in place. Caution: use a piece of cardboard or similar
underneath the clamps to protect the paint on the exterior panels!
2. Tack weld Side Plate and double check their position. Ensure that the plate is pushed
against the structure (no gaps are allowed between components).
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
3. Weld Side Plates to the side wall structure per page 2 of drawing # V01-6055-901.
4. Place forward Supports (P/N V01-6055-102 for both sides - see item # 9 on drawing # V016055-901) and tack weld them to the side plates. Refer to page 3 of drawing # V01-6055901.
5. Weld forward Supports to the side plates per page 3 of drawing # V01-6055-901.
Side plate
6. Place aft Supports (P/N V01-6055-103 for the street side and -103T for the curb side - see
item # 10 and 11 on drawing # V01-6055-901) and tack weld them to the side plates. Refer
to page 3 of drawing # V01-6055-901.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
7. Weld aft Supports to the side plates per page 3 of drawing # V01-6055-901.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
8. Place Radiator Support Frame assembly (P/N V01-6055-300 – see item # 13 on drawing #
V01-6055-901) into the Supports. Position the Radiator Support Frame assembly to the
center of the bus (the gaps at the ends of the Radiator Support Frame assemble must be
the same – see red circles below that show the street side gaps). Use clamps to secure the
Radiator Support Frame assembly in place then tack weld it to the Supports at all four
corners.
9. Weld Radiator Support Frame assembly to the Supports per page 4 of drawing # V01-6055901.
10. Visually inspect welds. Repair/re-weld as required.
11. Place four Plates (P/N V01-6055-308 – see item # 15 on drawing # V01-6055-901) to the
top of the Supports and tack weld them.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
12. Weld four Plates to the Supports and to the Radiator Support Frame assembly per page 4 of
drawing # V01-6055-901.
13. Cut the original legs of the air filter bracket to fit between the side plate and the air filter
bracket. Weld them around with continuous fillet welds. See photo below.
14. Visually inspect welds. Repair/re-weld as required.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
Cross Bar Removal
15. Cut both ends of the original Cross Bar beside the side wall structure. Discard original Cross
Bar assembly.
16. Grind side wall structure smooth.
New Cross Bar Assembly Installation
17. Install new Cross Bar assembly (P/N V01-6055-120 – see item # 12 on drawing # V016055-901) per drawing # V01-6055-901.
Cross Bar
Weld
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
18. Weld Cross Bar assembly per page 4 of drawing # V01-6055-901.
19. Install four Gussets (P/N 10C-1301-325 and -333 – see item # 5 and 6 on drawing # V016055-901) to the ends of the Cross Bar assembly.
20. Weld Gussets to the Cross Bar assembly and to the side wall structure per page 4 of
drawing # V01-6055-901.
P/N: 10C-1301-333
P/N: 10C-1301-325
Street side gussets shown
21. Weld Brackets (P/N V01-6055-307 – see item # 14 on drawing # V01-6055-901)to the Cross
Bar assembly per page 4 of drawing # V01-6055-901.
P/N: V01-6055-307
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
22. Weld two ¼-20x1” studs (bolts) to the street side wall for the backup alarm. Use the alarm
as a template to locate the studs.
23. Visually inspect welds. Repair/re-weld as required.
24. Prep and paint according to the General Surface Protection section.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
General Surface Protection
1. Clean welded area with wire wheels.
2. Scuff surfaces by using 120G abrasive disc and vibrating/rotating tool.
3. Degrease all grinded/sanded surfaces by using acetone and clean white color rags.
4. Protect surrounding components (threads of hardware, electric and air system components,
etc.) against paint by using masking tape or cardboard-shields why spraying paint.
5. Apply industrial gray color primer to the degreased areas. Follow instructions written on the
can.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
Reassembly
1. Place 2” wide tape to the top of the Radiator Support Crossmember.
2. Install closeout panel. Replace bulb seals on closeout panel as required.
3. Place a 1/8” thick foam tape to side wall structure where the air intake box will meet the side
wall.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
4. Bend the lower mounting tab of the air filter housing as photo shown below. Install air intake
box to the structure. Enlarge the mounting holes on the air intake box if required so the
original threaded holes of the side wall can be reused to secure the air intake box. Use
11/16” OD stainless steel flat washers with new #10-32x3/4” long stainless steel self-tapping
screws to secure air intake box to the side wall. On buses equipped with square surge tank,
the top of the air intake box maybe need to be cut to provide clearance between the surge
tank and the air intake box. See details below.
Bend lower mounting tab of the air intake
box, place a piece of pinch welt on the
edge and secure the tab to the structure
with a #10-32x3/4 self-tapping screw as
photo shown.
Modify the air intake box as photo shown.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
5.
6.
7.
8.
Install air filter housing.
Reconnect hose to the air filter housing. Use new clamp if required.
Install compartment lights.
Install lower radiator and CAC mounts. Replace them if they are damaged. Do not tighten
the mounting bolts of the mounts. They need to be loose so the mounts can be aligned with
the radiator/CAC assembly during the installation.
9. Install EMP or Modine electric fans per supplier instruction. If original belt driven fans will be
reinstalled then reinstall components (after radiator/CAC assembly has been installed) the
opposite way as they were removed.
10. Reinstall radiator/CAC assembly by lifting it in place using a forklift. Tighten the upper
mounting bolts first so the radiator/CAC assembly is secured to the structure.
11. Install lower mounting bolts of the radiator/CAC assembly through the lower mounts. Tighten
all bolts of the lower mounts.
12. Reinstall upper and side closeout panels. Replace bulb seals on closeout panels as
required.
13. Install coolant hoses with new clamps to the radiator. Replace hoses as required.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
14. Install hoses to the CAC. Replace hoses as required. Torque existing constant tension
clamps to 110 in-lb. Install new clamp if required.
15. Install rear hazard lights as shown on photos below. Drill and tap ¼-20 threads for the
mounting bolts. Use new ¼-20x1” hex head grade 8 Zn bolts with lock washer and flat
washer. Apply anti-seize onto the threads.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
34
NABI -NJT: Radiator Support Crossmember Rework
16. Install harnesses with the original P-clamps to the Cross Bar assembly. Use new 10/32-3/4”
long stainless steel screws. Ensure to plug original belt driven fan control harness if it is not
used any more.
Plug
17. Install back up alarm to the curb side wall structure.
18. Reinstall belt guard.
19. Reinstall and adjust rear engine compartment doors.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
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NABI -NJT: Radiator Support Crossmember Rework
Final Operation
1. Refill coolant system. Pump coolant into the surge tank. When the coolant level reaches the
full hot level open the two ¼-turn coolant valves those were closed at the paragraph 13 of
the Disassembly section.
Example of coolant pumps that can
be used to fill the roof mounted
surge tank up
2. Reconnect battery cables.
3. Turn battery disconnect switches on.
4. Connect Amerex fire suppression system test tool to the connector at the Amerex bottle.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
36
NABI -NJT: Radiator Support Crossmember Rework
5. Check the control panel of the Amerex fire suppression system and ensure that a green
LED light is on that would indicate that the system is in good operating condition. In this
case disconnect test tool and connect harness to the Amerex bottle. If yellow light is on or
flashing on the Amerex control panel, then contact to the garage foreman and ask for help
with troubleshooting. Check for loose connection or damaged cables of the fire suppression
system especially at the engine compartment where the rework was done.
Amerex fire suppression system test tool
6. Start the bus and ensure that no warning lights (check engine, check transmission, etc.) are
on.
7. De-aerate and refill cooling system per NABI work instruction # L3-FSV-026.
8. Clean bus inside and out. Ensure that the driver’s area is clean, the driver’s seat, front and
side control panels are wiped off.
9. Double check for coolant leaks. Repair as needed.
10. Present the repaired bus for inspection to a delegated person.
11. Record bus number, mileage, date of completing and the name of the technician who
completed the repair.
Work instruction number: L3/FSV-311
L4/QUA-003
Revision: A
Date: 04/13/2015
Revision: Initial
37
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TSB/Document ID: SB-L3-FSV-311
Replacement Service Bulletin Number:
MFR Communication Date: 2015-04-13
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Communication Type: Service Bulletin/Repair Instructions
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