INSTRUCTION TO SERVICE
ITS: 60969

April 2024

SECTION:

400-Structures

WRITTEN BY:

Troy Stutsky

SUBJECT:

ISSUE:

SUMMARY:

Rework Center Axle Radius Rod Support Casting to Add Wall Thickness to the
Lower Radius Rod Mounting Holes
The lower radius rod mounting holes may have been located incorrectly during
production of the parts and may be too close to the wall of the casting which
could possibly cause the casting to crack at the lower radius rod mounting
holes. Both the RH & LH casting could be affected
Add wall thickness to any center axle lower radius rod mounting holes that
were identified to be below the allowed minimum wall thickness as identified in
ITS-60966

ITS60969
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
ITS60969

PROCEDURE AFTER ITS-60966 HAS BEEN PERFORMED:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
WARNING: Disconnect all modules and prepare the bus for welding. Follow all Welding
Procedures that are outlined in your New Flyer Service Manual in Section 11 “ Welding
Procedures” and follow all local shop Safety procedures. Use proper PPE as required.
WARNING: The following safety equipment must be available at the work station:
•

Safety shields must be set up around the weld area to protect against flash hazards

•

Fire extinguishers must be kept at each work station. Each operator should know the location of
the extinguisher and how to operate it.
WARNING: Raise the bus in accordance to the “Raising the Vehicle” procedures and precautions
that are outlined in your New Flyer Service Manual. Follow all shop procedures and safety
practices while raising the bus. Use proper PPE per shop requirements.



NOTE: Use welding blankets around the area that will be welded to prevent damage to any

components. Including all electrical and airlines.



NOTE: Repair welding shall be performed by companies certified to CSA W47.1 Division 1 or 2, by

a CWB certified welder. Alternatively, AWS qualified welders and welding fabricators may be used and
are considered an approved equal.
3. On the center axle radius rod support castings in the lower radius rod mounting locations on the mounting
hole(s) that were identified to have too thin walls after ITS-60966 has been completed, please add wall
thickness by adding a surface weld as shown in Figure 1. Follow the weld procedure shown below:
WELD REPAIR PROCEDURE:
•

PREHEAT THE CASTING TO 200-250 F PRIOR TO WELDING.

•

USE .045" METAL SHIELD MC6 WIRE. WELD EACH JOINT WITH SUGGESTED SETTING TO BE AT
257-270 AMPS AS SHOWN IN W.P.D.S. 10-FF OF WELDING PROCEDURE SPECIFICATION NF-2.

•

GAS MIXTURE TO BE: -17% CO2-83% ARGON (RECOMMENDED GAS IS STARGOLD C-17 OF
PRAXAIR INC) OR -20% CO2-80% ARGON (RECOMMENDED GAS IS STARGOLD C-20 OF
PRAXAIR INC)

•

CJP WELD TO FILL USING REASONABLY SIZED PASSES TO AVOID EXCESSIVE STRESS AND
DISTORTION. ALLOW TO AIR COOL. GRIND FLUSH. MPI ON THE REPAIRED AREAS REQUIRED.
NO POST REPAIR HEAT TREATMENT REQUIRED.

•

AFTER ALL REPAIRS ARE COMPLETED PART MUST MEET DRAWING POROSITY
SPECIFICATION.

ITS60969

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April 2024

INSTRUCTION TO SERVICE
ITS60969

Figure 1: Surface Weld Center Axle Castings Lower Radious Rod Mounting Holes

ITS60969

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April 2024

INSTRUCTION TO SERVICE
ITS60969

4. Grind the weld flat to meet the allowable wall thickness as shown in Figure 2.

Figure 2: Allowable Wall Thickness

ITS60969

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April 2024

INSTRUCTION TO SERVICE
ITS60969

5. Ensure the lower radius rod mounting holes in the casting are clean and free from any debris. Fasten the
radius rod to the center axle radius rod support casting using two washers (NF PN 6407959), two spacers
(NF PN 6490019) and two bolts (NF PN 6490020) per radius rod end. Apply a thin layer of Never Seize (NF
PN 5928660) to the mounting surfaces of the washers, spacers and to the entire length of the bolt and under
the bolt head. Ensure only a thin layer is applied and wipe off any access. Assembled bolted connection as
shown in Figure 3 and torque the hardware to 300Ft/Lbs.

Figure 3: Radius Rod Hardware Stack Up
6. Clean up all tools and debris and return the bus to service condition.
7. Turn on all the modules that were turned off.
8. Turn the main battery disconnect switch to the “ON” position.
9. Ensure all systems are functioning as they should.

ITS60969

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April 2024

INSTRUCTION TO SERVICE
ITS60969

LABOUR ESTIMATE
Operation
1

Add wall thickness to any center axle lower radius rod

Number of
Technician(s)
1

Hours
2.0

Labor Time
T X HR
2.0

mounting holes

PARTS REQUIRED

Units
EA

Source Locally

Item

Part Number

1

5928660

NEVER SEIZE

2

6407959

WASHER

4

EA

Order as Required

3

6490020

BOLT-M18 X 1.5 X 100

4

EA

Order as Required

4

6490019

SPACER-BUSH 32 L X 38 O.D. X 20.6 ID

4

EA

Order as Required

ITS60969

Description

Qty.
per
Coach
0.01

Page 6 of 6

Notes

April 2024