INSTRUCTION TO SERVICE
ITS: 61487

11/14/2025

SECTION:

400 – Structure

SUBJECT:

Repair cracked bracket at rad door support.

ISSUE:

Cracking found on welds/bracket on radiator door support.

SUMMARY:

Rework to repair radiator door support.

ITS61487
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
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SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY STANDARDS
AND LOCAL/PROPERTY REQUIREMENTS.
PROCEDURE:

1. Park bus on a leveled surface and apply parking brake. Place wheel chocks underneath the front wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Locate the radiator door on the rear side streetside of the coach. Refer to Figure 1.

FIGURE 1: LOCATION OF THE RADIATOR DOOR ON COACH

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Affected door bracket.

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Example of cracked
bracket and welds.

FIGURE 1A: SHOWN BACKSIDE VIEW OF THE RADIATOR DOOR (VIEW WITH CRACKS)

 NOTE:

The following instructions cover all these processes; use discretion as to which processes
are required. Following the welding sheets as per Appendix D.

WARNING: Ensure the following components are disconnected before welding:
•

Battery cable

•

Engine ECM – disconnect vehicle interface harness connecto00r

•

Transmission ECU – disconnect vehicle interface harness connector

•

Vansco Multiplexing Modules (VMM) – disconnect all modules

•

Destination sign – disconnect vehicle interface harness connector

•

HVAC controller (if equipped) – disconnect vehicle interface harness connector

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•

Auxiliary heater (if equipped) – disconnect vehicle interface harness connector

•

3 connection points on the DPIM on the roof – P1120, P1121 & P1122
Note: Special insulated gloves for high voltage must be used when disconnecting from the DPIM
on the roof. This only affects HYBRID buses.

WARNING:

The following safety equipment must be available at the workstation:

•

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

•

Fire extinguishers must be kept at each workstation. Each operator should know the location of
the extinguisher and how to operate it

Note: Use welding blankets around the area that will be welded to prevent damage to any components.

4. Using a wire wheel or similar tool, remove all primer and Sika sealant from the required weld areas. Extend
past the weld location 2.0 inches to ensure adequate welds are obtained. See weld specification sheets
(Appendix A).
5. Locally clean repair areas with vacuum to remove dust and debris. Wipe the weld areas clean with a clean lint
free cloth.

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NOTES:
1. CUT-OUT A SECTION OF THE EFAN DOOR BRACKET
03-31-5129 TO BE 1/8" AROUND THE NEW BRACKET 1143394.
2. SECURE BRACKET 1143781 USING EFAN MOUNTING BOLTS.
3. GRIND FLUSH WITH ALONG THE EDGE OF BRACKET 03-31-5129.
4. SEE WELDING DETAILS FOR LATCH BRACKET 03-31-2552
ON ASSEMBLY 03-31-5128

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FIGURE 2: SHOWN WELD DETAILS FOR REWORK

6. Cut out a section of the EFAN door bracket (PN: 03-31-5129) to be 1/8” gap around the new bracket (PN:
1143394). Remove all sharp edges.
7. Secure bracket (PN: 1143781) using EFAN mounting bolts (existing).
8. Grind flush along the edge of the bracket (PN: 03-31-5129).
9. See welding details (Appendix A) for latch bracket (PN: 03-31-2552). Follow weld details shown in Figure 2.

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10. After welding has been completed, grind off sharp edges. Check for any weld defects such as undercut and
porosity.

 NOTE:

Visual inspection of all tubes in the area must be performed once welding is complete. This
is to ensure that all cracks have been repaired, the tubes and gussets have been correctly
installed, and no further cracking has occurred.

11. All welding must comply with MCI welding specifications in accordance with CSA WPS 25-28-0001-9 GTAW
A1.
12. Wrap welds around corners, where practicable, for a distance of at least twice the nominal size of the weld
bead. Do not start/stop welds at the corners.
13. Visually inspect welds to ensure all welding meets quality standards for cyclically loaded structures detailed in
WPS 25-28-0001-9 GTAW A1.
14. Grind welds to provide a smooth surface on the repaired structure tube. Follow weld profile as per WPS 25-280001-9 GTAW A1.
15. Once welding is complete, apply sealant at all weld seams. Use white sealant (PN: 055701).
16. Once all welding is completed, clean surface of the tubes with mineral spirits. Let it flash off for 5 minutes. Scuff
the surface area of the new metal or the area that has been welded with a scotch pad for proper adhesion.
Follow instructions on Appendix B to apply zinc primer. Apply 2 to 3 light coats.
17. Remove all tools and debris and return the bus to service condition.
18. Turn the main battery disconnect switch to the “ON” position.

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Appendix A:
Aluminum Welding Procedure

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Appendix B
Axalta Zinc Primer

NF PN: 606945 & 638699
Page 1 of 4

General Industrial
Technical Data Sheet
GANICIN™ 2.8 MC-U™ MOISTURE-CURED ZINC-RICH PRIMER

Ganicin™ 2.8 MC-U
Moisture-Cured Zinc-Rich
Polyurethane Primer
GENERAL
DESCRIPTION
A high solids, two-component, 2.8 lbs/gal VOC conforming, moisture-cured organic zinc-rich
coating based on Axalta polyurethane technology. The resulting coating is designed to be
highly durable and to deliver outstanding corrosion resistance.
SUGGESTED USES
As a high performance primer on carbon steel or as a touch-up for inorganic zinc coatings
where:
A coating with 85% zinc in the dried film with low VOC is required
Spray application, or by brush when touch-ups may be necessary
Application is recommended down to 35°F (2°C)
No induction time and long pot life may improve productivity
Ganicin 2.8 MC-U is intended to be used as a primer and should be topcoated.
COMPATIBILITY WITH OTHER COATINGS
Ganicin 2.8 MC-U Moisture-Cured Zinc-Rich Primer may be topcoated with Corlar® epoxies
and/or Imron® polyurethane Primers. Do not apply Imron polyurethane topcoats, directly to
Ganicin 2.8 MC-U. Ganicin 2.8 MC-U may also be used to touch up inorganic and organic
zinc-rich coatings. Testing for lifting, bubbling and adhesion is recommended to assure
compatibility with unknown coatings. Contact your Axalta representative for specific
recommendations.
NOT RECOMMENDED FOR
Immersion service
Exposure to acid or alkali environments without suitable topcoats
PERFORMANCE PROPERTIES
Chemical Excellent
Humidity Excellent
Water spray Excellent

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