INSTRUCTION TO SERVICE
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02/14/2025

SECTION:

400 - Structure

SUBJECT:

R&R with new (4 place mtg cast) K-member.

ISSUE:

Found cracks on gussets and welds on K-members.

SUMMARY:

R&R with new cast k-member.

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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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PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Raise coach in accordance with the New Flyer Service Manual.
4. Support the front, center, and rear of the coach with jack stands at the jacking pad locations (8 places). There
should be no weight on the wheels of the bus. See Figure 1.

 NOTE:

Please leave the wheel lifts in place with no weight on them for safety reasons.

FIGURE 1: JACK STAND LOCATIONS (60 FOOT)

FIGURE 1A: JACK STAND LOCATIONS (40 FOOT)

5. Locate the area around the K-Member forward of the rear axle. See Figure 2.

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Xcelsior 40ft K-member location

Xcelsior 60ft K-member location

K-member

FIGURE 2: LOCATION OF K-MEMBER WITH FUEL TANK

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REMOVE K-MEMBER TO REPLACE WITH NEW CAST K-MEMBER

6. Using jack stands or equivalent, support the K-Member from falling before the hardware has been removed.
Remove and discard the hardware. For steps 6 - 14, refer to Appendix A & B. See Figure 3.

FIGURE 3: JACK STANDS SUPPORTING K-MEMBER

7. Loosen all the existing K-Member mounting hardware. Check to determine if sealant was used to seal the fuel
tank to the K-Member. If the K-Member is sealed to the fuel tank, carefully cut the sealing bead, and remove it.
Use a pry bar to loosen the existing K-Member on the coach. Reference arrows below showing area, see Figure
4.

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K-member (ref)

FIGURE 4: AREAS TO CHECK TO DE-BOND TO ALLOW REMOVAL OF K-MEMBER

8. Remove and discard all the existing hardware; remove the K-Member from the bus. Two people are required
for this step.

RE-INSTALL NEW CAST K-MEMBER ON THE BUS

Installation & removal of K-member
1. First align the corner of the K-member mounting pad and the center chassis structure. Then install the
hardware to locations 1 thru 4, hand tighten nuts.
2. Tap the K-member into position over to the curbside of the coach using a rubber mallet to align the
angle on the K-member to the angle on the structure. Ensure no gaps remain between bolting surface
of K-member and corner of structure.
3. Install rear chassis shims (PN: 520803, qty.2 per side) and torque center chassis hardware to 100-200
FT-LB dry using pressure regulated impact gun.
9. If the neoprene strips are damaged or not useable, new strips will need to be installed on top of the K-member.
Install by applying the neoprene strip with PSA backing facing down to adhere and line up with the holes on the
K-member. Align so that the plastic pine-tree clips (PN: 265353) can be pushed through the holes in the rubber
and the structure. Repeat for the installation of other strips. These are the neoprene strips (PN: 433355, 433252,
433353 & 444276). Refer to Figure 5.

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PN: 433352
PN: 433355

PN: 433353

PN: 444276

PN: 265353

FIGURE 5: SHOWN NEOPRENE STRIPS AND FASTENER TO ATTACH TO TOP OF K-MEMBER

10. Clean the mounting surface, nut and washer surface on the chassis using a grinder and a 7.0” diameter or
larger, 60 grit and sanding disk. See Figure 6, 7, 8, 9 and 10. Make sure there are no raised welds on the
mounting surface of the chassis. If there are raised welds, grind them flat before installing the K-Member.

FIGURE 6: Grinder with Sanding Disk

Figure 7: Cleaned Bolt and Washer Location on K-

Member

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Figure 8 & 9: Cleaned Mounting Plate Edges and surface on the Chassis Surface of K-Member

Figure 10: Cleaned Bolt and Washer Seat on the Chassis

11. Clean the four threaded rear mounting holes in the chassis. Use Loctite 20162 ODC-Free Cleaner & Degreaser
(NF PN 6405975) or equivalent, and a brush that will fit in the holes to clean them. Dry the holes with
compressed air making sure the holes are completely clean and dry.
12. Lift the new K-Member into place in the coach. Use the jack stands to support the K-Member. This step will
require two people.
13. Install the new hardware according to the defined bolt torque sequence in Appendix A & B. For the front
hardware use four 0.75” x 4.25” bolts (NF PN 10B12068), eight 0.75” washers (NF PN 20W12000) and four
0.75” lock nuts (NF PN 40N12000). For the rear hardware use four 0.75” x 1.75” bolts (NF PN 10B12028) and
four 0.75” washers (NF PN 20W12000). If shims required, install new shims (PN: 520803) – F-SST with no
coating. See Figure 11.

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 NOTE: When installing the hardware be sure to follow the bolt torque sequence outlined in Appendix A
& B as this sequence is very important to achieving the proper alignment of the K-Member on the coach.

4 x Bolt (NF PN 10B12028) 4 x Washer (NF PN
4 x Bolt (NF PN 10B12068) 8 x Washer (NF PN

20W12000)

20W12000) 4 x Lock Nut (NF PN 40N12000)

Front of bus

Shim (PN: 520803) locations if
required
FIGURE 11: HARDWARE LOCATION

14. After new hardware and new K-Member have been installed, re-apply the zinc primer around the perimeter of
the four mounting plate locations. See Appendix C for mixing procedure.
15. Once the zinc primer has fully dried, apply Sika Activator (NF PN 055702) around the entire perimeter of the
four K-Member mounting plates. Let the Sika Activator flash off for five minutes and then seal the entire
perimeter of the four K-Member mounting plates with Sika sealant (NF PN 055701) to seal out moisture and
debris. You will need to use a ten-inch piece of 0.50” airline and attach it to the end of the Sika tube to make an
extension to apply the Sika to the top of the mounting plate locations. See Figure 12.

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New all cast mount K-member (4 mtgs)

View of rear cast mounts on K-member
(toward rear of bus)

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View of forward cast mounts on Kmember (toward front of bus)

FIGURE 12: VIEWS OF NEW ALL CAST MTG K-MEMBER

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K-Frame

Sika sealant
FIGURE 13: SIKA TUBE EXTENSION

16. Once the Sika has been applied, apply undercoating over the zinc primer and Sika sealant (apply a minimum 2
light coats). Make sure to fully cover all areas without undercoating on them. See Appendix D for undercoating
application procedure.
17. Once the undercoating has cured, apply witness marks to the eight bolt heads and four nuts.
18. Remove all tools and debris from work area to return coach to service.
19. Lower coach in accordance with the New Flyer Service Manual.
20. Turn the main battery disconnect switch to the “ON” position.

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Appendix A

Torque Sequence Procedure

3

7

5
1

4
6

2

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8

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Appendix B
TORQUE PROCEDURE
FOR FUEL TANK STRUCTURE REINSTALLATION
Note: A spreader (air-hydraulic) maybe required to remove and re-install K-member.
1. Insert the (x4) front through bolts into locations 1, 2, 3 and 4 and hand tighten the nuts on.
2. Tap the K-member in location 8 over to the curb side of the coach as far as it will go with a rubber mallet (Note:
To align the angle on the structure to the angle on the K-member).
3. Using only the torque wrench, torque bolt 3 to 380 FT/LBS.
4. Hand tighten bolts (so bolts are snug against K-member) into the chassis in locations 5, 6, 7 and 8.

 NOTE: Once a bolt is torque to 380 FT/LBS, it cannot be reused. If the bolt is removed, it needs to be
replaced.
5. Using only the torque wrench, torque the front hardware at the bolt head to 380 FT/LBS dry in sequence. Start
with bolt location 1, then location 2, then location 4.
6. After bolts 1 – 4 are torqued, bolts (5 – 8) need to be loosened to see if there is a gap.
7. Use shim (PN: 520803) if required to minimize gap between K-member and structure. Total Qty = 2; maximum
per location.
Rules:
•

Where gaps are 0.030” to 0.060” or 0.090” to 0.120”, tech should spread the chassis until the shim fits.
NF will not tolerate a larger gap than 0.030”.

•

Where a face is not uniform, determine the action by the largest gap.

Examples – Maximum Gaps:
Note: Variation in gap size; top to bottom on the K-member flanges of 0.020” is possible in the gap. Therefore,
use the maximum gap to determine the appropriate shim thickness required
•

0.000 – 0.030” gap = no shim required

•

0.031 – 0.090” gap = 1 x 0.06” shim required, spreading of chassis maybe required.

•

0.091 – 0.150” gap = 2 x 0.06” shims required, spreading of chassis maybe required.

•

0.151 – 0.210” gap = 3 x 0.06” shims required – “DO NOT USE 3 SHIMS”

Contact NF service/engineering if gaps require 3 shims.
Install shims (as required) and hand tighten bolts (5 – 8).
8. Set the torque wrench to the 370-390 FT/LBS dry in sequence marked 1 thru 8. Using the crow foot adaptor
tool (NF PN 353762) and torque wrench combination, torque bolt 5. Make sure the adaptor tool and the torque

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wrench are in as straight of a line as possible. (Using the combination of the crow foot adaptor and the torque
wrench at the 330 FT/LBS setting will achieve the desired torque of 380 FT/LBS on this bolt.) (This adaptor
tool is required to gain access to the bolt head)

 NOTE:

The overall length of the torque wrench and adaptor tool combination is important. The

torque setting on the torque wrench will change if the overall length of the tool combination changes. The
torque setting value of 330FT/LBS in step 8 has been calculated using the crow foot adaptor tool and a ¾”
drive, 600 FT/LBS maximum torque wrench, with a combined overall length of 45”. If the overall length of
the tool combination you are using is not 45”, please consult your New Flyer Service Representative.
9. Using only the torque wrench, torque the hardware at the bolt head to 380 Ft/LBS in sequence. Start with bolt
location 6, then location 7, then location 8.

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Appendix C
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

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Chemical Excellent
Humidity Excellent
Water spray Excellent
Weather Excellent with durable topcoat
(will chalk if left untopcoated)
COLOR
Grey green
The products referenced herein may not be sold in your market. Please consult your
distributor for product availability.

MIXING
COMPONENTS
63P1500 primer base 1 short fill gallon container (0.46 gallon)
347YB1500™ zinc dust 1 gallon container (13.4 lbs.)
MIX RATIO
Component Part by Volume
63P1500 primer base 1 container short fill (0.46 gallon)
347YB1500 zinc dust 1 container (13.4 lbs.)
NOTE: Mixed amount will makes 0.70 gallon.
Page 2 of 4

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

ACTIVATION
Thoroughly stir 63P1500 primer, then slowly add 347YB1500 zinc dust with consistent
agitation. After mixing, filter through a 40 mesh screen. Filter into an agitated spray pot.
Constant agitation during application is recommended to prevent settling of zinc dust.
Minimize contact with humid air.
Reduction
No reduction should be necessary. However, if conditions require thinning, Axalta 8685S™
may be used up to 5 oz./gal. To remain @ 2.8 lbs/gal VOC, use no more than 2 oz/gal.
APPLICATION THINNERS
Spray or brush: Axalta 8685S up to 2 oz./gal. may be added and still remain conforming at
2.8 lbs/gal VOC. Amounts up to 5 oz./gal. Max can be used if required for various
application conditions. Use no alcohol-containing thinners.
POT LIFE
At least 8 hours if moisture is excluded, shorter in high humidity and temperature.

APPLICATION
SURFACE PREPARATION
An SSPC-SP 6 Commercial Blast Cleaning is preferred for optimal performance. For touchup
over inorganic zinc, Hand Tool Clean to an SSPC-SP 2 or Power Tool Clean to an
SSPC-SP 3 can be used. Note: You can prep surface by using 100 – 150 grit sand paper.
APPLICATION CONDITIONS
Do not apply if material, substrate or ambient temperature is below 35°F (2°C) or above
110°F (43°C). The substrate must be at least 5°F (3°C) above the dew point. Relative
humidity should be below 90%.
For best results, apply by spray. Product can be brushed for small spot applications or
repairs. Note that in high humidity, the coating will gradually accumulate on the brush.
BRUSH APPLICATION
Manufacturer: Wooster China Bristle - 3”- 4” brush
SPRAY APPLICATION
Manufacturers listed below are a guide. Others may be used. Changes in tip size or
pressure may be required to achieve proper application.
Conventional Spray
Binks DeVilbiss
Spray Gun: 2001 JGA
Fluid Nozzle: 67SS FF (1.4)
Air Cap: 67PR 704
HVLP Spray
Binks DeVilbiss
Spray Gun: Mach 1 GTi

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Fluid Nozzle: 94 (1.4) 1.4
Air Cap: 94P 2000
Airless Spray
Pump: Graco Extreme 33:1
Airless Gun: Graco 946853