TSIB 15-02 - New Flyer!
Contents
1. Diameter Bolts if required If bolt 2 is broken replace bolts 2 3 and 4 per Section C b Replace the 5 8 Diameter Bolts if required If any of bolts 7 8 9 or 10 are broken replace all four per Section C c Replace the Four 7 8 Diameter Bolts if required SZ NOTE Coated hardware provides better corrosion protection Depending on the operating environment coated hardware may need to be considered Refer to Section F for a listing of the coated hardware part numbers SZ NOTE Apply Loctite 2047 NF P N 460317 on all mating surfaces bolts washers and spacers and bolt length to ensure connection is water sealed Figure 4 Bolts Requiring Inspection TSIB 15 02 rev C Page 5 of 20 November 5 2015 TET NEW FLYER 5 Inspect for missing or misaligned torque stripes If missing or misaligned apply a torque stripe to track rotation torque to specification as shown in Figure 14 and check for movement i If movement is greater than an 1 8 turn 45 to reach final torque back off 1 full turn apply 10 of the final torque value apply a torque stripe to track rotation and apply final torque If the fastener required more than a 1 2 turn 180 to reach final torque the fastener will require replacement ii If movement was less than an 1 8 turn 45 to reach final torque apply a torque stripe Recheck for signs of misalignment in 1 year per PM schedule 6 Replace other broken2. Refer to Figure 7 3 Remove and discard the 5 8 cylinder bracket bolts 4 Remove the cylinder brackets NF P N 6354539 Store brackets for reinstallation Refer to Figure 7 SPLIT PIN PN 6354536 CASTLE NUT PN 6354537 WASHER PN 6354538 i Kat B e j 8 BRACKET PN 6354539 CYLINDER PIN PN 6354540 Figure 7 Cylinder Bracket Assembly 5 Remove the screws retaining the valve assembly in place and move the assembly away so it does not interfere when working on the flex plate 6 Deflate the suspension air springs TSIB 15 02 rev C Page 9 of 20 November 5 2015 KC NEW FLYER 7 Using wheel lifts raise the bus to allow space to work beneath the vehicle approximately 2 feet reference 8 Ensure all jacking points are supported as shown in Figure 9 SZ NOTE At all times the articulated joint support frame must move in synchronization with the front half of the bus ZS NOTE Maximum height difference between the front half of the bus to the rear half of the bus is 6 Exceeding this height difference may cause harnesses or hoses in the joint to disconnect 9 Remove and discard the sixteen 16 5 8 bolts washers and spacers that mount the joint to the flex plate Figure 8 Accumulator Valve Body MAX HEIGHT DIFFERENCE FRONT TO REAR 6 JACKING POINTS Figure 9 Jacking Points TSIB 15 02 rev C Page 10 of 20 November 5 2015 KC NEW FLYER A WARNING HEAVY OBJECT Ensure the flex
3. bolts as required per Section D c Reassemble the Articulated Joint to the Structure TSIB 15 02 rev C Page 6 of 20 November 5 2015 KC NEW FLYER b Replace the 5 8 Diameter Bolts if required SZ NOTE Inspect flex plate threads The flex plate must be replaced if it has thread damage Refer to Section D REPLACE THE FLEX PLATE for procedure SZ NOTE Apply Loctite 2047 NF P N 460317 on all mating surfaces bolts threads washers and spacers and bolt length to ensure connection is water sealed ZS NOTE Bolts must be clean and free of debris prior to installation All mating surfaces should be clean of dirt debris primer and paint as well SZ NOTE Ensure 5 8 bolts do not interfere with counter bore in rear structure See Figure 11 1 Remove replace and torque one at a time the six 5 8 bolts and spacers to 135 ft lbs Wet with Loctite in the sequence as shown in Figure 14 Then torque the six 5 8 bolts to a final torque of 240 10 ft lbs Wet with Loctite in the sequence as shown in Figure 14 See Section F Part Number table for the list of part numbers Mark torque stripe across bolt head washers spacers and joint structure Step 1 Torque six 5 8 bolts to 135 ft lbs Wet with Loctite Step 2 Torque six 5 8 bolts to a final torque of 240 10 ft lbs Wet with Loctite Figure 5 5 8 Diameter Bolts TSIB 15 02 rev C Page 7 of 20 November 5 2015 KC NEW FLYER c
4. plate is supported before removing the 7 8 bolts 10 Support the flex plate using floor jacks before removing the 7 8 bolts 11 Remove and discard the eight 7 8 bolts washers and nuts that mount the flex plate to the rear structure 12 Lower the floor jacks to lower the flex plate from the joint assembly Remove the old flex plate and discard 13 Clean remove corrosion from the mating surfaces on the articulated joint and rear structure SZ NOTE Corrosion must be removed to ensure proper clamp force within the joint 14 If required one half of the bus may be raised or lowered independent of the other half of the bus to a maximum 6 height difference to allow better access for cleaning the mating surfaces on the articulated joint structure and rear structure SZ NOTE JAtall times the articulated joint support frame must move in synchronization with the front half of the bus TSIB 15 02 rev C Page 11 of 20 November 5 2015 TER NEW FLYER Replace Flex Plate and Apply Shims 1 Inspect the tubular spacer inserts on the structure using a straight edge tool as per Figure 10 Ensure the tubular inserts protrude outward past or equal to the welded blocks surfaces marked as A and B and C in Figure 10 Use the new flex plate or a straight edge tool placed flush against the surface that protrudes the furthest to determine if shims are required Use a feeler gauge to measure and record the gap distance and location Any
5. QNVH LV 13 YSHSVM 0G 7 X ONN S S X3H 1109 INN 8 6 X901 XSH LNAN 8 5 Q3N3QNHVH LV 14 H3HSVM 00 Z7 X ONN 8 S XSH 1109 sen Ao eet el SL wondusseg wei ee 9JeMpJeH po9jeo MOV 18 ZvO0C 311L90 1 1ieoop 910501 MHL 0c0 133l1S SNIS INIHS MHL SLO 133lS S9NIS INIHS MHL 0L0 1331S SNIS INIHS MHL S00 1331S 9NIM WIHS NOILISNVYL LNIOf ASSV JO 9jeld X9 3 LYOHS d3oVvds 38n L 0S X JYNN8 G DOS M3SHOS ANN vL 8 Z NO TAN 990 1 LON 48 2 GANSQHYVH LV 1s H3HSVM 9 1Z X JANN v1 8 7 L 108 ONN LL 8 6 NO IAN 990 1 LOAN 48 8 Q3N3QSHVH LV I3 H3HSVM GLX ONN 8 S X3H L1OS8 ONN LL 8 S NO TAN 990 1 LON 48 8 Q3N3QSHVH LU H3HSVM 00 Z7 X ONN 8 65 X3H L IO L7S89e OOOVLNLV 00071 MOZ KOL 0000LNOFT 00001 MOC OcLOL8OI 00001 NOT 00001 MOZ CLLOLEOL aJeMpleH pJepuejs November 5 2015 Page 20 of 20 TSIB 15 02 rev C
6. QUE TO 135 FT LBS Wet with Loctite STEP 2 220 10 FT LBS Wet with Loctite ees d i emm Fz N 4 CS 1 i3 J 5 67 JOINT FLEX PLATE 7 8 14 UNF 7LG BOLT X8 FOLLOW INCLUDED TORQUE SEQUENCE STEP 1 TORQUE TO 520 20 FT LBS Wet with Loctite STEP 2 TORQUE TO 520 20 FT LBS Wet with Loctite TO CONFIRM TORQUE NOTE TORQUE FASTENERS FROM BOLT HEAD 7 Q 9 s O O O o OO O O O o O O OOOO OO ane OO OOOO ZS O O O o Oo o o o 9 FEX 8 3 2 e Figure 14 Torque Sequence TSIB 15 02 rev C Page 17 of 20 November 5 2015 TET NEW FLYER E REASSEMBLE THE ARTICULATED JOINT AREA 1 Reinstall rear half cover plate NF using the original hardware Apply grease to the support if necessary 2 Reinstall the inside and outside bellows and tighten the J channel assembly 3 Reinstall the screws that hold the bottom flap underneath the coach 4 Reinstall seats and stanchions in the joint area as necessary 5 If necessary lower coach in accordance with New Flyer Service Manual 6 Turn the main battery disconnect switch to the ON position TSIB 15 02 rev C Page 18 of 20 November 5 2015 SS NEW FLYER F PART NUMBER TABLE TSIB 15 02 rev C Page 19 of 20 November 5 2015 NEW FLYER MHL 0c0 133lS SNIS INIHS MHL SLO l33lS S9NIS INIHS MHL 010 133lS SNIS INIHS MHL S00 l33lS 9NIM WIHS ANN 8 Z X901 XSH LNN 8 2 Q3N3QNHVH LV 13 H3HSVM 9 1Z X JNOvL 8 7 L 1OS INN 8 6 X901 XSH LAN 8 5 Q3N3
7. RTICULATED JOINT INSPECT FOR FLEX PLATE DEFORMATION AND CRACKS REPLACE THE FLEX PLATE IF REQUIRED A B C INSPECT THE ARTICULATED JOINT BOLTS AND REPLACE IF REQUIRED D E REASSEMBLE THE ARTICULATED JOINT AREA F PART NUMBER TABLE A ACCESS THE ARTICULATED JOINT Turn the main battery disconnect switch to the OFF position N Raise coach in accordance with the New Flyer Service Manual or use a service pit Open the interior bellows and remove the rear cover plate to gain access to the flex plate a From the interior of the coach remove the screws holding the bellows REMOVE SCREWS Hi Figure 1 Bellows Removal b Remove the seats and stanchions located on the artic joint if required Store parts for reinstallation Tie the rear half of the bellows to allow more space for ease of work d Remove the hardware retaining the rear half cover plate Store cover and hardware for reinstallation TSIB 15 02 rev C Page 2 of 20 November 5 2015 TER NEW FLYER 4 If required the exterior bellows can be opened to ease access to the flex plate a Remove the screws retaining the bellows flap to the coach on the underside Store hardware for reinstallation b Use a knife or screw driver to pry off the Sika holding the bellows to the rear section of the coach if necessary c Disconnect J clip by removing the stud terminal nut and washer This allow for the bellows to be pushed back Store har
8. Replace the Four 7 8 Diameter Bolts if required SZ NOTE Apply Loctite 2047 NF P N 460317 on all mating surfaces bolts threads washers flex plate structure nut and bolt length to ensure connection is water sealed SZ NOTE Bolts must be clean and free of debris prior to installation All mating surfaces should be clean of dirt debris primer and paint as well SZ NOTE Any shims installed between the bus structure and flex plate must be kept in place 1 Oneata time remove replace and torque the four 7 8 bolts to 520 20 ft lbs Wet with Loctite to the bolt head in the sequence as shown in Figure 14 Torque the bolts a second time to 520 20 ft lbs Wet with Loctite to the bolt head in the sequence See Section F Part Number table for the list of part numbers Mark torque stripe across bolt head washer and flex plate and on the nut side torque stripe across bolt nut washer and tube structure See Figure 6 Figure 6 7 8 Diameter Bolts Nuts amp Washers TSIB 15 02 rev C Page 8 of 20 November 5 2015 RE NEW FLYER D REPLACE THE FLEX PLATE if required Required only if threads are damaged or if the flex plate deformation gap is gt 0 030 see Section B a Separate the Bus at the Articulated Joint and Remove Flex Plate 1 Depressurize the articulated joint system 2 Disconnect the end of the cylinders by removing the cotter split pin and hardware Store hardware for reinstallation
9. TSIB 15 02 rev C Page 15 of 20 November 5 2015 TET NEW FLYER 8 Reattach the hydraulic cylinder bracket back to the flex plate using new 5 8 X 7 bolts washers and nuts See Section F Part Number table for the list of part numbers Torque bolts in two steps to the the sequence as shown in Figure 14 Mark torque stripe across bolt head and cylinder bracket and on the nut side torque stripe across bolt nut washer and tube structure otep 1 Torque to 135 ft Ibs Wet with Loctite Step 2 Torque to 220 10 ft lbs Wet with Loctite 9 Reinstall the articulated joint valve assembly in place and use original hardware 10 Reattach the cylinder components to the brackets Torque nut on the cylinder pin to 74 ft lbs 11 Re pressure the articulated joint system to 20 7 Bar and add oil as needed 12 Reassemble the articulated joint closure per Section E Reassemble the Articulated Joint Area TSIB 15 02 rev C Page 16 of 20 November 5 2015 KC NEW FLYER REAR BULKHEAD FRAME 9 8 X 5 LG BOLT X8 TYPICAL 2 PLACES FOLLOW INCLUDED TORQUE SEQUENCE Wi ge APPLY LOCTITE 2047 NF P N 460317 TO BOLTS 5 0 3 7 STEP 1 TORQUE TO 135 FT LBS Wet with Loctite STEP 2 TORQUE TO 240 10 FT LBS Wet with Loctite REAR BULKHEAD CYLINDER BRACKET 9 8 11UNC X 7LG BOLT X4 5 8 11 UNC X 7 5LG BOLT X2 TYPICAL 2 PLACES FOLLOW INCLUDED TORQUE SEQUENCE APPLY LOCTITE 2047 NF P N 460317 TO BOLTS STEP 1 TOR
10. UE TECHNICAL SERVICE NEW FLYER INFORMATION BULLETIN TSIB 15 02 rev C November 5 2015 TITLE Annual Inspection of the Articulated Joint Flex Plate Bolts This TSIB applies to New Flyer Low Floor LF LFR amp LFA articulated buses with a flex plate within the ATG articulated joint APPLICABILITY NOTE This does not affect the Xcelsior bus model This bulletin outlines the steps required for the annual inspection of the articulated joint flex plate bolts and adding Loctite sealant to the hardware to provide a water tight seal to help prevent corrosion This inspection should be carried out during the annual articulated joint service interval or if the flex plate bolts have been broken in service This is a supplement to existing New Flyer preventative maintenance information for the articulated joint flex plate bolts Please ensure that the articulated joint flex plate bolts are maintained in accordance with this Technical Service Information Bulletin and the New Flyer Service Manual This is a highly dynamic area of the bus and inspection compliance is critical If you experience high failure rates of bolts on individual buses please contact New Flyer Direct all inquiries regarding this bulletin to Ted Kosokowsky Technical Service Manager New Flyer Service Organization Ge 204 224 6859 ER Ted_Kosokowsky newflyer com TSIB 15 02 rev C Page 1 of 20 November 5 2015 TET NEW FLYER CONTENTS ACCESS THE A
11. ast the end of the flex plate See Figure 11 See Section F Part Number table for the list of part numbers NOTE Apply Loctite 2047 NF P N 460317 on all mating surfaces bolts washers spacers flex plate and bolt length to ensure connection is water sealed SZ NOTE Bolts must be clean and free of debris prior to installation All mating surfaces should be clean of dirt debris primer and paint as well TSIB 15 02 rev C Page 13 of 20 November 5 2015 TET NEW FLYER II 5 8 X 5 BOLTS x16 4 AND SPACERS X32 FLEX PLATE Figure 12 Flex Plate amp Hardware Portions of the Structure Removed for Clarity 2 Ensure that the mounting holes in the flex plate are flush and aligned with the rear structure s tubular inserts 3 As per recorded information in Figure 10 apply the appropriate number and thickness of shims between the flex plate and the rear structure 4 Secure the flex plate to the rear structure with the 7 8 X 7 bolts 7 8 washers and 7 8 nuts inserting the correct sized shims onto the other side of the flex plate between the flex plate and the structure Only lightly tighten the 7 8 bolts at this time to a torque of 50 ft lbs Wet with Loctite See Figure 12 5 Slowly torque the 5 8 bolts x16 between the articulated joint and flex plate to 40 ft lbs Wet with Loctite See Figure 11 By hand check to ensure that the spacers are not free to rotate Any
12. dware for reinstallation SZ NOTE J Clip removal and moving the bellows will require two people REMOVED J CLIP LOCATED UNDERNEATH THE COACH STREET AND CURBSIDE FLAT WASHER STUD TERMINAL Zeie NOT TO BE REMOVED e STUD TERMINAL NUT Figure 2 J Clip Removal d Tie the rear half of the bellows to allow more space for ease of work TSIB 15 02 rev C Page 3 of 20 November 5 2015 TER NEW FLYER B INSPECT FOR FLEX PLATE DEFORMATION AND CRACKS 1 Inspect the flex plate for cracks If any cracks are found proceed to Section D REPLACE THE FLEX PLATE 2 Inspect flex plate deformation gap between the articulated joint and the flex plate at the 5 8 bolts that fasten the articulated joint to the flex plate with the 5 8 bolts installed at proper torque Feeler gauges can be used to measure any gap in this area If the gap is greater than 0 030 the flex plate requires replacement proceed to Section D REPLACE THE FLEX PLATE SZ NOTE The gap between the flex plate and the bus structure does not need to be measured Figure 3 Flex Plate Deformation Gap TSIB 15 02 rev C Page 4 of 20 November 5 2015 TER NEW FLYER C INSPECT THE ARTICULATED JOINT BOLTS AND REPLACE IF REQUIRED a Inspect the Articulated Joint Bolts 1 2 Inspect 5 8 and 7 8 diameter articulated joint bolts highlighted in Figure 4 If bolt 1 is broken replace bolts 1 5 and 6 per Section C b Replace the 5 8
13. gap equal to or greater than 0 010 is unacceptable and shims must be applied ZS NOTE Ensure the tubular inserts and end blocks protrude outward past or equal to the center welded blocks surfaces marked as A and B and C in Figure 10 Tubular Inserts VERTICALLY Tubular Inserts GOOD Straight edge tool is placed on the tubular insert flush against the surface that protrudes the furthest parallel to the rear structure BAD Straight edge tool is placed diagonally against multiple surfaces AA vay Figure 10 Tubular Inserts Flatness Inspection TSIB 15 02 rev C Page 12 of 20 November 5 2015 CHE NEW FLYER Te M m pe pr Aye Te Counter bore a at pe p A SH Wie U Dep ape i LL TOUR e 4 4 ee U U 1 1 1 i i U 1 i 1 l i l l gef D m i Rear Structure Portions of the otructure Removed for Clarity The bolt can t interfere with the counter bore in the Rear Structure Flex plate Figure 11 Ensure Bolts Do Not Interfere With Counter Bore in Rear Structure b Reassemble the Articulated Joint to the Structure A WARNING HEAVY OBJECT Prior to installing the flex plate ensure the flex plate is supported 1 Attach the flex plate to the joint first using new 5 8 X 5 bolts x16 and spacers x32 with Loctite Only screw the new 5 8 bolts far enough so the end of the bolt does not protrude p
14. rotation of the spacers may indicate thread damage or interference with the counter bore in the rear structure check threads for damage and check for interference 6 Torque the 5 8 bolts between the articulated joint and flex plate in two steps in the sequence as shown in Figure 14 Mark torque stripe across bolt head washer spacers and joint structure Step 1 Torque to 135 ft lbs Wet with Loctite Step 2 Torque to 240 10 ft lbs Wet with Loctite TSIB 15 02 rev C Page 14 of 20 November 5 2015 TET NEW FLYER 7 Torque 7 8 bolts to 520 20 ft lbs Wet with Loctite from bolt head in the sequence as shown in Figure 14 Torque the bolts a second time to 520 20 ft lbs Wet with Loctite to the bolt head in the sequence Mark torque stripe across bolt head washer and flex plate and on the nut side mark torque stripe across bolt nut washer and tube structure ZS NOTE Apply Loctite 2047 NF P N 460317 on all mating surfaces bolts washers spacers flex plate structure nut and threads to ensure connection is water sealed SZ NOTE Bolts must be clean and free of debris prior to installation All mating surfaces should be clean of dirt debris primer and paint as well SZ NOTE Atall times the articulated joint support frame must move in synchronization with the front half of the coach Maximum height difference front to rear 6 Detail A Detail A Figure 13 Flex Plate Installation
Download Pdf Manuals
Related Search