SMB-184 – Corrosion Protection – Galvanized Coated Structures – New Flyer Xcelsior, MiDi, Invero, Low Floor, High Floor

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SMB-184 1 of 6
SERVICE MANUAL BULLETIN
This Service Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. Refer to details below.
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
ISSUE DATE: April 30 2019
SMB-184
APPLICABILITY
VEHICLE LENGTH  30ft.  35ft.  40ft.  60ft.  ALL
VEHICLE TYPE
 Xcelsior®  MiDi®  Invero®
 ALL
 Low Floor  High Floor
FUEL TYPE
 Diesel  Diesel/Electric  CNG  LNG
 ALL
 Fuel Cell  Trolley/Electric  Battery/Electric
SUBJECT Corrosion Protection – Galvanized Coated Structures
SECTION TITLE Preventive Maintenance
11- Structures & Chassis
DETAILS This bulletin provides additional information and inspection requirements
for galvanized coated components installed on your New Flyer
vehicle.
☞NOTE:
New Flyer Industries requires that the inspection, maintenance and
record keeping requirements covered in this document be performed.
Failure to perform these procedures may void the corrosion warranty
on affected units
This bulletin supersedes any prior information on this subject already
provided in your New Flyer Service Manuals. Make this Service Bulletin
available to service personnel to inform them of changed information.
2 of 6 SMB-184
SERVICE MANUAL BULLETIN
SMB-184
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
1. Galvanized Coated
Structures
Certain rack structures are located in
areas that are more prone to corrosion and
require additional protection in the form of
a galvanized (zinc) coating.
The following galvanized components are
found on New Flyer vehicle configurations:
❒ Rear Suspension Beam. See “Fig. 1-1:
Rear Suspension Beam.
❒ Rooftop Fuel Tank Racks. See “Fig. 1-2:
CNG Tank Rack.
❒ Rooftop and Rear ESS Battery Racks. See
“Fig. 1-3: Rooftop ESS Battery Rack.
❒ Rooftop Inverter and Electronics Racks.
See “Fig. 1-4: Rooftop Inverter Rack.
1.1. Galvanized Coated Inspection
All galvanized coated structures and racks
on the vehicle require a yearly inspection
and cleaning to maintain the corrosion protection
properties.
Fig. 1-1: Rear Suspension Beam
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SMB-184 3 of 6
SERVICE MANUAL BULLETIN
SMB-184
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
.
Fig. 1-2: CNG Tank Rack
.
Fig. 1-3: Rooftop ESS Battery Rack
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4 of 6 SMB-184
SERVICE MANUAL BULLETIN
SMB-184
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
Fig. 1-4: Rooftop Inverter Rack
1.1.1. Inspection
☞NOTE:
The following inspection apples to all galvanized
structures on the vehicle.
1. Gain access to the structure being
inspected. If necessary, raise vehicle and/
or remove compartment access covers.
2. Inspect the access cover or doors, as
applicable, to ensure the rubber seals are
properly fitted and in good condition.
3. Inspect any associated hinges or latches
on the compartment doors. Spray hinges,
pins, and latches with Krown T-40 rust protection
or Krown KL-FSM lubricant.
4. Inspect along all sides of the galvanized
steel structure for any evidence of corrosion.
See “Fig. 1-5: Wet Storage Stains.
☞NOTE:
Zinc corrosion will change the appearance
of the galvanized coating from a gray
smooth finish to a surface with white or
gray powdery deposits known as wet storage
stain
5. Assess the level of wet storage staining
and proceed as follows:
a. Light wet storage stains – thin, light
powdery stains are, for the most part,
superficial and will not compromise the
corrosion protection properties of the
zinc coating. Refer to 1.1.2.1. “Light
Cleaning” on page 6 in this section for
light cleaning procedures.
b. Medium wet storage stains – heavier
powdery stains do not indicate serious
degradation of the zinc coating but
should be removed. Refer to 1.1.2.2.
“Medium to Heavy Cleaning” on page 6
in this section for medium cleaning procedures.
c. Heavy wet storage stains – thick corrosion
products that appear crusty or
bubbly must be removed immediately in
order to avoid severe damage to the
underlying zinc coating. Refer to
1.1.2.2. “Medium to Heavy Cleaning”
on page 6 in this section for heavy
cleaning procedures.
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SMB-184 5 of 6
SERVICE MANUAL BULLETIN
SMB-184
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
d. Inspect any zinc-primered brackets or
other parts that are attached to the galvanized
rack. If rust is evident, clean
and re-apply primer. Refer to 1.1.2.3.
“Zinc-Primer Parts Cleaning & Reapplication”
on page 6 in this section for procedure.
w
Fig. 1-5: Wet Storage Stains
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6 of 6 SMB-184
SERVICE MANUAL BULLETIN
SMB-184
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
1.1.2. Cleaning
Observe all workplace safety standards
and procedures. Wear safety glasses
and protective gloves when working
with chemicals. ALWAYS follow the
manufacturer’s instructions for product
use.
Depending on the level of the wet storage
stain, proceed with either the light cleaning
or heavy cleaning process.
1.1.2.1. Light Cleaning
Use a stiff nylon brush and scrub the
affected surface. Hard scrubbing may be
required to remove all traces of the stain.
1.1.2.2. Medium to Heavy Cleaning
Ensure the work area is properly ventilated
when working with cleaning
chemicals. ALWAYS follow product
manufacturer’s application instructions.
Any of the following readily available products
may be used to clean medium to
heavy staining:
❒ CLR
❒ Lime Juice
❒ Naval Jelly Rust Dissolver (light and
medium stains only)
❒ Picklex 10G
❒ White Vinegar
Clean the affected area as follows:
1. Use a stiff nylon brush to apply the cleaning
product. Use a little cleaning chemical
as possible to scrub off the wet storage
stain.
2. Rinse the surface thoroughly with fresh
water as soon as the stain is removed.
3. Dry the surface immediately.
1.1.2.3. Zinc-Primer Parts Cleaning &
Reapplication
Use either of the following methods to
clean rust from parts and reprotect surface:
Mechanical Cleaning
1. Wire brush the rusted area down to bare
metal.
2. Apply zinc primer, using two to three light
coats to achieve 3-4 mils of dry film thickness.
Refer to Section 11 of your New
Flyer Service Manual for procedure.
Chemical Cleaning
1. Use a stiff nylon brush to remove any loose
rust.
2. Apply any of the following products to
remove the rust:
❒ CLR
❒ Lime Juice
❒ Naval Jelly Rust Dissolver (light and
medium stains only)
❒ Picklex 10G
❒ White Vinegar
3. Rinse and dry the surface.
4. Apply two light coats of Rust Bullet.