FSV-196 Service Bulletin/Repair Instructions

SB-10054552-6936

WMATA: Corrosion Repair
Prepared by:
Kalman Takacs

Sr. Field Service Engineer
Approved by:
Dan Allen

Chief Engineer
Property name and Top bus number:
WMATA 221000
Issue:
Corrosion issues were reported by the customer.
Solution:
Repair the effected area per this work instruction.
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
1
WMATA: Corrosion Repair
Effected buses: 22

Estimate repair hours/bus: 16 hours/bus

Necessary parts:

L-profile, 1.5x1.5x8.5”, left,

Part #: 634-3968,

L-profile, 1.5x1.5x8.5”, right,

Part #: 634-3969,

Bracket, shop air,

Part #: 634-3972,

Closeout panel, 17”, SS,

Part #: 634-3971,

Closeout panel, 27”, SS,

Part #: 634-3970,

Slotted bar, 2 slots,

Part #: 5007037,

PINCH WELT, 1/4" WIDE x1/2", BK,

Part #: 416.00.9402.915,

Welding wire, ER 70S, dia. 0.035”

Part #: NPN,

Industrial primer,

Part #: NPN,

Sikaflex 221, White, sealer,

Part #: 416.00.7311.909,

Rubberized undercoating:

Part #: NPN,

See some pictures below about the possible usable products.
1/bus,

1/bus,

1/bus,

1/bus,

2/bus,

2/bus,

2’/bus

as required,

1 can / 10 buses,

1 tube/5 buses,

1 can / 10 buses,
Example
Example

Necessary tools:

Usual hand tools (wrenches, screwdrivers, hammer, chisel, etc.) putty knife, Sika applicator gun, angle

grinder, GTAW Welding machine, 1/8” diameter drill bits, drill, wire wheel, 36G and 60G abrasive discs, deburr bits
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
2
WMATA: Corrosion Repair
SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY

STANDARDS AND LOCAL/PROPERTY REQUIREMENTS.

Stop welding 45 minutes before planning to leave the bus.

1. Park the bus above a service pit or on a suitable bus lift. For the chassis inspection/repair

the bus needs to be lifted (see page 12). Follow safety precautions when lifting the bus.

Only trained personnel can operate bus lift. Use jack stands underneath the official jacking

pads.

2. If bus parked above a service pit or on a scissors type lift then apply parking brake and also

place wheel chocks underneath the C-axle wheels.

3. Turn off the battery disconnect switches.
4. Tag and disconnect the battery cables.

5. Disconnect the ECU of engine, transmission, ABS. Disconnect the destination signs. Turn

off and disconnect the PA system.

6. Remove rear engine compartment door. Refer to NABI Maintenance Manual about

removing / installing components and about the required safety precautions.
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
3
WMATA: Corrosion Repair
7. Disconnect the two twist lock connectors at the back of the rear engine control box and

remove the engine control box.
8. Remove belt guard assembly.
9. Remove engine compartment light.
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
4
WMATA: Corrosion Repair
10. Remove air filter housing assembly. Cover all open air intake pipes to prevent contamination

during the rework.
11. Drain air and remove shop air fitting/hose.
Insert this adapter into the shop air connector and

drain air before removing shop air connector
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
5
WMATA: Corrosion Repair
12. Cover the entire engine compartment with a fire proof blanket.
13. Cut the existing horizontal sheet metal panels out of the structure. Use air chisel, air and

electric cutting and grinding tools. Do not cut the structural tubes.
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
6
WMATA: Corrosion Repair
14. Sand the structural tubes smooth by using 36G and 60G abrasive discs.
Remove any corrosion around the

AC hoses. Do not cut the hoses!
15. Weld the two angle pieces of the control box to the structure according to the picture below.

Use the control box to locate the correct position of the angle pieces. Use GTAW (MIG)

welding equipment with 75%Ar-25%CO2 shielding gas-mix and 0.035 ER70S welding wire.

Place the ground cable (clamp) of the welding equipment as close to the welding area as

possible.
a3
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
7
WMATA: Corrosion Repair
16. Weld the shop air bracket to the same location as it was originally on structure according to

the picture below.
Slotted bars for engine

compartment light
a3

17. Weld the two slotted bar pieces (for the interior light) to the structure according to the picture

above. Use the light to locate the position of the slotted bars.

18. Remove weld splatters as required. Clean the welded areas with wire wheels.

19. Degrease sanded surfaces by using acetone and clean painter’s rags (white color rags).

20. Apply industrial primer to the cleaned surfaces. Follow instructions written on the can.
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
8
WMATA: Corrosion Repair
21. Apply rubberized undercoating to the primed surfaces. Follow instructions written on the

can.
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
9
WMATA: Corrosion Repair
22. Install new closeout panels. Secure panels to the chassis with the existing screws and new

flat and lock washers. Ensure that the new closeout panels are secured correctly so they

won’t make noise. See details below.

Drill a 1/8” size hole and install

a #10 self-tapping PH SS

screw at the middle of this

closeout panel
Existing closeout panel
Slide the new closeout panels underneath the existing

closeout panel and use new large OD size SS flat washers

and new lock washers with the original screws to secure the

new closeout panels.

New closeout panels
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
10
WMATA: Corrosion Repair
23. Install pinch welts to the edges of the closeout panels.
Place two 3” long equally placed

pinch welt pieces to this edge of

the closeout panels to secure the

closeout panel tight to the

structure.
24. Reinstall engine compartment light to the new brackets (slotted bars). Secure harnesses

with wire ties.
25. Reinstall shop air fitting/hose to the new bracket.

26. Reinstall control box to the new angle pieces. Use new ¼-20x1.5 hex head mounting bolts

as required.

27. Reconnect the twist lock connectors at the back of the control box.

28. Reinstall air filter assembly. Ensure that all of the hoses and clamps are installed correctly.

29. Reinstall belt guard assembly.

30. Reinstall rear engine door.

Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
11
WMATA: Corrosion Repair
31. Reconnect the ECU of engine, transmission, ABS. Reconnect the destination signs.

Reconnect the PA system.

Chassis inspection / corrosion repair

32. Lift the bus. Follow safety precautions when lifting the bus. Only trained personnel can

operate bus lift. Use jack stands underneath the official jacking pads.

33. Inspect chassis from front to back and identify areas (if any) that needs to be repaired. If

corrosion was found follow the steps written below. The below repair is an example and

other area of the chassis should be repaired the same way.

34. Remove corrosion from the effected area. Use electric grinder first then the 36G abrasive

wheel and finally the 60G abrasive wheel. Use different size and shape of wire wheels as

required. Ensure that all corrosion is removed.

Original condition of the corroded

area.
Loose paint and corrosion

removed.
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
12
WMATA: Corrosion Repair
35. Degrease surface with acetone.

36. Apply industrial grade primer to the degreased area. Follow instructions written on the can.
37. Apply rubberized undercoating to the primed area. Follow instructions written on the can.

Final operation

38. Lower the bus.

39. Reconnect battery cables.

40. Turn battery disconnect switches on.

41. Start the bus (WMATA technician) and ensure that no warning lights (check engine, check

transmission, etc.) are on.

42. Present the repaired bus for inspection to a delegated person.

43. Record bus number, mileage, date of completing and the name of the technician who

completed the repair.
Work instruction number: L3/FSV-196

L4/QUA-003
Revision: Initial
Date: 09/26/2013

Revision: Initial
13

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