NHTSA ID Number: 10054552
Manufacturer Communication Number: FSV-196
TSB/Document Date: 2014-02-04
Summary
NABI: INSTRUCTION INFORMATION PROVIDED REGARDING THE REPAIR OF AN EFFECTED AREA THAT HAS CORROSION ISSUES. MODEL WMATA 221000. NO YEARS LISTED. *PE
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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TSB/Document ID: FSV-196
Replacement Service Bulletin Number:
MFR Communication Date: 2013-09-26
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE:BODY
MFR Component System:
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