SERVICE BULLETIN
SB1569
ADDRESSEES

: ABC Customer Care and Parts Source
Owners and operators

VEHICLE MODEL

: All coaches

SYSTEM/SUBSYSTEM

: 10.38 Body and body accessories – Body structure

BULLETIN TYPE

: Service Information

DATE

: October 25th, 2018

SUBJECT

: General welding requirements for body structure

TERMS & CONDITIONS

: This service bulletin does not entitle to any reimbursement.

DESCRIPTION
This service bulletin has been released to assist in carrying out repairs on the vehicle structure
caused by corrosion or damage..

JOB QUALIFICATION:
The welding job should be executed by a qualified and experienced welder.

SPECIAL TOOLS:
The job requires the use of:
•
•

an angle grinder
a MIG welding equipment. Refer to the proper table under “welding data” for type of material
being welded.

WELDING DATA:
Welding data for mild steel to mild steel (according to AWS A 5.18 ER 70S-6)
• Welding wire section: 1.0 mm (0.039 inch)
• Welding wire feed speed: 2.9-8.4 m/min (115-330 inch/min)
• Current: 80-190 Amps
• Welding gas: 75% Argon + 25% CO2 (option: 80% Argon + 20% CO2)

Welding data for stainless steel (according to AWS A 5.9-93 ER 309LSi)
• Welding wire section: 1.0 mm (0.039 inch)
• Welding wire feed speed: 2.9-8.4 m/min (115-330 inch/min)
• Current: 80-190 Amps
• Welding gas: 88% Argon + 10% Helium + 2% CO2

NOTE: Welding gas with a high Helium content introduces a lot of heat in the welding
area leading to a harder and more brittle weld.

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EQUIPMENT CONDITION:
•
•
•
•
•
•

Park the coach on a level-surfaced service pit.
Apply the parking brake and shut down the engine.
Switch off all systems and turn off the battery master switch.
Put a “DO NOT OPERATE” tag on the instrument panel.
Remove necessary vehicle components to gain access to affected areas.
Read the entire procedure before starting to work.

WARNING!
Observe safe shop practices at all times.

SHOP PRACTICE AND SAFETY RULES:
Welding safety rules:
•

The following information pertaining to welding should be read before beginning any such
procedure. The prohibitions and requirements contained herein must be followed during such
procedure.

•

Welding must be done only by a qualified and experienced person. It is the responsibility of the
welder to make sure that his/her personal safety equipment and the welding equipment he/she
is using are in a condition that will not endanger his/her health and safety or the health and
safety of others.

•

Adequate ground contact and barriers must be positioned as required to protect components
(wiring, air-lines, hydraulic lines, fuel lines etc.) from damage due to heat, contact by weld
spatter, arcing or other potentially damaging events associated with welding.

•

The following precautions must be taken to protect the vehicle’s electronic equipment:
- Disconnect the 24V-system batteries (disconnect ground cable first, reconnect ground
cable last).
- Disconnect the wiring harness connectors from all electronic control units (ECU’s).
- Disconnect the wiring harness connectors from all multiplex nodes.
- For any other electronic equipment (radio, video, ICE…) refer to the OEM prescriptions.
- Position the welding machine ground clamp as close as possible to the work and make
sure the clamp makes perfect contact with the chassis frame.
- Make certain the welder is properly grounded.

•

Never look at the arc unless wearing a suitable helmet or face shield.

•

Wear protective clothing and gloves.

•

Do not permit bystanders, unless they are wearing protective gear.

•

Never weld while standing in water or on damp ground.

•

Have adequate ventilation.

•

Do not adjust machine settings while the machine is under load.

•

Keep cables tight in the sockets.

•

Do not touch hot metal.

•

Do not allow the welding rod/wire to touch anything but the work.

•

Make sure there is nothing flammable near the working area.

•

Always have a fire extinguisher of the correct type available.
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Grinding safety rules:
Grinders can be dangerous. When improperly used, they are responsible for many serious and
lasting injuries to the eyes, hands, face and body. Therefore you must always observe the following
safety rules:
•

Always wear eye protection (safety goggles, face shield). Wear leather gloves.

•

Adequate barriers must be positioned as required to protect components (glass, wiring,
airlines, hydraulic lines, fuel lines, drive shaft etc.) from damage by grinding sparks.

•

Before doing any grinding on the coach, thoroughly clean the affected area.

•

Keep abrasive discs tight, clean and true.

•

Allow grinder to reach full rpm before using.

•

Do not put aside the grinder until the wheel has completely stopped revolving.

•

Never strike a grinding wheel while revolving. It may shatter and explode.

•

Do not grind in the presence of explosive vapors (gasoline, paint thinner, batteries…).

•

Before installing a new grinding disc, disconnect the electric mains or air supply line.

•

When installing a new disc make certain:
It is designed for the rpm of the grinder.
It has the correct size.
It is properly fixed.

•

Never remove the grinding disc guard.

Aftertreatment:
1.
2.
3.
4.
5.

With all welding complete, remove welding equipment and barriers.
Coat the new parts and the tubing with black chassis paint. Allow to dry.
Coat the joints with undercoating.
Spray the inside of the new tubes (through a hole) with a good rust preventive liquid.
Re-install all removed components.

HELP DESK:
Before welding any Van Hool structure, it is recommended to consult ABC Customer Care &
Parts Source toll-free for guidance on 1-877-427-7278. Listen for the prompts for warranty and
select that option.

DISCLAIMER:
The procedures contained herein are not exclusive. Van Hool cannot possibly know, evaluate,
or advise the transportation industry of all conceivable ways in which a procedure may be
undertaken or of the possible consequences of each such procedure. Other procedures may be
as good, or better, depending upon the particular circumstances involved. Each carrier who
uses the procedures herein must first satisfy itself thoroughly that neither the safety of its
employees or agents, nor the safety or usefulness of any products, will be jeopardized by any
procedure selected.

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INFORMATION HANDLING:
Important supplements to and modifications of technical information not yet included
in the manual, are communicated by means of Service Bulletins.

VAN HOOL CUSTOMER PORTAL:
Consult the customer portal regularly for the latest service documentation. Beside the
maintenance manual, you will also find the operating manual and the spare parts catalogue of
your vehicle on the customer portal. The customer portal is accessible through
www.vanhool.be, and only with a code (password) from Van Hool. If you do not have a
password yet, request it by using the link on the Van Hool website.

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