WORK PROCEDURE
for distributors and service points

WP1078
ADDRESSEES

: ABC Customer Care and Parts Source

VEHICLE MODEL

: TD925US 10-wheeler

MANUAL SECTION

: 02.10 Engine - fuel system

DOCUMENT TYPE

: Fix-On-Fail

DATE

: November 7th, 2019

SUBJECT

: To isolate fuel tank from understructure

CONDITIONS

: Refer to chapter "Warranty" further on in this bulletin.

DESCRIPTION:
This work procedure explains how to isolate the fuel tank from the understructure to prevent fuel
tank cracking due to structural loads during severe operating conditions.

Figure 1: Improved fuel tank installation

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

SPECIAL TOOLS, EQUIPMENT OR SERVICES:
No special tools, equipment or services are required.
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COMPONENTS AND PRODUCTS:
Components of retrofit kit VH11679395

Figure 2

VH reference
660671001-00150
660671001-00900
660671001-00200
660670502-00900
621201940-00430
621201940-00520
621201940-00260
10924627-01395
11030461
621201370

Description
Stainless steel strip (40 mm x 5 mm; length 6 inch/150 mm)
Stainless steel strip (40 mm x 5 mm; length 35 inch/900 mm)
Stainless steel strip (40 mm x 5 mm; length 8 inch/200 mm)
Stainless steel strip (25 mm x 5 mm; length 35 inch/900 mm)
Self-adhesive rubber strip (60 mm x 4 mm; length 17 inch/430 mm)
Self-adhesive rubber strip (60 mm x 4 mm; length 21 inch/520 mm)
Self-adhesive rubber strip (60 mm x 4 mm; length 10 inch/260 mm)
Rubber profile (40 mm x 4 mm; length 55 inch/1395 mm)
Stainless steel socket head screw M10x1.5; length 3.55 inch
Gasket for floating sensor

Qty
2
2
2
1
1
2
1
1
4
1

PREPARATIONS:
•
•
•
•
•
•
•

Park the coach on a level-surfaced service pit.
Apply the parking brake and shut down the engine.
Put chocks in front of and behind the wheels remaining on the ground.
Switch off all systems and turn off the battery master switch.
Turn off the mechanical battery switch.
Put a “DO NOT OPERATE” tag on the instrument panel.
Read the entire procedure before beginning to work.

WARNING!
Observe safe shop practices at all times.
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WELDING DATA:
Table: 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

WORKSHOP PRACTICE AND SAFETY INSTRUCTIONS:
Welding safety instructions:
The following information on welding should be read before beginning any such procedure. The
prohibitions and requirements contained herein must be followed during any such procedure.
•

The welding works have to be carried out by a trained and experienced welder. It is the
responsibility of the welder to make sure that his/her personal safety equipment and the
welding equipment that he/she is using are in a condition that will not endanger his/her health
nor the health and safety of others.

•

Use barriers of fire-resistant material to protect components (wiring, air lines, hydraulic lines,
fuel lines, ...) from damage due to heat, contact by weld spatter, arcing and other possible
damage associated with welding.

•

Take the following precautions to protect the electronic equipment of the vehicle:
• Disconnect the 24V-system batteries (disconnect ground cable first, reconnect ground cable
last).
• Remove the plugs/connector sockets from all electronic control units.
• Remove the connector sockets from all multiplex nodes.
• For all other electronic devices (radio, video, ...), consult the manufacturer's instructions.
• Position the welder ground clamp as closely as possible to the weld. Make sure there is a
perfect metal-to-metal contact between the clamp and the chassis frame.
• See to it that the power supply line of the welder is connected to a properly grounded socket.

•

Never look into the arc unless you are wearing a suitable helmet or face shield.

•

Wear protective clothing and gloves.

•

Do not allow any bystanders, unless they are wearing adequate protective gear.

•

Never weld while standing in water or on a damp surface.

•

Welding generates smoke and gases. Provide adequate ventilation! If ventilation is bad, use an
approved gas mask.

•

Do not adjust the settings of the welder while it is under load.

•

Keep cables tight in the sockets.

•

Do not touch hot parts with bare hands. Use the appropriate equipment to seize hot parts
and/or wear heavy welding gloves and clothing to avoid burns.

•

Do not allow the welding electrode/welding wire to touch anything but the part that has to be
welded.

•

Do not allow any flammable materials in the vicinity of the welding works. If this is
impracticable, cover any flammable material adequately with fire-resistant material.

•

Always have a fire extinguisher of the correct type nearby.

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Grinding safety instructions:
Grinders can be dangerous if improperly used. They can cause severe and lasting injuries to eyes,
hands, face and body. Therefore, always observe the following safety instructions:
•

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

•

When necessary, provide appropriate barriers to protect parts (glass, wiring, air lines, hydraulic
lines, fuel lines, ...) against damage by grinding sparks.

•

Before starting grinding works, first thoroughly clean the area.

•

Allow the grinder to reach full rpm and slowly bring the grinding wheel into contact with the
work piece.

•

Only put the grinder aside when the grinder wheel has stopped turning completely.

•

Do not allow the grinding wheel to hit anything while it is turning. It may shatter and explode.

•

Do not grind with explosive vapors in the vicinity (gasoline, paint thinner, batteries).

•

Before installing a new grinding wheel, disconnect the current supply or the compressed-air
supply line.

•

When installing a new wheel, make sure:
It is designed for the rpm of the grinder.
It has the correct dimensions.
It is properly fitted.

•

Never grind with grinding wheel guard removed.

Aftertreatment:
Coat the reinforcement plate and other bare metal with primer and rust-protective paint. Leave to
dry.

PROCEDURE:
Step
1
2
3
4
5
6
7
8

Action
Remove the drive axle wheels.
Drain the fuel tank as explained under “STEP 2 IN DETAIL”.
Remove the fuel tank as explained under “STEP 3 IN DETAIL”.
Modify the fuel tank understructure as explained under “STEP 4 IN DETAIL”.
Install the fuel tank in reverse order of removal. Use the four screws 11030461 from
the kit for installation of the fuel tank straps. Tightening torque: 30 ± 5 ft.lbf.
Install the fuel floating sensor in reverse order of removal. Use the new gasket
621201370 from the kit. Tighten the screws to a torque of 2 ft.lbf.
Re-install the drive axle wheels. Tighten the wheel nuts to a torque of 445 ± 15 ft.lbf.
Register the works through the registration button located behind work procedure
WP1078 on the Van Hool customer portal. Write the text "WP1078 completed on
VIN…" in the "Remark" field.

End of procedure.

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STEP 2 IN DETAIL: To drain fuel tank
Step
2.1

Action
In the luggage compartment: remove the floor traps above the fuel tank.
NOTE: Screws are not identical! Note therefore the position of the screws for
reinstallation purposes.

Figure 3

2.2

Remove the floating sensor as follows:
a. Disconnect the electric connector.
b. Remove the five screws and washers.

Figure 4

2.3

Make use of the hole for the floating sensor to extract the fuel from the tank. Make
sure that the tank is as empty as possible before removing the tank.

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STEP 3 IN DETAIL: To remove fuel tank
Step
3.1

Action
Remove the floor trap structure above the tank.

Figure 5

3.2

Disconnect the fuel lines at the fuel tank:
• the engine fuel supply line (2);
• the engine fuel return line (4).
• the coolant heater fuel supply line (1).
• the coolant heater fuel return line (3).

Figure 6

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3.3

Remove the fuel tank as follows:
a. Only if tank is secured with an additional third strap at the front: remove
retaining strap (1). This strap is not being reused!
b. Disconnect rubber hoses (3 and 5).
c. Remove metal retaining straps (2 and 4).
d. Remove the fuel tank.
e. Remove both brackets (6) at the right and left side.

Figure 7

STEP 4 IN DETAIL: To modify fuel tank understructure
Step
4.1

Action
Weld the stainless steel strips from the kit as indicated in figures 8 and 9:
•
•

At the left side: stainless steel strips 660671001-00200 (1, figure 9), 66067100100150 (2, figure 9) and 660671001-00900 (3, figure 9) at the outside; stainless
steel strip 660670502-00900 (7, figure 9) at the inside.
At the right side: stainless steel strips 660671001-00900 (4, figure 9),
660671001-00150 (5, figure 9) and 660671001-00200 (6, figure 9).

Figure 8: Exact location of stainless steel
strips (measures in mm)

Figure 9: Exploded view with location of
stainless steel strips

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4.2
4.3

Clean the surfaces of the steel to ensure the "self-adhesive rubber strips" which will
be installed in next step stay attached.
Install the self-adhesive rubber strips and the rubber profile from the kit as follows:
• At the left side: apply self-adhesive rubber strips 621201940-00520 (1) and
621201940-00260 (2) at the outside, and install rubber profile 10924627-01395
(3) at the inside.
• At the right side: apply self-adhesive rubber strips 621201940-00520 (4) and
62201940-00430 (5).

Figure 10

WARRANTY:
1. Conditions
Van Hool accepts claims for this retrofit during warranty period as follows:
Compensation for labor hours: 10 hours per vehicle
2. Claim references:
•
•

Job code: O51078N
Monitoring and performance: The claim records pertaining to this Work Procedure will be
used to determine that the remedy has been executed in accordance with the
manufacturer’s instructions and to evaluate the status of this problem.

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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