ISSUE DATE:
SERVICE BULLETIN SUBJECT:
VINs or MODELS AFFECTED:
COMPLETE BY:
SERVICE BULLETIN #:
LABOR OPERATION CODE:

12-1-2020
Bus Body Drain Retrofit
Service Specified Buses
Next Service Opportunity
SC-20-165
WD42Z

NOTICE! It is expected that this process will require 5 hours per bus. Please
schedule appropriately to minimize vehicle downtime.

BUS BODY DRAIN RETROFIT
Description

This procedure adds additional drains to the to the bus body.

Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

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Tools/Parts Required
Tools and Supplies Required:
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Power drill
Ballpeen hammer
Pencil grinder
Torx head bits – various sizes
C-Clamps
Orbital sander 36-grit sandpaper discs
Tongue depressor or putty knife
Air pump
Shop vacuum
Acetone wipes
Calibrated Torque wrench
T-25 Torx Socket
Gloves appropriate for Resin mixing
Syringe or plastic bag with corner cut off for application of potting solution
Masking Tape
Hacksaw
Wheel Lifts 4 EA
Jack Stands 4 EA
Plexus Gun

Parts Required:
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044639
VALVE, DUCKBILL, 32MM
4 EA
122-8546 GAROLITE SLEEVE
4 EA
025127-006 SCREW: BUTTON FLANGE: TORX: M5-0.8X16X16
12 EA
019660
INSERT, 150 SERIES, 35-0.8X10.5
12 EA
122-8459 BODY, PLATE, DUCKBILL, WELDED MOUNT
4 EA
122-0901 REAR CURBSIDE AND STREETSIDE DRILL FIXTURE
1 EA
122-0900 FRONT CURBSIDE AND STREETSIDE DRILL FIXTURE 1 EA
017043
SIKAFLEX, SEALANT
300 ml
018362
PLEXUS, MA-530
1 EA
009479
RESIN, EPOXY, WEST SYSTEMS
1 EA
009499
HARDENER, EPOXY, FAST, WEST SYSTEMS
1 EA
027017
FILLER, HIGH DENSITY, WEST SYSTEMS
1 EA

Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

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Procedure:
1. Complete the Proterra approved Lockout/Tagout procedure to make the bus safe for work.
2. Using Wheel Lifts raise the bus. Use four Jack Stands to support the bus after it is lifted.

Safely Raise
and Secure
the Bus

3. This procedure will add Duckbill drains to the underside of the bus body. The following
illustration shows the drain locations and the fixture locations for installing the drains. This is a
bottom view of the bus.

Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

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4. Using Acetone Wipes, clean the area underneath the bus in the areas shown for fixture
mounting in the previous illustration.
5. Using the following illustration as a guide, place the Fixture (123-0901) as shown underneath
the Front Curbside of the bus.
1) Insert Fixture between battery and body
2) Slide as far outboard as possible
3) Slide as far forward as possible
4) Clamp and hold securely

Front Curb Side Location
Fixture P/N 123-0901

6. Use C-Clamps to secure the Fixture (123-0901) in place.

Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

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7. Using a Power Drill with a 17/32-Inch Drill Bit, drill holes in each of the marked locations
shown in the previous illustration. These holes should be drilled all the way through the body.
8. Using a 17/32-Inch Center Punch, dimple the bus body in the location shown in the previous
illustration. This location will be drilled for a drain hole.
9. Remove the C-Clamps and the Fixture (123-0901).
10. Using a Power Drill with a 1-3/8 Inch Hole Saw, cut a hole through the body in the dimpled
location. Ensure that the drill is aligned 90 degrees to the body.
11. Using compressed air, blow out any dust and debris from the holes.
12. Using Acetone Wipes, clean the inside of all the holes.
13. Working through the Drain Hole, apply masking tape to the top of each hole as shown in the
following illustration.

Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

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14. Using Fixture (123-0901), repeat the process to drill the holes on the front Streetside Front of
the bus.
Note: The remaining mounting positions have limited access for clamping. The following
illustration shows the best area for clamping in the remaining areas.

15. Clean the holes and apply masking tape to the tops of the holes.
16. Using Fixture (123-0900), drill the holes in both rear locations.
17. Clean the holes and apply masking tape to the tops of the holes.
18. Using a Hacksaw, cut each piece of Garolite Sleeve (122-8546) to match the depth of each
drain hole. Variations in body thickness require that each Sleeve be custom fit to each drain
hole.
19. Mix West Systems 105 Epoxy Resin with West Systems 205 Hardener to get the amount
required to install the Inserts (019660).
20. Mix in West Systems 404 High Density Filler until the mixture has the consistency of
mayonnaise.
21. Partially fill each 17/32-Inch Hole in the Curbside Front Drain mounting location. Each hole
should be 2/3 full. Do not completely fill the holes.
22. Using a plastic bag with a corner cut off or a tongue depressor, apply the Epoxy to the outer
surfaces of the three Inserts (019660).
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

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23. Place an Epoxy covered Insert (019660) into the three mounting holes. Make sure that the
Inserts are square with the body and flush with the lower surface. Use the small Plastic
Keepers that are supplied with the Inserts to keep them square to the floor. Make sure that
the small potting holes on the installation tab are aligned with the Insert slots going down the
sides.

24. Working through the Drain Hole, remove the Masking Tape from the top of the holes.
25. Apply a layer of Epoxy to the top of the Inserts (019660).
26. Clean up any excess Epoxy.
27. Repeat the process to install Inserts (019660) into the remaining Drain locations.
28. Allow ninety minutes for the Epoxy to cure before continuing this procedure.
29. Using a Plexus Gun, apply Plexus (018362) to the outside of the Garolite Sleeve (122-8546)
that was custom cut to fit the Curbside Front Drain Hole. Do not allow the Plexus to get inside
the Sleeve.
30. Carefully install the Garolite Sleeve (122-8546) into the Curbside Front Drain Hole.
31. Clean up any Plexus (018362) from the bus body and the inside of the Garolite Sleeve (1228546).
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

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32. Using Masking Tape, support the Garolite Sleeve (122-8546) so that it does not shift during
the curing process.
33. Repeat the process to install each custom cut Garolite Sleeve (122-8546) into its
corresponding Drain Hole.
34. Allow thirty minutes for the Plexus to cure before continuing this procedure.
35. Assemble one of the Duckbills (044639) and Body Plates (122-8459) as shown in the
following illustration.

Drain Assembly
P/N 122-8459 Body, Plate,
Duckbill Welded Mount

Lower Body Surface

Duckbill
P/N 044639

36. Using a T-25 Torx Driver, install the assembled Duckbills (044639) and Body Plate (1228459) onto the Inserts (019660) that were installed at the Curbside Front Drain location using
three M5 Screws (025127-006).
37. Using a Calibrated Torque Wrench with a T-25 Torx Socket, torque the screws to 53 inch
pounds.
38. Repeat the process to install drains into the three remaining locations.
39. Lower the bus.
40. Remove the Lockout/Tagout devices and return the bus to service.

Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

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