CORROSION PROTECTION

All VDL Bus & Coach models

System manual

1437 DD0684_02
All VDL Bus & Coach models

Foreword
This system book contains safety regulations which must
be strictly observed.
Work which is not described in this system book is
described in the VDL Bus & Coach Workshop Instruction
Manual or the Workshop Instructions for the component
concerned.

Experienced mechanics
The technical information and the explanations given in
this system book have been compiled with the utmost
care.

Whilst compiling this system book, it has been assumed

that the mechanic has the necessary experience and has
had the required education or training to be able to carry
out the work in a responsible and safe manner.

Vehicle type.
The information in this system book has been updated
until the time of printing and concerns All VDL Bus &
Coach models.

DD0684_02
 CONTENTS
All VDL Bus & Coach models

Inspection and cleaning

Chassis and underbody ............................... 1-1
0
General information ........................................ 1-1
Cleaning the underside of the vehicle ............. 1-1

Coats of paint and layers of zinc 1

Preservation .................................................. 1-1
Repairing coats of paint and layers of zinc ..... 1-1

Sealant seams
2
Removal and installation.............................. 1-1
Sealant seams ................................................ 1-1
3
Antichip coating
Antichip coating............................................ 1-1
General information ........................................ 1-1
Checking/repairing the antichip coating .......... 1-1 4
Waxing
Anticorrosion coating................................... 1-1
Why apply anticorrosion treatment ................. 1-1 5
Treatment when storing the vehicle ................ 1-3

Special instructions
Service Bulletins ........................................... 1-1
Service bulletin VDL Bus & Coach 1215......... 1-1
Documentation Report Form ......................... -1

DD0684_02
All VDL Bus & Coach models

Disclaimers

© 1437 VDL Bus & Coach bv, Valkenswaard,

The Netherlands.

In the interest of continuous product development VDL

Bus & Coach reserves the right to change specifications
or products at any time without prior notice.

No part of this publication may be reproduced and/or

published by printing, by photocopying, in digital format
or in any way whatsoever without the prior consent in
writing of VDL Bus & Coach.

This manual shall be governed by and applied in

accordance with the laws of the Netherlands.
Any dispute here under shall be referred to the decision
of the District Court of ’s-Hertogenbosch in the
Netherlands

Next remark is relevant if the text has been translated for

your convenience from the English original into an other
language.
A translation, however, can have the consequence that
differences of interpretation arise with respect to the
content and meaning of the text.
In all cases, therefore, the English version of this
document will be regarded exclusively as the single and
authentic source to establish the content and the
meaning of the text in case of a dispute.

DD0684_02
 INSPECTION AND CLEANING
All VDL Bus & Coach models

INSPECTION AND CLEANING

0

DD0684_02
 INSPECTION AND CLEANING
All VDL Bus & Coach models

DD0684_02
 INSPECTION AND CLEANING
All VDL Bus & Coach models Chassis and underbody

1. CHASSIS AND UNDERBODY

0
1.1 GENERAL INFORMATION
If necessary, all VDL Bus & Coach vehicles must be given an
antichip coating and an anticorrosion coating after the repair
and/or replacement of any chassis or bodywork components.
This applies to both products with a powder coating and
products with a conventional paint system.
If the chassis and bodywork are not regularly checked and
regularly maintained in accordance with the guidelines, this
may have consequences for the warranty of the entire vehi-
cle.

1.2 CLEANING THE UNDERSIDE OF THE

VEHICLE
The paint used on the vehicles offers excellent protection
against ageing during the vehicle's lifespan. In order to main-
tain this protection, it is important for the vehicle to be regu-
larly cleaned. This should be done at least once a year, and
should definitely be done at the end of the winter. Gritting salt
has a negative effect on the chassis, the driveline and the
bodywork. The underside of the vehicle must be checked for
damage after the vehicle has been cleaned. A number of
points of attention when cleaning the underside of the vehicle
are given below.

After cleaning the underside of the vehicle, the antichip coat-

ing must be inspected and, if necessary, repaired (see
3 - 1.2 Checking/repairing the antichip coating (1 - 1)).

Furthermore, certain components must
be rewaxed after cleaning the underside
of the vehicle and/or the engine
compartment (see 4 - 1.1.3 Components
to be treated (1 - 2)).

Using a high-pressure hose

• The water temperature must not exceed 50 °C.
• The water pressure must not exceed 80 bar.
• Maintain a minimum distance of 30 cm from the surface to
be cleaned.
• It is not permitted to use additives.
• Avoid spraying valves, connectors, oil seals, seals and
other sensitive parts, because this may lead to faults.

Car wash
• The water temperature must not exceed 50 °C.
• The water pressure must not exceed 80 bar.
• The minimum distance to the chassis is 30 cm.
• It is not permitted to use additives.
• The pH value must be between 6 and 8.
• Always rinse the vehicle with clean water.

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 INSPECTION AND CLEANING
Chassis and underbody All VDL Bus & Coach models

1-2 DD0684_02
 COATS OF PAINT AND LAYERS OF ZINC
All VDL Bus & Coach models

COATS OF PAINT AND LAYERS OF ZINC

DD0684_02
 COATS OF PAINT AND LAYERS OF ZINC
All VDL Bus & Coach models

DD0684_02
 COATS OF PAINT AND LAYERS OF ZINC
All VDL Bus & Coach models Preservation

1. PRESERVATION

1.1 REPAIRING COATS OF PAINT AND

LAYERS OF ZINC
1.1.1 GENERAL INSTRUCTIONS 1
This section gives instructions for respraying and repairing
VDL Bus & Coach paint systems which have been applied to
various surfaces.
The products to be used are supplied by a number of manu-
facturers. However, only use products from reputable manu-
facturers that provide all the products for a complete paint
layer structure. The processing of these products should be
described in the instructions provided by the manufacturer.

Work according to the guidelines listed below:

• For rust-removal, use a rust-removal agent with a phos-
phoric acid base (see 1 - Removing rust (1 - 1)).
• For cleaning, use an organic solvent without chlorine addi-
tives.
• Use a two-component epoxy or polyester-based primer.
• Use a two-component epoxy or polyester-based basic
filler.
• Use a two-component epoxy or polyester-based spray
filler.
• Use a two-component epoxy or polyester-based filler.
• Use a two-component PUR finishing coat, with a gloss
level of 70 units for a chassis finishing coat (measured at
60 degree geometry).
• Maximum drying temperature of 80°C.
• For the paint layer structure, only use products from a sin-
gle manufacturer.
• Use the products according to the manufacturer's instruc-
tions.
• Never use products in a spray cabin that contain silicon.

Removing rust
• Apply the rust-removal agent in accordance with the man-
ufacturer's instructions.
The concentration of the rust-removal agent must be in
ratio to the amount of rust.
• Preferably use a rust-removal paste on vertical parts.
• Prevent rust-removal agents entering overlap joints.
• Leave the rust-removal agent to work for the time specified
by the manufacturer.
• Rinse the area where rust has been removed at least twice
with plenty of clean tap water.
• Dry the area where the rust has been removed from.

Failure to follow the applicable safety
instructions for using paints and related
products can result in serious injury and/
or danger.

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 COATS OF PAINT AND LAYERS OF ZINC
Preservation All VDL Bus & Coach models

Wear protective gloves and protective
glasses when working with a rust-
removal agent.

To avoid unnecessary environmental
pollution when using paints and related
1 products and when handling paint waste,
always work according to the applicable
environmental requirements.

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 COATS OF PAINT AND LAYERS OF ZINC
All VDL Bus & Coach models Preservation

1.1.2 RESPRAYING/REPAIRING PAINT SYSTEMS

WITH A POWDER COAT

General information
• This section gives guidelines concerning respraying and
repairing paint systems with a powder coat.
• Only use the products stated in the guidelines, because
only then can the paint system be properly repaired.
1
• Carefully follow the paint manufacturer’s instructions when
applying paint.
• After welding, also treat the back of welded objects as
described below.

Work according to the guidelines listed below:

Cleaning
1. Chisel away the burnt powder coat residue around the
areas to be repaired immediately after welding, before
the weld has cooled down.
If the welder has not done this, grind the powder coat
away approximately 10 cm around the weld.
2. After removing the powder coat, sand the metal with
P40-P60 sandpaper.
3. Use a rust remover to remove any rust.
4. Use a solvent to clean the area to be treated.
5. Sand the area to be treated using P80 sandpaper, so that
it is completely clean and free of rust.
Also sand approximately 1 cm of the intact (original) pow-
der coat to ensure that the repaired area makes a good
bond with the original coat.
6. Remove any dust from the sanded area with a tack rag.
7. Remove any grease and dirt from the area to be treated.

Applying the undercoat

Primer to be used: Permafleet® EP Grundierfüller 4400

kieselgrau by Spies Hecker or an equivalent product.
Hardener to be used: Permafleet® EP Härter 4401 or an
equivalent product.
1. Apply an EP primer according to the manufacturer's
instructions to the bare metal areas and to the edges
(approximately 5 mm) of the sanded area of the original
coat.
The thickness of the coat must be 40 - 80 µm. The EP
primer can be applied with a brush or a roller.
2. Leave the primer to evaporate for approximately 10 min-
utes.
Next, dry the primer for 30 - 60 minutes at a temperature
of 60°C or for 12 hours at room temperature, depending
on the thickness of the layer of primer.

The primer cannot be dried using infrared
radiation.

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 COATS OF PAINT AND LAYERS OF ZINC
Preservation All VDL Bus & Coach models

Applying the topcoat

Topcoat to be used: Perco Top® 2K 540 Steinschlagschut-

zlack halbmatt RAL 7020 Graphitgrau by Spies Hecker or an
1 equivalent product.
Hardener to be used: Perco Top® Activator 3840 CS704 or
an equivalent product.
1. Remove any dust from the area with a Tack rag and
clean the area with a solvent.
2. If the basecoat was applied more than two weeks previ-
ously, sand the primered areas. Use P320 - P500 sand-
paper for dry sanding and P600 - P800 sandpaper for
wet sanding. Remove any dust from the sanded area
with a Tack rag and clean the area with a solvent.
3. Apply the topcoat over the primer and the sanded areas
according to the manufacturer’s instructions. The thick-
ness of the coating must be 80 - 100 µm. Perco Top can
be applied with a brush or a roller.
4. Allow the topcoat to evaporate for at least 60 minutes.
Next, dry the topcoat for 60 minutes at a temperature of
70 °C or for 16 hours overnight at room temperature (20
°C).

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 COATS OF PAINT AND LAYERS OF ZINC
All VDL Bus & Coach models Preservation

1.1.3 RESPRAYING/REPAIRING CONVENTIONAL

PAINT SYSTEMS

General information
• This section gives guidelines concerning respraying and
repairing conventional paint systems.
• Only use the products stated in the guidelines, because
only then can the paint system be properly repaired.
1
• Carefully follow the paint manufacturer’s instructions when
applying paint.
• After welding, also treat the back of welded objects as
described below.

Work according to the guidelines listed below:

Cleaning
1. Use sandpaper (P40 - P60) to remove the burnt paint
residue from the area to be repaired.
2. Use a rust remover to remove any rust.
3. Use a solvent to clean the area to be treated.
4. Sand the area to be treated using P80 sandpaper, so that
it is completely clean and free of rust.
Also sand approximately 1 cm of the intact (original) coat
to ensure that the repaired area makes a good bond with
the original coat.
5. Remove any dust from the sanded area with a tack rag.
6. Remove any grease and dirt from the area to be treated.

Applying the undercoat

Primer to be used: Permafleet® EP Grundierfüller 4400

kieselgrau by Spies Hecker or an equivalent product.
Hardener to be used: Permafleet® EP Härter 4401 or an
equivalent product.
1. Apply an EP primer to the bare metal parts according to
the manufacturer’s instructions.
The thickness of the coat must be 40 - 80 µm. For fitting
faces (surfaces that are clamped together by a bolt con-
nection, etc.), the thickness of the primer coat must be
20 - 25 µm. The EP primer can be applied with a brush
or a roller.
2. Leave the primer to evaporate for approximately 10 min-
utes.
Next, dry the primer for 30 - 60 minutes at a temperature
of 60°C or for 12 hours at room temperature, depending
on the thickness of the layer of primer.

The primer cannot be dried using infrared
radiation.

DD0684_02 1-5
 COATS OF PAINT AND LAYERS OF ZINC
Preservation All VDL Bus & Coach models

Applying the topcoat

Topcoat to be used: Perco Top® 2K 540 Steinschlagschut-

zlack halbmatt RAL 7020 Graphitgrau by Spies Hecker or an
equivalent product.
Hardener to be used: Perco Top® Activator 3840 CS704 or
1 an equivalent product.
1. Remove any dust from the area with a Tack rag and
clean the area with a solvent.
2. If the basecoat was applied more than two weeks previ-
ously, sand the primered areas. Use P320 - P500 sand-
paper for dry sanding and P600 - P800 sandpaper for
wet sanding. Remove any dust from the sanded area
with a Tack rag and clean the area with a solvent.
3. Apply the topcoat over the primer and the sanded areas
according to the manufacturer’s instructions. The thick-
ness of the coating must be 80 - 100 µm. Perco Top can
be applied with a brush or a roller.
4. Allow the topcoat to evaporate for at least 60 minutes.
Next, dry the topcoat for 60 minutes at a temperature of
70 °C or for 16 hours overnight at room temperature (20
°C).

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 COATS OF PAINT AND LAYERS OF ZINC
All VDL Bus & Coach models Preservation

1.1.4 GALVANIZED STEEL

Repairing the layer of zinc

• Only use the products stated in the guidelines, because
only then can the paint system be properly repaired.
• Carefully follow the paint manufacturer’s instructions when
applying paint.
• After welding, also treat the back of welded objects as
1
described below.
• Observe the guidelines given below which meet the
requirements of NEN-EN-ISO 1461.

1. Cleaning
• Remove any loose flakes of zinc.
• If the surface to be treated cannot be lightly blasted,
clean it with a steel brush and/or coarse sandpaper.
• It the still intact layer of zinc 10 mm around the surface
to be treated cannot be lightly blasted, clean it with a
steel brush/coarse sandpaper.
• Use a Tack cloth to remove any dust from the area to
be treated.
• Degrease the surface to be treated and the surround-
ing area with a solution of, for example, paint thinner.

It is not permitted to treat galvanized
steel with a primer with an alkyd resin
base.

2. Applying zinc paint

• Primer to be used: Redox EP Multi Primer by Sikkens
or 622-UniBar Zinkrich Primer by Baril Coatings.
• Apply a 2-component EP primer (enriched with zinc) to
the pre-treated surface in 2 or 3 layers in accordance
with the manufacturer's instructions.
The minimum thickness is 100 µm. The EP primer can
be applied with a brush or a roller.
3. Applying the topcoat
• Topcoat to be used: Redox PUR Finish by Sikkens or
an equivalent product.
• Apply the topcoat over the primer in accordance with
the manufacturer’s instructions. The minimum thick-
ness is 50 µm. Redox PUR Finish can be applied with
a brush or a roller.
• Apply an antichip coating to the entire treated area (see
3 - 1.2 Checking/repairing the antichip
coating (1 - 1)).

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 COATS OF PAINT AND LAYERS OF ZINC
Preservation All VDL Bus & Coach models

1-8 DD0684_02
 SEALANT SEAMS
All VDL Bus & Coach models

SEALANT SEAMS

DD0684_02
 SEALANT SEAMS
All VDL Bus & Coach models

DD0684_02
 SEALANT SEAMS
All VDL Bus & Coach models Removal and installation

1. REMOVAL AND INSTALLATION

1.1 SEALANT SEAMS

1.1.1 GENERAL INFORMATION

The seams between panels are sealed with an elastic seal-

ant to prevent the penetration of dirt and moisture. The seal-
ant may be burnt in the event of repair work close to the
sealant seams. It is very important that the sealant seams
are carefully repaired so as to prevent corrosion between the
panel elements. Sealant seams must be demonstrably
2
inspected every year and, if necessary, repaired.

ILAf0019
A. Incorrect (too thick)
B. Incorrect (too thin)
C. Correct
D. Incorrect (too thick)
E. Incorrect (too thin)
F. Correct

DD0684_02 1-1
 SEALANT SEAMS
Removal and installation All VDL Bus & Coach models

1.1.2 REPAIRS TO SEALANT SEAMS

Follow the procedure given below to repair sealant seams:

Always read the manufacturer's
instructions before use.

Preparing the surface

1. Remove the old sealant.
2. See 1 - 1.1 Repairing coats of paint and layers of
2 zinc (1 - 1) for instructions on how to repair damaged
coats of paint and damaged layers of zinc.
3. Clean the surface with Sika Cleaner-205 (or an equiva-
lent product) using a clean, lint-free cloth or tissue.
Drying time of at least 10 minutes and no longer than 2
hours at 20°C.
4. The surfaces must be clean, dry and free of all traces of
grease, oil and dust.

Sealing
Do not apply sealant at a temperature below 5 °C or above
40 °C. The optimal application temperature is between 15 °C
and 25 °C.
5. Apply sealant (Sikaflex-221 or an equivalent product)
and smooth out the joins using Sika Tooling Agent N as
shown in the diagrams above.

The seam must be smoothed out before a skin forms.

Clean the sealant seam with water after they have been
smoothed out.
The sealant seam must be continuous and must not have
any gaps (where moisture can penetrate).
6. Use Sika Remover-208 or an equivalent product to
remove any excess sealant which has not yet hardened.
Sealant that has hardened can only be removed
mechanically.

Never use a rinsing liquid with a citric-
acid base to remove unhardened sealant.

Spraying
7. Sikaflex-221 or an equivalent product can be sprayed
after a skin has formed. If desired, apply a layer of
Schaepman Belticryl chassis paint (C4p000790) or an
equivalent product over the sealant seam.
A topcoat may only be applied after the sealant has fully
hardened.

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 ANTICHIP COATING
All VDL Bus & Coach models

ANTICHIP COATING

DD0684_02
 ANTICHIP COATING
All VDL Bus & Coach models

DD0684_02
 ANTICHIP COATING
All VDL Bus & Coach models Antichip coating

1. ANTICHIP COATING

1.1 GENERAL INFORMATION

If necessary, all VDL Bus & Coach vehicles must be given an
antichip coating and an anticorrosion coating after the repair
and/or replacement of any chassis or bodywork components.
This applies to both products with a powder coating and
products with a conventional paint system.
If the chassis and bodywork are not regularly checked and
regularly maintained in accordance with the guidelines, this
may have consequences for the warranty of the entire vehi-
cle.

1.2 CHECKING/REPAIRING THE ANTICHIP 3

COATING
The underside of the vehicle is treated with an antichip coat-
ing (UBC underbody coating) during manufacture.
This coating should be checked for damage every year (see
3 - 1.2.2 Inspecting the antichip coating (1 - 2)).

Damage to the antichip coating must be
repaired as quickly as possible.

This coating must be replaced no later than every three

years.

1.2.1 PRODUCTS

Type of vehicle Product Minimum layer thickness

Public transport Dinitrol UBC 4942 or an equivalent 300 µm a
product
Coach Rhitex 222 or an equivalent product b 250 µm dry and 360 µm wet
a. For chassis components with a powder coat, the antichip coating must be at least 650 µm thick, including the powder coat.
b. Investigate or test the bond if an equivalent product is used. Bonding of water-based UBC products sometimes causes a problem.

It must be applied according to the
manufacturer's instructions.

DD0684_02 1-1
 ANTICHIP COATING
Antichip coating All VDL Bus & Coach models

1.2.2 INSPECTING THE ANTICHIP COATING

1. Clean the underside of the vehicle (see 0 - 1.2 Cleaning

the underside of the vehicle (1 - 1)).
2. Check all the external components for damage and
check the bond of the protective coatings, such as the
antichip coating and the paint.
3. Thoroughly check the corners where dirt can collect and,
if necessary, remove any dirt.
4. Make sure the wheel arches and the surrounding areas
are clean.
5. Make sure the water drainage holes are not blocked.

Cracks may appear in time in the corners
3 where the antichip coating is applied.

Small cracks must be repaired. In the case of
large cracks, the antichip coating must be
locally removed and then reapplied.

1.2.3 RE-TREATMENT/REPAIR OF THE ANTICHIP

COATING

1. Remove the loose coating and the surface rust with a

steel brush. Note: do not use a sanding disc or a similar
tool, because this will affect the structure of the basecoat.
See 1 - 1.1 Repairing coats of paint and layers of
zinc (1 - 1) for instructions on how to repair damaged
coats of paint and damaged layers of zinc.
2. Make sure all the parts are dry and free of dust and
grease.
3. Apply an antichip coating to all the specified parts where
it has come loose/worn away.
4. Pay particular attention to the box girders, cross points of
the crossbeams, cross points of the diagonals, the seal-
ant seams, the longitudinal beams and the wheel arches.

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 ANTICHIP COATING
All VDL Bus & Coach models Antichip coating

1.2.4 COMPONENTS NOT TO BE TREATED

An antichip coating must not be applied to the following com-

ponents, because this may have an adverse effect on their
operation:
General Identification plates
Grease nipples
Allen screws and Phillips screws
Drive line All the drive components, such as the engine, the gearbox, the drive shaft
and the exhaust
Wheel suspension Air bellows
Shock absorbers
Disc brakes and brake calipers
Height control rods
Height control valves
Height control sensors 3
Steering mechanism Steering shaft
Universal joints
Hydraulic lines
Bevel gear case
Pneumatic Valves
components Couplings
Air reservoirs
Brake cylinder bleed valves
Spring brake booster nut + bolt
Electrical Connectors/connections
components Electronic units
Distribution box or fuse box
Cables Gearbox cables, if present.
Fuel tanks See the "Fuel tanks" table for each vehicle type.
Axles See the "Axles" table for each vehicle type.

FUEL TANKS Treat Do not treat

Citea MLE Yes
Citea LLE Yes - steel No - aluminium
Citea SLF Yes - aluminium a No - plastic
b
Citea SLE/XLE Yes - aluminium No - plastic
c
Futura Classic Yes - steel
Futura No
Magic No
Synergy No
SB4000/SB230 No
a. Only the underside
b. Only the underside
c. With the exception of the top

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 ANTICHIP COATING
Antichip coating All VDL Bus & Coach models

AXLES Treat Do not treat

ZF front axle Axle beam permitted a/not compulsory
ZF rear axle Axle beam permitted/not compulsory
Dana front axle Not permitted
Dana rear axle Compulsory - in Europe b No - outside of Europe c
a. Not on hinge points
b. At ambient temperatures up to 22 0C
c. At ambient temperatures above 22 0C

Absorption and insulation material must never be coated, painted or sprayed, because the
absorbing, insulating and fire-resistant properties will then be lost.

3
1.2.5 GALVANIZED STEEL

General information
It is necessary to apply an antichip coating to galvanized
steel for the following reasons:
Dirt and salt in combination with water means that the water
(conductor) cannot run off. These damp conditions create an
electrolyte, which dissolves the zinc and the zinc oxides in
various other bonds.

In areas subjected to heavy contamination, the thickness of

the zinc coating is reduced by 10 - 20 µm/year for a coating
which is 80 µm thick. It is easy to calculate when the zinc has
eroded and, therefore, when the component is no longer pro-
tected.

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 WAXING
All VDL Bus & Coach models

WAXING

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 WAXING
All VDL Bus & Coach models

DD0684_02
 WAXING
All VDL Bus & Coach models Anticorrosion coating

1. ANTICORROSION COATING

1.1 WHY APPLY ANTICORROSION

TREATMENT
Some places cannot be painted and that is where the mate-
rial will be exposed to the air.
If these places are then exposed to water and salt, they will
start to rust.
This rust may lead to the thickness of the material reducing
by approximately 0.6 mm per year, which will have a nega-
tive effect on the strength of the construction.
A preservative can prevent rust from forming if it is applied
correctly.
Good preservation is, therefore, extremely important for the
strength and lifespan of a chassis.

1.1.1 INSPECTING THE ANTICORROSION COATING

Check hollow areas and the inside of beams every year for
4
faults and, if necessary, rectify them.
They should be re-treated with a preservative every three
years.
Hollow cavities should be treated for corrosion after repair to
the chassis or bodywork in order to prevent them from rusting
on the inside.

Re-treatment
1. Remove all the loose dirt.
2. Use a flexible tube to apply the wax.
3. See the supplier's specifications for the specified thick-
ness.

1.1.2 PRODUCT

Product Use Required quantity

Waxoyl 120-4 Spray with a tectyl spray gun, Approx. 1 litre per vehicle
max. pressure 2 bar.
Layer thickness approx. 50 µm

It must be applied according to the
manufacturer's instructions.

Personal protection: face mask with carbon
A filter.

DD0684_02 1-1
 WAXING
Anticorrosion coating All VDL Bus & Coach models

1.1.3 COMPONENTS TO BE TREATED

Apply an anticorrosion coating to the following components.

Bare, untreated components
Hose clips and clamping straps
for:
Engine and gearbox
Miscellaneous
4 3cr12 stainless steel
Wheel nuts, if they do not have protective caps.
Nut-bolt connections.
Line coupling nuts (if bare).
Internal part of the tubes in the chassis.
Hoses.
Air reservoirs and clamping straps around air reservoirs.
Fuel tanks and connections to the fuel tanks (also underneath).
Apply an extra coating to the valve cover an engine.
Treat bare components on the engine and gearbox.
Treat places where water can accumulate as normal.
Copper lines of the air conditioning system.
Pedal attachment bolts.
Engine brake valve lock nut.
Steering column tube (if fitted).
Connection seams of installed components (e.g. front axle mounting brack-
ets, engine brackets, etc.).
Attachments (threaded rods and nuts) of air bellows on the chassis.
Internally spray the side wall tubes up to the height of the passenger floor.

Avoid Waxoyl between the drive belts.

Use a UV light to check for the presence of
Waxoyl.

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 WAXING
All VDL Bus & Coach models Anticorrosion coating

1.1.4 COMPONENTS NOT TO BE TREATED

Galvanized steel
Just like other oils, wax is a good insulator, does not form an
electrolyte and cuts off the supply of oxygen. The inside of
tubes may be treated, but this will not be of much added
value with regard to the actual prevention of corrosion,
because there is a layer of zinc on the inside of the tubes
which is not contaminated from the outside, so rust is not
expected in these places.

Do NOT treat the following components with Waxoyl:

• Brake discs
• Brake caliper
• Brake drums
• Pneumatic brake components
• Battery trays (have been treated with an acid-proof paint)
• Generators
• Turbo compressor
• Radiation shields
• All exhaust components
• Tyres and the spare tyre
• Steering wheel and floor
4
• Steering damper rod
• Air bellows
• Galvanized lines
• Sealant seams

1.2 TREATMENT WHEN STORING THE

VEHICLE
If the vehicle is not going to be used for a long time, meas-
ures must be taken to safeguard the quality of the vehicle.
These measures depend on the estimated storage time.

Storage for less than four weeks

• Place protective covers over: dashboard + EDC, steering
wheel, battery and the wooden transport box for the deliv-
ery of materials.

Storage for more than four weeks

The same measures as for a storage period of less than 4
weeks plus the measures given below:
• Disconnect the earth cable from the battery.
• Drain the water from the air reservoirs and the water sepa-
rator. Also check for extreme oil, water and air leaks, so
that they can be repaired in time.
• Check the attachment and functionality of the covers and,
if necessary, replace them.

Storage for more than eight weeks

The same measures as for a storage period of more than 4
weeks plus the measures given below:
• Remove the batteries from the vehicle and give them to the
Inspection department, which can check the acid concen-
tration and, if necessary, recharge them. The batteries can
be used in other vehicles in order to make optimal use of
DD0684_02 1-3
 WAXING
Anticorrosion coating All VDL Bus & Coach models

the first-in-first-out principle and to minimize battery main-

tenance.
• Place chocks in front of the wheels and release the parking
brake by unscrewing the release bolts in the spring brake
cylinder as far as possible.
• Measure the antifreeze concentration in the cooling system
and, if necessary, top it up to bring it to the concentration
required for the lowest expected temperature.

1-4 DD0684_02
 SPECIAL INSTRUCTIONS
All VDL Bus & Coach models

SPECIAL INSTRUCTIONS

DD0684_02
 SPECIAL INSTRUCTIONS
All VDL Bus & Coach models

DD0684_02
 SPECIAL INSTRUCTIONS
All VDL Bus & Coach models Service Bulletins

1. SERVICE BULLETINS

1.1 SERVICE BULLETIN VDL BUS & COACH

1215

6(59,&(),(/'$&7,21

Subject: Waxoil treatment Vehicle type: SB200 Euro 4
Service Bulletin: SB1215 Modify before: 30-9-2014
Released: 30-9-2013 Labor: 150 periods
Defect code: 0131215
Return Parts: Yes No

5
Discription
The chassis modules from VDLBUS Chassis were powdercoated in the past.
Mistake in the procedure is causing an Faraday cage around the crossmember.
Wherefore the space in between was not covered with paint.
As a result the crossmember is rusted. To slow down this process it is necessary that the rusty
areas is treated with Wax from high density and capillary effect

Location :
The concerned area is right above the airbellow,
where the crossmember crossed the sidemember.

Page 1 of 6

Service Bulletin VBC 1215

DD0684_02 1-1
 SPECIAL INSTRUCTIONS
Service Bulletins All VDL Bus & Coach models

6(59,&(),(/'$&7,21

Subject: Waxoil treatment Vehicle type: SB200 Euro 4
Service Bulletin: SB1215 Modify before: 30-9-2014
Released: 30-9-2013 Labor: 150 periods
Defect code: 0131215
Return Parts: Yes No

Required materials.

The required materials must be ordered at VDLPARTS.

5 These materials are not available in de aftermarket

Label Waxoyl
Type 120 P-
Aerosol
Package 500 ml
Productnr. 90308
EAN nr. 76 4011
465 0123
VDL Parts nr. 20230652
Required per 1 bus
vehicle

Page 2 of 6

Service Bulletin VBC 1215

1-2 DD0684_02
 SPECIAL INSTRUCTIONS
All VDL Bus & Coach models Service Bulletins

Figuur 1 Waxoil

Working procedure
Make sure that the vehicle and the affected area for the wax treatment is clean and dry. 5
See maintenance procedure DD035300.
Wax treatment is NOT WORKABLE if vehicle or the affected area are wet.
The working temperature preference is above 15 degrees Celsius.
.

1 Lift the vehicle up, make sure to use the safety guidelines.
2 Remove the wheels
3 Remove using a fillingknife, all the loosing paint in the cross/sidemember area as
good as possible.
4 Make sure that the spray is well shaken, mount the hose to the spay.
5 Spray on the cleaned area on both sides of the vehicle, crossmember and above the
sidemember a capacious amount of wax.The spray is enough to treat both sides of
the vehicle.
6 Mount the wheels back
7 Make sure that the treated area is well dry before the vehicle leave the dry area.
8 Check treated area yearly for the presence of wax.

Page 3 of 6

Service Bulletin VBC 1215

DD0684_02 1-3
 SPECIAL INSTRUCTIONS
Service Bulletins All VDL Bus & Coach models

Page 4 of 6

Service Bulletin VBC 1215

1-4 DD0684_02
 SPECIAL INSTRUCTIONS
All VDL Bus & Coach models Service Bulletins

Page 5 of 6

Service Bulletin VBC 1215

DD0684_02 1-5
 SPECIAL INSTRUCTIONS
Service Bulletins All VDL Bus & Coach models

Page 6 of 6

Service Bulletin VBC 1215

1-6 DD0684_02
All VDL Bus & Coach models Documentation Report Form

DOCUMENTATION REPORT FORM

If you have any suggestions and/or comments regarding

our documentation, or if you have observed any errors,
then please complete this form and return it to:
VDL Bus & Coach
Training and Documentation Company name : .........................................................

P.O. Box 298

Name : ..............................................................
5500 AG Veldhoven
The Netherlands Signature : .................................................................
Fax: +31 (0)40 2048822

Chassis number .........................................................

Concerns document order number: ......................................................... Version: .........................................

Driver Climate system

Type of document: Maintenance Electrical circuit diagram

(tick what is applicable) Workshop Training

Components Other
Linguistic (description is not Error in the technical information
Type of error: Illustrations
correct) (values)
(tick what is applicable)

..........................................................................................................................................
Additional information: ..........................................................................................................................................
(texts, page number, etc.) ..........................................................................................................................................
..........................................................................................................................................

Your report will be taken seriously by VDL Bus & Coach

and, if necessary, will be immediately incorporated in the
document.

DD0684_02
All VDL Bus & Coach models Documentation Report Form

DD0684_02