0 - Training Registration System - VDL Bus & Coach

CORROSION PROTECTION 

Citea LLE/SLF/SLE/XLE 

Euro 5 

1208 DD068401


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 only concerns the following 

series of vehicles: 

Citea LLE / SLF / SLE / XLE. 

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CONTENTS 

Antichip coating 

Antichip coating............................................ 1-1 

General information ........................................ 1-1 

Washing the underside of the vehicle ............. 1-1 

Checking/repairing the antichip coating .......... 1-2 

Sealant seams ................................................ 1-7 

Paint treatment................................................ 1-9 

Anticorrosion treatment 

Anticorrosion treatment ............................... 1-1 

Why apply anticorrosion treatment ................. 1-1 

Treatment when storing the vehicle ................ 1-3 

Documentation Report Form ......................... -1 

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CONTENTS 


Disclaimers 

© 1208 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. 

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ANTICHIP COATING 


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1. ANTICHIP COATING 

1.1 GENERAL INFORMATION 

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All VDL Bus & Coach vehicles must undergo an antichip 

treatment followed by an anticorrosion treatment after the 

repair or replacement of chassis or bodywork components. 

This is applicable to both the products which have a powder 

coating/layer of zinc and the products which have a conventional 

paint system. 

If the chassis and the bodywork are not regularly checked 

and regularly maintained in accordance with the guidelines, 

then this may have consequences for the warranty of the 

entire vehicle. 

1.2 WASHING THE UNDERSIDE OF THE 

VEHICLE 

The paint used on the vehicles offers excellent protection 

against ageing during the vehicle's lifespan. In order to maintain 

this protection, it is important for the vehicle to be regularly 

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. After the vehicle has been cleaned, the underside 

of the vehicle must be checked for damage. Below are a 

number of points of attention when washing the underside of 

the vehicle. 

High-pressure hose 

• The water temperature must not be greater than 50 °C. 

• The water pressure must not be greater than 80 bar. 

• Maintain a minimum distance of 30 cm from the surface. 

• 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 be greater than 50 °C. 

• The water pressure must not be greater than 80 bar. 

• Maintain a minimum distance of 30 cm to the chassis. 

• It is not permitted to use additives. 

• The permitted pH value is between 6 and 8. 

• Always rinse the vehicle with clean water. 

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1.3 CHECKING/REPAIRING THE ANTICHIP 

COATING 

The underside of the vehicle is treated with an antichip coating 

(UBC underbody coating) during manufacture. 

This coating should be demonstrably checked for damage 

every year. 

This coating must be replaced no later than every three 

years. Damage to the antichip coating must be repaired as 

quickly as possible. 

1.3.1 PRODUCTS 

Product 

Dinitrol UBC 4942 or an equivalent 

product. 

When/where to use 

All areas. 

Comments 

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

• The antichip coating must be at least 300 µm thick in all 

areas. 

• The antichip coating of the chassis components must be at 

least 650 µm thick, including the powder coating. 

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1.3.2 INSPECTING THE ANTICHIP COATING 

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

the underside of the vehicle (1 -1)). 

2. Check all the external components for damage and 

check the adhesion of the protective layers, such as the 

antichip coating and the layer of 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. 

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Comment 

Cracks may appear in time in the corners where the antichip 

coating is applied. 

Small cracks must be repaired. The antichip coating should 

be re-applied if any large cracks appear. 

1.3.3 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 undercoat. 

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 sealant 

seams, the longitudinal beams and the wheel arches. 

5. Finish the paint in accordance with the paint instructions. 

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1.3.4 COMPONENTS NOT TO BE TREATED 

An antichip coating must not be applied to the following components, 

because this may have an adverse effect on their 

operation: 

General information 

Wheel suspension 

Steering mechanism 

Drive line 

Pneumatic 

components 

Electrical 

components 

Cables 

Fuel tanks 

Absorption materials 

Insulation materials 

Identification plates 

Grease nipples 

Allen screws and Phillips 

screws 

Air bellows 

Shock absorbers 

Disc brakes and brake calipers 

Height control rods 

Height control valves 

Height control sensors 

Steering shaft 

Universal joints 

Hydraulic lines 

Bevel gear case 

All the drive components, 

such as the engine, the gearbox, 

the drive shaft and the 

exhaust 

Valves 

Couplings 

Air reservoirs 

Brake cylinder bleed valves 

Spring brake booster nut + 

bolt 

Connectors/connections 

Electronic units 

Distribution box or fuse box 

Gearbox cables, if present. 

All the fuel tanks provided by 

VDL Bus & Coach, with the 

exception of the top 

All. 

All. 

Absorption and insulation material must 

never be coated, painted or sprayed, 

because the absorbing, insulating and 

fire-resistant properties will then be lost. 

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1.3.5 GALVANIZED STEEL 


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. 

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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 protected. 

Repairing the zinc coating 

• 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 

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 surrounding 

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. 

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2. Applying zinc paint 

• Primer to be used: Redox EP Multi Primer from 

Sikkens or 622-Unibar Zinkrich from 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 from Sikkens or 

an equivalent product. 

• Apply the topcoat over the primer in accordance with 

the manufacturer’s instructions. The minimum thickness 

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 

1.3.2 Inspecting the antichip coating (1 -3)). 

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1.4 SEALANT SEAMS 

1.4.1 GENERAL INFORMATION 

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The seams between panels are sealed with an elastic sealant 

to prevent the penetration of dirt and moisture. The sealant 

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 

inspected every year and, if necessary, repaired. 

A. Incorrect (too thick) 

B. Incorrect (too thin) 

C. Correct 

D. Incorrect (too thick) 

E. Incorrect (too thin) 

F. Correct 

ILAf0019 

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1.4.2 REPAIRS TO THE SEALANT JOINT 

Follow the procedure given below to repair the sealant joint: 

Always read the manufacturer's 

instructions before use. 

Preparing the surface 

1. Remove the old sealant coating. 

2. Repair the damaged layer of paint: 

• Apply a 30 µm layer of wash primer (Schaepman 

Nibralux wash primer (P41000076) or an equivalent 

product) to the damaged surface. 

• Drying time of the wash primer: minimum of 15 minutes 

at 20 °C. 

3. Clean the surface with Sika Cleaner-205 (or an equivalent 

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 joins must be smoothed out before a skin forms. 

Clean the sealant joints with water after they have been 

smoothed out. 

The sealant join 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. 

Spraying 

7. Sikaflex-221 or an equivalent product can be sprayed 

after a skin has formed. If desired, apply a layer of 

Schaepman Beticyl chassis paint or an equivalent product 

over the sealant seam. 

A topcoat may only be applied after the sealant has fully 

hardened. 

1 - 8 

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1.5 PAINT TREATMENT 

1.5.1 GENERAL INSTRUCTIONS 

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This section gives instructions for respraying and repairing 

VDL Bus & Coach paint systems which have been applied to 

various base materials. 

The products to be used are supplied by a number of manufacturers. 

However, only use products from reputable manufacturers 

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 phosphoric 

acid base. 

• For cleaning, use an organic solvent without chlorine additives. 

• 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 single 

manufacturer. 

• Use the products according to the manufacturer's instructions. 

• Never use products in a spray cabin that contain silicon. 

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Removing rust 

• Apply the rust-removal agent in accordance with the manufacturer'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. 

Wear protective gloves and protective 

glasses when working with a rustremoval 

agent. 

To avoid unnecessary environmental 

pollution when using paints and related 

products and when handling paint waste, 

always work according to the applicable 

environmental requirements. 

1 - 10 

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1.5.2 RESPRAYING/REPAIRING PAINT SYSTEMS 

WITH A POWDER BASE 


• This section gives guidelines concerning respraying and 

repairing paint systems with a powder coating base. 







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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. 

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: Priomat ® EP Grundierfüller 4090 kieselgrau 

from Spies Hecker or an equivalent product. 

Hardener to be used: Priomat ® Härter 3110 or an equivalent 

product. 

1. Apply an EP primer to the bare metal parts according to 

the manufacturer’s instructions. 

The thickness of the coating must be 60 - 90 µm. The EP 

primer can be applied with a brush or a roller. 

2. Leave the primer to evaporate for approximately 10 minutes. 

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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Applying the topcoat 

Topcoat to be used: Percotex ® Steinslagschutz halbmatt 

RAL 7024 graphitgrau from Spies Hecker or an equivalent 

product. 


product. 

1. Sand the primed areas with sandpaper. Use P320 - P500 

sandpaper 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. 

2. Apply the topcoat over the primer and the sanded areas 

according to the manufacturer’s instructions. The minimum 

thickness is 40 µm. Percotex can be applied with a 

brush or a roller. 

3. 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 24 hours at room temperature (20 °C). 

1.5.3 RESPRAYING/REPAIRING CONVENTIONAL 

PAINT SYSTEMS 


• This section gives guidelines concerning respraying and 

repairing conventional paint systems. 








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. 

5. Remove any dust from the sanded area with a tack rag. 

6. Remove any grease and dirt from the area to be treated. 

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Applying the undercoat 

Primer to be used: Priomat ® EP Grundierfüller 4090 kieselgrau 

from Spies Hecker or an equivalent product. 


product. 

1. Apply an EP primer to the bare metal parts according to 

the manufacturer’s instructions. 

The thickness must be 20 µm. For clamped surfaces 

(surfaces that are clamped together by a bolt connection, 

etc.), the thickness of the primer must be 20 µm to 45 µm. 

The EP primer can be applied with a brush or a roller. 

2. Leave the primer to evaporate for approximately 10 minutes. 

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. 

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The primer cannot be dried using infrared 

radiation. 

Applying the topcoat 

Topcoat to be used: Percotex ® Steinslagschutz halbmatt 

RAL 7024 graphitgrau from Spies Hecker or an equivalent 

product. 


product. 

1. Sand the primed areas with sandpaper. Use P320 - P500 

sandpaper 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. 

2. Apply the topcoat over the primer and the sanded areas 

according to the manufacturer’s instructions. The minimum 

thickness is 40 µm. Percotex can be applied with a 

brush or a roller. 

3. 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 24 hours at room temperature (20 °C). 

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ANTICORROSION TREATMENT 


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1. ANTICORROSION TREATMENT 

1.1 WHY APPLY ANTICORROSION 

TREATMENT 

Some places cannot be painted and that is where the material 

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 negative 

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 

1.1.1 INSPECTING THE ANTICORROSION COATING 

Hollow cavities and the inside of beams should be checked 

every year for faults. 

They should be re-treated 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 thickness. 

1.1.2 PRODUCT 

Product 

Waxoyl 120-4 

Uses 

Spray with a tectyl spray gun, 

max. pressure 2 bar. 

Thickness approx. 50 µm. 

Comments 

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

• Required quantity: approx. 1 litre per vehicle. 

Personal protection: face mask with 

carbon A filter. 

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1.1.3 COMPONENTS TO BE TREATED 

Apply an anticorrosion coating to the following components. 

1 

Bare, untreated components. 

Wheel nuts, if they do not have 

protective caps. 

Nut-bolt connections. 

Hose coupling nuts (if bare). 

Hose clips and clamping 

straps of: 

Engine and gearbox 

Miscellaneous 

3cr12 stainless steel 

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. 

Pedal attachment bolts. 

Engine brake valve lock nut. 

Steering column tube (if fitted). 

Connection seams of installed 

components (e.g. front axle 

mounting brackets, engine 

brackets, etc.). 

Attachments (nuts and studs) 

of air bellows on the chassis. 

Spray the inside of side wall 

tubes up to floor height. 

NOTE: AVOID GETTING WAXOYL 

BETWEEN THE DRIVE BELTS. 

Use a UV light to check for the presence 

of Waxoyl. 

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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. 

1 

Do NOT treat the following components with Waxoyl: 

• Sealant seams 

• Brake discs 

• Brake drums 

• Battery trays (have been treated with an acid-proof paint) 

• Brake booster rods 

• Galvanized lines 

• Heat shields 

• Exhaust 

• Tyres and the spare tyre 

• Steering wheel and floor 

• Steering damper rod 

• Air bellows 

• 

1.2 TREATMENT WHEN STORING THE 

VEHICLE 

If the vehicle is not going to be used for a long time, measures 

must be taken to safeguard the quality of the vehicle. 

These measures depend on the estimated storage time. 

Components to be treated 

• Generator 

• Front and rear axles 

• Gearbox 

• Coolant lines 

• Air reservoir ring valves 

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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 

P.O. Box 645 

5550 AP Valkenswaard 

The Netherlands 

Fax: +31 (0)40 2084499 

Company name 

Name 

Signature 

: ............................................................................ 

: ............................................................................ 

: ............................................................................ 

Chassis number: ........................................................ 

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

Type of document: 

(tick what is applicable) 

Driver 

Maintenance 

Climate system 

Electrical circuit diagram 

Workshop 

Training 

Components 

Other 

Type of error: 

(tick what is applicable) 

Language 

(description is not correct) 

Error in the technical information 

(values) 

Illustrations 

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. 

DD068401

Documentation Report Form 


DD068401

0 - Training Registration System - VDL Bus & Coach

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