SECTION 18: BODY
DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
1
CONTENTS
1.
VEHICLE EXTERIOR ............................................................................................................................ 4
2.
VEHICLE STRUCTURE ........................................................................................................................ 6
2.1
W
ELDING
.......................................................................................................................................... 6
3.
VEHICLE EXTERIOR MAINTENANCE ................................................................................................ 6
4.
CORROSION PREVENTION ................................................................................................................ 6
5.
PREVENTIVE MAINTENANCE SCHEDULE ....................................................................................... 8
6.
RUST INHIBITOR APPLICATION ........................................................................................................ 8
7.
COMMON FIBERGLASS REPAIR PROCEDURE ............................................................................. 14
8.
REPAIR USING FIBERGLASS CLOTH ............................................................................................. 14
9.
REPAIR USING FIBERGLASS PASTE .............................................................................................. 14
10.
TYPICAL FIBERGLASS HOLE REPAIR PROCEDURE ................................................................ 15
11.
COMMON PAINTING PROCEDURE .............................................................................................. 16
12.
NEW PAINT CARE .......................................................................................................................... 16
13.
PAINT TOUCHUP ............................................................................................................................ 16
14.
PAINTING ........................................................................................................................................ 17
14.1
SAFETY ........................................................................................................................................ 17
14.2
SURFACE
PREPARATION
AND
PAINT
APPLICATION
RECOMMENDATION ......................... 18
15.
X3-45 COACHES EXTERIOR FINISHING AND BODY REPAIR ................................................... 19
15.1
ZONE
1 ......................................................................................................................................... 19
15.1.1
Front Bumper ......................................................................................................................... 20
15.1.2
Headlights .............................................................................................................................. 21
15.1.3
Rear View Mirrors (Rosco) .................................................................................................... 21
15.1.4
Windshield Wipers ................................................................................................................. 22
15.1.5
Windshield ............................................................................................................................. 22
15.1.6
Bi-Fold Entrance Door ........................................................................................................... 24
15.1.7
Front Electrical & Service Compartment Door ...................................................................... 28
15.1.8
Front Cap ............................................................................................................................... 31
15.2
ZONE
2 ......................................................................................................................................... 32
15.2.1
Lateral Fixed Window ............................................................................................................ 33
15.2.2
Emergency Exit Windows ...................................................................................................... 34
15.2.3
Roof Escape Hatch ............................................................................................................... 35
15.3
ZONE
3 ......................................................................................................................................... 37
15.3.1
Rear Cap ............................................................................................................................... 38
15.3.2
Engine Compartment Door .................................................................................................... 38
15.3.3
Rear Bumper ......................................................................................................................... 38
15.3.4
Exhaust Aftertreatment System Access Door ....................................................................... 38
15.4
ZONE
4 ......................................................................................................................................... 39
15.4.1
Rear Fender .......................................................................................................................... 40
15.4.2
Engine Compartment R. H. Side Door .................................................................................. 40
15.4.3
Engine Radiator Door ............................................................................................................ 40
15.5
ZONE
5 ......................................................................................................................................... 42
15.5.1
Baggage Compartment Doors (Aluminum) ........................................................................... 43
15.5.2
Wheelchair Lift Cassette Compartment Door ........................................................................ 45
15.5.3
Evaporator Compartment Door ............................................................................................. 47
