Service Bulletin No. 2771

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Shavonne Fleming
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1 MODEL TYPE SECTION/GROUP DATE DL Series Coaches Product Improvement 2 - Rear Axle Nov. 13, 2000 SUBJECT CONDITIONS UPGRADE OF THE SELF-STEERING TAG AXLE LOCK MECHANISM Parts may be purchased from Universal Coach Parts Inc., Des Plaines, Ill. or from MCI Service Parts Division, Newcastle, Ontario. Description: Effective with unit # 52564, MCI made design changes to the tag axle lock mechanism installation. An improved lock pin has been added to the installation, on 102 DL3 model coaches. This improved lock pin will provide extended service life. Note: It is recommended that 102 DLcoach customerswith unitsprior to 50163, ensurethat the instructions and procedures outlined in Customer Service Bulletin 2724 have been carried out. Parts Qty. Old P/N Description 1 12L Pin Qty. New P/N Description 1 12L Pin 1 12L Pin Qty. Old P/N Description 1 12L Spring Qty. New P/N Description 1 12L Spring 1 12L T-Nut 1 12L Spacer - Boss Qty. Old P/N Description Capscrew Qty. New P/N Description Capscrew Lockwasher Tyrap 50ml Perma-Lok a/r Acetone Service Information: 1. Old and new parts are notinterchangeable. Botholdandnew partsshouldcontinuetobeservicedasof this date. Service Procedure: General notes Read this entire procedure before beginning work. Use Safe Shop Practices At All Times. 1. Drive the coach over a pit, or use a lift to perform the steps in this procedure. Note: If the steps in this procedure are performed over a pit, apply the parkbrake andchock the tires. Note: If the steps in this procedure are performed with the coachon a lift, raisethe coachto the desired height. Position jackstands atthe frontand rear framesupportpoints, according to Figure 1, to ensure that the coach is securely supported before attempting work underneath the coach. Refer to Section 3G / Jackstand Points, in the MCI 102D Series Maintenance Manual, for the basic rules, procedures and safety precautions thatmust be followed before a coach is to be lifted.

DATE PAGE 2 Roadside View from top of floor --- looking downward Front of Coach Rear of Coach

Bogie Beam DL Series Coach axles not shown for clarity Figure 1.

Ensure that the tag axle is locked. 3. Turn the main battery disconnect switch to OFF. 4.

using the drain valve at the bottom of the tank. Refer to Section 4D, in the Maintenance Manual. 5.

2 DATE PAGE 2 Roadside View from top of floor --- looking downward Front of Coach Rear of Coach Curbside Side View of Lower Frame --- Curbside Tag Axle Bogie Beam Drive Axle Bogie Beam FrontAxle Bogie Beam DL Series Coach axles not shown for clarity Figure 1. DL Series -- Under Frame Jackstand Points ( Section 3G / Maintenance Manual ) 2. Ensure that the tag axle is locked. 3. Turn the main battery disconnect switch to OFF. 4. Dump the air from the front accessory reservoir, ( located in the LH front service compartment ), using the drain valve at the bottom of the tank. Refer to Section 4D, in the Maintenance Manual. 5. Mark the air lines and the installation location at the air cylinder ( Figure 2 ). air lines tag lock cylinder assembly Figure 2. Tag Lock Mechanism location.

DATE PAGE 3 6. Disconnect the air lines from the lock cylinder. Note: When the air line is cracked loose, the residual air will drain from the air lines. 7.

3 DATE PAGE 3 6. Disconnect the air lines from the lock cylinder. Note: When the air line is cracked loose, the residual air will drain from the air lines. 7. Remove and discard the capscrews and washers that mount the air cylinder to the boss. 8. Disconnect the lock cylinder s electrical harness by: a. cutting all tyraps on the harness, b. disconnecting the lock cylinder harness at the connector located in the engine compartment. Note: Open the LH side service door to access the lock cylinder harness. 9. Pull back the electrical harness and remove the complete lock cylinder assembly. 10. Submerge the cylinder and the shaft in lukewarm water ( Figure 3 ). Note: Submerging the cylinder and shaftin water will ensure thatthe shaftand seals will not be damaged by the heat. Note: The shaft should be in the fully extended position. Note: Do not place the connector end of the harness into the water. lock pin Figure 3. Heating the locking pin. 11. Place a thin flanged fork wrench onto the flats between the shaft end and the lock pin ( Figure 4 ). Note: Do not attempt to clamp the shaft, since this may damage the shaft surface, causing seal leakage.

4 DATE PAGE 4 Lock Pin (to be replaced) Place thin flanged open wrench here Spring (to be replaced) Figure 4. Tag Lock Cylinder Assy ( BEFORE MODIFICATION ). 12. Remove the lock pin from the cylinder shaft by: a. heating the pin with a propane torch, sweeping the torch back and forth on either side of the pin. b. using an appropriate tool to unscrew the lock pin from the shaft. CAUTION Wear appropriate protective clothing when working with an open flame. Note: Step 12a should take approximately one minute. Note: Do not exceed a temperature of approx. 600 F ( 315 C ) at the base of the cylinder shaft. 13. Remove and discard the lock pin and the spring ( Figure 4 ). 14. Using acetone, or an equivalent cleaning agent, clean and degrease the thread end of the cylinder shaft. 15. Position the new spring ( part number 12L ) around the cylinder shaft ( Figure 5 ). 16. Apply perma-lok ( part number ) on the shaft thread. Immediately screw the T-nut ( part number 12L ) onto the cylinder shaft ( Figure 5 ). Torque T-nut to 30 ft. lbs.. Note: Remove any excess perma-lok from the cylinder shaft.

Drop the lock pin ( part number 12L-4-326 ) into the support (

5 DATE PAGE 5 t-nut new spring air cylinder shaft Figure 5. Tag Lock Cylinder with T-Nut and new Spring. 17. Drop the lock pin ( part number 12L ) into the support ( part number 12L ) ( Figure 6 ). Lock Pin drop lock pin into support Figure 6. with Lock Pin.

6 DATE PAGE Slide the T-nut on the lock cylinder assembly into the support. Ensure that the spring and the support are centered on the cylinder shaft ( Figure 7 ). connect shop air line here align the spring with support and center to cylinder shaft t-nut align the support with spring and center to cylinder shaft new lock pin Figure 7. Tag Lock Cylinder Assy ( AFTER MODIFICATION ). 19. Connect an air line to the lower fitting on the cylinder, to fully retract the cylinder shaft. Note: Cycle the cylinder a few times to remove water. 20. Position the spacer ( part number 12L ) on top of the boss ( Figure 8 ). spacer tag lock plate assembly boss Figure 8. Tag Lock Plate Assy with Spacer. 21. Insert the modified lock cylinder assembly into the boss. Turn until the lock pin is centered, and partially engages in the locking slot in the upper plate ( Figure 9 ). 22. Remove the shop air line. 23. Using the four screws ( part number ) and lockwashers ( part number ), secure the lock cylinder to the boss ( Figure 9 ). Torque the capscrews to 40 in. lbs..

7 DATE PAGE 7 mounting screws ( 4 ) spacer cylinder shaft fully retracted boss tag lock plate assembly Figure 9. Tag Lock Cylinder in Boss 24. Re---connect the air lines to the cylinder. 25. Re---connect the harness to the connector in the engine compartment. 26. Tyrap ( part number ) the lock cylinder harness and the latch cylinder harness together. Note: If the steps in this procedure are performed with the coachon a lift, then the coachwill have to be lowered to the ground. 27. Turn the main battery switch to the ON position. 28. Start the engine, and allow the air system to completely charge. 29. Lock the tag axle, by pressing the TAG LOCK switch on the LH driver s switch panel. Note: Ensure that the lock pin fully engages through all plates of the tag lock plateassembly. 30. Repeat the locking procedure several times to ensure proper function of the lock mechanism. Note: Leave the tag axle locked before driving the coach. Procedure complete.

Service Bulletin No. 3085

Service Bulletin No. 3085 MODEL SUBJECT J4500 Series TYPE SECTION/GROUP DATE Product Improvement 7-Electrical Dec. 19, 2014 FOG LIGHTS CONDITIONS Parts may be purchased from MCI Service Parts, Louisville, Kentucky. Description: