Service Bulletin No. 3063 MODEL TYPE SECTION/GROUP DATE J4500 Series Coaches Service Information 3--Body Aug. 03, 2011 SUBJECT CONDITIONS FENDER PANEL STUD ASSEMBLY Parts may be purchased from MCI Service Parts, Louisville, Kentucky. Description: The following MCI service bulletin outlines the necessary procedure steps to replace the front and rear fender panel stud assembly on J4500 coaches. Replacing the mild steel stud assembly with a stainless steel stud assembly will improve the reliability of the fender panel installation. In addition, service part numbers for the steel strip mounts are included in this service bulletin. Parts Qty. New P/N Description a/r 03-35-1338 Stud Assy., Stainless Steel, Front and Rear Fender a/r 03-35-1340 Stud Strip, Short, Roadside and Curbside, Front Fender a/r 03-35-1538 Retainer, Curbside, Front Fender a/r 03-35-1539 Retainer, Roadside, Front Fender a/r 03-35-1553 Bracket, Roadside and Curbside, Front Fender a/r 03-35-1531 Retainer, Roadside, Rear Fender a/r 03-35-1532 Retainer, Roadside, Rear Fender a/r 03-35-1533 Upper Fender Mount, Curbside, Rear Fender a/r 03-35-1534 Fender Mount, Curbside, Rear Fender a/r 03-35-1546 Mount, Roadside and Curbside, Rear Fender a/r Lord 403, Adhesive ( Procure locally ), or, a/r Lord 406, Adhesive ( Procure locally ), or, a/r Lord 606, Adhesive ( Procure locally ), or, a/r Plexus MA830, Adhesive ( Procure locally ), or, a/r Pliogrip 1005C, Adhesive ( Procure locally ) a/r Fiberglass Repair Kit ( Procure locally ) Kit Contents Should Contain: Resin Activator Fiberglass Cloth or Mat Mixing Sticks Applicator Brush Mixing Cups Service Information: 1. New parts will be available for service replacement.
Service Bulletin No. 3063 DATE AUG. 03, 2011 PAGE 2 Service Procedure: Read this entire procedure before beginning work. UseSafeShopPracticesAtAllTimes. 1. For E / J model coaches prior to 65013, turn the main battery disconnect switch to the OFF position. For E / J model coaches effective with 65013, activate the disconnect feature of the main battery disconnect ( MDS ) system by pressing ( for one second only ) the momentary toggle switch on the MDS module to OFF. An audible click can be heard from the main solenoids in the MDS module. Position the rotary switch to the DOWN ( OFF ) position. 2. Chock both sides of the tires. 3. Remove and retain any electrical components ( light, switch, etc. ) from the applicable fender. 4. Locate the stud assemblies on the applicable fender. Remove and retain the mounting hardware. 5. Lift to release the fender panel from the retainers. Place the fender panel on a workbench. 6. Follow the steps and instructions in the attached Fender Bonding Process Procedure, including observing all warnings and cautions contained therein. 7. Prior to re--- instaling on coach, position one ( 1 ) fender washer orientated with the weld nut towards the inside of the fender, on each stud. 8. Orient the reworked, fully cured fender on the coach frame retainers and apply downwards force to engage. 9. Apply Loctite to the threads of the studs. Install the mounting hardware, removed in Step 4., on the studs asshowninfigure 1. Figure 1. 10. Visually inspect to ensure that the horizontal and vertical gaps between the fender and sidewall, as well as compartment doors are equal ( typical 0.72 inch ). Adjust as necessary. 11. Torque nut to 20---24-lbs. 12. Orient the applicable harness through the opening on the fender. Re---connect the harnesses and secure with mounting hardware removed in Step 3. Start up the coach and visually inspect to ensure that the component removed in Step 3. is operating correctly. 13. After replacement of component and the proper curing time has elapsed, pull test stud assy. to 50 lbs. to ensure correct installation. Procedure complete.
Bonding Achieving the Strongest Bond Possible Before any bonding is done, there are six important points that must be reviewed: 1. The parts being bonded and the adhesive must be at room temperature. This is a factor in colder climates. If the fender, hardware or adhesive is cold the bond created will not be as strong. Let the parts and adhesive warm up to room temperature (around 25 C, or 77 F) before any bonding is done. 2. The parts being bonded must be clean Use alcohol or water with a clean rag to clean the part surfaces (fiberglass and hardware). If alcohol is used, allow time for the alcohol to completely evaporate before applying adhesive to the cleaned area. 3. After cleaning the part and the hardware, do not contaminate the bonding surfaces. Avoid handling the parts after they have been cleaned to avoid contamination. 4. Rub bonded surfaces together When parts are joined together after applying adhesive, rub the parts together. 5. Do not separate the parts. Separating the parts will allow air to get trapped in the adhesive, weakening the bond. If the parts are separated, wipe all of the adhesive form the hardware and fender and start the bonding process again. 6. Allow sufficient time for bonding. The time period varies and is dependant on the temperature. On warmer days less time is required and on cooler days more time is required Refer to the instructions provided with the adhesive. Reminder: As stated earlier, the bonding should be done at room temperature. Page 1 of 9
Equipment and Materials Fender Bonding Process Belt or Disk Sander with 80 100 grit Sandpaper: Adhesive and Applicator: Methacrylate Alcohol: Isopropyl Fiberglass Repair Kit Items in a commonly found in a Fiberglass Repair kit: 1. Gloves 2. Resin 3. Activator (Hardener) 4. Fiberglass cloth or fiberglass mat 5. Mixing Sticks 6. Applicator 7. Brush 8. Mixing cups Other General Items: Clean rag: for cleaning and surface prep Weights: for added pressure during bonding Hammer and Chisel: to remove old hardware Page 2 of 9
Removing the Hardware (if necessary) Fender Bonding Process If the old piece of hardware is still bonded to the fender, use a chisel and hammer to remove it: If there is any adhesive, residue or rust from the previous assembly it will be addressed on the following pages in the steps provided for bonding. Page 3 of 9
Locating the Hardware In regards to the Rear Fender, the hardware and dimensions are shown below: 1 03 35 1338, Stud Assy. 2 03 35 1531, Curbside. 03 35 1534, Roadside 3 03 35 1532, Curbside. 03 35 1533, Roadside 4 03 35 1546, typ. Curbside & Roadside fender A B C D E F G H I 22.06 inch, typ. Curbside & Roadside fender 1.91 inch, typ. Curbside & Roadside fender 48.25 inch, typ. Curbside & Roadside fender 11.01 inch, typ. Curbside & Roadside fender 30.43 inch, typ. Curbside & Roadside fender 3.62 inch, typ. Curbside & Roadside fender 54.60 inch, typ. Curbside & Roadside fender 11.38 inch, typ. Curbside & Roadside fender 103.2 inch, typ. Curbside & Roadside fender Page 4 of 9
In regards to the Front Fender, the hardware and dimensions are shown below: 1 03 35 1338, Stud Assy. E 21.02 inch, typ. Curbside & Roadside fender 2 03 35 1340, typ. Curbside & Roadside fender F 36.77 inch, typ. Curbside & Roadside fender 3 03 35 1538, Curbside. 03 35 1539, Roadside G 40.55 inch, typ. Curbside & Roadside fender 4 03 35 1553, typ. Curbside & Roadside fender H 17.54 inch, typ. Curbside & Roadside fender A 3.46 inch, typ. Curbside & Roadside fender I 48.31 inch, typ. Curbside & Roadside fender B 13.36 inch, typ. Curbside & Roadside fender J 10.54 inch, typ. Curbside & Roadside fender C 4.79 inch, typ. Curbside & Roadside fender K 69.28 inch, typ. Curbside & Roadside fender D 2.55 inch, typ. Curbside & Roadside fender Page 5 of 9
Bonding Hardware to the Fiberglass part 1. Preparing the Fiberglass Surface Scuffing the Bonding Surface Using a belt or disk sander, clean the area where the hardware will be bonded using an 80 100 grit sandpaper. Using a disk or belt sander, any residue from the previous assembly is easily removed. 2. Preparing the Fiberglass Surface Cleaning with Surface with Isopropyl Alcohol Apply the alcohol and scrub the area with a clean rag. Old rags may contain grease or dirt which will contaminate the bonding surface. 3. Preparing the hardware surface Scuffing the Bonding Surface Using a belt or disk sander, scuff the area of the hardware that will be bonded. Again, use an 80 100 grit sandpaper. Bonding a rough surface will provide a stronger bond between the hardware and adhesive than a smooth surface. 4. Preparing the Hardware Surface Cleaning with Surface with Isopropyl Alcohol Apply the alcohol and scrub the area with a clean rag. Reminder: Avoid handling the parts after they have been cleaned to avoid contamination. The less the parts are handled, the less the chance there is for contamination. Page 6 of 9
5. Apply the Adhesive to the Hardware When applying the adhesive, use a generous amount and try to apply it in a single continuous bead to avoid air getting trapped in the mixture. 6. Place the Hardware on the Fender Reminder: When parts are joined together after applying adhesive, rub the parts together. Reminder: Do not separate the parts. 7. Scrape away the Excess Adhesive In order to skin coat the hardware to the fender with the fiberglass cloth or mat, the excess adhesive must be scraped away. 8. Allow Sufficient Time for Bonding Reminder: The time period varies and is dependant on the temperature. On warmer days less time is required and on cooler days more time is required. Refer to the instructions provided with the adhesive. Page 7 of 9
Skin Coating the Hardware to the Fiberglass part The skin coat is an extra layer of fiberglass placed over the hardware and surrounding area of the fender as an extra bonding process. 1. Preparing the Fiberglass Cloth or Mat Given the dimensions of the hardware is 1.88 x 2.50 inches, and a 1 inch overlap is required: The fiberglass cloth or mat should be cut to 4.5 x 3.9 inches. Cut a hole in the middle for the Stud (as shown below). 2. Prepare the Laminating Area: Use tape or a plastic cover to protect the thread on the hardware. Again using the belt sander, scuff the hardware and a 1 inch area around the hardware. Clean the area with water and alcohol Page 8 of 9
3. Resin Mixture The mixture is dependant on the type of resin and catalyst used. Follow the instructions provided for the materials used. 4. Fiberglass Cloth or Mat Using a brush, apply some resin to the hardware and 1 inch area surrounding the hardware. Place the fiberglass on the resin and brush on more resin. The outline of the fiberglass cloth highlighted in red. 5. Allow Sufficient Time for Curing Different resins required different curing time. Refer the instructions provided with the resin. Page 9 of 9