P 03-265

Procedure 03-265
Date: 02/28/2019
J Coach Drip Rail Rework
Description:
This procedure outlines the rework to address water leaks through the drip rail
The procedure applies to J4500 coaches.
Read this entire procedure before beginning work.
Use Safe Shop Practices At All Times.
To avoid personal injury:
a. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses
and protective gloves are required for working with DEF Fluid.
b. Turn the main battery disconnect switch to the OFF position.
c. Ensure that both the front and the rear wheels are chocked.
d. Positioning the ENGINE RUN and ENGINE START switches on the engine
compartment remote control box to the OFF position.
e. Allow enough time for components to cool down prior to working in the
engine compartment.
Motor Coach Industries Ltd.
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Procedure 03-265
1.0 Material Requirements:
The service kit T03-3016 contains following parts:
ITEM PART NO.
QTY
U/M
DESCRIPTION
1
23-02-0116
0.001 OZ
Sealant Sikaflex -521 UV black
2
23-02-0015
1
EA
250ml primer-250ml container
3
19-13-0330
2
EA
Rivet-SST, ¼ dia
T03-3010, Teroson primer, can also be used instead of 23-02-0015 primer
2.0 Special Tools:
¼” Rivet gun
3.0 Rework instructions
3.1 Remove the existing adhesive
Scrape the existing adhesive between the front cap and the drip rail.
Front cap
Existing
adhesive
Drip rail
Repeat the process for the rear cap.
Motor Coach Industries Ltd.
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Procedure 03-265
3.2 Adding a rivet
Drill a hole of 0.261- 0.276inch diameter at both ends of the front cap at below
mentioned location.
1.78”
1.78”
2 new holes
0.55”
0.55”
New hole
Using a rivet gun, install a rivet, 19-13-0330, at each hole.
Rivet, 19-13-0330
Motor Coach Industries Ltd.
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Procedure 03-265
3.3 Applying adhesive
Clean the bonding surfaces in the front and rear of the coach with primer, 23-020015, and allow 20 minutes flash off time.
Then apply ½” bead of Sikaflex, 23-02-0116, on either side of the joining edge of
front cap. The height of the bead should to be 3/16”.
½” bead of 23-02-0116
Allow 5 minutes flash off.
Motor Coach Industries Ltd.
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Procedure 03-265
Repeat the process for the rear cap with ¼” bead on either side of the joining
edge and 1/8” height
¼” bead of 23-02-0116
Allow 5 minutes flash off time.
End of the procedure
Motor Coach Industries Ltd.
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