P 03-266

Procedure 03-266
Sliding WCL door rework
Description:
This procedure outlines the steps to rework the sliding WCL door used on some of the MY18
J4500 units. This rework is necessary to ensure reliable operation of the sliding door.
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.
1 | 18 Pages
Procedure 03-266
1.0
2.0
Material requirements:
ITEM
1
2
3
PART NO
03-31-4619
19-05-0325
19-05-0354pk
QTY
1
1
1
U/M
EA
EA
EA
4
23-03-0077
1
EA
5
6
7
3L-31-2084
3L-31-2289
19-04-0288
1
2
29
EA
EA
EA
DESCRIPTION
ARM - MID, HINGE, WCL SLDG DR
BUSHING-BRONZE,.38 X 1.25 LG
FASTENER-RATCHET TYPE
TAPE-BUTYL,2-SIDED,1"WIDE x
3/32"THICK
ROLL SIZE 45 FT.75 DIA x 1.38
BEARING-CAM,
BEARING-CAM, .56 DIA, .31-18UNC
FASTENER-RATCHET, PSH IN .281 DIA
Special Tools:
Flat file tool
Loctite 262 (MCI P/N: 21-7212-26)
4” x 4” Wooden block with channel
0.5”
2”
1.4”
5/8”
3.5”
3.0
Middle arm rework
Remove and discard the 3 ratchets securing the wall panel to the sliding door. Save the
wall panel.
Ratchets
Wall panel
2 | 18 Pages
Procedure 03-266
Remove and discard the 7 ratchets securing the heat duct panel. Save the heat duct
panel.
Remove and discard
the ratchets
Remove and discard the 15 ratchets securing the interior panel. Save the interior panel.
Remove and discard
the 3 ratchets on
each side
Remove and discard
the ratchets
Open the door to where the middle arm is just on the straight area of the track.
Arm on the straight
area of the track
3 | 18 Pages
Procedure 03-266
Support the door with the WCL, using a block of wood with a channel cut for the door.
Use the manual operation of the lift to make contact with the door.
Wooden block with
channel for the door
Remove and save the 6 bolts securing the middle hinge to the sliding door.
Remove and
save the bolts
4 | 18 Pages
Procedure 03-266
Remove and save the screw securing the rubber bumper at the end of the track. Save
the rubber bumper
Remove and
save the screw,
bumper
Slide the middle hinge to the end of the track and separate it from the coach.
Remove and save the nut and bolt securing the arm to the middle hinge. Discard the arm
from the middle hinge.
Remove and
save the bolt, nut
5 | 18 Pages
Procedure 03-266
Insert the bushing, MCI P/N: 19-05-0325, into the middle hinge arm, MCI P/N: 03-314619, as shown below.
Bushing, MCI
P/N: 19-05-0325
Middle arm, MCI
P/N: 03-31-4619
Install new bearings 3L-31-2084 and 3L-31-2289 as shown below to the arm and torque
them to 30 In-Lbs.
3L-31-2289
3L-31-2084
Add two drops of Loctite 262, MCI P/N: 21-7212-26, to the bolt and install the new arm to
the middle hinge. Torque the nut to 11 ft-Lbs.
Add 2 drops of
Loctite 262
6 | 18 Pages
Procedure 03-266
Apply butyl tape, MCI P/N: 23-03-0077, on the back of the middle hinge where it meets
the sliding door.
Apply butyl tape along
the outer edge
Slide back the middle hinge with new arm through the track and install the middle hinge
to the sliding door using existing hardware. Torque the bolts to 11-13 Ft-Lbs.
Install and torque the
bolts to 11-13 Ft-Lbs
7 | 18 Pages
Procedure 03-266
4.0
Heat duct panel rework
Mark the panel as shown below using masking tape.
2”
Trim the marked area.
5.0
Upper and lower latch rework
Remove the 4 screws and the ratchet securing the hinge cover. Save the screws and
discard the rachet. Remove and save the hinge cover.
Remove and
discard the ratchet
Remove and save
the 5 screws
8 | 18 Pages
Procedure 03-266
Remove and save the two nuts, bolts on the cylinder bracket. Save the shims, if any
present.
Remove and save
the nuts, bolts
Using a flat file tool, file the rugged inside edge of the cylinder bracket as shown below.
File the edge
Install the cylinder bracket using the existing hardware.
9 | 18 Pages
Procedure 03-266
Remove and discard the 3 ratchets holding the post cap. Save the post cap.
Remove and
save the ratchets
Remove and save the two nuts, bolts on the cylinder bracket. Save the shims, if any
present.
Remove and save
the nuts, bolts
Using a flat file tool, file the rugged inside edge of the cylinder bracket as shown below.
File the edge
10 | 18 Pages
Procedure 03-266
Install the cylinder bracket using the existing hardware.
6.0
Other checks
6.1
Lubrication of the secondary latch
Lubricate the secondary latch including the contact between the latch and striker.
Lubricate the secondary latch
6.2
Upper latch clearance
Check if the upper latch is clear of the bracket when cylinder is retracted.
No gap between bracket and latch
11 | 18 Pages
Procedure 03-266
If no visible gap is observed install shims, MCI P/N: 3R-76-20, as required between the
bracket and the latch to achieve clearance between the bracket, plunger when cylinder is
retracted.
Ensure plunger
clears the bracket
when cylinder is
retracted
6.3
Shims, MCI P/N: 3R-76-20
Lower latch clearance
If the door is not opening, check if lower latch is angled in and is contacting the portal.
If the lower latch is found angled in, look for the trimmed edge in the portal.
Trimmed edge in the portal
12 | 18 Pages
Procedure 03-266
If the lower latch is angled in and no trim is observed in the portal, adjust the slots to clear
portal at lower latch.
Adjust slots
6.4
Door jamb switch alignment
If the door sensors are not responding even though door is opening, check for contact
point on door jamb switches and alignment of the magnetic switches at the upper track.
Misalignment in the buttons
Misalignment in the
magnetic switch
13 | 18 Pages
Procedure 03-266
If the buttons are observed to not contact at the center, use lithium grease to mark the
contact points and adjust the door jamb by trimming the panel and re-mount the contact
button assembly.
If the magnetic switches are observed to be misaligned, align the switches in such a way
that magnetic faces of the switch and fixed magnet on the upper track are in contact with
each other.
6.5
Clearance on door open hold latch
If the door is not fully open because of a negative lift clearance check for door open hold
latch for engagement.
14 | 18 Pages
Procedure 03-266
Adjust the latch using the locknut. The locknut must be in place and tightened to prevent
the adjustment backing off
Locknut
If the latch is adjusted down too far it will not ramp up the catch ramp.
Catch ramp
Latch
6.6
Secondary lock alignment
If door is not opening, check the secondary lock for its alignment behind the inside cover.
15 | 18 Pages
Procedure 03-266
If deflection is observed in the bracket, remove and save the bolts mounting the bracket.
Remove and save
the bolts
Install a new bracket, MCI P/N: 03-32-2658, in the same location using the existing
hardware and torque them to 11-13 Ft-Lbs.
New bracket, MCI
P/N: 03-32-2658
Torque the bolts to
11-13 Ft-Lbs
7.0
Install the panels
Install the post cap using 3 rachets, MCI P/N: 19-04-0288.
Location of the
ratchets
16 | 18 Pages
Procedure 03-266
Install the hinge cover using the existing 5 screws and a new rachet, MCI P/N: 19-040288.
Location of the
ratchet
Install the existing
5 screws
Install the interior panel to the sliding door using 15 rachets, MCI P/N: 19-04-0288.
Install 3 ratchets on
each side
Location of the
ratchets
Install the heat duct panel to the sliding door using 7 rachets, MCI P/N: 19-04-0288.
Location of the
ratchets
17 | 18 Pages
Procedure 03-266
Install the wall panel to the sliding door using 3 rachets, MCI P/N: 19-04-0288.
Ratchets
Wall panel
End of the Procedure
18 | 18 Pages