P15-04
Service Bulletin Details
Public Details for: P15-04
This procedure is to inspect the alignment and correct if needed and is to be used at service centers equipped with hunter alignment machine, wt470.
- 2019 - 2018 - 2017 - 2016 - 2015 - 2014 -
Models from 2019
2019 MCI J4500 |
Models from 2018
2018 MCI J4500 |
Models from 2017
2017 MCI J4500 |
Models from 2016
2016 MCI J4500 |
Models from 2015
2015 MCI J4500 |
Models from 2014
2014 MCI J4500 |
Subject: J4500 Coach wheel Alignment Field Change Program: Procedure Procedure Number: 15-04 Coach Section: 15- wheels P/N: Revision: A 15-01-1459, 15-01-1354 Date: 11/26/2019 Type: Product Improvement Application: Coach Model Model Year VIN J4500 2014 - 66579, 66595, 66596, 66609, 66638, 66640, 66649, 66650, 66747, 66796, 66826, 66953, 69700 - 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. P15-04 J4500 coach wheel alignment 1.0 Description This procedure is to inspect the alignment on J4500 coaches and correct if needed. This procedure is designed to be used at the Servicer Centers equipped with Hunter Alignment Machine, WT470. 2.0 Material requirements No material required. 3.0 Special Tools Hunter Alignment Machine WT470. Steering Knuckle lock tool (MCI P/N: 39761). 4.0 Procedure Make sure the coach ride height/ ground clearance are set to specification as per procedure 12-24. 4.1 Coach Preparation 4.1.1 Locking tag axle Line the Coach up with the pit in the parking lot. Turn the “Tag Lock “on. Press the switch Tag Axle light should be illuminated on dash. Tag lock telltale Motor Coach Industries Ltd. Page 2 of 19 P15-04 J4500 coach wheel alignment Pull the Coach forward and backward outside the shop 3 times in a straight line to ensure the tag is locked and the suspension is relaxed. 4.1.2 Locking turn tables Lock all turn plates so plate will not move when driving over them. Turn the knob to lock Drive the coach over the pit or on the alignment rack and position front axle wheels 24.00” behind the centerline of the front turn plate. Center of the wheel Center of the turn plate 24” Motor Coach Industries Ltd. Page 3 of 19 P15-04 J4500 coach wheel alignment 4.1.3 Verify tire pressure Check the smart wave gauge under the Front Junction box for air pressure and verify if they are set to the manufacturer specifications on the decal next to the driver seat. If they are not set to the specifications inflate the tires to the manufacturer specified values. Driver’s seat Decal Smart wave Gauge Open the RH rear service door and install an external air supply to the fitting on the remote junction box. Set the pressure to 125 PSI. Airline Remote Junction box RH rear service door Motor Coach Industries Ltd. Page 4 of 19 P15-04 J4500 coach wheel alignment 4.2 Alignment machine setup 4.2.1 Setting up the program Turn the Hunter Alignment machine on by pressing the power switch button of the console central processing unit located inside the hardware storage cabinet. When the logo screen appears click on the ‘WinAlign’ icon, if necessary. WinAlign Icon Click on ‘Begin’ to start the alignment program. Click on ‘Begin’ Input the coach and Technician information and click on ‘OK’. Then choose Rear Steer Axle and click on ‘OK’. Rear Steer Axle Motor Coach Industries Ltd. Page 5 of 19 P15-04 J4500 coach wheel alignment Open all baggage bay doors to avoid miscommunication between the sensors and then click on ‘Mount Sensors’. Click on ‘Mount Sensors’ Baggage bay doors 4.2.2 Setting up sensors Install the alignment fixtures on the driver and curbside of front wheels and then install the sensors on the fixtures. Repeat the process for the drive and tag wheels. Sensor Fixture Note: Read the labels on the sensors as to which wheel, they should be installed on. Front wheel highlighted on the label Press the power button ‘ON’ on the sensor and turn the knob to unlock it. Knob Power button Motor Coach Industries Ltd. Page 6 of 19 P15-04 J4500 coach wheel alignment Check the screen to ensure all the sensors are in green color. If any of the sensors is in red color refer to Hunter manual for troubleshooting instructions. Green on all sensors Once all sensors are communicating follow instruction on the screen. Do not enter values in the frame offset. Just leave then blank and click on ‘OK’. This will let the machine set the centerline for the alignment. Click on ‘OK’ Motor Coach Industries Ltd. Page 7 of 19 P15-04 J4500 coach wheel alignment Obtain the remote box and press the power button to turn it “on”. Make sure turntables are unlocked. Remote box Turn table Press the button 4.3 Front Axle Camber Adjustment Click on “Measure Caster” on the screen. Ensure the service brakes in the coach are locked and follow instructions on Hunter screen to turn the wheel. Instructing on how to turn the steering wheel Motor Coach Industries Ltd. Page 8 of 19 P15-04 J4500 coach wheel alignment Follow instructions on Hunter screen to complete the caster measurement. Once the steering is centered exit the coach and click on “Ready”. Steering wheel Indexed Click on ‘Ready’ If the camber values on the front axle are all green (within the specs) continue to Section 4.4. If any of the front axle camber values are in red continue this section. Front axle camber values Click on the front axle on the screen and then click on camber on remote box. Click on ‘Camber’ Click on Front axle Motor Coach Industries Ltd. Page 9 of 19 P15-04 J4500 coach wheel alignment Adjust camber by installing shims (MCI P/N: 12-05-1310,1/32” thick; 12-05-1311, 1/16” thick; 12-05-1312, 1/8” thick) in between control arms and frame as follows: • • If the camber is positive install shims on the lower control arm or remove them from the top control arm. If the camber is negative install shims on the upper control arms or remove shims from the lower control arm. To install the shims, use a jack under the lower control arm to release pressure on the control arms. Once pressure is released, pry control arm back and install shim. Start with the smallest shim and remove and replace it with larger shim as needed. Control arm Jack Lower jack down, hand tighten bolts and check reading on hunter screen. Repeat until all the camber readings are green. Front axle camber values in green Once the adjustment is complete, torque bolts to 292 - 356 Ft. Lbs and apply torque seal. Torque to 292-356 Ft-Lbs. Remove all fixtures, sensors on all wheels and drive coach. Repeat Section 4.1 and Section 4.2. Motor Coach Industries Ltd. Page 10 of 19 P15-04 J4500 coach wheel alignment 4.4 Thrust Angle Adjustment Click on “Ready” to display Measurement and Adjustment. This is the current vehicle measurement. Click Save “Before” measurements. Save “Before” Measurements Click on the drive axle. Then click on ‘thrust/steer’ on the remote box. Drive axle Thrust/Steer If the value is observed in green (within spec) continue to Section 4.5 if not continue performing the next steps. Install shims (MCI P/N: 12-05-1310,1/32” thick; 12-05-1311, 1/16” thick; 12-05-1312, 1/8” thick) on the suspension as shown on the Hunter screen. Use the shims as required based on the adjustment value shown on the screen. Initial thrust angle Adjustment value Motor Coach Industries Ltd. Page 11 of 19 P15-04 J4500 coach wheel alignment Loosen the bolts on the suspension and using a pry bar create a gap to install the shim shown below. Hand tighten bolts. Loosen the bolts Pry bar Repeat the step until the thrust angle value turns green. Thrust angle value in green Once the adjustment is complete, torque the bolts to 292 - 356 Ft. Lbs and apply torque seal. 4.5 Tag Axle Camber Adjustment Relevel the sensors and turn the knob to lock them. Turn the knob to lock the sensor Level the sensor Motor Coach Industries Ltd. Page 12 of 19 P15-04 J4500 coach wheel alignment Click on “Show Next Axle” on the screen to display the Rear Axle 2 (tag axle values). If the camber values are in green (within spec) continue to Section 4.6 if not continue performing the next steps. Click on “Show Next Axle” Rear Axle 2 values Camber values Click on camber on the remote box. Click on “Camber” Use a jack under the upper control arm to release pressure on the control arms. Once pressure is released, pry control arm back. Pry bar Jack Motor Coach Industries Ltd. Page 13 of 19 P15-04 J4500 coach wheel alignment Adjust camber by installing shims (MCI P/N: 12-05-1310,1/32” thick; 12-05-1311, 1/16” thick; 12-05-1312, 1/8” thick) in between control arms and frame as follows: • • If the camber is positive install shims on the lower control arm or remove them from the top control arm. If the camber is negative install shims on the upper control arms or remove shims from the lower control arm. Loosen the bolts Control arm Once shims are installed, lower the jack and hand tighten bolts. Repeat the step until the camber values are green. Green camber values Once the adjustment is complete, torque bolts to 292 - 356 Ft. Lbs. Mark to torque seal. Torque to 292-356 Ft-Lbs Remove all fixtures, sensors on all wheels and drive coach. Repeat Section 4.1 and Section 4.2 Motor Coach Industries Ltd. Page 14 of 19 P15-04 J4500 coach wheel alignment 4.6 Toe Adjustment 4.6.1 Tag Axle Toe Adjustment Click on “Show Next Axle” on the screen to display the Rear Axle 2 (tag axle values). If the toe values are in green (within spec) continue to Section 4.6.2 if not continue performing the next steps. Click on “Show Next Axle” Rear Axle 2 values Tag axle toe values Click on the toe on the remote box to switch to toe settings. Loosen the toe rod clamps and turn tie rods clockwise or counter clock wise until toe values are observed to be in green. toe rod ends toe rod clamps Torque tie rod clamps nut to 35 Ft.-Lbs. and mark torque seal. Torque to 35 Ft-Lbs Motor Coach Industries Ltd. Page 15 of 19 P15-04 J4500 coach wheel alignment 4.6.2 Front Axle Toe Adjustment Press the button “K1” on the remote box and then press “Thrust/Steer” button. If the values on the left and right on the remote box are within the range 0.02-0.06 continue to Section 5.0, if not continue performing the next steps. K1 button Toe button Install the steering knuckle lock tool into the U-joint of steer driveshaft and center frame member of front bogie. Lock knob of the tool to keep steer driveshaft U-joint in the center and to ensure it does not move when both tie rods are turned to adjust the toe. U-Joint of steer driveshaft Steering knuckle lock Knob Loosen tie rod clamp bolts. Tie rod clamp bolts Motor Coach Industries Ltd. Page 16 of 19 P15-04 J4500 coach wheel alignment Turn the tie rod clockwise or counterclockwise on both driver side and curbside to adjust the toe as required. Tie rod Once the toe is adjusted tighten the tie rod clamp bolts. Torque tie rod clamp nut to 59 Ft. Lb. and mark to torque seal. Remove steering knuckle tool. Toque to 59 Ft-Lbs Steering knuckle tool 5.0 Verification Print out before and after readings and attach to RO. Remove the alignment fixtures and sensors. Put them in the correct position on the rack. Motor Coach Industries Ltd. Page 17 of 19 P15-04 J4500 coach wheel alignment Remove the batteries and install batteries in the charger. Drive coach down a level road to ensure coach drives straight. Motor Coach Industries Ltd. Page 18 of 19 P15-04 J4500 coach wheel alignment 6.0 Appendix End of the procedure Motor Coach Industries Ltd. Page 19 of 19