Service Bulletin No. 3089

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1 MODEL SUBJECT CONDITIONS J4500 Series TYPE SECTION/GROUP DATE Service Information 3-Body Jan. 25, 2016 TOW PROCEDURE Service Information Only. Description: MCI is releasing this Service Information bulletin to inform customers of the only two authorized procedures to properly tow a J4500 Series coach equipped with ZF axles. Parts ( Aftermarket Service Parts to prevent contamination during towing ) Qty. Old P/N New P/N Description a/r Kit, Tow, ZF Drive Axle Flange Shaft Kit Contents are: Towing Cover Seal, O-ring M18x bolt Service Information: 1. Service information only. 2. New parts are available from MCI Service Parts. Tow from the FRONT of the coach only. Use only tow truck operators who are experienced in towing intercity coaches. Do not use sling lift tow trucks, as they will damage the coach. The drive axle flange shafts must be removed when the coach is being towed to avoid the possibility of damage to the transmission. Do NOT allow passengers on the coach while the coach is being towed.

2 Date January 25, 2016 Page 2 MCI recommends that only one of the following two ( 2 ) authorized procedures be used to properly tow a J4500 series coach equipped with ZF axles: 1. Lift the coach by the front axle tires, as shown in Figure 2, without exceeding a maximum height of 22 inches from the bottom rail of the front junction box to ground level ( refer to Figure 1 ). EXCEEDING A MAXIMUM HEIGHT OF TWENTY TWO ( 22 ) INCHES WILL RESULT IN COMPONENT DAMAGE. Figure 1. Maximum tow height. 2. Utilize a flatbed to move the coach.

3 Date January 25, 2016 Page 3 These procedures and safety precautions must be followed when towing. Apply the parking brakes when waiting for assistance from a tow vehicle. TOW PROCEDURE Use only towing vehicles that are rated to tow a coach of a gross vehicle weight of over 54,000 lbs. Tow vehicles must have hydraulic booms that can extend under the front of the coach. The tire cradle attachment should be positioned directly under the front tires ( refer to Figure 2 ) Figure 2. Tow procedure. Item Description 1 Hydraulic boom 2 Tire cradle attachment Careful attachment of towing equipment is the responsibility of the towing operator. Therefore, it is very important to select an operator experienced in towing coaches. When a coach is to be towed, make sure the parking brakes are in the Applied (up) position. This will safely keep the coach stationary when the tow vehicle device is being attached to the coach. When the supply line from the tow vehicle is attached to the whole coach air connection, the parking brakes will remain in the Applied (up) position. When the tow vehicle device is attached and the coach is ready to be towed, the operator must enter the coach and push the parking brake knob in the driver s area to release the brakes.

4 Drive Axle Shaft Removal Procedure Service Bulletin No Date January 25, 2016 Page 4 The drive axle flange shafts must be removed before towing the coach. There is oil behind the flange shaft which comes out during disassembly. Position a container as shown in Figure 3 to capture escaping oil and utilize a clean rag to wipe the oil residue off of the flange shaft. Waste oil must be handled and disposed of in accordance with all applicable legal requirements. After towing, ensure axle oil level is checked and filled to proper level. Figure Remove the ten M18x bolts securing flange shaft to hub using 14mm hex head with 1/2 in. drive ( refer to Figure 4 ). 2. Remove the drive axle flange shafts. 1 Figure 4. Removing Flange Shafts. Item Description 1 Drive axle flange shaft

5 Date January 25, 2016 Page 5 Ensure both hubs are oil tight. Use axle oil to lube O-ring on hub cover. The hub covers include an O-ring to ensure a tight seal. 3. Install the hub covers with two of the M18x bolts ( refer to Parts list ). Torque the bolts to 74 ft-lb (100 Nm). Figure 5. Hub Cover Figure 6. Installing Hub Covers Item Description Qty 1 Hub Cover 2 2 M18x bolt 4 3 O-Ring (Not Shown) 2

6 Flange Shaft Installation (After Towing) Service Bulletin No Date January 25, 2016 Page 6 1. Inspect flange shaft O-ring for damage and replace if necessary. 2. If replacing O-ring, it must be greased before installing. 3. Remove hub covers. 4. Install flange shafts. 5. Inspect the ten M18x bolts previously removed for any thread damage and replace if needed. 6. Install the M18x bolts and torque to ft-lb ( Nm). Attaching Coach to Tow Vehicle Make certain that the coach is securely attached to the tow vehicle before attaching the supply line, or manually releasing the parking brakes. Otherwise, the coach may move, with the potential to cause serious personal injury. 1. Verify that the parking brakes are applied, and that the tow provision supply line is not connected or pressurized. 2. Allow the tow operator to extend and connect the boom device to the front axle. 3. Connect the tow quick connector and then energize the supply line. The park brake circuit and at least one service brake circuit require full air pressure, preferably the primary circuit. This will allow the park brake push-pull valve to be pushed down, allowing the locks to release and permitting the park brakes to retract. Do not tow the coach without external air pressure applied to the whole coach air connection unless the coach engine and its air compressor are in operation. Without system air pressure, the park brakes will apply automatically if parking air pressure falls to approximately 40 psi (276 kpa). If all circuits are low, and the air system is intact, the entire system may be filled through the quick connector in the curbside rear service compartment. If all circuits are low and the coach won t run or generate air pressure, fill at least one service circuit and the park brake circuit using the appropriate emergency fill valves in the roadside front service compartment. In the event that the coach has sustained enough damage that the coach system cannot maintain enough system air pressure to release the park brake, the drive axle brake chambers will have to be caged ( Refer to Section 4E in the MCI J4500 Maintenance Manual ).

7 Date January 25, 2016 Page 7 4. Operate the coach engine during the tow to maintain brake system air pressure. If the engine cannot be used, attach an external air pressure line from the tow truck to the tow quick connector behind the front bumper. The air pressure must be 100 psi (690 kpa) minimum and the line should be attached via screw type or clamp on type air connector. 5. Tag axle lock switch should be in the locked position if the coach is towed with the master switch ON. 6. Make a service brake application from the tow vehicle and verify the rear service brake function on the coach. 7. Activate tow vehicle brake lights and turn signals and verify coach responds accordingly. Observe the normal precautions including, but not limited to, the ones listed below when towing the coach: Make sure the park brake is released before towing. Do not allow passengers inside the coach during towing. Do not exceed a prudent, safe towing speed. Be aware of changing conditions. Avoid tight turning. Accelerate and decelerate slowly, with caution. After towing approximately two miles, check the connections between the tow vehicle and the coach, including air and electrical connections.

8 Air Connections for Towing Service Bulletin No Date January 25, 2016 Page 8 The coach has provisions to allow air connections from the tow vehicle to operate the rear service brakes and maintain air pressure in the reservoirs. The connection points are in the roadside, front service compartment door, below the front junction box as shown in the Figure 7. DO NOT INSTALL SOLID PLUGS. The parking brakes may not release properly if this connection cannot vent to the atmosphere. Figure 7. Connection points. Routing the Air Lines Route the hoses away from the steering gear and linkage. Ensure that the tow vehicle hoses will not be pinched or damaged during towing. 1. Route the tow vehicle hoses to the air connection located in the roadside, front service compartment door, below the front junction box.

9 Date January 25, 2016 Page 9 Connecting the Air Lines Two lines connect to the tow vehicle, which are similar to those for an air-braked trailer: 1. Use the whole coach air connection for the line from the tow vehicle that charges the air system. (This line is sometimes called the Emergency line.) This line allows air from the tow vehicle to fill and maintain the air pressure in the coach air system. It assumes that the entire coach air system is intact. Figure 8. Tow Hose connection. 2. Use the service brake connection for the line from the tow vehicle that operates the service brakes. This line energizes only when the tow vehicle s brakes are applied and will operate the brakes on the two rear axles to help stop the vehicle combination. If the entire system is not intact, you can move the supply connection to the rear air connection shown in Figure 8 (provided the rear system is intact). Only the rear service reservoir will be filled and maintained. The parking brakes must be manually released by pushing the button down after the coach is blocked and safely attached to the tow vehicle. Procedure Complete.

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