NHTSA ID Number: 10168838
Manufacturer Communication Number: P15-04
TSB/Document Date: 2019-12-07
Summary
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.
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
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”
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
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
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’
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
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
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.
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
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.
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
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.
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
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.
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.
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.
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.
Page 18 of 19
P15-04
J4500 coach wheel alignment
6.0
Appendix
End of the procedure
Page 19 of 19
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TSB/Document ID: P15-04
Replacement Service Bulletin Number:
MFR Communication Date: 2019-11-26
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT ADAPTIVE/MOBILITY
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