NHTSA ID Number: 10171201
Manufacturer Communication Number: FCP 3129
TSB/Document Date: 2020-02-07
Summary
This Service Bulletin outlines the necessary steps to inspect the power steering system for proper operation. It also lists the necessary steps to replace the power steering seals if needed.
Subject: Steering System Inspection
Field change Program:
Service Bulletin
Bulletin Number:
3129
Coach Section:
11- Steering
P/N:
Revision:
A
11-07-1084
Date:
01/21/2020
Type:
Service Information
Application:
Coach Model
Model Year
VIN
J4500
All coaches beginning with MY 2013, VIN: 66554
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. Position 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.
SERVICE BULLETIN 3129
Steering System Inspection
1.0
Description
This service information bulletin outlines the necessary steps to inspect the power
steering system for proper operation. It also lists the necessary steps to replace the power
steering seals if needed.
2.0
Material Requirements
See Section 5.0.
3.0
Special Tools
Power steering system analyzer with hose, MCI
P/N: T20-1256.
Thrust Pad, MCI P/N: T20-1257
Extraction tool, MCI P/N: 20-141.
Power steering system
analyzer with hose
Thrust Pad
Extraction tool
Page 2 of 14
SERVICE BULLETIN 3129
Steering System Inspection
3.0
Steering system inspection
3.1
Visual Inspection
Start the engine and run at idle speed (700 rpm). Check the power steering reservoir and
ensure that the fluid level is between minimum and maximum lines as shown below.
Maximum fluid level
line
Minimum fluid level
line
Power steering reservoir
Start at the power steering pump, inspect the lines from the pump to the bulkhead fitting,
then inspect the lines from the bulkhead to the center tunnel. Then inspect the lines from
the front bulkhead to the steering gearbox.
If a leak is observed in any of the lines or fittings, refer to the MCI maintenance manual
for troubleshooting and corrective action.
Inspect the steering gear for any signs of fluid leakage. If fluid leakage is observed
proceed to Section 5.0. Otherwise, continue to next section.
3.2
Steering gear inspection for flow rate and pressure
3.2.1 Removing engine access panel
Open the wheelchair lift compartment door and extend the wheelchair lift, if present.
Wheelchair lift
compartment door
Remove and save the eight bolts on the engine access panel. Remove and save the
panel.
Remove and save
the screws
Page 3 of 14
SERVICE BULLETIN 3129
Steering System Inspection
3.2.2
Installing power steering analyzer tool
If the coach is equipped with a dampener tube, remove the lower fitting of the dampener
tube and attach it to the hose of the tool.
Hose of the tool
Lower fitting of dampener tube
Install the dampener end of the line to the analyzer line of the tool.
Dampening End of the line
Analyzer line
If the coach is equipped with a dampening canister assembly, remove the fitting on the
supply line from the power steering pump. Attach the power steering pump supply line to
the hose of the tool.
Power steering pump
supply line
Motor Coach Industries Ltd.
Hose of the tool
Page 4 of 14
SERVICE BULLETIN 3129
Steering System Inspection
Install canister end of the supply line to the analyzer line on the tool.
Analyzer line
Canister End
3.2.4
Bleeding the system for testing.
Start the engine and run at idle speed (700 rpm). Rotate the steering wheel all the way to
the LH and RH three times, holding the steering wheel in the end position for no more
than five seconds. When finished, move the steering wheel to the straight-ahead position.
3.2.5
Checking Pressure and Flow
Run coach at idle until the power steering fluid reaches 50±3° C or 122±6° F.
Once the temperature is reached, position the steering wheel in straight-ahead position
and record pressure and flow.
To check flow rate, slowly close the shut-off valve on the tool and confirm the flow is
above 13 LPM (3.4 GPM).
To check pressure, close and open the valve completely 3 times.
See if the pressure is between 100 Bar (1450 PSI) and 120 BAR (1740 PSI).
CAUTIONS
Do not hold the valve closed as it will damage the pump and/or gear.
If either flow rate is observed below 13 LPM (3.4 GPM) or the pressure is not between
100 Bar (1450 PSI) and 120 BAR (1740 PSI), replace the power steering pump (refer to
the MCI Maintenance manual for instruction).
Flow Rate
Shut off Valve
Pressure
Page 5 of 14
SERVICE BULLETIN 3129
Steering System Inspection
3.3
Internal gear leakage
Fully open the shut-off valve.
Insert the thrust pad tool, MCI P/N: T20-1257, between the lock stops as shown below
and hold it in place.
Thrust pad, MCI
P/N: T20-1257
Record flow rate and pressure readings on the power system analyzer tool while rotating
the steering wheel in clockwise direction.
Repeat the test in the opposite direction. Hold thrust pad tool, MCI P/N: T20-1257, in the
same way on the opposite side. Record the flow rate and pressure readings on the power
steering system analyzer tool.
Page 6 of 14
SERVICE BULLETIN 3129
Steering System Inspection
If either flow rate is observed above 16 LPM (4.22 GPM) or the pressure is above 180bar
(2610 PSI), replace the steering gear (refer to the MCI Maintenance manual for
instruction).
4.0
Removing Tool
Remove the tool from the dampener tube/ dampener canister.
Re-install the power steering hose to the dampener and torque the fitting to 60-65 Ft-Lbs.
Torque to 6065 Ft-Lbs
Install the engine access panel using the existing 8 bolts.
Page 7 of 14
SERVICE BULLETIN 3129
Steering System Inspection
5.0
Steering Gear Box Seal Replacement
5.1
ITEM
1
Material requirements
PART NO
T11-1115
QTY U/M
1
EA
DESCRIPTION
Gasket and Seal kit, ZF
Input shaft seal
Protective Cap
Stop Ring “CR 23”
Output Seal and Dust Cover
come as one piece.
Pitman Arm Nut
5.2
Special tools
Renolit CX-FO 20 grease.
Spectron FO20 grease.
5.3
Steering gearbox removal
Refer to the Maintenance Manual to remove the steering gear from the coach.
5.4
Input shaft disassembly
Rotate steering gear to position marks on the steering gear cylinder in straight line.
Line up the marks
Page 8 of 14
SERVICE BULLETIN 3129
Steering System Inspection
Remove and discard protective cap and seal.
Seal
Protective Cap
Remove and save 4 hexagon bolts. Save the cylinder cover.
Cylinder cover
Hexagon Bolts
Remove and save the needle cage and washer on the cylinder cover.
Needle cage
washer
Page 9 of 14
SERVICE BULLETIN 3129
Steering System Inspection
5.5
Input shaft assembly
Clean all components thoroughly.
Check each component for wear and oil before reassembly.
Grease the new input seal, part of kit T11-1115, using Renolit CX-FO 20 grease.
Input shaft seal
Slightly grease needle cage and the washer with Vaseline and insert them into the
cylinder cover.
Needle Cage
Washer
Using existing bolts, install the cylinder cover to the steering gear. Torque the bolts to 254
Ft-Lbs.
Cylinder Cover
Torque bolts to
254 Ft-Lbs
Page 10 of 14
SERVICE BULLETIN 3129
Steering System Inspection
Install new seal and protective cover form kit, MCI P/N: T11-1115.
Seal
Protective Cover
5.6
Output shaft seal removal
Remove and discard the pitman arm nut using extraction tool, MCI P/N: 20-141. Save
pitman arm.
Pitman Arm Nut
Remove and discard the dust seal, stop ring, and output seal.
Stop ring
Output Seal
Dust seal
Page 11 of 14
SERVICE BULLETIN 3129
Steering System Inspection
5.7
Output shaft seal installation.
Grease the dust seal and output seal, part of kit T11-1115, using Spectron FO20 grease.
Line up the housing as shown below, and insert the stop ring into housing.
Line up the arrows
Install dust seal and output shaft and press it into the housing until the stop ring is level
with housing.
Output Seal
Dust seal
Page 12 of 14
SERVICE BULLETIN 3129
Steering System Inspection
Install the pitman arm onto the shaft using new pitman arm nut, part of kit T11-1115, and
torque the nut to 378-462 ft/lbs.
Torque pitman arm
nut to 378-462 Ft-Lbs
Once the nut is torqued, secure nut with punch as shown in illustration below.
5.8
Steering gear installation
Refer to the Maintenance Manual for steering gear removal and installation.
Page 13 of 14
SERVICE BULLETIN 3129
Steering System Inspection
5.9
Bleeding the system
Check the power steering reservoir for fluid level. If the fluid is below the required level,
add fluid to reach the required level.
Power steering reservoir
Minimum fluid level
line
Start coach and let idle.
Bleed system by turning steering wheel to lock each way 10 times.
Test drive the coach, and after test drive re-check the steering fluid and add as needed.
5.10
Verify
Check for leakage on all the power steering hoses. If no leak is found procedure is
completed.
If a leak is found, retorque the fittings on the leaking hoses and clean surrounding area
to remove oil.
End of the procedure
Page 14 of 14
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TSB/Document ID: FCP 3129
Replacement Service Bulletin Number:
MFR Communication Date: 2020-01-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STEERING
MFR Component System:
MFR Component Subsystem:
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