MCi Crusader II 1989 User manual

MC-9
CRUSADER :0:
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MAINTE . NANCE
· MANUAL
0anuary 1 888

THIS DOCUMENT HAS BEEN PROVIDED IN THE ADOBE PDF FORMAT AS A
SERVICE TO THOSE WHO MAY NOT BE ABLE TO LOCATE A HARD COPY OF
THIS VINTAGE INFORMATION.
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KNOW THE NEED TO MAKE SURE MANUALS AND OTHER DOCUMENTS ARE
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And
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AND ARE ON OCCASION OFFERED ON EBAY.
MANUALS AND DOCUMENTS ARE ADDED TO OUR LISTING ON A REGULAR
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WE VERIFY EACH PAGE TO INSURE THAT ALL PAGES SUPPLIED IN THE
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IVl.41NTl:I\IAI\ICE
. 'MANUAL,-·
.. Jantiary 1989
Fl.,IN 3G"-15-176E', · 1-1!!1119, -
PRINTE!) IN U,SA
i ...
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MC-9 MAINtENUJCE
MANUAL
. • • . . . .
~
.. . . - . I
. ,
··Front,_
Axle
._:
_· -Rear.
·Al(1e·
-Bo(.iy...
Brakes &
Ai_r
System
. _ . . .Clutch
'
.
'
.Cooling ·Syst~llJ
•_.•
E·lectrical',_
~System
':
,_
:
-·
·_·.:
··
-·.
En_girie
Fuef·"SysteO,
Lubrication
..
·
'•
steenn9
·
·.
··
.·
.Susj.)ensiora
. .
Trans~jssio"r-1
· -
:Propeller:>
SJ1~'"1
Wheels,-·
-H_ub~f
:J-·•;_Tires·
Heating
·a
Air·
·conditioning
. Lavatory
1
2i
3
4·
s·
6
7-
8
9
10
1~
12
1:3_
14
~
..
15
16
17

Me~9:,M.AI.NTENANCE MANUAL
WELDING CAUTION
Since welding is a procedure which may be carri_ed out either as allowed
(explicitly -or implicitly) by instructions in this manual or carried out by an
independent decision
of the coach owner/operator, the following information
pertaining-to welding
should be read before beginning any welding procedure.
Theprohibitionsand requirementscontainedtherein
must befollowed during the
' Welding:procedure. ·
1. Welding ~~st be done only ,by a qualified and experienced person.
2. Adequateground contacts andbarriers must bepositioned as required to
pro,tect- components (wiring, brake lines, hydraulic lines, etc.) from
damage
due to heat contact by weld splatter arcing or other potentially
damaging events associated with welding.
3. On any coach. turn battery switch to "OFF."
4. Forcoach.es equipped with a battery equalizer. after performing step 3
above:
a. Disconnectthe ground at the equalizer.
b. Disconnect the battery leads.
5. If coach has ATEC or DDEC, remove the ATEC/DDEC power control
fuses.
6. Anyapplicablewelding instructions or prohibitionsgiven bya procedure
must be heeded.
ii

Date
January 1989.
INTRODUCTION
Thismanual contains operation, maintenance andoverhaul information on MC-9 Model Coach.Information in this manual pertains_,,,)
to standard and commonly used optional equipment
Vehicle operation from the driver's standpoint is contained in a separate operator's manual. Detroit Diesel engine information is
found inaseparateservicemanual. Allison transmission infonnationiscontained in the appropriate vendor servicemanual which, like
the engine manual, is supplied separately. .
Allinformation containedin this manualis basedon the latestproductinformation available at time of publication. We reserve the
right
to make publication changes at any time.
HOW TO USE THIS MANUAL
This manual is divided into major sections in the sequence shown on the section index. Ail major sections are divided into
sub-sections
containing descriptions, operation, maintenance, replacement, overhaul and specificatipn information on. related
systems and components. A section
index appears on the first page of each major'section.
PAGE ANO ILLUSTRATION NUMBER
Manual pages and illustrations are numbered consecutively within each major ~ction.
SPECIFICATIONS
Servicedata, torque limits and tolerances are listed at the end of most sections under the headi11g "Specificatioris." !'llanufacturer's
model orpart
numbers areprovided where applicablefor component identification.Detail service partnumbers must be obtainedfrom
the MC-9
Model Parts Manual.
SERVICE INFORMATION BULLETINS
Service Bulletins are issued, when required, to supplement or supersede infonnation in this manual. Information in the bulletins
should be noted and filed for future use.
CUSTOMER SERVICE
Universal Coach Parts of Northlake, IL and Motor Coach Industries, Ltd., Service Parts Division of Canada, know your coach best _j
and are interested in your complete satisfaction. Both offer genuinefactory parts for this MC-9 Model and aii other TMC/MCI Coach
Models. · .
.• .
Servicedepartmentsin both Roswell, N.M.
(U.S. service)and in Winnipeg, Canada{all Canadian service)stand ready to serve you.
Their addresses are:
Transportation Manufacturing Corporation
Service Department
P.O. Box 5670 (R.1.A.C.)
Roswell, N.M. 88202-5670
Motor Coach Industries, Ltd.
Service Parts Division
of Canada
1149 St Matthews Ave.
Winnipeg, Manitoba, Canada R3G0J8
Proper maintenance is important to the safe and reliable operation of the
MC-9 Model coach. The service procedures recommended and described in
this manual are effective methods for performing service operations.
In so.me
instances, the use of special tools is recommended. These tools iiiould be
used when
and as recommended.
Various WARNINGS, CAUTIONS and NOTIC_ES. are contained In this
manual. Theyshouldbe read carefullytom~nimizetherisk of personal injury or
the possibility that improper service methods may be used whic,h could
damage the coach and render it-unsafe. It is important to note that these
cautions and notices are
not all inclusive. We could not evaluate and·advise
users
of all conceivable ways in which service may be done or'ofthe'possible
hazardous consequences of each way. We have not attempted _to· do )his.
Therefore, anyonewho uses aservice procedure or tool not reconimended'by.
the manufacturershouldfirst satisfy himselfthat neitherhissafety riorvehicle
safety
will be jeopardized by the particular method he selects. REFER TO
PAGE ii FOR CAUTIONARY INFORMATION PERTAINING TO WELDING.

Date 1-1-89
MC-9 MAINTENANC.E.,MANLJP.L-
.~.:·•-.-.\(1',-r:::w!"NQ& ..... " it
.FRONT .AXLE
EF:FECTIVE
W:ITH UNIT 41089
STEERING GEAR
FRONT AXLE
PRIOR
TO UNIT 41089
STEERING ARM
Figure 1-1. Front Axle Assemblies.
FRONT AXLE ASSEMBLY
DESCRIPTION
Effectivewith unit41089 the frontaxleassembly is atubu,lar
type of Reversed Elliotdesign. Axle construction consists
of a
tempered seamlesssteel tube with forged steel king pin ends.
On units
prior to 41089, the front axle is a forged steel drop
centerI-beam type.King pin ends are integral parts of the axle
center. See figure 1-1.
Steeringknuckleshavegreasefittingsinbothkingpin bosses
f~r lubrication of the knuckle bushings.The bushingsareof the
sy Steer" type on all models after September 1986. Prior to
·that. the bushings are bronze. Covers and prugs prevent dust
and moisture from entering bushings and serve as seals.
The brakeshoe
spider isdoweledand bolted to the steering
knuckle. Dowel pins are also used to
locate air suspension
mountings.
The
two steering knuckleassemblies are connectedto each
other by a tie rod. Tie rod is threaded at each end and held in
position by clamp bolts. i":iight-hand and left-hand threads are
provided on the tie rod to facilitate toe-in adjustment. Stop
screwsinstalled
at each end ofaxlecenterlimitturningangleof
front wheels.
On the tubular style axles. to detectdevelopment of fatigue
cracks. approximately two quarts of diesel fuel·are installed in
the
hollow tube section. Any axle which leaks should be
replaced.
,mr ■

Date Page
1-2
MC-9 MAINTENANCE MANUAL
Steering knuckles are bushed in the upper and lower pm
bosses
so thatthey mayturn fr:eel¥.about the pins. Bushings are
grooved on the inside to allow grease to flow uniformly to
high-pressure areas. Grease fittings areinstalled at both upper
and lower king pin bosses.
On the earlierMC-9 front axles the tapered steering knuckle
pins are drawn into the axle center by tightening the nut at the
upper end of the pin. Onthe laterMC•9s a straight type knuckle
pin is used. The straighttype pin i~ held in placeby draw keys in
the knuckle. "
Wheel bearings. air suspension. steering and brake parts
which are mounted on thefrontaxlearedescribe<;l in the appli-
cable sections of this manual.
LUBRICATION
Periodic lubrication according to the recommendations in
the
lubrication section of this manual should be carried out.
Points
which require lubrication are the steering knuckle pins.
tie-rod ends and drag link ends. These are provided with
grease fittings for pressure lubrication.
MAINTENANCE
Periodic mspection of the front axle assembly should be
made
to see that all. bolts are tight and that no damage or
distortion has taken place. Suspension support stud nuts.
U-bolt nuts. tie-rod armand steering arm nuts. and stop screws
should be checked and tightened 1f necessary to the torque
specifications shown at the end of this section.Attention should
also be given ·to the condition of the steering knuckle pin and
bushings. If excessive looseness is found• at this point. the
bushings and pins should be replaced.
The
axle manufacturer recommends that the bronze or
"Easy Steer" king pin bushings be replaced when the range of
side-to-side tire movement reaches .030 inch or when the
bushings are worn to amaximumof .010 inch on their diameter.
NOTE: These measurementsaremade with
thewheel bearingstightened on
the spindle.
With new bushings installed. the range of side-to-side tire
movement should not exceed .010 inch maximum. Refer to
Figure 1-2.
Looseness in the steering linkage under normal steering
toads is
sufficient cause to immediately check all pivot pomts
tor wear. regardless of accumulated m!leage. Steering
linkage
p,vot points should be checked each time the axle assembly ,s
lubricated. If any 1nd1cat1on of lateral movement is found. cross
tube ends should be removed for inspection. Looseness at the
steering
linakge pivot points can be visually detected during
movement of the ven1cle steering wheel.
Steering knuckles. king pins. and
bushings may be replaced
without removing the axle from the coach.
.010 INCH MAX.
SIDE-TO-SIDE
TIRE MOVEMENT
FRONT OF TIRE
NEW
BUSHINGS
.030 INCH MAX.
SIDE-TO-SIDE
TIRE MOVEMENT
(OR BUSHING
DIAMETER
WORN .010")
..,&.-·----
FRONT OF TIRE
WORN
BUSHINGS
Figure 1-2. Side-To-Side Tire Movements With New And
With Worn King Pin Bushings.
If extensive overall work or straightening of the front axle
center ,s necessary. the axle should. of course. be removed.
WARNING: Do not attempt to repair,
remove or reinstall front axle with the vehi-
cle supported by jacks only.
FRONT AXLE REMOVAL (Prior to unH 41089)
To remove the entire front axle assembly first block the rear
wheelsto preventthevehiclefrom rolling.Raisethe frontend of
the coach with jacks until the bottom of the coach body is
approximately
18" (45 7.2 mm) from the floor. Block the body in
this position as indicated in Section 3
under Coach Jacking
Points.
CAUTION: Do not raise the body in such a
way that the entire weight of the front axle
will hang on the suspension bellows
assemblies. Damage to the bellows may
result.

Date 1-1-89 Page
1-3
MC-9 MAINTENANCE MANUAL
1. -Remove tires and wheels from axle. See Section 15.
2. Exhaust air pressure from the suspension air tank by
opening the drain
cock at the bottom of the air filter.
3. Disconnect the heightcontrol valve link, and pull down on
height control valve arm to exhaust air from the front inner
beams.
4. Disconnect the hose from the front brake chambers.
5. Disconnect the steering drag link.
6. Disconnect both ends of all radius rods as outlined in this
section
under Radius Rods.
7. Remove nuts from all bolts attaching air springs to the
bracket assel"[lblies.
8. Remove shock absorbersasoutlined in this section under
Shock Absorbers.
9. Lower the axle assembly on jacks until air spring bead
ring bolts are cleared ofthe suspension supports. The axle can
now be carefully removed from
under the vehicle.
Reinstallation
of the axle assembly isthe reverse of removal.
Make sure that air springs mounting pads on axle towers are
-:lean.
FRONT AXLE REMOVAL (Effective with Unit 41089)
To remove the entire front axle assembly first block the rear
wheelsto preventthe
vehicle from rolling. Raise thefrontend of
the
coach with jacks until the bottom of the coach body is
approximately 18" (457.2 mm) from the floor. Block the body in
this position as ir:idicated in Section 3
under Coach Jacking
Points.
CAUTION: Do not raise the body in such a
way that the entire weight of the front axle
will hang
on the suspension bellowsassem-
blies. Damage
to the air springs may result.
1. Remove tires and wheels as detailed in Section 15.
2. Exhaust air pressure from the suspension air tank by
opening drain tank
at bottom of ,he air filter.
3. Disconnect the height control valve link, and pull down on
the
height control valve arm to exhaust air from the front inner
beams.
4. Disconnect the hose from the front brake chambers.
5. Disconnect the steering drag link.
6. Disconnect both ends of all radius rods as outlined in this
section
under Radius Rods.
7. Remove nuts from all bolts attaching a,r spririgs lower
bead rings to the axle tower.
8. Remove shock absorbers as outline-dinthis section under
Shock Absorbers. iit.- ••
9. Lower the axle assembly on Jacks until air spring bead
ring
bolts are cleared of the suspension supports. The axle can
now be carefully removed from under the vehicle.
Reinstallation
of the axle assembly isthe reverse c,f removal.
Make sure that air springs mounting pads on axi•e towers are
clean.
STRAIGHTENING AXLE CENTER -Before Unit 41089
The earlier MC-9 front axle center is a steel forging, heat
treated for strength and
resistance to bending and torsional
strain. If the
center is bent or twisted less than approximately 5
degrees from the original shape, it may be straightened. How-
ever. itis recommended that this work be done only by mechan-
ics who are thoroughly familiar with such operationsand where
the proper facilities are available. Parts whjch are distorted
more than approximately 5 degrees from the original shape
must be replaced, since such distortion exceeds theelastic limit
of the material causing fractures which may result in failure
under ordinary operating conditions.
CAUTION: Do not attempt to straighten
front axles with tubular style axle centers.
Never apply heat
to a front axle forging.
Front axle should be straightened cold
only.
STEERING KNUCKLE
DESCRIPTION
Later MC-9 coaches have front axles w:!h straight knuckle
pins. The earlier MC-9 models have axles with tapered knuckle

Date 1-1-89 Page
1-4
MC-9 MAINTENANCE MANUAL
pins. Figures 1-3 and 1-4 show the steering knuckle construc-
tion
of the two differentaxles.
1. Draw Key -Upper
2. Knuckle Pin
3. Knuckle Bushing • Upper
4. King Pin Cap -Upper
S. Shims
6. Draw Key • Lower
7. Thrust Bearing
8. King Pin Cap • Lower
9. Knuckle Bushing • Lower
10. Knuckle/Spindle
Figure 1-3. Steering Knuckle (Later MC-9)
1. Knuckle Upper Bushing 7. Expansion Plug Lock Ring
2. Knuckle Pin Sleeve ·
8. Expansion Plug
3. Upper Dust Cap 9. Knuckle Lower Bushing
4. Knuckle Pin Nut 10. Tapered Knuckle Pin
5. Shims
11. Knuckle/Spindle
·
6. Thrust Bearing
Figure 1-4. Steering Knuckle {Earlier MC-9).
STEERING KNUCKLE REMOVAL
1. Block the·rear wheels to prev·ent the vehicle from rolling.
Jackupfront
of coach so thattiresclearfloor. Block up securely
at this position and remove jacks. Refer to Section
3. Coach
Jacking Points.
WARNING: Do not attempt
to disassemble
orperform knuckle repairwith vehicle sup-
ported by jacks only.
2. Remove front wheels. hubs and bearings as directed 1n
Section 15.
3. Remove brakechambers and brake shoe hardwarefrom
steering t\!1uckle. Detach brake shoe spider from knuckle and
remove spider. camshaft and slack adjuster as
an assembly.
4. Remove drag link and tie rod from steering arm. Refer to
Steering. Section 11.
5. Remove nuts from steering arms and drive arms out of
steering knuckles.
NOTE:
It is not necessary to remove steer0
ing arms unless service or inspection is
necessary.
6. Upper and lower knuckle pin covers are present on the
newer style axles with straight type knuckle pins. The original
MC-9 axle, withthetapered knucklepin, hasacoveronthe top of
the pin only. Remove the capscrews from the cover(s) and the
gasket(s) beneath the
cov_er. See figure 1 -5. ·
Figure 1-5. Removing Knuckle Pin Cover.
The tapered type knuckle pin has an expansion plug and
lock ring at its tower end. Remove the lock ring with a pair of
snap ring pliers. Dislodge and remove the expansion plug with
a small drift.