Service Bulletin No.

3044
MODEL TYPE SECTION/GROUP DATE

D Series Coaches Service Information 6-- Cooling Nov. 6, 2010

SUBJECT
LINNIG THREE SPEED CLUTCH SERVICE KIT
CONDITIONS
Parts may be purchased from MCI Service Parts, Louisville, Kentucky

Description:
MCI has released service kits for the Linnig three ( 3 ) speed clutch.
Customers are instructed to replace the bearings every 75,000 miles ( 120,000 km ) and replace the bearings and clutch
disc every 150,000 miles ( 241,000 km ) using the service kits listed below.
Parts
Qty. New P/N Description
1 06-06-1135 Clutch, Linnig, Three ( 3 ) Speed, or
1 06-06-1583 Clutch, Linnig, Three ( 3 ) Speed
Service Kits Available :
1 06-06-1322 Service Kit, Linnig Clutch, Three ( 3 ) Speed, 75,000 miles ( 120,000 km )
1 06-06-1323 Service Kit, Linnig Clutch, Three ( 3 ) Speed, 150,000 miles ( 241,000 km )
1 20-06-0004 Tool Kit, ( required for 06-06-1322 and 1323 Service Kits )

NOTICE
The 75,000 mile ( 120,000 km ) service kit consists of bearings and accessories.

The 150,000 mile ( 241,000 km ) service kit consists of clutch disc, bearings and accessories.

Service Information:
1. New parts will be available for service replacement.

Service Procedure:

Read this entire procedure before beginning work.

Use Safe Shop Practices At All Times.

1. Turn the main battery disconnect switch to the OFF position. Chock both sides of the tires.

To avoid personal injury, allow enough time for hot coach components to cool down prior to working in
direct area.

2. Open the rear engine service compartment doors. Position the ENG RUN and FRONT START switches to
the OFF position.

REFER TO MANUAL
Refer to Section 6A / Radiator & Charge Air Module --- Linnig, in the MCI D Series Maintenance Manual, in
conjunction with this procedure for Removal and Installation procedures.

3. Place clutch assembly on a workbench.

Printed in Canada
 Service Bulletin No. 3044 DATE NOV. 6, 2010 PAGE 2

LINNIG 3--SPEED FAN--CLUTCH SERVICE KITS

Delivery / Supplementary Tools

Clutch 75,000 Mile (120,000 km) Kit Description

06--06--1135 / 06--06--1583 06--06--1322 Bearings + Accessories

Clutch 150,000 Mile (241,000 km) Kit Description

06--06--1135 / 06--06--1583 06--06--1323 Front Assembly + Bearings + Accessories

Figure 1.
Item Description
1 Self--locking slotted nut, M35x1.5
2 Socket head cap screw, M6x12
3 Shim ring, 25x35x0.1
4 Flange screw, M6x16
5 Flange nut, M20x1.5
6 Double ball bearing, 30.5x90x46
7 Front assembly part, 3--speed
8 Double angular ball bearing, 35x72x30.2

Printed in Canada
 Service Bulletin No. 3044 DATE NOV. 6, 2010 PAGE 3

Figure 2.
Supplementary Tools
Item Description
1 Hand lever press DP3
2 Loctite 270
3 Impact wrench
4 Hot--air drier
5 Vice
6 Torque key
7 Extractor tool
8 Circlip pliers J3 for hole Ø72
9 Socket WAF10, WAF24, WAF30 (Not Shown)
10 Socket for allen screw WAF5 (Not Shown)

Printed in Canada
 Service Bulletin No. 3044 DATE NOV. 6, 2010 PAGE 4

Tool Kit

Clutch Tool Kit

06--06--1135 / 06--06--1583 20--06--0004

Figure 3.

Item Description
1 LW044T1 Disassembling device
2 LW053T5 Mounting sleeve
3 4x50.054 Socket head cap screw M6x8
4 2x50.013 Socket head cap screw M6x25
5 LW023 Tool for slotted nut 70.002
6 LW053T3 Sleeve
7 LW058T5 Mounting sleeve
8 LW020T3 Spacer sleeve
9 LW058T1 Stretching block
10 LW053T6 Mounting sleeve
11 LW058T4 Clamping device for flange nut 70.109

Printed in Canada
 Service Bulletin No. 3044 DATE NOV. 6, 2010 PAGE 5

Exploded Assembly

Figure 4.
Item Description
1 Cap nut, M35x1.5
2 Connection flange
3 12 socket head cap screws, M6x12
4 Spacer disc
5 Cooling ring
6 3 Flange screws, M6x16
7 Flange nut, M20x1.5
8 Engaging unit
9 Rotor
10 Magnet with cable
11 Pulley assembly

Printed in Canada
 Service Bulletin No. 3044 DATE NOV. 6, 2010 PAGE 6

Disassembly of Cooling Ring, Flange Nut, Connection Flange, Pulley

1. Remove the three ( 3 ) flange screws M6x16 (WAF10) from cooling ring ( refer to Figure 5 ). Remove cooling ring and
spacer disc.
2. Remove the twelve ( 12 ) socket head cap screws M6x12 (WAF5) from rotor.
3. Place the clutch into stretching block LW058T4 and clamp it in the vice ( refer to Figure 5 ). Using the tool LW023
(WAF24) and a wrench, remove cap nut.

NOTICE
Ensure cable is not damaged.

4. Center up the sleeve LW53T3 to the shaft end ( refer to Figure 5 ). Remove connection flange from clutch by using an
extractor tool.
5. Repeat steps to remove pulley with bearing on.

Figure 5.
Item Description
1 3 flange screws M6
2 Cooling ring
3 Spacer disc
4 LW023 Tool for slotted nut
5 LW058T4 Clamping device
6 Extractor tool
7 LW053T3 Sleeve
8 LW058T4 Clamping device

Printed in Canada
 Service Bulletin No. 3044 DATE NOV. 6, 2010 PAGE 7

Disassembly of Flange Nut, Front Assembly Part

6. Slide the stretching block LW058T1 on the shaft ( refer to Figure 6 ). Clamp it in the vice with LW058T1.
7. Heat the hexagon screw M20x1.5 to 150 degrees C to solve the Loctite. Remove the screw (SW30) by using a
wrench.
8. Place the clutch in the disassembling device LW044T1 ( refer to Figure 6 ). Put the small end of the spacer sleeve
LW020T3 on the shaft. Press out the shaft with coil.

Figure 6.
Item Description
1 Flange nut, M20x1.5
2 LW058T1 Stretching block
3 LW020T3 Spacer sleeve
4 Front assembly part
5 LW044T1 Disassembling device

Printed in Canada
 Service Bulletin No. 3044 DATE NOV. 6, 2010 PAGE 8

Replacement of Bearing 33.007

9. Remove the circlip of the pulley assembly. Place the pulley to the mounting sleeve LW053T5 ( refer to Figure 7 ).
Position the mounting sleeve LW053T6 on the inner ring of the bearing. Press out the bearing.
10. Turn pulley 180 degrees. Put the mounting sleeve LW053T6 on the outer ring of the new bearing 33.007 and press in
the bearing ( refer to Figure 7 ). Insert the circlip.

Figure 7.
Item Description
1 LW053T6 Mounting sleeve
2 Double angular ball bearing
3 33.007 New double angular ball bearing
4 LW053T5 Mounting sleeve

Printed in Canada
 Service Bulletin No. 3044 DATE NOV. 6, 2010 PAGE 9

Assembly of Pulley Assembly, Connection FLange, Slotted Nut

11. Place the mounting sleeve LW058T5 on the shaft ( refer to Figure 8 ). Slide the pulley assembly with new bearing
( threads must face downwards ) on the shaft end of the magnet. Position the mounting sleeve LW053T5 on the inner
ring of the bearing and press the pulley assembly on the shaft.
12. Press the connection flange on the shaft by using the mounting flange LW053T5 ( refer to Figure 8 ).

NOTICE
Do not use an impact wrench to torque fasteners.

13. Bolt on the new cap nut M35x1.5 (70.002) by using the tool for cap nut LW023 (WAF24) and a wrench. Center up the
pulley assembly to the rotor. Bolt on the twelve ( 12 ) new socket head cap screws DIN 912 --- M6x12 (WAF5) and
tighten down with Loctite 270. Torque cap nut M35x1.5 to 175---180 ft-lbs. Torque M6 to 7---8 ft-lbs.

NOTICE
Ensure cable is not damaged.

Figure 8.

Item Description
1 LW053T5 Mounting sleeve
2 Connection flange
3 Pulley assembly with new bearing
4 LW058T5 Mounting sleeve
5 LW023 Tool for slotted nut 70.002 New slotted nut
M35x1.5
6 12x50.008 New socket head cap screws M6x12
7 LW058T1 Stretching block

Printed in Canada
 Service Bulletin No. 3044 DATE NOV. 6, 2010 PAGE 10

Assembly of New Front Part Assembly

14. Measure the distance, shown as X, between the bearing and small armature disc ( refer to Figures 9 and 10 ).
Use the appropriate number of shim rings that are required between bearing and magnet shaft, to ensure that the
air---gap is between 0.4 --- 0.6 mm:
X is less than or equal to 18.4 mm...0 shim ring
X = 18.5 mm...1 shim ring
X = 18.6 mm...2 shim rings
X = 18.7 mm...3 shim rings
X = 18.8 mm...4 shim rings
X greater than or equal to 18.9 mm...5 shim rings
15. Press the new front assembly part on the shaft by using the mounting sleeve LW058T5.

Figure 9.
Item Description
1 NOTE: Press out the bearing in the direction of the arrow
2 LW058T5 Mounting sleeve
3 B0697 New front assembly part
4 NOTE: To remove the bearing (40.029), one must remove 3 hex bolts (65.003) to gain access (EB0148)

Figure 10.
Printed in Canada
 Service Bulletin No. 3044 DATE NOV.6, 2010 PAGE 11

Assembly of Flange Nut, Cooling Ring

NOTICE
Do not use an impact wrench to torque fasteners.

16. Place tool LW023 in the vice ( refer to Figure 11 ). Bolt on the new flange nut M20x1.5 (70.019)(WAF30) and tighten
down with Loctite 270, using a wrench. Torque to 170---180 ft-lbs.
17. Insert the spacer disc into the cooling ring. Center up the cooling ring and spacer disc to the rotor and bolt on with
6 new hexagon screws DIN 6921 --- M6x16 (120.079)(WAF10). Torque to 7---8 ft-lbs.

Figure 11.
Item Description
1 70.019 New flange nut M20x1.5
2 LW023 Tool for slotted nut
3 3x120.079 New flange screws M6x16
4 Cooling ring
5 Spacer disc

18. Re---install the clutch assembly.

19. Position the switches to ENG RUN and FRONT START.
20. Close the rear engine service compartment and rear side service compartment doors.
Procedure complete.

Printed in Canada