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Driver Handbook - Central States Bus Sales, Inc.

1. 10004176 2007 Blue Bird Corporation All rights reserved All Blue Bird products sold for use in the United States of America and its insular areas comply with all applicable Federal Motor Vehicle Safety Standards FMVSS adn applicable Federal ADA requirements Many of the components of Blue Bird buses are obtained from outside suppliers Where maintenance and or service information conflicts with the component manufacturer s documentation the manufacturer s documentation prevails In the event of any conflict between the requirements of this publication an dany applicable legal requirement the legal require ment prevails Technical requirements that exceed the legal requirements are not considered to conflict Blue Bird Corporation continually endeavors to improve its products and reserves the right to change without notice Text illustra tions and specifications in this manual are based on information available at the time of printing CONTENTS INTRODUCTION About This Manual 7 Reporting Safety Defects 9 Noise Emissions Warranty 9 About 2007 Emissions Standards 10 Regarding Modifications 11 Before Placing the Bus in Service 12 ORIENTATION Vehicle Identification 13 ENTRANCE AND EXIT Outward Opening Door 14 Outward Opening Air Door 14 Power Doors 14 Emergency Pneumatic Power Door Release 14 Electric Outward Opening Door 15 Emergency Electric Power Door Release 15 Entrance Door
2. Warning Devices amp Signs Lubricate Stop Arm Electric 4 Point Pivot Lubricate four hinge pivot ponts with Try Flow lubricant Inspect amp Tighten Stop Arm Electric Fasteners Check interior and exterior fasteners for loosening Windows Lubricate Passenger Windows Latches amp Slides Use silicone lubricant Electrical Inspect Battery Electrolyte Level Replenish with distilled water Warning Devices amp Signs Adjust Stop Arm Air Air Pressure Axle amp Suspension Rear Every Month or 6000 Miles Adjust for full deployment and retraction Every Month or 10 000 Miles Inspect Rear Axle Lubricant Level If low refil to bottom of filler opening Use same lubricant type as already installed Brakes Inspect Hydraulic Brakes Fluid Every Month or 300 000 Miles DOT 3 brake fluid Every 3 Months or 3000 Miles Cooling System Inspect Radiator Fins Clean debris from fins Inspect Water Pump Belt Inspect condition and tension of belt 113 114 KAA ALL AMERICAN DRIVERS HANDBOOK Brakes Lubricate Air Brakes S Cam Every 3 Months or 5000 Miles See Meritor Cam Brakes Appendix in Air Brakes Chapter for guidelines Lubricate Hydraulic Brakes Calipers Lube per meritor specs Driveline Lubricate Driveshafts Slip Joint NLGI Grade 1 or 2 multipurpose grease Lubricate Driveshafts U Joint Bolts NLGI Grade 1 or 2 multipurpose g
3. The Check Engine alert appears The above indicates that a Manual Regeneration must be performed as soon as pos sible Because the engine is automatically de rated it may not be possible to drive at sufficient speed to cause active regeneration to occur With Cummins engine depending upon the severity of the accumulation the regeneration switch may not be allowed to initiate a regeneration without use of Cummins s PC based diagnostic software Insite Level 4 Notification Stop Engine Indicator Appears If the bus continues to be operated without taking the measures indicated by a Level 3 Notification particulate accumulation reaches a critical level Engine power is auto matically further de rated by the ECM The indicators differ slightly between Caterpil lar and Cummins equipped buses Cummins The DPF Regeneration alert deactivates e The audible alert sounds continuously The engine is further de rated e The Check Engine alert deactivates The red Stop Engine alert appears Caterpillar The DPF Regeneration alert continues to flash e The audible alert sounds continuously e The engine is further de rated e The Check Engine alert remains on The red Stop Engine alert appears The above indicates that accumulation has progressed to critical levels and the bus should be stopped with the engine off as soon as it is safe to do so The bus should remain shut down until the aftertreatment system has been servi
4. Shock Length eye to eye 18 5 25 Inspect amp Tighten Parasteer Suspension Shock Absorbers Inspect for leakage or damage Torque upper and lower mount bolts to 50 70 ft Ib Inspect amp Tighten Parasteer Suspension Transverse Rod Bolts Torque to 138 159 ft Ib Axle amp Suspension Rear Inspect Comfort Air Suspension Ride Height Shock length eye to eye 24 68 25 Inspect Comfort Air Suspension Ride Height Shock length eye to eye 21 75 25 Inspect amp Tighten Comfort Air Suspension Inspect for leakage or damage Torque upper mount bolts Shock Absorbers to 50 70 ft Ib Torque lower mount bolts to 160 180 ft Ib Inspect amp Tighten Comfort Air Suspension Torque to 150 205 ft Ib Torque Arm Bolts Inspect amp Tighten Comfort Air Suspension Torque 7 8 bolts to 400 450 ft Ib Torque 3 4 bolts to U Bolts 260 320 ft Ib Cooling System Test Entire Cooling System Pressure Test Cooling system Engine Test Engine Starting Aid Block Heater Steering Inspect Hydraulic Pump Body amp Seals Inspect for leaks Inspect Steering Gear Body amp Seals Inspect for leaks Every 12 Months or 24 000 Miles Brakes Clean Air Brakes Pop Off Valves Steering Replace Hydraulic Reservoir Filter Element Replace element and fluid Replace more frequently in severe operating conditions Dextron III Transmission Replace Transmission Fluid Use Dextron
5. Visually inspect for damage or misalignmnent Inspect amp Tighten Parabolic Spring Suspension Hangar Bracket Bolts Tighten to 75 85 ft Ib Inspect Parabolic Spring Suspension Shock Absorbers Visually inspect for leakage or damage Inspect amp Tighten Parasteer Suspension Air Spring Fasteners Torque to 20 30 ft Ib Inspect amp Tighten Parasteer Suspension Front Pivot Bolts Torque to 450 480 ft Ib Inspect amp Tighten Parasteer Suspension Ride Height Shock Length eye to eye 18 5 25 Inspect amp Tighten Parasteer Suspension Shock Absorbers Inspect for leakage or damage Torque upper and lower mount bolts to 50 70 ft Ib Inspect amp Tighten Parasteer Suspension Transverse Rod Bolts Torque to 138 159 ft Ib Axle amp Suspension Rear Inspect Comfort Air Suspension Ride Height Shock length eye to eye 24 68 25 Inspect Comfort Air Suspension Ride Height Shock length eye to eye 21 75 25 Inspect amp Tighten Comfort Air Suspension Inspect for leakage or damage Torque upper mount bolts Shock Absorbers to 50 70 ft Ib Torque lower mount bolts to 160 180 ft Ib Inspect amp Tighten Comfort Air Suspension Torque to 150 205 ft Ib Torque Arm Bolts Inspect amp Tighten Comfort Air Suspension Torque 7 8 bolts to 400 450 ft Ib Torque 3 4 bolts to U Bolts 260 320 ft Ib Cooling System Test Entire Cooling System Pressure Tes
6. under the driver s seat Electrical switches and mechani cal diffusers control the volume and direction of airflow The main heater has a three speed control switch for 75 so A CA ALL AMERICAN DRIVERS HANDBOOK manual low or high speed operation and an additional maximum output position for flash defrosting or extreme conditions All the air from the main heater blower is directed to defrosting when the main outlet and foot warmer outlet are closed The Heater Master Switch turns off all heaters and radio to allow the driver to hear sounds outside the bus for example at a railroad crossing When the switch is in the on position neither the heater blowers nor the radio will operate Defrosting Windshield fogging and frosting is caused by warm humid air coming into contact with a colder windshield which causes the moisture in the air to condense and freeze if the windshield is cold enough The warmer the windshield the less mois ture will condense During initial warmup the defroster blowers should be operated at low speed to preheat the inside of the windshield glass If the defrosters are not turned on until after condensation starts it is more difficult to heat the glass and drive moisture away As passengers are loaded the moisture content of the air inside the bus increas es This moisture content tends to be lowered by opening the heater fresh air inlet Conditions will be especially difficult when large pa
7. Clean Air Brakes Spring Brake Valve See Bendix Appendixes in Air Brakes Chapter 134 Maintenance Locations Spring Pins Rear Axle Lubricant Axle Vent King Pin Tie Rod Drag Rod Steering Gear ONO Sf w NS Not Applicable Brake Camshaft Brake Slack Adjusters Automatic Transmission ee a Universal Joints w Driveline s Intake Air Restriction Indicator 0 O 5 42 4 9 4 4 p F wE fi Ir i 135 soe ACA ALL AMERICAN DRIVERS HANDBOOK General Data Dimensions HEADROOM 74 TO 77 INCHES EXTERIOR HEIGHT APPROXIMATELY 118 TO 121 INCHES EXTERIOR HEIGHT W AC ADD 16 INCHES EXTERIOR WIDTH 96 INCHES INTERIOR WIDTH 90 75 INCHES Fluid Capacities In Quarts Crankcase Oil Engine Coolant Auto Trans Fluid w Filter w o Filter Caterpillar C7 22 0 20 0 41 0 20 0 Cummins ISC 24 0 20 0 38 0 19 0 John Deere 6 826 0 24 0 30 0 20 0 John Deere 8 132 0 30 0 42 0 20 0
8. If so equipped does the wheelchair chime sound 42 ROUTINE OPERATION e gt Starting the engine e Be sure parking brakes are on Put the transmission in Neutral With the key in the ON position check the fuel gauge Check the brake warn ing buzzer or light and the neutral safety switch Start the engine Look and listen for trouble signs check the gauges e Does the wheelchair lift interlock function properly if so equipped With the engine running check from driver s seat Mirrors interior and stepwell lights service door seal Does the steering feel OK Is there any unusual noise e Check the horn defroster and heater blower and windshield wiper opera tion e Does the brake pedal have the right height and feel Is the gauge reading OK If so equipped does the wheelchair interlock function properly Outside checks required before driving away e Check turn signals in front and rear Are they clean and flashing Are flasher warning lights in front and rear clean and flashing Is stop arm clean and working e Check high and low beam headlights Are brake lights and taillights clean and working Is hazard flasher working Final check while moving the bus Is seat belt fastened e Do brakes stop and hold Does steering feel OK Are there any unusual noises Is bus under control and tracking straight Brake to a stop Are all gauges OK Remember Safety on the road depends on you Ob
9. Replinish to full mark Dextron III Tires amp Wheels Inspect All Tires amp Wheels Check air pressure Visually inspect tires tread wear lug nuts including spare Transmission Inspect Transmission Fluid Level Check production order for proper type of fluid to be added 109 ALL AMERICAN DRIVERS HANDBOOK 110 KAA Every Week Seats Inspect amp Tighten Passenger Seats Cusion Screws Inspect for loose cushions clips Inspect Passenger Seats Seat Belts Lubricate buckles clean webbing as required Replace any damaged webbing straps Inspect Passenger Seats Upholstery Inspect for cuts tears wear and soiled areas Brakes Inspect Hydraulic Brakes Pads Replace if worn to within 1 8 lining remaining Every Month or 3000 Miles Doors Clean amp Lubricate All Doors Rubber Seals Lubricate with Silicon Spray or protectant Lubricate All Doors Vandal Locks Spray Apply lubricant into key locks Use LPS 1 for sliding bolt locks Adjust Jack Knife Door Air Pressure See Body Construction Doors Jack Knife Door Adjust Jack Knife Door Control Rod Adjust for proper open closed position Adjust Jack Knife Door Control Rod Bracket Adjust to prevent pivot pin binding Lubricate Jack Knife Door Hinge Pins LPS 1 Adjust Jack Knife Door Roller Bracket Adjust for proper open closed position Adjust Jack Knife Door Switch See
10. weaken the assembly Seat Inspection And Maintenance Blue Bird seats are built to meet Federal Motor Vehicle Safety Standards In order to provide a greater margin of safety during passenger transportation follow these guidelines Inspect and if necessary tighten seat leg and wall side mounting bolts every 90 days Inspect and if necessary tighten cushion attachments weekly Inspect upholstery for cuts and tears every 90 days If upholstery is torn re move it by taking out the staples at the bottom front of seat back or bottom of cushion and pulling the cover away For installation of new cover reverse this procedure e School bus seats are equipped with a special foam back pad If the pad be comes damaged it should be replaced with an approved part Aftermarket suppliers should be checked for compliance with Federal standards DRIVER S SEAT LUBRICATION Moving parts of the driver s seat require lubrication for ease of operation as well as longevity of the seat and prevention of excessive wear Currently available is white lithium based grease in an aerosol can It gives excel lent coverage when carefully directed into moving part joints The very light coating of lubrication provided by aerosol carried solvent type solution works very well for penetrating into a joint and cleaning away dirt but it should only be depended on for lubrication if it is applied frequently A common 10W30 or 10W40 motor oil will provide good
11. 1 when pulling through mud or snow or driving up steep grades This position provides maximum engine braking power Use R reverse for backing the bus The bus should be completely stopped before shifting from a forward gear to reverse Reverse gear provides the greatest traction Allison 2000 Bus Series Transmission Gear Selection CEN When leaving the vehicle while the engine is running the opera tor must be sure the transmission is in Neutral the parking brake is engaged and the wheels are chocked The vehicle may move unexpectedly without these precautions R Reverse Use reverse to back up the vehicle The vehicle must stop completely with the engine returning to idle speed before shifting from forward to reverse or from reverse to forward If your bus is equipped with a reverse warning signal it will activate when shift selector is in reverse Co NOLEN Do not idle in R reverse for more than five minutes Extended idle time in R reverse may cause transmission overheating and damage Always select N neutral whenever time at idle exceeds five minutes N Neutral Use neutral to start the engine to check vehicle accessories and for extended periods of engine idle operation If the vehicle starts in any other range seek service immediately CEN Do not allow your vehicle to coast in neutral This practice can result in transmission damage Engine retard and braking assistance is not available w
12. 1ft from outside body 7 7 77 6 ft from outside body 12 ft from outside body and tighten if necessary 23 so IAPA ALL AMERICAN DRIVERS HANDBOOK Standard Driver s Seat To adjust seat position forward or backward hold lever A to the left To adjust the height 1 Aw FWD Loosen handle in front B Lift height adjust handle on side Slowly sit or stand to position seat at desired height Release height adjust handle prior to applying full weight Tighten handle in front Fasten and adjust seat belt To adjust the back angle lean forward slightly to remove pressure from seat back Hold the handle C rearward to adjust to D 1 24 any position within the seat s range eluxe Driver s Seat Weight and Height Adjustment to adjust push in valve knob to raise seat and pull out to lower When adjusted properly the seat will not rest against the top or bottom limits of vertical motion under normal driving conditions Adjustment position should also provide for driving visibility and vehicle control Fore and Aft Adjustment Hold lever to the left to ad just seat position forward or backward Back Angle Adjustment Lean forward slightly to re move pressure from seat back Hold handle rearward to adjust to any position within range Cushion Tilt Adjustment Rotate seat tilt knob to de crease or to increase seat tilt Lumbar Adjustment Rotate knob for
13. 31 so ACA ALL AM ERICAN DRIVERS HANDBOOK EMERGENCY EQUIPMENT Each state or province has unique laws regarding emergency equipment Your unit may have some or all of the items listed below Because of variations in option pack ages the placement of this equipment inside the bus may vary from one unit to another but it is important for you to recognize and know the locations of all the emergency equipment on your bus It is important that you to read and understand all literature labels and other written materials supplied by the equipment manu facturers Be sure you familiarize yourself with all aspects of the emergency equip ment before attempting to drive the bus Fire Extinguisher The fire extinguisher is normally located to the left of the driver s seat or on the right hand side of the hood ledge near the step aia f FIRST AID well when space is available Your unit may be equipped with a 2 75 4 5 5 or 6 pound RILI MRD extinguisher depending on the laws of your state or province Inspect the pressure gauge every 30 days or as required by indi vidual state fire laws to be certain the unit is fully charged Inspect mounting fasten ers periodically to be sure they are secure First Aid Kit The first aid kit is mounted in the front of the bus body just above the right windshield Size and contents of first aid kits vary due to state specifications The co
14. Heaters amp Defrosters Inspect Front Heater Hoses amp Clamps Inspect for evidence of leaks or deterioration replace with proper parts Axle amp Suspension Front Inspect amp Tighten Parasteer Suspension Torque to 260 320 ft Ib Axle To Suspension Fasteners First 5000 Miles Then Every 12 Months or 24 000 Miles Transmission Replace Transmission Sump Filter First 5000 Miles Then Every 24 Months or 24 000 Miles Transmission Replace Transmission Main Fluid Filter First 11 000 Miles Then Every 3 Months or 5000 Miles or 250 Engine Hours Engine Inspect All Belts Inspect condition and tension of belt First 11 000 Miles Then Every 6 Months or 250 Engine Hours Brakes Replace Air Brakes Air Compressor Filter First 11 000 Miles Then Every 6 Months or 6000 Miles Cooling System Inspect Charge Air Cooler Inspect for clogging debris As Specified by Engine Manufacturer Cooling System Replace Coolant See your Engine Ooperator s Manual Use only premixed coolant s approved by the engine manufacturer Never mix different types or brands of coolant Engine Replace Oil amp Filter See Engine operators manual for oil and filter specifications and maintenance interval Adjust Valves See Engine manufacturer s Service Manual for interval 122 As Specified by Transmission Manufacturer Transmission Adjust Transmission Shift Cable See Transmission Chapter Every Da
15. If the engine fails to start after a reasonable time determine the cause of the failure Pumping the accelerator will not assist in starting the engine Refer to the engine manufacturer s recommended procedures ATOI Do not race the engine during the Warmup period Starting With Boost Cables CEN Batteries can emit corrosive and potentially explosive fumes Prevent sparks near the batteries Do not allow battery cable ends to contact each other or the engine Do not smoke when observing the battery electro lyte levels Electrolytes are corrosive and can cause personal injury if they con tact skin or eyes Always wear protective glasses when working with batteries The Blue Bird All American bus has a 12 volt starting system Use only 12 volts for boost starting The use of a higher voltage will damage the electrical system Always connect the boost cables in parallel with the bus battery cables negative to negative and positive to positive Do not reverse the battery cables The alternator can be damaged Attach the ground cable last and remove it first 1 Fasten the positive clamp of the boost cable to the positive post of the battery 2 Fasten the negative clamp of the boost cable to the negative post of the battery Start the engine 4 After the engine starts disconnect the negative boost cable from the bat tery 5 Disconnect the positive boost cable from the battery 45 soe
16. If this light is activated during normal vehicle operation the driver may complete the trip but the vehicle must be serviced as quickly as possible Hydraulic Brakes CEN Do not tap into the brake system or the power steering system to provide pressure for accessories Tampering with either of these systems could result in loss of braking ability and or steering ability CoAT Hydraulic brake systems are power assisted Braking capacity is reduced without engine assist Do not move bus with dead engine The electric power backup pump will operate whenever the engine is not operat ing and the key switch is in the ON position or when the key is in the OFF position and the brake pedal is depressed Test daily by feeling for the electric motor opera tion while applying the brakes with the engine not operating or when the key switch is in the ON positions and the engine is not operating Initially the pedal will be hard to push but will become softer as the electric motor starts CZA Do not drive the bus when the electric backup pump does not operate properly Dual Brake System The dual brake system allows the driver diminished brake capacity in case either the front or the rear brake circuit fails of NU eB When one section of the dual system fails the following condi tions will exist 1 Bus stopping distance will increase Drive the bus only with extreme cau tion Service immediately 2 The brake pedal will be s
17. s manual prior to loading passengers on the lift All lifts have maximum weight limits that should never be exceeded These lifts are operated by an independent electro hydraulic power system and are controlled by the operator from outside the bus There is a master switch located in the driver s area that must be activated as well The bus electrical system powers a hydraulic pump internal to the lift which moves the lift up The down function is gravity type and is controlled by pressure release valves Manual operation of the down function requires that the operator manually control the pressure release valves To provide for the manual up function the lift is fitted with a hand operated hydraulic jack located on the right hand from inside the bus side of the lift assembly A buzzer sounds when the door is unlatched or partially opened The buzzer stops if the door is completely open 17 A CA ALL AMERICAN DRIVERS HANDBOOK 18 Se DRIVER S AREA Driver s Compartment 1 Auxiliary fans 2 Radio 3 Interior mirror 4 Emergency equipment compart ment 5 Switch panel 6 PAsystem 7 Horn button sounds electric horn 8 Instrument panel 9 Automatic transmission shift control range selector or electronic push button pad location 10 Warning light door and stop arm controls 11 Hazard light flasher switch 12 Tilt telescopic steering lever 13 Parking brake 14 Igniti
18. A CA ALL AMERICAN DRIVERS HANDBOOK Using The Engine As A Brake While going down a steep or long grade it is a good practice to use the engine to retard vehicle speed Reduce speed before the grade and shift into a lower gear with either automatic or manual transmissions being careful to select a gear which will slow the vehicle without over speeding the engine Under such conditions use the brakes sparingly to prevent overheating Overheating will cause the brakes to fade that is be less effective CEN Do not take transmission out of gear when the bus is moving You may not be able to get the transmission back in gear and the drastic slow ing of engine speed could reduce air pressure supply to the air brake system and result in a reduction of brake capacity Engine Warning System Your All American bus may have an optional alarm system to signal low oil pressure and high engine temperature If the engine temperature exceeds the manufacturer s recommendations or if the oil pressure drops below the manufacturer s recommen dations a buzzer sounds and an indicator light glows Co NU LOND If the alarm system sounds shut the engine off immediately Operation of the engine after the alarm sounds could cause serious engine damage 46 ROUTINE OPERATION e gt Exhaust System New federally mandated emission standards affect all buses equipped with 2007 or newer diesel engines The exhaust systems of both Caterpillar and C
19. Body Construction Doors Jack Knife Door Adjust Outward Opening Door Control Rod Adjust Outward Opening Door Control Rod Bracket Adjust for full and secure closure without binding Adjust amp Lubricate Outward Opening Door Linkage Adjust linkage for firm closure and to ensure rear panel closes first Lubricate Outward Opening Door Pivots Lubricate pivot pins with LPS 1 Adjust Outward Opening Door Roller Adjust for full and secure closure without binding Bracket Lubricate Power Jack Knife Door Air LPS 1 Pressure amp Switch Lubricate Power Jack Knife Door Hinge LPS 1 Lubricate Wheelchair Lift Lube Points See model specific literature provided with lift 111 112 L A ALL AMERICAN DRIVERS HANDBOOK Emergency Exits Lubricate All Emergency Exits Hinges LPS 1 Lubricate Rear Emergency Door Hinges Lubricate at hinge grease fittings Lubricate Rear Emergency Door Hold Open Apply ASTM D4950 GC LB Grade 2 Lubricate Roof Hatch Hatch Seal and Latch Silicone lubricant to prevent sticking of rubber seal Spray silicon lubricant into latch mechanism Floor Inspect Floor Drains Check drawin hole in each body section under window for debris obstruction Seats Lubricate Driver s Seat Lubricate per manufactuers recommendation Inspect amp Tighten Passenger Seats Mountings Use standard torque for bolt size tread type and grade
20. CA ALL AMERICAN DRIVERS HANDBOOK the rear of the bus This will effectively move the door panel away from the doorstop rubber 4 4 Clean the stepwell rubber treads and lower the door rubber sweeps regularly Cleaning these surfaces will reduce friction as the door is operated 5 Ensure that the door control rod end bracket is mounted squarely on the door If it is not the yoke end pivot pin will bind Adjust it by loosening screws and tightening after the bracket has been squared up 6 Inspect the pivot nut on the rod end bracket for burrs or other surface ir regularities Grind or file the pivot nut so that its upper and lower surface is smooth 7 Lubricate the door hinge pin with a spray type lubricant LPS No 1 or equiva lent Lubricant should penetrate behind each hinge lug Door hinges will operate quietly if properly lubricated Power Jackknife Door Adjustment The following adjustments and lubrications should be performed on the power jack knife door to ensure its proper operation 1 Lubricate the center hinge with LPS No 1 or equivalent lubricant 2 Adjust the actuator yoke so when the cylinder rod is fully extended the door is not forced beyond its normal stopping point at the front stepwell band Adjust the actuator mounting bracket when required Improper adjustment of the cylinder yoke can cause premature failure of door components 3 Adjust the switch striker plate on the actuator to prevent binding in the
21. However if engine governed speed is ex ceeded the transmission may upshift to the next higher range Use the vehicle brakes to prevent exceeding engine governed speed in the held range 68 ROUTINE OPERATION e gt CEN f you only downshift or only use the service brakes when driv ing down a steep grade you can lose control To maintain control combine downshifting braking and other retarding devices Downshifting to a lower transmission range increases engine braking and helps maintain control The transmission has a feature to prevent automatic up shifting above the lower range selected However during downhill operation if the engine governed speed is exceeded in the lower range the transmission may upshift to the next higher range This will reduce braking and could cause a loss of control Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected Electric Retarder If Equipped The electric retarder control switch is mounted on the vertical panel left of the driver It has five positions one off and four retard positions Each high er number increases the amount of retardation to slow the vehicle Remember the retarder is a vehicle slowing device not a stopping device A full stop must be accomplished with the service brakes Always release the accelerator completely before applying the retarder Do not use the retarder when road surfaces are s
22. III fluid Inspect Transmission Shift Cable Inspect Transmission Vent Clear vent hose of debris or obstruction Every 12 Months or 50 000 Miles Axle amp Suspension Rear Replace Rear Axle Petroleum Based Hypoid Gear Oil Viscosity depends upon operating climate Lubricant See Viscosity Temperature chart Every 12 Months or 100 000 Miles Axle amp Suspension Rear Replace Rear Axle Synthetic Lubricant Viscosity depends upon operating climate See Viscosity Temperature chart 119 VA ALL AMERICAN DRIVERS HANDBOOK Every 18 Months or 20 000 Miles Cooling System Lubricate Shutters Pivots Use Never Seize spray lubricant Every 24 Months or 24 000 Miles Brakes Clean Air Brakes Parking Brake Valve See Bendix Appendixes in Air Brakes Chapter Clean Air Brakes Quick Release Valves See Bendix Appendixes in Air Brakes Chapter Clean Air Brakes Relay Valves See Bendix Appendixes in Air Brakes Chapter Clean Air Brakes Spring Brake Valve See Bendix Appendixes in Air Brakes Chapter 120 Maintenance Task Schedule A3RE Ensure that the Safety information warnings and instructions are read and under stood before operation or maintenance procedures are performed Use whichever interval listed time mileage engine hours occurs first Engines operated in severe operating conditions may require more frequent maintenance See engine manufac turer s specifications for more information
23. The elliptical cross view mirrors are designed to allow a seated driver to view all areas around the front of the bus not directly visible The elliptical cross view mirrors are designed to be used to view pe destrians while the bus is stopped CAN Do not use the elliptical cross view mirrors to observe traffic while the bus is moving A convex mirror is designed to provide a wide view with mini mum distortion However persons or objects seen in a convex mirror will ap pear farther away than when seen in a flat mirror or viewed directly Use care judging the size or distance of objects seen in a convex mirror Proper adjustment is necessary for any mirror system to perform as designed The following adjustment sequence should be used to allow the driver maximum viewing area with the mirror system 1 Adjust the driver s seat to the desired position 2 Adjust the right side flat driving mirror so that the tops of the side windows are visible in the upper edge of the mirror and the right side of the bus body is visible in the inside edge of the mirror 3 Adjust the right side convex driving mirror so that the view in the top of the mirror overlaps the view provided by the right side flat driving mirror and the right side of the bus body is visible in the inside edge of the right side convex mirror 4 Adjust the left side flat driving mir ror and the left side convex driving mirrors using the same procedures de sc
24. an operating range and the Check Transmission light will be illuminated When the transmission fluid temperature is between 24 F and 20 F 31 C to 7 C the transmission will operate in 1st 2nd or Reverse only If there is no other problem with the transmission the Check Trans mission light will not be illuminated For transmission fluid temperatures above 20 F 7 C the transmission will shift and operate in a normal manner Be sure to read and understand the cold weather operation instructions in the Allison Transmission Operator s Manual supplied with the bus Using the Engine to Slow the Vehicle To use the engine as a braking force shift the range selector to the next lower range If the vehicle is exceeding the maximum speed for a lower gear use the ser vice brakes to slow the vehicle to an acceptable speed where the transmission may be downshifted safely After reaching the lower speed the ECU will automatically downshift the transmission Engine braking provides good speed control for going down grades When the vehicle is heavily loaded or the grade is steep it may be de sirable to select a lower range before reaching the grade If engine governed speed is exceeded the transmission will upshift automatically to the next range The transmission incorporates a hold feature to prohibit upshift ing above the range selected during normal driving For downhill operation select a lower transmission range
25. available number 1 and number 2 highway diesel fuels are Ultra low sulfer diesel This fuel must be used in all 2008 model buses pow ered by a 2007 emission standards diesel engine as indicated by a decal located near the fuel filler door reading The engine in this vehicle must be operated only with low ash engine oil and ultra low sulfur diesel fuel meeting EPA specifications for highway diesel fuel including a 15 ppm sulfur cap For detailed information on recommended fuels and other fluids always follow your engine manufacturer s guidlines 10 INTRODUCTION e gt Regarding Modifications Blue Bird Corporation offers many items as standard and optional equipment to meet federal state and local specifications and individual customer requirements Those interested in modification of thisvehicle should consult the Service Man ual and Blue Bird Engineering Department for a more complete understanding of the vehicle Vehicle modifications which may cause non conformance with the emission control and or Federal Motor Vehicle Safety Standards FMVSS are expressly not authorized by Blue Bird Corporation It is the responsibility of the entity undertaking the modification to ascertain compliance of the modified vehicle with any and all applicable regulations The en tity performing modification of this product must certify that all applicable regula tions are met In order to certify a modified vehicle the upfitter or other entity
26. equipment components including flooring and or carpet ing which will obstruct the functioning of the brake and accelerator pedals For the terms of the Limited Warranty of this Blue Bird product refer to the War ranty certificate provided in the owner s documents that came with the vehicle In addition to the safety issues involved in the modification of the unit any un authorized modification may adversely affect the warranty of this product by Blue Bird Body Company All Blue Bird products are certified to meet or exceed all ap plicable motor vehicle regulations and standards in the as purchased con figuration Any modifications are the responsibility of the entity making those modifications Blue Bird engineering does not authorize any modification that affects the basic design The complete line of Blue Bird Service Parts is available from your Blue Bird dis tributor The use of original Blue Bird replacement parts and components will help ensure that your All American remains true to its original design best preserving performance efficiency and safety INTRODUCTION e gt This manual provides you with the most current operation information available We welcome your comments and suggestions regarding this manual Please direct all correspondence to Blue Bird Body Company Attn TECHNICAL PUBLICATIONS P O Box 937 Fort Valley GA 31030 Reporting Safety Defects If you believe that your vehicle has a defect
27. filled with Fleetguard ES Optimax 60 40 premix which is red in color Blue Bird installs decals on or near the deairation tank filler which state the type of coolant installed at the factory The decal states the approved premixed coolant and coolant manufacturer s part number for one gallon quantities The decal also lists the manufacturer s part number for the concentrate which is approved for mix ing with the premix for stronger glycol concentration When replenishing or replacing coolant only use coolant of the same type already installed Never mix coolants of different color type or brand Plain water is corrosive at engine operating temperatures Never add plain water to the system When using concentrated coolant to raise the glycol concentration for extreme temperature environments Blue Bird recommends only mixing the concentrate with pre mixed coolant of the same type not mixing with water Coolant Testing and Replacement Each engine manufacturer has its own specific requirements for coolant testing and maintenance Therefore refer to the engine Operator s Manual for your bus and fol low the engine manufacturer s maintenance specifications Blue Bird recommends that Caterpillar cooling systems with red extended life Shell Rotella ELC coolant should be tested according to the Caterpillar Operation and Maintenance Manual Blue Bird recommends that Cummins cooling systems with red extended life Fleetguard ES Optimax coolant shou
28. is located on the right area of the dash The transmis sion and selector must be in neutral to start the engine The service brake must be applied before the transmission will shift from neu SELECT MONITOR tral to drive or reverse If an attempt is made to shift the transmission into drive or reverse without applying the service brake it will remain in neutral an audible alarm will sound and the Range Inhibit light on the instrument panel will come on If this occurs apply the service bake and then select the desired gear Transmission and shift selector will return to N when engine is stopped and power switched off If it does not return to N or if it starts in any other gear the unit has malfunctioned Seek service immediately The push button shift selector has R N D down arrow up arrow a MODE button and a digital display When a range button is pressed a tone sounds the SELECT indicator displays the chosen operation if the Electronic Control Unit ECU determines the shift is acceptable and the transmission shifts to the starting range as indicated on the monitor display In DRIVE selection of a specific gear can be accomplished by pressing the UP or DOWN arrow buttons Conditions resulting in the CHECK TRANSMISSION light located in the instrument cluster will disable the pad and no tones will sound see Check Transmission Light The MODE button located on th
29. link between the doors causes the rear door to close well ahead of the front door so that the front nosing seal rubber always overlaps the rear Oil impregnated bronze bearings in the lower corners of the framework serve as pivots not supports All controls and mechanisms and the complete lower step tread are sealed inside the bus and out of the weather when the door is closed The manual control is the Blue Bird over center locking type with built in Saf Latch The door s ease of operation allows use of a short handle arm so the handle is six inches closer to the driver in the open position than with the jack knife door Your bus s outward opening door may be actuated by an optional electric control connected to a lever on the front door panel Mechanically operated switches control automatic stop positions as well as stepwell and warning lights Outward Opening Air Door The pneumatic actuator is a cylinder connected to a lever on each door located in side the header cover An interconnecting link between the doors controls the opera tion sequence A safety release valve is located over the door Air switches inside the header cover operate Stepwell lights A three position spring loaded switch signals a valve controling the flow of air to open or close the doors Air pressure holds the door either open or closed The operation speed is adjustable by use of flow control valves located on the actuator Power Doors Power doors have an a
30. may require removal and treatment using specialized equipment Therefore to minimize disruption of your bus operation the regeneration related alerts should be heeded and responded to at their early stages as a matter of routine Aftertreatment Terms The following summarizes some of the terms associated with the exhaust systems of Blue Bird buses equipped with 2007 emission standards compliant engines Both the driver and technician should become familiar with the following terms Aftertreatment The process of highly filtering engine exhaust in order to reduce emissions and of purging the exhaust system of accumulated exhaust residue DPF Diesel Particulate Filter A component in the exhaust system which takes the place of a traditional muffler A DPF contains a special dissimilar metals filter which traps particulate accumulation soot which is then converted to carbon dioxide by the aftertreatment process The Cummins DPF also contains a catalytic converter Regeneration The process of cleaning accumulated soot from the filtering compo nents inside the DPF Regeneration occurs at high exhaust system temperatures to turn the soot into carbon dioxide gas Regeneration can be thought of as conceptu ally similar to the clean cycle of a self cleaning oven ARD Aftertreatment Regeneration Device A component of the Caterpillar Regen eration System located on the right side of the engine at the outlet of the turbo charger The ARD
31. means that natural gas is lighter than air In the event of a natural gas leak the gas will rise and dissipate given open conditions There is no possibility of CNG accumulating in pools on the ground beneath a spill Odorants have been added that allow natural gas to be detected before reaching dangerous concentrations In the case of LNG releases the cold vapor is initially heavier than the surrounding warmer air so it stays low near the ground a visible vapor cloud is often formed from the condensation of water in the cold air gas mixture As the vapor cloud warms it will increase in volume rapidly rise and dissipate in an open environment Fuel Toxicity And Safety Natural gas is a nontoxic gas However it is flammable under proper conditions Also it can cause suffocation if it displaces enough oxygen LNG has the added safety con cern of being a cold 260 F liquid under pressure Contact with LNG or associated cold components may cause severe frostbite Furthermore many common materials change their strength characteristics when exposed to LNG temperatures thus pre senting additional hazards CAN LNG tanks have the potential for explosions under circumstanc es such as those described for LPG explosions Although natural gas has odorants to aid in detection of leaks these odorants are removed during liquefaction thus LNG vapors cannot be detected by smell LNG odorants have been developed but are not commonly used due to
32. of it to provide compart mentalization required by Federal Motor Vehicle Safety Standards As you reconfig ure your bus you may need additional barriers which are available from Blue Bird Body Company Part Sales 92 FEDERAL STANDARD REQUIREMENTS FOR TRACK SEAT PLACEMENT ALL PASSENGER SEATS MUST HAVE A SEAT OR BARRIER THE SAME WIDTH AS THE SEAT IN FRONT OF IT ee 27 00 MIN 11 00 MIN 31 00max gt gt 15 00 MAX REAR SEAT PLACEMENT DRIVER S SIDE REAR SEAT ON ENTRANCE DOOR SIDE MAY TOUCH BODY SEAT SPACING MEASURED EMERGENCY EXIT AT AISLE SIDE EMERGENCY DOOR CLEAR AISLE RELEASE CLEARANCE 93 A CA ALL AMERICAN DRIVERS HANDBOOK 94 so SIGNS amp SIGNALS Stop Arms Stop arms are required on Blue Bird All American school buses by and in accordance with Federal Motor Vehicle Safety Standard 131 Stop arm assemblies are purchased as a kit to meet state requirements The stop arm is located on the left hand side of the body under the driver s window A manual switch on the switch panel most com monly operates stop arms For pneumatically operated stop arms the manual switch acti REGULATOR vates an electric solenoid valve controlling the flow of air Option ally the solenoid valve may be activated by the warning lamp sys tem This system is operated by the air system on the chassis No special preventive maintenance procedures are required with these systems however the air p
33. personnel responsible for maintenance of the bus CEN Exercise extreme care when removing the cap from the engine coolant reservoir Always allow time for the engine to cool before removing the cap The pressurized coolant may be very hot and can spray out causing serious burn injuries Coolant Types Engine coolant is generically divided between two types standard and long life or extended life Extended life coolants generally allow longer intervals between coolant changes sometimes requiring additives to be added near the midpoint of their service life and or for special testing to be performed at certain intervals En gine manufacturers however differ somewhat in regards to specificaitions for cool ants which they recognize as long life when used in their respective engines Blue Bird buses built as of August 2006 come from the Blue Bird factory with one of three types of coolant The standard coolant is John Deere Cool Gard 50 50 pre mix which is green in color This coolant is considered extended life when installed in John Deere engines It is to be considered standard life coolant when installed in Caterpillar or Cummins engines 97 So A CA ALL AMERICAN DRIVERS HANDBOOK Caterpillar equipped buses purchased with a long life coolant option have been filled with Shell Rotella ELC 60 40 premix which is red in color Cummins equipped buses purchased with a long life coolant option have been
34. relieving pressure which is trapped between the check valve in the fill noz zle and the main system check valve The owner operator should establish a service interval based on quality of gas from the compressor station It is recommended that the filter sump be checked after the initial fill and every fifth fill thereafter or on a schedule based on need The secondary filter has a black anodized housing and is adjacent to the fuel shut off solenoid close to the engine The secondary filter can be checked after relieving system pressure This is best accomplished by closing the main shutoff on the frame and running the engine until the fuel supply is depleted and pressure is zero Con tamination of the secondary filter should not occur if a proper maintenance schedule has been followed at the fill point primary filter Contamination of the secondary filter indicates that the CNG storage cylinders on the vehicle are contaminated The owner operator should insist that fuel from a compressor station be clean and dry 58 ROUTINE OPERATION e gt Replacement filter elements are available through the Blue Bird Service Depart ment CAN Compressed natural gas is highly flammable and pressurized gas can cause serious personal injury or death Refueling CEN Refueling must be conducted in well ventilated areas to prevent accumulation of dangerous gas levels The National Fire Protection Association has recommended guidelines for CNG refueli
35. reserve failure the low air pressure warning buzzer will activate indicating trouble and the respective air gauge on the dash will show which system has lost air pressure The bus must not be operated under those conditions but repaired before continuing operation The rear spring brakes can also be controlled by a dash mounted valve located on the lower portion of the instrument panel The spring brakes cannot be fully re leased until the air reserve pressure is above 60 psi These brakes are in the released position when the control valve is pushed in and in the applied position when the control valve is out In the event there is a loss in air pressure the valve will automati cally move to the brake applied position and cannot be released until the air reserve pressure has been replenished Air Brake Throttle Interlock System Optional All Americans equipped with air brakes may include an optional Brake Throttle Inter lock feature which when active automatially applies the service brake and disables the throttle when the vehicle ignition is on and the lift door is open An Interlock Override switch in the Driver s left switch panel enables the Driver to temporarily override the interlock system When used with the existing vehicle parking brake the brake interlock uses the vehicle s service brake system to provide additional brake holding action CEN The brake interlock is a safety device and is not intended to be used a park
36. the hub slightly to position the wheel on the studs lugs Hand tighten all lug nuts Using the lug wrench tighten all the lugs about a quarter turn Remove the blocks or jack stand Lower the bus enough to lock the wheel in place Tighten the lug nuts to 50 ft Ibs 68 Nm in the sequence shown Check the wheel for proper positioning on pilots and proper seating against the flange Tighten the nuts to 450 500 ft Ibs 610 678 Nm in the sequence shown Lower the jack and remove it from under the axle Stow the damaged wheel and tire assembly and the tools ENROUTE EMERGENCIES e gt Schrader Valve The bus is equipped with a Schrader valve which is located at the end of the wet tank It allows the air brake reservoir to be charged with a com m P Schrader Valve mon type air hose normally used by service stations and garages Charg ing the system in this manner is only a means of providing air pressure for the air brake system with an inoperable air compressor or without Tank cranking the engine and should only be used for moving the bus while servicing or in case of emergency Releasing Spring Brake Manually When air pressure fails in the rear service brake chamber the power spring applies the rear service brakes Unless pressure can be re established the service brakes must be released as follows to move the bus CEN Do not release the spring brake until the bus is secured b
37. the relatively re stricted use of LNG at this time Flammability Auto ignition temperature for natural gas at atmospheric pressure is 1 004 F com pared to an auto ignition temperature range of 442 to 880 F for gasoline and ap proximately 500 F for diesel fuel The risk of fire in the presence of an ignition source exists when the ratio of air to fuel is within flammability limits i e fuel can not ignite if it is mixed with too much or too little oxygen The flammability limits for natural gas are 5 3 to 15 volume of gas in air For comparison the flammability limits of unleaded gasoline are 1 to 7 6 volume of gasoline in air As a practical matter there is no oxygen present in CNG cylinders or LNG tanks therefore ignition within the 60 ROUTINE OPERATION e gt cylinder or tank is not possible In the event of a fuel leak there will be a small area in which the air fuel ratio is within the flammability limits In a closed garage or within the passenger compartment ignition conditions are more likely to be met Odorants used in CNG allow its detection before the lower flammability limit is reached Antiknock Properties Natural gas has a research octane rating of about 130 making it relatively resistant to engine knock The antiknock property is a result of the high ignition temperature resistance to auto ignition and the relatively low flame speed of natural gas An tiknock properties allow the use of engine compress
38. 0 cm from high heat sources i e engine exhaust system transmission etc e Always use an appropriate rubber grommet when the wires must pass through a hole Protect all hot primary and ignition wires with an appropriate loom e Never route a wire in contact with a fuel line Do not route wires in contact with plastic components 6 Always be certain that all ground connections are replaced when wiring is performed on engine components e The alternator ground strap must be a minimum 6 gauge wire e The engine must have a ground strap that connects to the transmission housing Use a bolt that connects the engine and transmission to ground to the frame Use a star lock washer to make this connection Allow adequate slack for motion between the engine transmission and the frame 7 Do not splice into existing wires when adding components Run new wiring full length to an appropriate source connection and provide proper fuses 8 When accessories are added check installation guides very carefully You may need to install a control relay for proper operation 80 e Use a blank circuit breaker in the electrical panel if possible If the accessory must be on during cranking connect directly to the hot bar Always install the appropriate fuse in the circuit 9 Always install insulating rubber boots on 6 gauge hot connections whether to the alternator ammeter shunt or another junction CAEN To avoid sparks
39. 6 1156 4433A 4433R 4636 H3 409 194 1073 1157 1157 1156 1156 1156 1157 1156 1156 89 TS93 Doran Warning Light Monitor Warning lights are such an essential safety feature it is important to know when they are not working properly This is the function of the Doran monitor Its display is a schematic of the lights as they appear outside the bus If current is flowing through a particular bus lamp circuit i e the light is on the monitor senses this and lights the corresponding monitor bulb If the bus lamp burns out current ceases and the corresponding monitor bulb goes out indicating a fault Once the defective lamp is replaced and the warning lights are working normally again this also should be shown by the monitor The Doran monitor is a reliable long life device but as with most electrical instru ments it can be overheated and damaged if an overload occurs in a bus light Such overloads can exist if a bus light circuit becomes shorted forcing current through a coil in the monitor which exceeds the coils rated capacity Short circuits can occur if improper connections are made during installations bus repairs etc If the moni tor has an optional thermistor overload protection the tail light circuits are over load protected thermistors are located on the bottom of the component side of the printed circuit board If the Doran monitor is not working properly check the troubleshoot
40. As with most new mechanical processes the introduction of more sophisticated ex haust systems in 2007 emission standards compliant engines has generated some degree of initial confusion Engine manufacturers have designed their own methods to accomplish the regeneration cleaning of the DPF and therefore describe the pro cess in somewhat differing terms Whether your Blue Bird bus is equipped with a Caterpillar or Cummins engine neither system is complicated Nor should the regeneration process be regarded with alarm Both Drivers and service technicians should be at least conceptually familiar with the regeneration process As soot builds up in the DPF filter the driver is notified in several stages by visual and audible alerts The alert system is designed to provide reasonable and comfort able fore warning and adequate opportunity for the needed regeneration As the need for regeneration becomes more severe the alerts become increasingly impera tive and the penalty for postponing the needed regeneration also increases When the earliest alerts occur there is typically ample time to complete a route and then have a Stationary Regeneration procedure performed at a proper facility If early alerts are ignored and the condition is allowed to worsen the engine will even tually de rate automatically and performance will reduce noticeably If the condition is allowed to become severe a Stationary Regeneration may not be possible and the DPF
41. Check engine oil level e Check automatic transmission fluid level Inspect engine air intake system especially the air cleaner service indicator See Air Intake System Inspection in the General Maintenane section of this manual Inspect the engine coolant level at the sight glass Remove any foreign material and dirt from the outside of the radiator core Body outside the bus e Clean the windshield mirrors front windows headlights taillights direction al lights and brake lights e Is the tailpipe clear e Does the rear emergency door open and close Check warning buzzer opera tion e Check the wheelchair lift operation if so equipped e Check tire pressure and the treads Are the lug nuts in place e Drain the air brake tank Is the area under the bus all clear e How is the general outside appearance Is it clean Is there a clear view of identifying features license plate school name bus number etc Are the mirrors clean and adjusted Body inside the bus Are the seats and floor clean Are the steps and aisle clear e Verify that all emergency exits open and close properly and do not stick e Check the emergency equipment and the first aid kit Is the fire extinguisher in place Are the windshield and windows around the driver s area clean Are the mirrors clean and adjusted e Are emergency doors windows unlocked and operating freely e Do buzzers activate when exits are not fully latched
42. Check the air pressure in all the tires e Check the torque on the driveline universal joint straps Inspection guidelines from individual state inspection manuals such as Com mercial Driver s License pre trip inspection procedures take precedence over those found in this manual Guidelines found herein are in addition to those in your state s inspection requirements The Driver is responsible for determining that the loading area is clear before stopping to load passengers The Driver must ensure that all unloaded passengers are clear before moving the bus CAEN Emergency equipment must be checked for proper operation daily It is the Driver s responsibility to report any damage to qualified Service Technicians and to ensure that the condition is corrected before transporting passengers ORIENTATION is section is to familiarize the Blue Bird All American Driver wiith the locations of controls and other bus features with which he will inter act daily Vehicle Identification The Vehicle Certification Plate certifies that the vehicle conforms to all appli cable Federal Motor Vehicle Safety Standards in effect at the date of manufacture Do not remove or deface this plate The Body Serial and Service Number Plate is located on the front upper inner panel above the windshield Refer to the data on this plate for registration purposes or for replacement part information The Axle Record and Chassis Service Number Plate is l
43. DJUSTMENT amp LUBRICATION Outward Opening Door Adjustment 86 Outward Opening Air Powered Adjustment 86 Jackknife Door Adjustment 87 Power Jackknife Door Adjustment 88 Sliding Bolt Vandal Lock 89 Security Lock Lubrication Outward Opening Door 89 Access Doors 89 SEATING CARE Seat Belt Inspection And Maintenance 90 Seat Inspection And Maintenance 90 SIGNS amp SIGNALS Stop Arms 94 Destination Signs 95 ENGINE amp RUNNING GEAR Air Intake System Inspection 96 Engine Cooling System 97 Shutters 99 Transmission 100 Rear Axle 101 Hydraulic Brakes 101 WINDSHIELD WIPERS Washer Solution Reservoir 102 Wiper Assembly Replacement 102 Wiper Refill Replacement 102 CLEANING Exterior Cleaning 103 Floor Cleaning 103 HEATER CARE Filter 104 Annual Maintenance 104 Cleaning Auxiliary Fans 105 MAINTENANCE SCHEDULE Maintenance Task Schedule A3FE 106 Maintenance Task Schedule A3RE 121 Maintenance Locations 135 General Data 136 INTRODUCTION ank you for selecting the Blue Bird All American The All American is the culmination of almost a century of Blue Bird heritage in student and public transportation which began in1927 As always the design and construction of the All American reflects Blue Birds concern for safety efficiency and quality About This Manual This Drivers Handbook has been prepared to acquaint you with the operation of the Blue Bird All American an
44. Engine Oil Pressure CATERPILLAR C7 48 psi 210 F cummins ISC 40 50 psi 2 500 RPM WARM JOHN DEERE 6 8 14 40 PSI IDLE TO RATED JOHN DEERE 8 1 20 58 PSI IDLE TO RATED 136 NOTES 137 NOTES 138 NOTES 139 NOTES 140 Post Office Box 937 Fo BLUE BIRD ey Georgia 31030 USA www blue bird com
45. First Month Then Every 3 Months or 3000 Miles Cooling System Inspect amp Tighten Hose Clamps Tighten radiator hose clamps to 90 in Ib Tighten heater hose clamps to 45 in Ib First 100 Miles Then Every 10 000 Miles Tires amp Wheels Inspect amp Tighten Lug Nuts Torque to 450 500_ft Ib with calibrated torque wrench Do not over tighten Do not lubricate nuts or studs Operating conditions may require more frequent checks First 1000 Miles Then Every 3 Months or 6000 Miles Frame Inspect amp Tighten Body Tie Downs Body Inspect for missing damaged rubber pads Tighten clamps Tie Down Clamps to 37 41 ft Ib Inspect amp Tighten Body Tie Downs Rear Inspect rubber discs for cracking or damage Inspect spring Isolator Mounts amp fastener for damage Tighten bracket to 70 80 ft Ib Tighten Isolator to 54 58 ft Ib First 1000 Miles Then Every 6 Months or 6000 Miles Axle amp Suspension Front Lubricate Parabolic Spring Suspension NLGI 2 Grease Spring Pins Axle amp Suspension Rear Inspect Comfort Air Suspension Ride Shock length eye to eye 22 68 25 Height First 1000 Miles Then Every 6 Months or 10 000 Miles Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Tighten 7 8 U Bolts to 400 450 ft Ib Tighten 3 4 U Bolts U Bolts to 260 320 ft Ib 121 oo A CA ALL AMERICAN DRIVERS HANDBOOK First 1000 Miles Then Every 12 Months or 12 000 Miles
46. OT 3 brake fluid 126 Every 3 Months or 3000 Miles Cooling System Inspect Radiator Fins Clean debris from fins Inspect Water Pump Belt Inspect condition and tension of belt 127 128 KAA ALL AMERICAN DRIVERS HANDBOOK Brakes Lubricate Air Brakes S Cam Every 3 Months or 5000 Miles See Meritor Cam Brakes Appendix in Air Brakes Chapter for guidelines Lubricate Hydraulic Brakes Calipers Lube per meritor specs Driveline Lubricate Driveshafts Slip Joint NLGI Grade 1 or 2 multipurpose grease Lubricate Driveshafts U Joint Bolts NLGI Grade 1 or 2 multipurpose grease Inspect amp Tighten Driveshafts U Joint Bolts Tighten to 45 50 ft Ib Electrical Inspect Alternator Connections Inspect for loose wires damaged terminals damaged insulators Inspect Battery Ground Strap Check for solid connection tight fasteners and absense of corrosion Fuel System Inspect Fuel Lines Inspect for leaks or signs of abrasion Lubricate Fuel Stop Solenoid Inspect Fuel Tank Vent Inspect for obstruction Intake System Inspect Air Cleaner Filter Element Inspect for proper seating secure lid Replace if soiled wet or damaged Inspect Intake Tract All Fasteners Inspect for signs of contaminate infiltration loose clamps wear spots holes in piping Inspect Intake Tract Charged Air Tubing Inspect for signs of contaminate infilt
47. RICAN DRIVERS HANDBOOK Transmission Transmission Breather The transmission has a self contained breather at the top left rear of the transmis sion main housing The breather provides a passage for normal expansion and con traction of air and fluid within the transmission Be careful to avoid plugging this breather with paint undercoating or any other material A small amount of oil mist comes out of the breather during normal operation If an excessive amount of oil is found in this area the cause should be investigated TAND When cleaning the transmission do not spray steam water or cleaning solution directly at the breather This may contaminate the transmis sion fluid Transmission Fluid Level Transmission fluid cools lubricates and transmits hydraulic power Always maintain proper fluid level If fluid level is too low the torque converter and clutches do not receive an adequate supply of fluid and the transmission will overheat If the level is too high the fluid aerates causing the transmission to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high Please see your Allison Transmission Operator s Manual for information on how to check fluid levels at both cold and hot engine temperatures Allison recom mends a transmission fluid that meets DEXRON III specifications Transmission Fluid And Filter Changes Please see your Allison Transmission Op
48. Security Lock 15 Security Lock Outward Opening Door 16 Emergency Door Vandal Lock 16 Sliding Bolt Vandal Lock 16 Wheelchair Lifts 17 DRIVER S AREA Driver s Compartment 18 Dash And Instrument Panel 19 Warning Bank 20 Tilt And Telescopic Steering 21 Switch Panel 21 Mirrors And Adjustment 22 SEATING Standard Driver s Seat 24 Deluxe Driver s Seat 24 Driver s Seat Belt Operation 25 Driver s Seat Belt With Shoulder Harness Optional 25 Passenger Seat Belts Optional 25 COMPARTMENTS amp ACCESS PANELS All American Front Engine 26 All American RE 26 Engine Access All American Front Engine 27 Engine Access All American Rear Engine 27 Rear Side Engine Compartment Doors 27 ENROUTE EMERGENCIES EMERGENCY EXITS Transpec Safety Vent 30 EMERGENCY EQUIPMENT Fire Extinguisher 32 First Aid Kit 32 Body Fluid Cleanup Kit 32 Fire Axe Crowbar 32 Flare Kit 33 Triangular Warning Devices 33 TIRE WHEEL EMERGENCIES Spare Tire Location And Removal 34 Damaged Tires 35 Wheel And Rim Safety 36 Jacking Instructions 37 Changing a Flat Tire 38 Schrader Valve 39 Releasing Spring Brake Manually 39 Towing Or Pushing 40 ROUTINE OPERATION BRAKING Antilock Braking Syst ABS 71 PRE ROUTE INSPECTION MA E T E Hydraulic Brakes 71 Weekly Inspection 43 Air Brakes 74 ENGINE OPERATION o 9 HEATERS Engine Exhaust Caution Ca
49. Slack Adjusters See Meritor lubricant specs in Air Brakes chapter Steering Lubricate Steering Column Vision manual says to lubricate steering column Where With what Check model applicability Every 12 Months Intake System Test Intake Tract Restriction Indicator Test indicator with vaccuum gauge and pump 117 118 VFA ALL AMERICAN DRIVERS HANDBOOK Every 12 Months or 12 000 Miles Heaters amp Defrosters Tighten Front Heater Fasteners All fasteners holding such heaters in place in unit For details on fasteners check installation prints Clean Front Heater Filter amp Core Clean dust from cores Replace filter elements Bleed Heater System Bleed air from heater circulation system This procedure is done to keep system operating correctly Clean Underseat Heaters Filter Elements Clean dust from cores Axle amp Suspension Front Inspect Parabolic Spring Suspension Entire Assembly Visually inspect for damage or misalignmnent Inspect amp Tighten Parabolic Spring Suspension Hangar Bracket Bolts Tighten to 75 85 ft Ib Inspect Parabolic Spring Suspension Shock Absorbers Visually inspect for leakage or damage Inspect amp Tighten Parasteer Suspension Air Spring Fasteners Torque to 20 30 ft Ib Inspect amp Tighten Parasteer Suspension Front Pivot Bolts Torque to 450 480 ft Ib Inspect amp Tighten Parasteer Suspension Ride Height
50. Tighten to 100 150 in Ib Inspect amp Tighten Comfort Air Suspension Lower Shock Mount Tighten to 260 320 ft Ib Inspect amp Tighten Comfort Air Suspension Quick Align Bolts Tighten to 525 575 ft Ib Brakes Lubricate Air Brakes Cam Shaft Housing NLGI 2 EP multipurpose grease rated GC LB or equivalent Use hand operated grease gun Lubricate Air Brakes Haldex Slack Adjusters See Haldex lubricant specs in Air Brakes chapter Lubricate Air Brakes Meritor Slack Adjusters See Meritor lubricant specs in Air Brakes chapter Steering Lubricate Steering Column Vision manual says to lubricate steering column Where With what Check model applicability Every 12 Months Intake System Test Intake Tract Restriction Indicator Test indicator with vaccuum gauge and pump 131 132 VFA ALL AMERICAN DRIVERS HANDBOOK Every 12 Months or 12 000 Miles Heaters amp Defrosters Tighten Front Heater Fasteners All fasteners holding such heaters in place in unit For details on fasteners check installation prints Clean Front Heater Filter amp Core Clean dust from cores Replace filter elements Bleed Heater System Bleed air from heater circulation system This procedure is done to keep system operating correctly Clean Underseat Heaters Filter Elements Clean dust from cores Axle amp Suspension Front Inspect Parabolic Spring Suspension Entire Assembly
51. a switch This procedure is generically referred to as stationary regeneration and should only be performed by or under the direction of a qualified service techni a Ss 0 ee a O LA EN a a aae FF om cian and in a controlled environment to avoid the potential for hu man injury or fire hazards 4 a The need for regeneration is communicated to the driver by a set of visual Ta a and audible signals in the instrument panel An additional alert the High x Exhaust System Temperature HEST indicator notifies the driver when ever exhaust system temperature is high due to recent regeneration Eventually the normal ash accumulation which results from the regeneration process must be removed from the DPF using equipment designed for the purpose at qualified engine service facilities Refer to the engine manufacturer s documenta tion for these service intervals The engine operator s manual provided with your bus contains additional information about exhaust system regeneration and should be read and understood by the driver The exhaust systems of 2007 and newer engines incorporate engine specific Diesel Particulate Filters which operate at higher temperatures during their Regeneration cycles The front exhaust pipes are insulated and heat shields are installed at locations along the exhaust tubing Caterpillar shown 47 48 so A CA ALL AMERICAN DRIVERS HANDBOOK DPF Regeneration In Blue Bird Buses
52. after turning the key Starting procedures are the same as for starting a gasoline engine vehicle With the vehicle in neutral turn the key until the engine catches Do not press the ac celerator If the engine has trouble starting depress the accelerator slightly and release when the engine catches Pumping the accelerator does not help start the engine Engine operation and characteristics should be similar to those of a gasoline engine 61 soe ACA ALL AMERICAN DRIVERS HANDBOOK Cold Start For cold starts in low ambient temperatures natural gas has an advantage over liq uid fuels because it is already in the vapor phase With correct conversion kit instal lation and vehicle maintenance cold start ability is better with natural gas than with gasoline Operation And Maintenance Of CNG Vehicle Components CNG vehicles require Department of Transportation DOT certified cylinders for the storage of pressurized maximum 3 600 psi natural gas Refueling port and lines with pressure safety valves must also be installed High pressure fuel lines from the storage cylinder lead to a pressure regulator reducer which reduces gas pressure in one or two steps In a fuel injected converted vehicle a mixer carburetor must be added for the injection of natural gas In carbureted fuel systems a specialized mixer carburetor for natural gas may be installed LNG vehicles require insulated pressurized 10 to 35 psi fuel tanks LNG is vapori
53. and arcing always connect the negative NEG battery terminal last Wiring Circuit Color Code Major Circuits FUNCTION COLOR LEFT REAR DIRECTIONAL LIGHT YELLOW RIGHT REAR DIRECTIONAL LIGHT DK GREEN STOP LIGHTS RED BACKUP LIGHTS BLUE TAILLIGHTS BROWN GROUND WHITE IGNITION FEED PRIMARY FEED BLACK Refer to the master wiring diagram for wire colors for other circuits 81 82 so ACA ALL AMERICAN DRIVERS HANDBOOK Interior Lights Lamp Description Trade Name Dome Weldon Weldon Stepwell Arrow Emergency Door Light Weldon Switch Panel Pilots Cole Hersee Dial Switch Panel Illumination Exterior Lights Directional KD Weldon Signal Stat Warning Light Arrow Weldon Warning Light Halogen Weldon Cluster and Marker Weldon Peterson Side Directional Truck Lite Arrow Stop Tail Tag Grote Signal Stat Backup KD Weldon Stop Weldon Arrow Signal Stat KD Destination Sign School Bus Sign Trade No Color 8005 Standard 8010 Deluxe 35 8025 PL19 41204 1211 1314962 772 9105 1010 Series Red Amber Plain w Arrow 1156 1604 B 776 A12 B 776 RR 1020 Series H3 12V 55W 5050 Amber and Red 122 Amber and Red 120034 059 9900021CP 01 5085 88 2103 854 5301 7 1010 1 1010 Red 438 1605 772 9105 Red and Amber non replaceable Bulb No 89 93 67 67 53 68 53 115
54. are expressly not authorized by Blue Bird Body Company It is the responsibility of the entity undertaking the modification of this product to ascertain compli ance with all applicable regulations Modification must be accomplished in accordance with strict government standards The entity completing modifi cation of this product must certify that all applicable regulations are met To certify a modified vehicle the upfitter must be a licensed vehicle manufactur er or obtain the services of a licensed vehicle manufacturer for that purpose Specifically Blue Bird does not authorize the following modifications e Do not modify the front or rear suspension Do not change the wheel base length Do not remove any chassis or body cross members Do not cut or drill the flange of the frame rails Do not weld on the engine radiator fuel tank s transmission or any compo nent on the engine radiator fuel tank s or transmission Do not modify any body or frame cross member without prior approval of the Blue Bird Body Company e Do not install any equipment or component that will obstruct the flow of air into around or from the cooling system Do not install equipment or components nearer than 2 inches 51 mm to the For replacement parts fuel tank s rotating components or jounce movement of driveline compo Contact your Blue Bird distributor or Parts Sales at nents Blue Bird Body Company e Do not install any
55. as can cause seri ous injury Avoid the hazard by relieving pressure before disconnecting any CNG fitting or line Properly tighten all connections and thoroughly check for leaks before applying pressure Never attempt to over pressurize the system 56 ROUTINE OPERATION e gt CAEN Protect against extremely cold escaping CNG Compressed natural gas is stored at an extremely high pressure If compressed natural gas escapes from a leak it will expand into an extremely cold 260 F gas Severe frostbite may occur from contact with escaping natural gas or its associated components Avoid the hazard by relieving the pressure before disconnecting any CNG fitting or line Properly tighten all connections and thoroughly check for leaks before applying pressure CEN Storage tanks must be tested according to specified procedures at required dates Failure to do so relieves the manufacturer of all responsibil ity and is a violation of federal law See the manufacturer s label CEN After an accident all tanks lines and fittings should be thor oughly checked by qualified personnel before the vehicle is used again All valves are closed when turned fully clockwise viewed from the top of the valve handle and open when turned counterclockwise viewed from the top of the valve handle CEN Always provide good ventilation including near the roof and or the ceiling Avoid working in noisy environments because the sound of leak ing gas may go u
56. ble to get the transmission back into gear while the bus is moving D Drive When D is selected the vehicle will start to move in first gear and the transmission will upshift automatically through each gear as the speed increases As the vehicle slows down the transmission will downshift automatically The select indicator will display the highest gear available and the monitor will display the cur rent operating gear 2 3 4 5 Gears Occasionally the road conditions load or traffic conditions will make it desirable to restrict the automatic shifting to a lower gear Positions 5 4 3 and 2 provide progressively greater engine braking for going down grades the lower the gear the greater the braking effect Push the Up or Down arrow to the desired gear The select indicator will display your choice and the monitor will display the gear the bus is operating in 1 Gear Use position 1 gear when pulling through mud and deep snow when maneuvering in tight spaces or while driving up or down grades Low gear provides the vehicle maximum power and maximum engine braking power The transmission incorporates a hold feature to prohibit upshifting beyond the gear selected during normal driving For downhill operation however the transmis sion may upshift beyond the selected gear when the engine s governed speed is ex ceeded and damage to the engine is possible Allison Model 2000 Bus Series Trans
57. brake capacity will be very limited and the bus should not be driven under these conditions Parking Brake Hydraulic Brakes The parking brake is designed to hold the loaded bus up to a 20 percent grade The parking brake is not to be used as a normal service brake but can be used to help stop in an emergency situation CEN The parking brake is designed to hold on a 20 grade ona clean dry and smooth road surface Parking on wet icy or snow covered grades is not recommended Chocking the wheel s is recommended when parking on any grade When the parking brake is applied and the ignition switch is ON a dash mount ed yellow light labeled PARK will warn the driver that the brake is applied The bus should not be driven when the parking brake is applied Doing so will prematurely wear the parking brake or damage other drive train components CANN Improper adjustment of the parking brake can significantly reduce the holding ability of the parking brake system 72 ROUTINE OPERATION e gt Hydraulic Brake Throttle Interlock System Optional The hydraulic brakes system of some All Americans include an optional Brake Throt tle Interlock feature which when active automatially applies the brakes and disables the throttle when the vehicle ignition is on and the lift door is open An on off switch in the Driver s left switch panel enables the Driver to activate or deactivate the interlock system When active the interlock a
58. cate Axle Steering Linkage King Pins NLGI 2 EP multipurpose grease rated GC LB or equivalent Lubricate Axle Steering Linkage Tie Rod NLGI 2 EP multipurpose grease rated GC LB or Ends equivalent Lubricate Intermediate Steering Shaft Slip Lubricate splines with multipurpose grease Joint Every 3 Months or 24 000 Miles Brakes Inspect Air Brakes Air Dryer See Bendix appendix for specific model in Air Brakes Chapter Inspect Hydraulic Brakes Booster amp Master Inspect for signs of leakage or physical damage Cylinder 115 116 VA ALL AMERICAN DRIVERS HANDBOOK Warning Devices amp Signs Lubricate Destination Sign Hinges Every 6 Months or 6000 Miles Lubricate Destination Sign Roller Gears Lightweight grease such as White Lube Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Shock Absorbers Inspect for signs of leakage wear or damage Tighten upper shock mounts to 50 70 ft Ib Tighten lower shock mounts to 150 180 ft Ib Inspect Comfort Air Suspension Whole Assmebly Visually inspect for damage Brakes Replace Air Brakes Air Compressor Filter Clean Air Brakes Check Valves Clean amp Lubricate Air Brakes Treadle Valve See Bendix Treadle Valve Appendix in Air Brakes Chapter Clean Air Compressor Governor Inspect Hydraulic Brakes Calipers Inspect for signs of leakage or physical damage Adjust Hydraulic Brakes Park Brake Lever Adju
59. ced With Cummins engine the regeneration switch will not be allowed to initiate a regeneration without use of Cummins s PC based diagnostic software Insite With Caterpillar engine depending upon the severity of the accumulation the regeneration switch may not be allowed to initiate a regeneration without the use of Caterpillar s PC based diagnostic software Electronic Technician With either Caterpillar or Cummins engine removal and cleaning of the DPF us ing specialized equipment may be required m Regen Needed Regen Needed The DPF Regeneration alert flashes in the Message Display OD WRN The audible alert The Check Engine alert sounds continuously appears in the warning bank Level 4 Cummins D ENGINE The audible alert sounds continuously The Stop Engine alert appears in the warning bank Level 4 Caterpillar Regen Needed us Regen Needed The DPF Regeneration alert flashes in the Message Display The audible alert sounds continuously ENGINE STOP WARN ENGINE The Check Engine alert The Stop Engine alert appears in the appears in the warning bank warning bank ROUTINE OPERATION e gt 51 So A CA ALL AMERICAN DRIVERS HANDBOOK Stationary Regeneration Precautions During active regeneration the exhaust system can reach extremely high temper atures Automatic active regeneration which occurs while driving the bus is pro grammed
60. check the windshield washer solution reservoir located behind the driv er s side front access panel of the All American Rear Engine It is located behind the front access panel on the entrance door side of the Front Engine Figure 1 model Be sure there is an adequate supply of fluid at all times The solution used is a 50 50 mixture of methanol and water Wiper Assembly Replacement To replace wiper assembly Figure 1 loosen lock nut remove screw and pull wiper assembly loose from wiper arm Replace the wiper assembly and use original screw and lock nut Tighten lock nut securely but do not tighten enough to compress the saddle Figure 2 Blade must be free to move on the axis machine screw and within the saddle Threading the lock nut until flush with the ma chine screw end will give a secure and serviceable installation Wiper Refill Replacement To remove wiper refills follow the procedure outlined below 1 Lift end clip with screwdriver as shown in Figure 2 This re leases locking indentations A in Figure 3 and allows end clip retainers B in Figure 3 to be removed through blade claw 2 Repeat procedure on the opposite end of the wiper 3 New end clips Figure 3 are provided with replacement Anco refills To install remove one clip and slide the refill through all claws until the end clip locks in position 4 Install the second end clip and snap lock devices A and B into p
61. closed position 4 Ensure that the roller bracket is installed squarely on the rear door panel 5 Ensure that the center hinge barrel is not binding against the outer skin of the rear door panel 6 Adjust opening and closing speed of the door with the valves located on cylinder Air pressure should be at normal operating range 100 to 125 psi during this adjustment 7 Torque the upper pivot bracket retaining screw at the lever assembly to 20 Ft Ibs 27 Nem Sliding Bolt Vandal Lock Lubricate the sliding bolt mechanism of the Sliding Bolt Vandal Lock every six months or 6 000 miles whichever occurs first Use LPS 1 spray lubricant or equivalent 88 Security Lock Lubrication Outward Opening Door If the Outward Opening Door Security Lock becomes difficult to operate remove the access plate on the inner door panel and lubricate with No 2 lithium grease Access plate shown removed in illustration Lubricate security locks every six months or 6 000 miles whichever occurs first Using LPS 1 or Apply lubricant or equivalent spray into the bushing and shaft in the center at the base of the lock handle Also spray lubricant into key lock mecha nism Rotate the lock handle to ensure smooth operation Manual Security Lock interior Access Doors Periodic maintenance is necessary to prolong the life of access door latches locks and hinges Each week clean and insp
62. d should be read by all Drivers before operating the unit Familiarity with automotive operation and control is assumed to be common knowledge to all who will be operating this bus This book does not address all driving situations which may arise and it is not a substitute for proper driver training It will however enable a School Bus driver to more quickly feel at home in this model All American Your Blue Bird All American may not have all of the equipment described in this manual You may find information on optional equipment not installed on your bus You are encouraged to contact your Blue Bird distributor if additional information or as sistance is needed For use as a convenient reference this Handbook also contains some general maintenance information Although the Driver will not likely be performing service procedures this information nonetheless serves to further familiarize the Driver with the bus The maintenance information contained herein is provided as a reference for systems and components that require periodic service The intervals given are component manufacturers recommendations and should be considered maximum intervals that is the very minimum maintenance schedules that will afford reasonable care of this vehicle Service technicians should refer to the Service Manual for more complete service information If this manual does not address your specific questions or concerns please contact your Blue Bird distributor The dist
63. ded with lift 125 VFA ALL AMERICAN DRIVERS HANDBOOK Emergency Exits Lubricate All Emergency Exits Hinges LPS 1 Lubricate Rear Emergency Door Hold Open Apply ASTM D4950 GC LB Grade 2 Lubricate Roof Hatch Hatch Seal and Latch Silicone lubricant to prevent sticking of rubber seal Spray silicon lubricant into latch mechanism Floor Inspect Floor Drains Check drawin hole in each body section under window for debris obstruction Seats Lubricate Driver s Seat Lubricate per manufactuers recommendation Inspect amp Tighten Passenger Seats Use standard torque for bolt size tread type and grade Mountings Warning Devices amp Signs Lubricate Stop Arm Electric 4 Point Pivot Lubricate four hinge pivot ponts with Try Flow lubricant Inspect amp Tighten Stop Arm Electric Check interior and exterior fasteners for loosening Fasteners Windows Lubricate Passenger Windows Latches amp Use silicone lubricant Slides Electrical Inspect Battery Electrolyte Level Replenish with distilled water Every Month or 6000 Miles Warning Devices amp Signs Adjust Stop Arm Air Air Pressure Adjust for full deployment and retraction Every Month or 10 000 Miles Axle amp Suspension Rear Inspect Rear Axle Lubricant Level If low refil to bottom of filler opening Use same lubricant type as already installed Every Month or 300 000 Miles Brakes Inspect Hydraulic Brakes Fluid D
64. e System Inspection Intake air must be filtered to prevent dirt and debris from entering the engine and causing premature wear Air intake piping should be checked daily as should charge air piping and engine air cleaner service indicator if equipped Repair any leaks in the system before operating the bus Never operate the engine without an air cleaner Intake Air Restriction Indicator Cat C7 and John Deere 8 1L Some engines are equipped with a gauge which displays the difference in air pres sure before and after the air cleaner As the air cleaner element becomes dirty the pressure differential rises The air cleaner element must be replaced when the differ ence is 25 inches on the Cat C7 and 15 inches on the John Deere 8 1L If your engine is equipped with a different type of service indicator follow the manufacturer s rec ommendations to service the indicator TOND Leaks in the intake system will prevent the Air Restriction Indica tor from reading accurately Always check the attendant piping for leaks especially between the indicator and the engine intake Maximum intake restriction clean air filter element 10 0 inches water 254 mm Maximum intake restriction dirty air filter element 25 0 inches water 635 mm Cat C7 Replace the engine air cleaner every 12 months or when the air cleaner service indicator shows restriction of 25 inches of water Do not rely completely on the restriction indicator A leak in the sy
65. e and to maintain the adjustment during the service life of the vehicle Mirrors provide additional driver visibility on buses To be used effectively mirrors must be properly adjusted for each driver and the driver must be aware of the limitations on viewing area that exist even when mirrors are properly used Mirrors are not a substitute for proper driver training and care that should be exercised when operating the vehicle and loading or unloading passengers Do not move the bus until you have accounted for each passenger that has disembarked and have confirmed that all passengers are clear of the bus Failure to follow these procedures could cause serious injury or death Interior Mirrors Inside rearview mirrors can be adjusted by loosening the bolts and nuts in slotted holes Adjust the mirror to give the operator a clear view of the bus interior and the roadway to the rear CEN After unloading passengers do not move the bus until you have confirmed the location of each disembarked passenger and you are confident all of them are clear of the bus Exterior Rearview Standard equipment on all school buses includes four outside rearview driving mir rors two per side and two elliptical cross view mirrors one per side The outside rearview driving mirrors include one flat and one convex on each side The outside rearview driving mirrors are designed to provide the seated driver a view of the roadway to the rear and to the sides of the bus
66. e is involved in an accident or fire causing damage to any part of the CNG fuel system the system shall be retested before being returned to service Damaged supply lines must be replaced not repaired The owner or user or both shall maintain all containers container appurtenanc es piping systems venting systems and other components in a safe condition As a precaution to keep pressure relief devices in reliable operating condition care shall be taken in the handling or storing of compressed natural gas containers to avoid damage Care shall also be exercised to avoid plugging by paint or other dirt accumulation of pressure relief device channels or other parts that could interfere with the functioning of the device Only qualified personnel shall be allowed to ser vice pressure relief devices Only assemblies or original manufacturer s parts shall be used in the repair of pressure relief devices unless the interchange of parts has been proved by suitable tests CODE OF FEDERAL REGULATIONS 49 states In addition to the requirements of this paragraph cylinders marked DOT 3HT must be qualified in accordance with CGA pamphlet C 8 and must comply with the following Cylinders built prior to implementation of FMVSS 304 must be subjected at least once in three years to a test by hydrostatic pressure in a water jacket for the determi nation of the expansion of the cylinder A cylinder must be condemned if the elastic expansion exceeds the mark
67. e left hand rear floorboard under the rear seat Inspect contents of the kit every 30 days or as required by local code to ensure proper operation Recommended Warning Device Positioning Some states allow a lockable Emergency Equipment compartment This optional compartment is located above the windshield toward the center of the bus Supplies are organized and labeled in the compartment The compartment locking mecha nism is fitted with a warning buzzer which will sound if the compartment is locked while the ignition switch is in the on position On rear engine units the emergency equipment is located in the front of the bus The compartment is located at the centerline of the bus at floor level depending on the options selected at the time of manufacture 10 Approximately 40 Paces Approximately 40 Paces 2 o ot TWO LANE TRAFFIC 100 g approximately 40 paces approximately 80 paces oe 10 from rear om Bt 4 4 FOUR LANE TRAFFIC 33 VFA ALL AMERICAN DRIVERS HANDBOOK TIRE WHEEL EMERGENCIES Spare Tire Location And Removal If your unit is equipped with a frame mounted spare tire carrier follow this procedure to remove and replace spare 1 Remove the two securing nuts and rotate tire out of holes 2 Open the access door if equipped through the access hole Insert the lug wrench placing the socket over the hex head on the shaft and t
68. e push button shift selector activates an alter nate shift schedule By default the start up is in primary or power mode Pressing the MODE button causes the transmission to enter the economy mode The display will indicate the economy mode is engaged In economy mode the transmission shifts to higher gear at lower engine rpm 64 ROUTINE OPERATION e gt Allison Model 3000 Bus Series Transmission Gear Selection CZENN When leaving the vehicle while the engine is running the opera tor must ensure the transmission is in Neutral the parking brake is engaged and the wheels are chocked The vehicle may move unexpectedly without these precautions R Reverse The vehicle must be completely stopped before shifting from forward to reverse or from reverse to forward The select indicator and the monitor will dis play R when the vehicle is in reverse N Neutral Use neutral to start the engine to check vehicle accessories and for extended periods of engine idle operation Under normal operation the trans mission is directed by the ECU to neutral during the startup procedure This occurs automatically with the push button selector If the vehicle starts in any range except neutral seek service immediately CEN Do not allow your vehicle to coast in neutral This practice can result in transmission damage Engine retard and braking assistance is not available when the transmission is in neutral It may not be possi
69. e secure SOLENOID VALVE De Destination Signs Hinged Sign Front Mounted on the outside of the front roof cap with internal control for changing the display Periodically lubricate hinges and lever assembly with lightweight lubricating oil Hinged Sign Rear Mounted on the outside of the rear roof cap manually changed from outside Peri odically lubricate hinges with lightweight lubricating oil One Station Lighted Curtain Replace bulbs as needed Because of vibration the curtain can loosen To tighten the curtain loosen the bolts pull the curtain taught and then tighten the bolts Roller Destination Sign with Lighted Curtain Replace bulbs as needed Curtain may occasionally require same adjustment as One Station Sign Periodically lubricate the roller gears with light grease such as White Lube Lubricate the hinges on the access door with lightweight lubricating oil To change the display turn the crank located on the front upper inner panel above the windshield Two Station Sign Front lighted with lettering on both sides Lubricate the interior door hinge on the front upper inner panel with lightweight lubricating oil Lighted School Bus Sign Back lighted yellow Plexiglas sign Replace bulbs as needed Lubricate the interior door hinge on the front upper inner panel with lightweight lubricating oil 95 so A CA ALL AMERICAN DRIVERS HANDBOOK ENGINE amp RUNNING GEAR Air Intak
70. e the vehicle is raised for an oil change e Whenever a change is noticed in the sound of the exhaust system e Whenever the exhaust system under the body or the rear of the vehicle is damaged Whenever there is an inspection of piping and joints Replace clamps that are leaking Exhaust system clamps are not reusable Seal with exhaust sealant and install new clamp Do not run the engine in a confined area such as garages longer than necessary to move the vehicle in or out of the area When your bus is stopped in an open area with engine running for more than a short period and if it is equipped with combination heating and external ventilation then adjust the heating or ven tilation system to force outside air into bus with the blower set at medium or high speed Keep the air inlet grille clear of snow or other obstructions at all times to assure proper operation of the ventilation system Sitting in a parked vehicle with engine running for an extended period in either a confined or open environment is danger ous Diesel Fuel All American units should take advantage of the high energy content and generally lower cost of No 2 diesel fuel Experience has shown that diesel engines will operate satisfactorily on No 1 fuel The engine in this vehicle must be operated only with ultra low sulfur diesel fuel meeting EPA specifications for highway diesel fuel includ ing a 15 ppm sulfur cap CANN Use caution when filling the fuel tank
71. eanser Ink Remove stain immediately using a damp cloth and alcohol SEAT CUSHION REMOVAL AND INSTALLATION DOT SEATS CENA If seat cushions are removed for maintenance they must be re installed using the following instructions Failure to comply with these instructions could result in injury from unattached seat cushions in the event of an accident Removal 1 Loosen the two front swivel type clamps at the front underside of the cush ion with a screwdriver Caution Do not remove clamps 2 Rotate the swivel clamps 180 to clear the front retaining channel frame 3 Lift the forward edge of the cushion 2 to 3 inches 5 to 8 cm and pull forward Installation 1 Place the rear edge of the cushion down on the base portion of the seat frame Lifting the forward edge 2 to 3 inches 5 to 8 cm slide the cushion to the rear to engage the positive type clamp into the rear retaining channel 2 Lower the forward edge to the frame making sure the swivel clamps are in side the frame and the positive type clamps are secure on the rear retaining channel 3 Rotate the swivel clamp to engage the forward retaining channel frame 4 Tighten with a screwdriver until clamps do not rotate SEAT CUSHION REMOVAL AND INSTALLATION DOT SEAT BELT SEATS Removal 1 Loosen the two front swivel type clamps at the front underside of the cush ion with a screwdriver Caution Do not remove clamps 2 Rotate the swivel clamp located at the rear underside of s
72. ear half of the fan guard can also be removed if necessary After pulling away the fan remove the two nuts and washers on either side of the center point and lift off the rear piece 105 ALL AMERICAN DRIVERS HANDBOOK 106 VFA MAINTENANCE SCHEDULE Maintenance Task Schedule A3FE Ensure that the Safety Information warnings and instructions are read and under stood before operation or maintenance procedures are performed Use whichever interval listed time mileage engine hours occurs first Engines operated in severe operating conditions may require more frequent maintenance See engine manufac turer s specifications for more information First Month Then Every 3 Months or 3000 Miles Cooling System Inspect amp Tighten Hose Clamps Tighten radiator hose clamps to 90 in Ib Tighten heater hose clamps to 45 in Ib First 100 Miles Then Every 10 000 Miles Tires amp Wheels Inspect amp Tighten Lug Nuts Torque to 450 500_ft Ib with calibrated torque wrench Do not over tighten Do not lubricate nuts or studs Operating conditions may require more frequent checks First 1000 Miles Then Every 3 Months or 6000 Miles Frame Inspect amp Tighten Body Tie Downs Body Inspect for missing damaged rubber pads Tighten clamps Tie Down Clamps to 37 41 ft Ib Inspect amp Tighten Body Tie Downs Rear Inspect rubber discs for cracking or damage Inspect spring Isolator Mounts amp fastener for damage Tighten brack
73. eat cushion 3 While lifting the rear edge of the cushion pull the cushion to the rear and remove Installation 91 So A CA ALL AMERICAN DRIVERS HANDBOOK 1 Place the forward edge of the cushion two inches 5 cm to the rear of the front retaining channel Slide the cushion forward engaging the positive clamps onto the forward retaining channel 2 Lower the rear edge to the frame and rotate the swivel clamps so they en gage the square tube cross member 3 Tighten screws in front and rear clamps with a screwdriver until clamps do not rotate TRACK MOUNTED PASSENGER SEATS If your bus is equipped with track mounted passenger seats and you relocate the seats or remove them to accommodate wheelchairs you must follow rules of spacing and placement to comply with Federal Motor Vehicle Safety Standard 222 School Bus Passenger Seating and Crash Protection and Federal Motor Vehicle Safety Standard 217 Bus Window Retention and Release A decal printed with these rules as shown below is installed on the interior body panel above the windshield CEN The federal rules governing passenger seating spacing and placement are explicit When the seats are moved the entity moving or rear ranging the seating assumes responsibility for compliance with FMVSS 222 School Bus Passenger Seating and Crash Protection and FMVSS 217 Bus Window Retention and Release All passenger seats must have a seat or barrier in front
74. eat nearby The refueling station must be in a safe working condition with approved operable relief and vent valves A ground stud is provided for attachment of the grounding cable at the compres sor station Check that the tank shutoff valves are open Any tank with an open valve will be filled any tank with a closed valve will not If the bus has been operating with some tanks closed it is preferable to fill the empty tanks first and then fill the re mainder Fill to the desired pressure Maximum is 3 600 psi at 70 F Most fill stations have a dome valve to make the temperature correction automatically When fueling is complete open the fill connector purge valve Use only fuel filling couplings de signed for use with the CNG Do not force damaged couplings together TOND A check valve is included in the system behind the fill connector to prevent backflow of fuel when purging and disconnecting the fuel nozzle 59 So A CA ALL AMERICAN DRIVERS HANDBOOK The tanks are full at 3 000 psi or 3 600 psi at 70 F The pressure will vary with temperature decreasing with lower temperature and increasing with higher tem peratures Filling apparatus compensates for the temperature effect CEANN Never fill to more than permissible pressure Contact the manu facturer if an accidental overfill occurs Specific Gravity The specific gravity of natural gas relative to air air 1 00 is 0 56 to 0 62 depending on gas composition This
75. ect the door hinges and latch mechanisms Clean with a nonabrasive degreaser or cleanser as required Every three months lu bricate with either a graphite type lubricant or a spray type lubricant such as LPS Following is a list of access doors for which these maintenance procedures are rec ommended e Battery Compartment Door Luggage Compartment Door e Tire Compartment Door Fuel Fill Door Radiator Fill Door Side Electrical Panel Door Left and Right Hand Front Access Doors Glove compartment and emergency equipment doors should be inspected on a daily basis Open and close to ensure proper operation If necessary follow the same lubrication procedure as outlined above CARE amp MAINTENANCE 89 so A CA ALL AMERICAN DRIVERS HANDBOOK Seat Belt Inspection And Maintenance Inspect seat belts and their attachments at least weekly Check seat belt buckles and adjustability to ensure proper operation If necessary lubricate the buckle with a graphite lubricant When a buckle is found to be inoperable replace it immediately If there are any defects in the webbing i e torn or frayed the seat belt must be replaced immediately to ensure passenger safety Hand wash webbing with warm water and mild soap Rinse thoroughly and dry in the shade Do not bleach or re dye because such processing may severely weaken the assembly CAN Do not bleach or dye the webbing Such processing may severely
76. ed rejection elastic expansion Cylinder service life must not exceed fifteen years Each cylinder must be inspected and hydrostatically tested every three years in accordance with 49 CFR 173 34 e as prescribed for DOT 8HT cylinders except that the rejection elastic expansion criteria does not apply permanent volumetric expan sion must not exceed 5 percent of total volumetric expansion at test pressure and retest dates must be imbedded in the epoxy coatings in a permanent manner other than stamping Retest dates may be steel stamped on the shoulder of the top head in accordance with 178 BB 15 c Re heat treatment or repair of cylinders is not au thorized Fuel System Description The fuel system begins with DOT certified tanks designed to hold compressed natu ral gas CNG up to 3 600 psi at standard day temperature 70 F or 21 C The tanks are high strength steel wrapped with fiberglass for additional strength The fuel flows from the tank to the engine through manually controlled shutoff valves These include an integral pressure relief valve consisting of a combination rupture disk for pressure and fuse plug for temperature to vent the contents of the tank should high pressure and high temperature occur such as ina fire The rated temperature for relief is 212 F From the valve fuel flows into a common fuel line through high pressure stain less steel compression fittings The tanks are joined to the common line through high
77. eel different from what is familiar In addition the driver operator must ensure that the loading area around the bus is clear of pedestrians before stopping and that all unloaded passengers are a safe distance away from the bus before moving For these reasons it very important from a safety standpoint to become familiar with bus operation through experience before attempting passenger transit CEN No one should attempt to operate this bus without 1 thorough knowledge of all instruments and controls 2 supervision or actual driving experience in this or a similar vehicle under supervision and 3 the appropriate license or permit to operate Do not drive the bus until the space in front on the sides and in the rear is unobstructed Most accidents occur because the operator did not ensure a clear path before driving Inspection guidelines from individual state inspection manuals such as Commercial Driver s License pre trip inspection pro cedures take precedence over those found in this manual Guidelines found herein are in addition to those in your state s inspec tion requirements 41 so A CA ALL AMERICAN DRIVERS HANDBOOK PRE ROUTE INSPECTION To keep your bus in the best operating condition any malfunction or defect should be corrected before the next trip Report needed services to responsible mainte nance personnel Engine Transmission e Check fuel level e Drain air tanks Drain fuel water separator e
78. en adding accessories and aftermarket components it is important to consider the results very carefully Does the component over burden the electrical system Does the accessory interfere with any of the driver s controls Does the accessory interfere with the driver s field of vision Heavy components and accessories must be mounted near or below the floor line to avoid raising the vertical center of gravity Will passenger safety and comfort be adversely affected 85 VFA ALL AMERICAN DRIVERS HANDBOOK DOOR ADJUSTMENT amp LUBRICATION Maintenance procedures for entrance doors must be performed by qualified techni cians at intervals of one month or 1 000 miles whichever occurs first Continuing Maintenance Requirements Keep working parts of control tightened Lubricate all working parts periodically including hinges and overhead con trols e Repair or replace worn seals e Maintain proper door opening and closing adjustment Outward Opening Door Adjustment Outward Opening Doors are mounted in a prefabricated framework which elimi nates the effect of body construction variations on door and seal operation Doors are suspended completely on sealed ball bearings located at the top corners of the framework inside the body The interlink connection between the doors is a single assembly with oppositely threaded spherical bearing rod end connectors at each end providing simple link length adjustment witho
79. er emergency locking or automatic locking depending on the option chosen The emergency locking retractor used for all shoulder harnesses and specified lap belts is dual sensitive The emergency locking retractor engages when the vehicle tips 15 or if belt payout speed exceeds a preset rate Automatic locking retractors for specified lap belts are self adjusting Adjust the shoulder belt bracket for driver comfort To use withdraw an adequate length of belt from the retractor or retractors to al low the buckle After engaging the buckle halves let the retractor withdraw the belt to a snug fit The buckle can be released by pushing the button in its center Passenger Seat Belts Optional Individual lap belts for passengers are retractable or non retractable depending on option ordered Insert the catch into the buckle test for positive latch and pull the loose end of strap until the belt fits snugly across the lower hips The buckle can be released by pushing the button in its center The adjustable end can be moved out ward on its strap by turning 90 to the strap and pulling CEN Be sure the lap belt is fitted snugly around the hips not the waist Failure to do so may increase the chance of injury in the event of a colli sion Do not bleach or dye the webbing because such processing may severely weaken the assembly 25 VFA ALL AMERICAN DRIVERS HANDBOOK COMPARTMENTS amp ACCESS PANELS All American Front Engine Release the
80. erator s Manual for procedures to change transmission fluid and filters and the intervals at which these should be done 100 Rear Axle All drive axles have a vent on the top of the axle housing that allows the axle to breathe as the axle temperature changes The vent must remain open to prevent seal failures It is normal for the vent to ooze a small amount of lubricant Hydraulic Brakes The brakes self adjust for lining wear Brake fluid in the reservoir located behind the driver s seat must be maintained to the correct level As the brake linings wear fluid level in the reservoir will go down displacing the lining loss TOND Use only DOT brake fluid in this reservoir CEN Put only brake fluid in the brake fluid reservoir and only power steering fluid in the power steering system Mixing fluids or failure to use the proper fluid could result in loss of braking or steering Parking Brake Adjustment On All Americans with hydraulic brakes the parking brake is adjusted by turning the a knob on the parking brake lever The knob is held in place with a set screw and can gt be adjusted when the parking brake is released When the parking brake is properly 90 100 Ibs force adjusted 90 100 pounds of force as measured 2 from the end of the lever is required to set the brake 101 so ACA ALL AMERICAN DRIVERS HANDBOOK WINDSHIELD WIPERS Washer Solution Reservoir Periodically
81. es Pads Replace if worn to within 1 8 lining remaining 124 Every Month or 3000 Miles Doors Clean amp Lubricate All Doors Rubber Seals Lubricate with Silicon Spray or protectant Lubricate All Doors Vandal Locks Spray Apply lubricant into key locks Use LPS 1 for sliding bolt locks Adjust Jack Knife Door Air Pressure See Body Construction Doors Jack Knife Door Adjust Jack Knife Door Control Rod Adjust for proper open closed position Adjust Jack Knife Door Control Rod Bracket Adjust to prevent pivot pin binding Lubricate Jack Knife Door Hinge Pins LPS 1 Adjust Jack Knife Door Roller Bracket Adjust for proper open closed position Adjust Jack Knife Door Switch See Body Construction Doors Jack Knife Door Adjust Outward Opening Door Control Rod Adjust Outward Opening Door Control Rod Bracket Adjust for full and secure closure without binding Adjust amp Lubricate Outward Opening Door Linkage Adjust linkage for firm closure and to ensure rear panel closes first Lubricate Outward Opening Door Pivots Lubricate pivot pins with LPS 1 Adjust Outward Opening Door Roller Adjust for full and secure closure without binding Bracket Lubricate Power Jack Knife Door Air LPS 1 Pressure amp Switch Lubricate Power Jack Knife Door Hinge LPS 1 Lubricate Wheelchair Lift Lube Points See model specific literature provi
82. ess CATON Engine and components can be very hot If the engine has been running be careful to avoid burns during engine access and removal process Engine Access All American Rear Engine To open press the release button on the latches located at the edges of the door right side shown Press the upper portion of the handle located in the lower center of the door for handle access When the handle swings around grip and pull to open door After closing press in the larger portion of the latch until it snaps to lock into position Rear Side Engine Compartment Doors To open press release button latches on the top and the bottom of the rear side access doors Opening the left side door gives access to the outside of the radiator Opening the right side door gives access to the right side of the engine After closing press in the larger portion of the latch until it snaps to lock into position 27 28 ENROUTE EMERGENCIES ssenger safety is the bus driver first priority In the event of enroute emergency or roadside hazard the driver must be confidently famil iar with the location and use of safety devices emergency equipment and roadside procedures in order to maintain order guide passengers to safety and properly position and secure the bus until assistance arrives 29 so A CA ALL AMERICAN DRIVERS HANDBOOK Emergency exits are clearly identified by the words EMERGENCY EXIT Operating in structio
83. et to 70 80 ft Ib Tighten Isolator to 54 58 ft Ib First 1000 Miles Then Every 6 Months or 6000 Miles Axle amp Suspension Front Lubricate Parabolic Spring Suspension NLGI 2 Grease Spring Pins Axle amp Suspension Rear Inspect Comfort Air Suspension Ride Shock length eye to eye 22 68 25 Height First 1000 Miles Then Every 6 Months or 10 000 Miles Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Tighten 7 8 U Bolts to 400 450 ft Ib Tighten 3 4 U Bolts U Bolts to 260 320 ft Ib First 1000 Miles Then Every 12 Months or 12 000 Miles Heaters amp Defrosters Inspect Front Heater Hoses amp Clamps Inspect for evidence of leaks or deterioration replace with proper parts Axle amp Suspension Front Inspect amp Tighten Parasteer Suspension Torque to 260 320 ft Ib Axle To Suspension Fasteners First 5000 Miles Then Every 12 Months or 24 000 Miles Transmission Replace Transmission Sump Filter First 5000 Miles Then Every 24 Months or 24 000 Miles Tramsmission _ _ _ _ O OOO Replace Transmission Main Fluid Filter First 11 000 Miles Then Every 3 Months or 5000 Miles or 250 Engine Hours Engine Inspect All Belts Inspect condition and tension of belt First 11 000 Miles Then Every 6 Months or 250 Engine Hours Brakes Replace Air Brakes Air Compressor Filter First 11 000 Miles Then Every 6 Months or 6000 Miles Cooling S
84. fication described above particulate accumulation continues and a more imperative notification occurs e The DPF Regeneration alert begins to flash e The audible alarm sounds continuously e The engine may be automatically de rated The above indications should be interpreted as a more imperative alert that the ex haust system is in need of regeneration soon As soon as practical the bus should be operated at or above the minimum speed needed to allow automatic regeneration to activate or a Stationary Regeneration must be performed Again situation specific variables apply Current data from Cummins suggest that at this level of notification the DPF needs to be regenerated within the next one to two hours of bus operation Otherwise the third level of notification will occur Regen Needed The DPF Regeneration alert appears in the Message Display 4 The audible alert a sounds one beep P em Regen Needed a Regen Needed The DPF Regeneration alert flashes in the Message Display 4 The audible alert sounds continuously A Level 3 Notification Check Engine Indicator Appears If the bus continues to be operated without taking the measures indicated by a Level 2 Notification particulate accumulation worsens These indicators are activated The DPF Regeneration alert continues to flash The audible alert sounds continuously The engine is automatically de rated
85. fort Air Suspension Shock Absorbers Inspect for signs of leakage wear or damage Tighten upper shock mounts to 50 70 ft Ib Tighten lower shock mounts to 150 180 ft Ib Inspect Comfort Air Suspension Whole Assmebly Visually inspect for damage Brakes Replace Air Brakes Air Compressor Filter Clean Air Brakes Check Valves Clean amp Lubricate Air Brakes Treadle Valve See Bendix Treadle Valve Appendix in Air Brakes Chapter Clean Air Compressor Governor Inspect Hydraulic Brakes Calipers Inspect for signs of leakage or physical damage Electrical Inspect Battery Battery Posts Clean and apply anti corrosion agent Exhaust System Inspect Exhaust Pipe Joints Inspect for loose clamps leaks damage Fuel System Replace Fuel Filter Filter Element Clean Fuel Filter Inlet Screen Clean Replace if damaged Steering Lubricate Steering Gear Pitman Arm Pivot NLGI 2 EP multipurpose grease rated GC LB or equivalent Use hand operated grease gun Every 6 Months or 10 000 Miles Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Air Spring Anchor Bolts Tighten to 20 30 ft Ib Inspect amp Tighten Comfort Air Suspension Air Spring Fasteners Torque to 30 35 ft Ib Inspect amp Tighten Comfort Air Suspension Leveling Valve Mount Bolt Tighten to 60 85 in Ib Inspect amp Tighten Comfort Air Suspension Lever Linkage Locknut
86. gularities Replace dam aged wheels or fans to prevent damage to parts fasteners and motors Switches are also maintenance free however loose wiring connections to switches or motors can cause excessive resistance and overheating damage Wires 104 to switches can be checked or repaired by removing the switch mounting panel next to the driver s seat Panels and Housings Fasteners should be checked and tightened as necessary A loose screw may allow a panel to vibrate resulting in excessive noise more loose screws and or metal fa tigue Cleaning Auxiliary Fans Auxiliary fan motor bearings are lifetime lubricated and do not require maintenance Clean the blade and guard occasionally with a soft bristle brush and a vacuum clean er or compressed air to help maintain efficiency As with any other fan if the blade is damaged or unbalanced vibration damage can occur to the motor or surrounding components If this is the case the blade should be replaced immediately CAEN Do not operate a fan without the fan guard properly installed Procedure 1 Remove the front half of the fan guard by gently separating the plastic tabs with a screwdriver or other hard instrument Be careful not to damage the tabs as these connect the front half of the fan guard to the rear half 2 To remove the fan blade use a 3 32 inch Allen wrench in the setscrew lo cated directly behind the fan This should loosen the fan blade for removal 3 The r
87. h at the time it left Blue Bird s control caused noise emissions to exceed Federal standards are covered by this warranty for the life of the vehicle so A CA ALL AMERICAN DRIVERS HANDBOOK About 2007 Emissions Standards Buses equipped with 2007 engines are designed to conform to new and stringent federal emissions standards These standards affect both the equipment installed at the factory and the fuel at the pump Buses powered by 2007 emissions standards engines are equipped with special exhaust systems to reduce emissions The technical details of the systems employed by various engine manufacturers differ but share common general principles The exhaust muffler is a particulate filter which traps and burns microscopic particles in a process referred to as regeneration When heat in the exhaust is insufficient to fully burn the particulates the system enters an active regeneration mode so the necessary catalytic reaction can take place During active regeneration events exhaust temperatures are elevated and an indicator light on the instrument panel illuminates to notify the Driver that regeneration is active This regeneration mode is automatic and normal and requires no special action on the part of the Driver As part of the 2007 emissions standards effective October 15 2006 the EPA has required fuel retailers to sell lower emission fuel designated ultra low sulfer diesel After that date all commercially
88. hat anyone involved in their use be completely familiar with the Department of Transportation Code of Federal Regulations Title 49 and the various Compressed Gas Association pamphlets that are available covering the care and use of high pressure cylinders Regulations do not permit filling Natural Gas Vehicle NGV cylinders with an overcharge The compressed natural gas CNG fuel system consists of DOT certified CNG storage tanks which replace the fuel tank a structure to hold and protect the stor age tanks metallic fuel lines to deliver the fuel high and low pressure regulators to reduce the pressure entering the throttle body a fuel shutoff solenoid and the throt tle body which delivers the CNG air mixture to the engine The regulator includes an integral heater to preheat the CNG for anti icing control A pressure relief system is part of the fuel system This system is designed to vent the tank contents when pressure and temperature become excessive A fill connection is located near the entrance of the bus If so equipped the en gine powering this bus is engineered specifically for use with CNG Operation and maintenance procedures are similar to those used on gasoline or diesel engine ve hicles Differences identified are obvious Owner Operator Responsibilities The owner operator should be aware of the code requirements and be familiar with applicable codes which apply to the area of operation The owner operator sh
89. he ae conditions under which the HEST indicator appears differ between Caterpillar and D Cummins equipped buses The HEST alert appears in the instrument With Caterpillar engine the HEST indicator appears whenever the exhaust tem panels warning bank perature is high 842 F or above and the bus is either stopped or moving at a slow speed approximately 5 MPH With Cummins engine the HEST indicator appears whenever the exhaust tem perature is high 752 F or above regardless of moving speed The driver should be familiar with and abide by all instructions warnings and The audible alert sounds one beep cautions in the engine manufacturer s operator s manual regarding safe operation when the HEST indicator is on o A e The HEST alert appears in the instrument panel e The audible alarm sounds one beep 49 50 so A CA ALL AMERICAN DRIVERS HANDBOOK Level 1 Regeneration Notification DPF Indicator Appears In low demand operating conditions it is possible that the regeneration system does not have sufficient opportunity to prevent particulate build up in the DPF The ECM senses that accumulation is occurring and that regeneration is needed The driver is notified as follows e The DPF Regeneration alert activates e The audible alert sounds one beep The above indicates that regeneration of the DPF is needed at the earliest conve nience The regeneration can be accomplished in either of two ways If
90. he driver and technician that the exhaust system temperature is high and that caution should be observed around the exhaust system DPF Indicator An instrument panel indicator which displays when particulate ac cumulation has reached a preset level in the DPF and regeneration is needed The bus should either be operated with a more demanding duty cycle until the indicator goes off or it should be scheduled for a Stationary Regeneration at a service facility Levels of Notification Regeneration the process which clears soot accumulation in the DPF occurs au tomatically as the bus is operated as long as certain operating conditions such as minimum speed thresholds are met When bus operating conditions do not provide adequate opportunity for the regeneration system to keep the DPF clear soot be gins to accumulate A system of driver alerts keeps the driver informed of when the exhaust system is in need of regeneration and of high exhaust temperature associ ated with regeneration Several levels of regeneration alerts occur in sequence each indicating a more imperative warning High Exhaust Temperature Notification C The High Exhaust System Temperature HEST indicator appears to alert the driver when exhaust temperature is unusually high and that prudent judgement should be applied regarding the proximity of people or combustibles to the exhaust sys tem For example the bus should not be parked on a surface of grass or weeds T
91. hen the transmission is in neutral It may not be possible to get the transmission back into gear while the bus is moving D Drive When D is selected the vehicle will begin to move in first gear and the transmission will upshift automatically through each gear as speed increases As the vehicle slows down the transmission will downshift automatically AID Do not idle in D drive for more than five minutes Extended idle time in D drive may cause transmission overheating and damage Always select N neutral whenever time at idle exceeds five minutes 2 3 4 Gears Occasionally the road conditions load or traffic conditions will make it desirable to restrict shifting to a higher gear Positions 4 3 and 2 provide pro gressively greater engine power and braking for going down grades the lower the gear the greater the braking effect 1 Gear Use position 1 gear when pulling through mud and deep snow when ma neuvering in tight spaces or while driving up or down grades Low gear provides the vehicle with its maximum power and maximum engine braking power Park If your bus is equipped with a Park selection use it only after coming to a complete stop and then apply the parking brake Do not rely upon the transmission park pawl position alone to prevent the bus from rolling Range Inhibited Light Under certain operating conditions the Transmission Control Mod
92. higher ignition temperature Despite these relative safety advantages fire poten tial does exist CNG is lighter than air so it can collect in the higher regions of a room and possibly go undetected creating fire potential Since the fuel system is a very high pressure system employing a flammable gas all safety issues normally considered in these situations should be applied Some of the more obvious precautions are listed below This list is not necessarily intended to be complete and responsibility for assuring full safety is that of the person s doing the work or operating the system CEN Handle natural gas with care Compressed natural gas is a volatile fuel stored under high pressure If fuel storage or delivery components are installed serviced or operated improperly fire explosion and or serious injury could result Do NOT smoke while working on or around natural gas equipment Avoid flames sparks and operation of electrical devices in or around a vehicle with a possible natural gas leak Properly tighten all connec tions and thoroughly check for leaks after servicing fuel system Natural gas fumes may cause sickness or death Work in a well ventilated area CAN Protect against high pressure CNG Compressed natural gas is stored and routed to the engine at a pressure up to 3 600 psi Do NOT attempt to remove or disassemble any fuel system component while it is pressurized Explosive separation of components and escaping natural g
93. hook Bumpers provided on Blue Bird buses are designed to protect the vehicle and occupants from front and rear collisions They are not designed for towing or jacking up the vehicle Blue Bird does NOT recommend towing or jacking the vehicle by the bumpers CEN Exercise extreme caution when the drive shaft is removed on a unit equipped with hydraulic brakes The parking brake becomes inopera tive when the drive shaft is disconnected Do not leave the bus unattended until taking appropriate measures to prevent vehicle movement Do not work under the bus when supported by bumper jacks Use only appropriate jack stands supporting frame rails when under the bus CEN Do not lift the bus with the rear tow hooks These tow hooks should be used for flat ground maneuvering only Tow Hooks ROUTINE OPERATION A Ithough the controls of a modern bus may appear similar to those of a regular passenger car or truck the size and weight of the bus and its payload require many differences in design components and operating procedures This section describes special considerations in operation of the engine transmission brakes and other systems Remember The bus is eight feet wide without outside mirrors and is 25 to 40 feet long Therefore it is two feet wider and two to three times as long as the average automobile Acceleration will be slower than that of an automobile The inexperienced operator may find that steering brakes and other systems f
94. iciency Care should be taken to keep the filter clean A dirty filter restricts airflow and reduces heater output To clean or replace the filter remove the filter access panel The operating conditions of your bus will determine how frequently the filter should be serviced STEPWELL AREA Annual Maintenance Hoses Check all water hoses for kinks that can prevent water flow or chafing that can cause failure Look and feel for hardening of rubber or cracks that result from aging Hoses should be replaced when cracks first appear Hoses under the bus and in the en gine area will deteriorate faster than those inside the bus Exposed hoses should be checked more frequently Cores The heater will be most efficient when the core is clean The core should be cleaned carefully with compressed dry air or vacuum and a soft bristle brush Damaged fins should be straightened with a fin comb to prevent airflow restrictions The forward heater core can be accessed through the right front inside access panel Under seat heaters are accessed by removing the passenger seat cushions that are over them Motors Switches Blowers and Fans Maintenance free motors are used and do not require lubrication or cleaning over their operating life However excessive vibration caused by damaged blower wheels or fans can cause motor damage Inspect wheels and fans for obstruction or damage by running each fan individually listening and feeling for irre
95. im manufacturer for the specific load speed and applica tion The inflation pressure embossed on the tire sidewall does not take the wheel or rim capacities into consideration Tires should not be inflated above the pressure listed on the label without consulting your tire wheel distributor 35 So A CA ALL AMERICAN DRIVERS HANDBOOK Wheel And Rim Safety Wheels and wheel components must be properly maintained to avoid adverse ef fects on the life of the tire and or wheel An inflated tire is potentially very destruc tive Careless handling and inexperience cause accidents Safety literature can be ob tained from your wheel and rim distributor a wheel and rim manufacturer NHTSA or OSHA If you have any questions consult the distributor or manufacturer directly The load carrying requirements of each vehicle should also be determined before selecting the proper tire wheel combination Always remember that the weakest weight carrying component of the vehicle i e the tires wheels axles bearings etc determines the load carrying capacity for the vehicle CEN Improper handling of wheels and rims has caused many injuries and deaths Failure to follow directions is the leading cause of such accidents Obtain procedures from wheel and rim manufacturer before working witha wheel or rim The tire and wheel must always be properly matched For example do not mount a 20 inch tire on a 22 1 2 inch wheel Failure to strictly adhere to
96. ine retarder is engaged 11 Park Parking brake is applied 12 Low Coolant Level Engine coolant is low 13 Service Brake Lights when service brakes are applied 14 Range Inhibit The transmission ECU is restricting BRAKE SYSTEM shifts 20 ORIENTATION e Switch Panel Front Dome Lights Rear Dome Lights Driver s Dome Light Fan Hi Off Lo Fan Hi Off Lo Warning Light Master Switch Defroster CO Soy or E w iS Master Heater Switch Note The function of the Master Heater Switch is to turn off all heaters and radio to allow the driver to hear sounds outside the bus for instance at a railroad crossing When the switch is in the up position heater blowers and the radio will not operate When the switch is down see illustration these devices will function in a normal manner Tilt And Telescopic Steering To adjust steering wheel position use the tilting lever located on the left side of steering column Press lever downward to tilt column into desired position To raise or lower the steering wheel position pull up on the tilting lever This will enable you to raise or lower the steering wheel to the desired position 21 22 so A CA ALL AMERICAN DRIVERS HANDBOOK Mirrors And Adjustment CEN The vehicle s mirror system has been designed to comply with all field of view requirements but it is the operator s responsibility to adjust the mirrors properly before placing the vehicle in servic
97. ing brake The Interlock system should never be used to stop the bus Do not open the bus door s while the vehicle is in motion Parking Use the dash mounted valve to apply the rear spring brake when parking the bus When the parking brake is applied and the ignition switch is ON a dash mounted yellow light labeled PARK will warn the driver that the brake is applied TATON Do not attempt to move bus before spring brakes are released Draining Air Tanks Condensation must be drained from the air tanks daily To drain tanks properly leave cocks open until all air escapes and draining stops 4 Blue Bird heaters depend on engine generated heat to function Heat from the en gine is picked up by the engine coolant which is pumped through the heater cores inside the bus and then back into the engine A typical heater inside the bus includes a heat exchanger coil core and fans which move air across the coil Air moving across the core picks up heat from the engine coolant and transfers it into the bus Satisfactory performance of the heaters is dependent upon Adequate engine coolant temperature which is controlled by the thermo stat rating which should never be higher than recommended by the engine manufacturer Some All Americans feature optional shutters on the radiator that help to regulate engine coolant temperature e Coolant flow which varies with engine speed It can be increased if necessary with the use of an auxi
98. ing chart on the next page to find a possible cause and solution The Doran Warning Light Monitor does not display any indicator LEDs EXTERIOR LIGHT MONITOR dD Front CED 83 84 So A CA ALL AMERICAN DRIVERS HANDBOOK An overload situation has created an open circuit Check the system fuses e An overload or physical damage has burned or broken a conductor on the printed circuit board Extra lights have been added to the circuit i e trailer lights etc Remove the extra lights from the circuit Replace the damaged printed circuit board e Excessive vibration or abuse has resulted in a damaged monitor Replace the printed circuit board A particular LED on the Doran Warning Light Monitor does not display but the bus running lights are operating properly e There is an open coil in the monitor The coil is burned due to an overload Replace the coil kit e A solder joint has weakened a cold solder joint Flow new solder on the connection The reed switch has failed The reed has broken or the contacts have failed Replace the reed switch kit e The printed circuit board is broken or burned Replace the printed circuit board There is an open in the LED circuit Replace the LED A monitor LED indicator is on but the bus running light indicated is not operat ing or the bus running light switch is in the off position and the monitor indicates the running lights are operating e Replace the coil and
99. ion ratios in the range of 15 1 compared to 8 1 to 10 1 for gasoline The low flame speed of natural gas results in a longer duration of combustion To compensate for the lower flame speed ignition timing is advanced As with other fuels knock may occur with advanced ignition timing prolonged combustion i e too lean a mixture and excessively high com pression ratios Energy Conversions 100 125 cubic feet NG 1 0 gallon gasoline 114 000 Btu 1 0 gallon gasoline 136 cubic feet NG 1 0 gallon diesel 83 700 Btu 1 0 gallon LNG 1 cubic foot NG 1 000 Btu Vehicle Performance And Emissions NGV performance fuel economy and emissions can be significantly altered with ve hicle tuning i e ignition timing air fuel ratio Appropriate tuning adjustments can optimize performance fuel economy and emissions Alternatively a compromise tuning may be effected Tuning optimization for power generally increases emis sions Substantial improvements in performance and emissions can be obtained using natural gas conversion kits specially designed for a given vehicle make and model Further improvements can be achieved with factory built dedicated NGVs Starting Procedure Make sure that the main shutoff valve and at least one tank valve are open The fuel gauge shows empty if no fuel is available to the mixer Check the tank and main fuel shutoff valves if no fuel is indicated on the fuel gauge Note that fuel gauge takes time to register
100. ir cylinder in the header for operation of jackknife entrance and exit doors The door operates with an air push pull valve located in the switch panel area Emergency Pneumatic Power Door Release An emergency release valve is located above the door in the header cover To use the EMERGENCY emergency release push the lever in the direction of the arrow This valve exhausts RELEASE air pressure in the door cylinder allowing the door to be opened and closed manu ally 14 Electric Outward Opening Door The electrically operated outward opening door has a linear actuator that moves a lever attached to the front door To open the door hold the spring loaded switch in the driver s area in the OPEN position until the door stops moving An automatic switch stops the action of the door To close the door move the switch to the CLOSE position the door will stop automatically when fully closed There is a keyed switch on the outside of the body on the cowl panel by the door which operates the door from outside the bus Emergency Electric Power Door Release With the door in the fully closed position pull the release lever in the header panel toward OPEN as far as possible The linkage will release and the lever will snap into a park position so it will not return forward when released Push the door open to exit the bus To reset the release mechanism move the lever to its forward position and hold the drive
101. is controlled by the engine s ECM and is activated when regenera CENNO Postponing regeneration beyond the early indications may result in the engine being automatically de rated and reduction of power while driving CAEN The aftertreatment regeneration process can cause extremely high exhaust gas tem peratures hot enough to ignite or melt common materials and to burn people Carefully read understand and abide by all instructions warnings and cautions in the engine manufacturer s operator s manual and other related engine manufacturer s literature regarding safe operation when the HEST indicator is on Carefully read understand and abide by all instructions warnings and cautions in the engine manufacturer s operator s manual and other engine man ufacturer s literature regarding safety conditions when perform ing Stationary regeneration ROUTINE OPERATION e gt tion needs to occur and the necessary conditions are met When not in regeneration mode the ARD is simply a chamber through which the exhaust flows During regen eration a charge of fuel and air is ignited in the ARD and the resulting combustion creates additional heat to facilitate regeneration HEST Indicator High Exhaust System Temperature An instrument panel indica tor which appears when the exhaust temperature is unusually high due to recent regeneration This is a normal behavior of the aftertreatment system intended to notify t
102. lace to secure refill Figures 102 CLEANING Exterior Cleaning The best way to preserve your vehicle s finish is to keep it clean by washing frequent ly Wash the vehicle in lukewarm or cold water Do not use hot water or wash in the direct rays of the sun Do not use strong soap or chemical detergents All cleaning agents should be promptly flushed from the surface and not allowed to dry on the finish Polishing with nonabrasive wax is recommended to remove accumulated resi due and eliminate any weathered appearance Pressure washing may cause damage to finish Pre test pressure washer on a similar surface before applying pressure and chemicals to your vehicle Pressure washers that recirculate should filter the water to remove abrasive grit Calcium chloride and other salts ice melting agents road oil and tar tree sap bird droppings chemicals from industrial chimneys and other foreign matter may dam age vehicle finishes if allowed to remain on painted surfaces Prompt washing may not completely remove all of these deposits Additional cleaners may be needed When using chemical cleaners developed for this purpose be certain they are safe for use on painted surfaces Any stone chips fractures or deep scratches in the finish should be repaired promptly Exposed metal will corrode quickly and may develop into a major repair expense Floor Cleaning Regular cleaning and care will prolong the life of floor covering and im
103. latches on the center panel and allow it to open downward for access to the heater bleeding valve radiator fill cap and to view to the radiator sight glass Release press button latches on front access doors to the left and right of the cen ter panel for access to windshield wiper motors windshield wash reservoir located on the entrance door side and power steering fluid reservoir located on driver s side All American RE On the Rear Engine models this allows access to windshield wiper motors wind shield wash reservoir etc After closing press in the larger portion of the latch until it snaps to lock into position 26 Engine Access All American Front Engine To open the hood disengage the latch mechanism located in two places on the en gine cover Lift the access cover and allow it to rest fully open on the forward portion of the hood assembly This will allow access to engine components such as the oil dipstick engine oil fill transmission fluid dipstick etc To remove engine cover assembly for better access to the engine components loosen the screw type latch mechanisms located at the upper front wall of the engine hood assembly Open the hood and locate three latches on the inner wall perimeter of the hood assembly One is located at the rear center and one is located on each side Releasing these latches will then allow entire hood assembly to be removed for mechanics acc
104. ld be tested by sending samples to a Fleetguard lab for a monitor C test as specified in the Cummins Operator s Manual The John Deere Cool Gard coolant may be tested by sending a sample to John Deere for a Cool Scan test or may be manually tested by qualified service technicians using a John Deere Three Way test strip which is included in John Deere 3 Way Heavy Duty Coolant Test Kit TY6175 Follow the engine manufacturer s procedure for draining flushing and refill Blue Bird buses equipped with Caterpillar or Cummins engines may also be equipped with an optional coolant filter The coolant filter element installed at the Blue Bird factory is compatible with all three of the above described coolants Biue Biro Numeer 0064641 Venpor Wix Part NumBer 24070 98 Shutters The optional radiator shutters assist in maintaining a constant engine temperature by limiting the air flow through the radiator The shutter blades are powered by air pressure from the brake system on the vehicle The shutters are controlled automati cally by an Alarmstat which is located in the upper radiator hose and an electric so lenoid in the air line controlling the shutters The shutters require no lubrication but must be cleaned as required or at least every two years or 24 000 miles whichever occurs first See the shutters installation diagrams provided with vendor mainte nance information for plumbing wiring and parts requirements 99 So A CA ALL AME
105. liary water pump The heaters are rated at six gallons per minute Blower motors have multiple speeds and can be checked by operating the motors individually while listening for variations in speed Heater Operation Be sure the engine radiator is full and all coolant flow 1 2 3 valves are open See charts on valve location o o O O O k l a LN CIS N5 nA TATON Do not leave the engine running while fas cai oe fe am Ah K Z 6 opening or closing valves O Warm the engine to operating temperature run ning at up to 1 800 rpm if possible and then turn on the heater fans and the auxiliary water pump if so equipped During extremely cold weather operating the O O Q heater fans will cause the engine temperature to drop noticeably as heat from the engine is transferred into the bus Also the engine will Q o O generate more heat as it works under load When the engine reaches operating temperature the driver can control heater blower speeds for optimal defrosting and overall passenger comfort Control Panel Outlet Locations The heater control panel is located on the dash to the Outlet Locations right of the instruments The indicated switches and le 1 Foot Warmer vers control the motors and air outlets as shown 2 Main The heater is located in the right front corner for 3 Defrost ward of the entrance door An auxiliary unit is located 4 Fresh Air
106. lippery e Consult the retarder manufacturer s Owner s or Operator s Manual for addi tional information 69 So A CA ALL AMERICAN DRIVERS HANDBOOK Transmission Indicators Check Transmission Indicator While driving be alert to any abnormal shifting unusual sounds or vibrations smells or frequent illumination of the CHECK TRANSMISSION light If you experience any of these get service immediately Transmission Oil Temperature Gauge An optional gauge on the instrument panel indicates the transmission oil tempera ture Extended operations at low vehicle speeds with the engine at full throttle can cause excessive oil temperatures These temperatures may overheat the engine cool ing system and lead to engine and or transmission damage If excessive temperature is indicated by the engine coolant temperature gauge stop the vehicle and check the cooling system If the cooling system appears to be functioning properly shift to neutral and accelerate the engine to 1 200 1 500 rpm This will reduce the transmission temperature to operating level within two or three minutes If high temperature persists stop the engine and have the overheating con dition investigated by service personnel If the transmission oil temperature gauge indicates excessive temperature check the oil level in transmission refer to the Oil Check Procedure in your Allison Transmis sion Operator s Manual Stop the vehicle and shift to neutral Accele
107. lubrication Remember that all moving part joints tilt pivots slide forward back adjustment and vertical motion pivots four in all require lubrication This should be done every six months or 6 000 miles whichever occurs first The use of lithium based grease in aerosol form is recommended 90 SEAT CARE AND CLEANING It is imperative that the interior of the bus be kept clean seats are an important part of this maintenance Regular cleaning and care will prolong the life of the seats and improve the general appearance of the bus Everyday dirt and soil Most everyday soil and dirt may be removed with a soap and water solution If the stain is persistent a stiff bristle brush may be used Fabric covered seats should be rinsed with clean water after the stain is removed Paint tar and asphalt Remove the stain immediately using a damp cloth and kerosene Rub gently using small strokes Rinse thoroughly This type of stain may become permanent if not cleaned immediately Nail polish and lacquer based stains Soak up as much as possible with dry cloth immediately Any remaining stain may be removed with a non flammable cleaning fluid such as Tuff Stuff or Armor All cleanser Rinse thoroughly with clean wa ter Gum grease and shoe polish Remove as much as possible immediately If left for any length of time shoe polish will stain permanently Clean any remaining stain with Tuff Stuff or Armor All cl
108. mission The Allison transmission provides four forward speeds and one reverse The trans mission is controlled with the selector lever located to the driver s right The selector lever must be in the N position neutral to start the engine If the engine starts in any other position the neutral start switch is malfunctioning and should be repaired immediately Use D drive for all normal driving conditions The service brake must be applied before the transmission will shift from neutral to drive or reverse If an 65 66 so A CA ALL AMERICAN DRIVERS HANDBOOK attempt is made to shift the transmission into drive or reverse without applying the service brake it will remain in neutral an audible alarm will sound and the Range In hibit light on the instrument panel will come on If this occurs apply the service bake and then select the desired gear The vehicle will begin to move in first gear and as you press the accelerator the transmission will upshift automatically As the vehicle slows down the transmission will automatically downshift to the correct gear Use 3 and 2 when the road load or traffic conditions make it desirable to restrict the automatic shifting to a higher range When the conditions improve return the range selector to the normal driving position D These positions also provide progressively greater engine braking power the lower the gear range the greater the braking ef fect Use
109. natural gas vehicle is dependent upon the qual ity of fuel used BTU content of natural gas can vary depending on locale Excessive moisture can cause loss of power and regulator freezing Other contaminants spe cifically lubricants and oil can cause serious damage which is not covered by the engine manufacturer s warranty In addition poor quality fuel can affect emission certification It is the owner s operator s responsibility to ensure that clean quality fuel is used to prevent damage to the fuel system components and power plant Damage caused by poor quality fuel is not covered by Blue Bird warranty Fuel control systems used on engines fueled by compressed natural gas contain electronic sensors and other delicate components that are not tolerant of contami nants Vehicle performance is dependent upon clean fuel and a regular schedule of vehicle maintenance Compressed natural gas is expected to be delivered from the compressor station and storage cascade free of contaminants including oil water and particulates Con ditions exist in some CNG fill stations that cause inferior fuel to load into the vehicle s fuel storage system Compressed Natural Gas Filters Particulate and coalesce type filters are installed in Blue Bird CNG fuel systems The primary filter is of stainless steel construction and is located at the fill point This filter can be checked for contamination by closing the main shutoff valve on the frame and then
110. nd refer to the manufacturer s dealer Engine Cooling System In today s modern engine designs accurate maintenance of the cooling system is critically important to engine life Simply maintaining coolant level and performing occasional coolant changes does not adequately ensure that the cooling system is healthy The chemical balance of engine coolant must always be correct This re quires dilligent adherance to the engine manufacturer s coolant specifications main tenance schedules and procedures Accurate coolant system maintenance records should be kept The engine coolant level in the reservoir should be checked daily as a part of routine pre trip inspection But whenever the coolant level is low it must be replen ished with only pre mixed coolant of the same type and brand installed Never top off coolant with plain water Careful pre trip inspection and a program of routine maintenance checks of the condition of the cooling system by service technicians should ensure against enroute emergencies such as worn hoses or loose clamps resulting in coolant loss In the case of such an emergency however if anything other than original premixed coolant is added in order to allow the bus to proceed to a service facility the coolant system must be completely drained flushed and properly refilled with approved coolant before being returned to routine service Any enroute event requiring topping off of the coolant should be reported to service
111. ndetected CEN Never attempt to find a leak with your hands A large leak can freeze burn the skin Never place your hands or any other part of your body on a leak Always have the properly rated fire extinguishers at hand Be that certain auto matic fire suppression equipment is in place and in operating condition CAN Avoid heat near pressure relief valves The manufacturer s rat ing is 212 F for the relief valve If it vents the area will be filled with natural gas CEN Rust or corrosion on tanks lines fittings and valves can bea serious problem Any part with serious corrosion should be replaced Fiber glass coating on tanks should be in excellent condition Any cracks or serious scrapes may require tank replacement Contact the manufacturer CEN Tanks cannot be filled to more than 3 000 psi or 3 600 psi temperature corrected Use only authorized refueling stations with adequate pressure controls and venting capacity Venting contents of tanks should fol low any federal and state guidelines including EPA 57 so A CA ALL AMERICAN DRIVERS HANDBOOK CEN Use only fuel connections designed for use with that on the bus Do not attempt to force damaged fittings Keep sources of heat and ignition away from fuel system and refueling apparatus For more information see drawing 1589001 in the owner s information pack age supplied with the vehicle Compressed Natural Gas Fuel The performance and reliability of a
112. ne wood paper plastics fabric compressed gas containers hydraulic lines is near the exhaust outlet Abide by all instructions warnings and cau tions in the engine manufacturer s operator s manual regarding safe operation when performing a Stationary Regeneration Park the bus securely e Set the parking brake Put the transmission in Neutral Chock the wheels 52 ROUTINE OPERATION e gt e Secure the exhaust area e If bystanders might enter the area set up barriers to keep people safely away from the exhaust outlet If the procedure is performed indoors at a service facility attach an exhaust discharge pipe rated for at least 1500 F e Keep a fire extinguisher nearby e Check exhaust system surfaces to confirm that no tools rags grease debris or any other objects are on or near the exhaust system Start the engine Operate the Regeneration Switch to begin the regeneration process e Monitor the process If any unsafe condition occurs shut off the engine imme diately During the regeneration process the engine may change speed and the turbocharger may whistle When the process is complete the engine will return to normal idle speed Exhaust gas and exhaust surface temperatures will remain elevated until they have had time to cool to normal levels 53 VFA ALL AMERICAN DRIVERS HANDBOOK COMPRESSED NATUAL GAS CAEN Due to the dangerous potential of high pressure cylinders it important t
113. ng condition such as engine RPM too high or service brakes not applied when attempting to shift from neytral Check for the illumination of the RANGE INHIBITED light or CHECK TRANS light See the appropriate section of the Allison transmission manual 67 So A CA ALL AMERICAN DRIVERS HANDBOOK Allison Automatic Transmission Driving Tips Accelerator Control The pressure of your foot on the accelerator pedal influences the automatic shift ing An electronic signal tells the ECU how far the driver has depressed the pedal This provides the accurate shift spacing and control necessary for maximum perfor mance Downshift or Reverse Inhibitor Feature with Allison 3000 PTS Transmission Although there is no limitation on upshifting there is a limit on downshifting and shifts from neutral into drive or reverse If a downshift or neutral to range shift is selected when the engine speed or throttle position is too high the ECU TCM will not allow the shift until reaching a lower speed If idle speed is too high shifts to range are prohibited A continuous beep tone sounds when reverse is selected dur ing forward movement or if a neutral to range shift is selected at too high an engine speed Cold Weather Starts Most Allison transmissions are programmed to restrict operation until operating temperature is reached When the transmission fluid temperature is below 25 F 32 C the transmission will not shift into
114. ng systems State and local regulation regarding NGV refueling may preclude economic feasibility of indoor refueling such as in New York City However the sig nificance of this issue may diminish if increased experience with fuel leads to less stringent regulations CNG refueling transfers natural gas under pressure and may be set up as either slow fill or fast fill Slow fill generally uses overnight refueling and requires less costly refueling station equipment than fast fill However fast fill refueling time is only slightly longer than gasoline refueling time LNG refueling transfers a cold 260 F liquid under pressure around 15 psi and generally takes slightly longer than con ventional refueling because a greater volume of liquid is transferred to compensate for its lower energy content The refueling station has a supply connection hose and a coupling that must be properly attached to the fuel system fill valve The supply side is regulated for maximum pressure and uses a proper purge valve when decoupling from the filler The regulators and relief valves of the fill station must be checked for proper values and operation Fuel enters the bus coupling from the filler connection travels through a one way check valve into the fuel lines and then into any open tanks Any tank that is open is in communication with any other open tank through the common fuel lines CEN Do not refill with the engine running or any source of ignition or h
115. ng the jacking device 2 Apply the parking brakes Place chocks at the front and rear of the tires opposite the wheel or wheels to be lifted first 4 Use jacks and jack stands or blocks of sufficient capacity to support the ve hicle Following the jack manufacturer s recommended pro cedure place the jack securely under the axle at a spring or suspension beam nearest the tire wheel to be repaired 5 Jack the bus only to the height necessary to service CEN Ensure any locking device on the jack is in place and operating properly Support the vehicle under the main frame rails with jack stands or blocks before working under or around the bus 6 After servicing is complete lift the bus just enough to remove the jack stands or blocks 7 Carefully lower the bus CEN Do not work under a bus supported by jacks Use only appropri ate lifts and or jack stands supporting frame rails when working under bus 37 38 soe ACA ALL AMERICAN DRIVERS HANDBOOK Changing a Flat Tire The lug nuts are tightened to a torque value of 450 500 Ft Ib 610 678 Nm With out the proper power tools it is very difficult to remove the lug nuts The lug nuts must be broken loose before lifting the wheel off the ground CEN Never work around or under a bus supported only with a bottle jack Ww wo en awn S 11 Remove the lug nuts Position the spare as near to the hub as possible You will probably need to raise
116. ns are printed near each exit Some units are equipped with an audible alarm which sounds if an emergency exit is unlatched or open If a buzzer sounds when turning on the ignition switch check emergency exits to see that they are closed All emergency exits meet Federal Motor Vehicle Safety Standard 217 Bus Window Retention and Release These illustrations show various types of emergency exits CEN All emergency exits should be checked daily to ensure they are clearly labeled and operate properly Exit windows doors and hatches must not stick or bind and must open smoothly and reliably without undue force Report any damage or defects immediately and repair before transporting passengers Transpec Safety Vent The roof hatch serves as an important emergency exit It is important that it is main tained properly and instruction labels are in place and clearly visible All emergency exits should be inspected and operated daily to ensure that they are labeled and operate according to the instructions provided Maintenance Cautions Transpec Safety Vents are designed to provide years of reliable service with a mini mum amount of maintenance All components are rustproof with lifetime finishes and moving parts are Teflon coated to eliminate need for lubrication Use of lu bricants paints or other coatings such as graffiti deterring spray is not recom mended Suggested maintenance includes periodic inspection of attaching fa
117. ntents of the kit should be FIRST AID inspected weekly or as required by local regula ALU RIRI tion to ensure that all contents comply with state specifications Body Fluid Cleanup Kit The body fluid cleanup kit is designed to contain accidental spillage of biological matter minimiz ing risk of exposure to potential health hazards The contents of the kit should be inspected monthly or as required by local regulation to ensure that all contents comply with state specifications Fire Axe Crowbar The fire axe and crowbar are located on the electrical panel access cover to the left of the driver s seat as near to the front as possible Every 30 days inspect installa tion mounting fasteners to ensure that they are secure Check fire axe and crowbar monthly to ensure that they are easily accessible and unobstructed 32 ENROUTE EMERGENCIES Flare Kit The flare kit is mounted on the left hand side panel behind the driver s seat Every 30 days or as required by local regulations ensure that the contents of the flare kit are in place Inspect mounting fasteners for flare kit box every 30 days to make sure they are tight Triangular Warning Devices For states requiring the triangular warning devices be located in the driver s compart ment this container is mounted above the windshield at the upper center near the roof line For other states it is located on th
118. ocated on the front upper inner panel above the windshield Refer to the data on these plates for registration purposes or for replacement part information MANUF ACTURED BY BLUE BIRD BODY COMP ANY DATE OF MFR M INC VEH MFG BY ME ATE SUIT ABLE TIR E RIM CHOICE GVWR GVWR FRONT E S E Ris AT MR PS COLD SINGLE GVWR REAR E S AE CORDDI 2S THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT IN iii VN i CLASSIFICA TON BLUE BIRD FORT VALLEY FORT VALLEY GEORGIA copy NO MODEL YEAR MRA Oua Usenet EQUIPPED CAPACITY SPECIFICATION YEAR O Y MAX DESIGN CAPACITY ESTA BLUE BIRD FURNISH INFORMATION BELOW WHEN ORDERING AXLE PARTS CHASSIS ENGINE SERIAL SERIAL AXLE NO amp FRICTION CODE DRUM REAR Po BRAKE LINING FMSI AXLE NO amp FRICTION CODE ORUM REaRaxLeRaTo s CHASSIS SERVICE NO 13 so A CA ALL AMERICAN DRIVERS HANDBOOK Outward Opening Door Outward Opening Doors are mounted in a prefabricated framework which elimi nates the effect of body construction variations on door and seal operation Doors are suspended completely on sealed ball bearings located at the top corners of the framework inside the body The interlink connection between the doors is a single assembly with oppositely threaded spherical bearing rod end connectors at each end providing simple link length adjustment without disassembly The geometry of the mechanical
119. of the hinged stop on the door control Emergency Door Vandal Lock The emergency door and the rear emergency window may have an optional vandal lock feature which prevents entry through the emergency door When the vandal lock cylinder is in the lock position the engine cannot be started To start the bus the cylinder must be removed from the lock and placed in the receptacle at the side of the door Sliding Bolt Vandal Lock The sliding bolt vandal lock for the emergency door and rear emergency window is an interior latch that prevents the door from being opened from the outside The bolt is connected to an interlock assembly which prevents the engine from starting when the door is locked If the lock is activated after the engine is running an alarm sounds in the driver s area CEN The bus must not be operated with the emergency exit locked 16 Wheelchair Lifts Blue Bird All American school buses may be fitted with lifting platforms designed to aid in loading and unloading passengers There are two optional wheelchair lifts available The units available are the Ricon Model 5010 and the Braun Model L919FIB Both offer a maximum of 48 inches 122 cm lift from the ground to the level of the bus floor For the correct operation and maintenance of the wheelchair lift on your bus please refer to the operator s manual supplied by the OEM CANN Operators should familiarize themselves with the lift manufac turer s operator
120. ofter to push 3 The brake pedal will travel farther than normal 71 So A CA ALL AMERICAN DRIVERS HANDBOOK Brake Warning System The brake warning system includes a buzzer and a dash mounted red light labeled BRAKE SYSTEM The light and buzzer will activate during the following conditions e Engine is running brakes not applied with a loss of electrical power to the electric backup pump motor e Engine is running brakes not applied with a loss of power assist from the power steering pump e Engine is running brakes are applied and either the front or rear section of the system has failed The backup pump buzzer and light will remain on even after the brake pedal has been released e Engine is not running brakes are not applied but ignition key is ON This condition should happen every time the driver starts the bus The bus should not be driven if the backup pump system is not working The backup system should go off when the engine starts Engine is not running brakes are applied and ignition is in ON position This is a method for checking the backup pump With the engine not running and the ignition OFF a depressed brake pedal will cause the backup motor to run with no light and buzzer The backup system should go off when the pedal is released Without the assist of the power steering pump and without the assist of the backup pump the master cylinder will allow the brakes to be applied However
121. on 15 Brake pedal or air treadle applies service brakes 16 Accelerator pedal controls engine speed 17 Heater and defroster controls ORIENTATION e Dash And Instrument Panel i 4in 1 Gauge Consist of the following clockwise from left to right Fuel Gauge Indicates fuel level in tank Voltmeter Indicates electrical system voltage Coolant Temperature Gauge Indicates engine coolant temperature Oil Pressure Indicates engine oil pressure Front Air Gauge Indicates air pressure in front brake reservoir Rear Air Gauge Indicates air pressure in rear brake res ervoir Speedometer Indicates vehicle speed Tachometer Indicates engine speed Transmission Oil Temperature Indicates transmission fluid temperature 7 Ammeter Indicates battery charge condition Headlight Switch First position activates front park lights and rear taillights Second position activates front park lights rear taillights and headlights Dimmer Switch Adjusts light level on instrument pan el High Idle Switch Sets engine at high idle speed Diagnostic Switch For use by qualified service person nel for diagnostic purposes only Tire Chains Switch Activates on spot automatic tire chain device 13 14 15 16 17 18 Adjust Pedal Two position momentary switch adjusts accelerator pedal to desired position Cruise Control On Off Activates or inactivates the cruise standby mode Cruise Con
122. ould be aware that fuel cylinders for CNG Compressed Natural Gas must be inspected ev ery three years in accordance with NGV 2 specifications The owner operator should be aware that cylinder expiration date is fifteen years after the date of the cylinder manufacture Compressed gas cylinders must be replaced at that time Testing and recertification of the compressed gas cylinders is not covered by Blue Bird warranty Replacement of compressed gas cylinders at the end of their service life is not covered by Blue Bird warranty National Fire Protection Association 52 States Cylinders shall be manufactured inspected marked tested retested equipped and used in accordance with U S Department of Transportation DOT or Canadian Transport Commission CTC regulations exemptions or special permits specifically for CNG service and shall have a rated service pressure of not less than 2400 psig at 70 F 16 5 MPa at 21 1 C Pressure vessels shall be manufactured inspected marked and tested in accor dance with the rules for construction of unfired pressure vessels Section VIII Divi sion 1 ASME Boiler and Pressure Vessel Code When a vehicle is involved in an accident or fire causing damage to the CNG container the CNG container shall be replaced or removed inspected and tested in accordance with the document under which it was originally manufactured before being returned to service 54 ROUTINE OPERATION e gt When a vehicl
123. per forming the modification must be a licensed vehicle manufacturer or must objtain the services of a licensed vehicle manufacturer for that purpose Specifically Blue Bird Corporation does not authorize any modifications to or such as the following e Front or rear suspension e Wheelbase length Body or chassis crossmembers Frame rail flanges e Welding on the engine radiator fuel tank s transmission or any component of those items e Cooling system Addition of any equipment or component nearer than 2 inches 51mm to the fuel tank s rotating components or jounce movement of driveline compo nents 11 12 Before Placing the Bus in Service It is the responsibility of the bus Owner Operator to ensure compliance with all fed eral state and local regulations for school bus operation and equipment As part of a daily pre trip inspection the Driver should consider it his her responsibility to verify that the vehicle is in satisfactory working order and that all emergency equipment is in place fully stocked First Aid Kit up to date Fire Extinguisher and in proper working condition e Check the suspension U bolt torque e Check the service brake adjustment e Check the park brake adjustment on units equipped with hydraulic brake sys tems e Check the torque on all the body tie down capscrews e Check the engine oil level e Check the transmission fluid level e Check the engine coolant level e
124. pplies the service brakes An audible alarm sounds in the event of an interlock malfunction When used with the existing vehicle parking brake the brake interlock uses the vehicle s service brake system to provide additional brake holding action CEN The brake interlock is a safety device and is not intended to be used a parking brake The Interlock system should never be used to stop the bus Do not open the bus door s while the vehicle is in motion The following are decals along with WARNINGS located forward of the switch panel below the driver s side window on All Americans with hydraulic brakes Read Warnings and Operating Instructions prior to using 690 Brake Lock TO LOCK 1 Set parking brake 2 Move lock switch to ON position TO RELEASE 1 Move lock switch to OFF position 2 Release parking brake AWARNING d Serious injury a or death can occur if these instructions are PREVENT not followed ROLLAWAY Vehicle equipped with Brake Lock System Operator must read and understand operating instructions before using vehicle Brakes will release if ignition is turned off when Brake Lock is remotely activated Do not use Brake Lock in place of original equippment parking brake Always set parking brake and use wheel chocks and outriggers with Brake Lock Do not use Brake Lock for overnight or prolonged parking Release Brake Lock before moving vehicle Brake Lock and warning circuit are disabled if batter
125. practical the bus could simply be operated for a while at a speed above the automatic regenera tion threshold or the bus could be taken to a suitable location to have a Stationary Regeneration procedure performed If the bus is operated at a minimum highway driving speed 20 mph Caterpil lar 40 mph Cummins the automatic regeneration system will activate If minimum speed is maintained long enough usually 20 30 minutes the automatic regenera tion mode can likely reduce the soot sufficiently to cause the DPF Icon to go off Therefore the first appearance of the DPF icon should be perceived by the driver as a normal notification of action that needs to be taken but not as an emergency situation Typically even if the bus route does not afford immediate opportunity for higher speed operation there is sufficient time to finish the bus route and return to the bus maintenance shop before the higher level of notification occurs Exactly how much warning time the first appearance of the DPF indicator represents is depen dant upon specific operating conditions However current data from Cummins sug gest that at this level of notification the DPF needs to undergo regeneration within the next two to six hours of bus operation If regeneration does not begin a more imperative notification will activate Level 2 Notification DPF Indicator Blinks If the bus continues to be operated without taking the measures indicated by a Level 1 Noti
126. pressure stainless steel Tees and crosses Any open tank is connected to any other open tank so for fueling the fuel flows through the common line to all tanks The tank shutoff valves isolate the tanks the Tees on the valves still have the high line pressure 55 So A CA ALL AMERICAN DRIVERS HANDBOOK Do not uncouple fittings until all tanks are closed and pressure has been purged from the line The lines are high pressure rated 3 8 stainless steel seamless tubing which carries the fuel to the high pressure regulator In refilling the fuel enters the fill valve on the entrance side of the bus and then flows through a check valve into the common tubing before reaching the tanks From the high pressure regulator the fuel flows to the shutoff solenoid The igni tion switch engine operation and the fire suppression system activate the shutoff solenoid The loss of any of these will shut off fuel supply to the low pressure regula tor LPR The fuel gauge is proportional to the pressure when corrected to 70 F Fuel level is only accurate for the tanks that are open Safety Cautions And Warnings Both gasoline and CNG are volatile flammable fuels yet they are safe to work around when necessary precautions are taken As on a gasoline fueled system carelessness with CNG can lead to a fire or explosion when a leak occurs CNG will not pool and spread like gasoline It has a narrower range of flammability than gasoline as well as a
127. prove the gen eral appearance Floor coverings should be swept daily and mopped weekly with a mild detergent and water Do not use floor sweeping compounds Be sure to remove dirt pencils paper and any other debris that may cause the emergency door to seal improperly Do not use harsh detergents or excessive amounts of water Do not use a water hose to wash out the bus Deterioration and damage to the wood floor could occur Petroleum products such as oil and grease quickly deterio rate the floor covering These types of products should be removed from the surface as soon as possible Continuous care must be exercised in the stepwell area where foreign objects can create a safety hazard The accumulation of dirt and foreign material in the stepwell area creates a hazard for passengers and could prevent the doors from operating properly Ensure that screws for floor trims and aisle trims are seated tightly 103 so A CA ALL AMERICAN DRIVERS HANDBOOK The front heater can be accessed from the curb DASH COVER side access panel outside the bus at the front and from the inside on the dash near the step well To access the heater core and filter inside the bus remove the interior heater access panel shown DASH Filter PANEL The main heater core is protected by an air filter which prevents dirt and dust from collecting on FILTER ACCESS PANEL the heat exchange surfaces and thereby lower ing heater eff
128. r operated spring loaded switch in the open position until it clearly engages or until door is in the fully open position Entrance Door Security Lock To activate the optional electric entrance door security lock pull the door to a fully closed position from outside the vehicle When this is done the security lock is activated To unlock insert the key into the lock forward of the door While turning the key press against the center section of the door to open ORIENTATION e gt WARNING LOCK LEVER MUST BE ROTATED TOWARD FRONT OF BUS AND KEY LOCKED WHILE NOT IN USE a HTT Manual Security Lock interior The manual security lock release handle is located in the lower kick panel of the entrance door It rotates in a counter clockwise direction to latch It can be locked in the latched position or in the unlatched position To use the vandal security lock the hinged stop on the door control cover must be down to prevent the door control arm traveling over center when closing the door Manual Security Lock interior 15 soe ACA ALL AMERICAN DRIVERS HANDBOOK Security Lock Outward Opening Door Outward opening doors have an optional key locking mechanism accessible from outside the bus A key operated bolt slides into a hole in the header when the door is in the closed position and locked This option also requires use
129. rate the engine to 1 200 1 500 rpm The temperature should return to normal within two or three minutes before the vehicle resumes operation Normal temperature for both on and off highway operation is 160 to 200 F Oil temperature should never exceed 250 F In units equipped with electronic transmissions if the sump oil temperature reaches 250 F the TCM will inhibit operation in the higher gears and turn on the OIL TEMP light located on the shifter cover If high temperature in either engine or transmission persists stop the engine and have the overheating conditions investigated by maintenance personnel The engine should never be operated for more than 30 seconds at full throttle with the transmission in gear and the vehicle not moving Prolonged operation of this type will cause the transmission oil temperature to become excessively high and will result in damage to the transmission 70 Antilock Braking System ABS In a vehicle equipped with an antilock braking system ABS motion sensors detect the speeds at which the wheels move These sensors transmit this information to an Electronic Control Unit ECU If the wheels start to lock the ECU signals the modula tor assembly to regulate the brake pressure of each locking wheel An ABS indicator lamp on the dash see Indicator Light Panel in Instrument Panel section warns the driver of possible system faults and provides blink code information to diagnose the system
130. ration loose clamps wear spots holes in piping Inspect amp Tighten Intake Tract Hose Clamps Tighten to 10 in Ib Inspect amp Tighten Intake Tract Spring Loaded Clamps Tighten to near full spring compression Inspect Intake Tract Support Bracket Visual inspection Repair damaged parts immediately Inspect amp Tighten Intake Tract T Bolt Tighten to 50 in Ib Clamps Inspect amp Tighten Intake Tract Worm Gear Tighten to 38 42 in lb Clamps Steering Lubricate Axle Steering Linkage Drag Link NLGI 2 EP multipurpose grease rated GC LB or equivalent Lubricate Axle Steering Linkage King Pins NLGI 2 EP multipurpose grease rated GC LB or equivalent Lubricate Axle Steering Linkage Tie Rod NLGI 2 EP multipurpose grease rated GC LB or Ends equivalent Lubricate Intermediate Steering Shaft Slip Lubricate splines with multipurpose grease Joint Every 3 Months or 24 000 Miles Brakes Inspect Air Brakes Air Dryer See Bendix appendix for specific model in Air Brakes Chapter Inspect Hydraulic Brakes Booster amp Master Inspect for signs of leakage or physical damage Cylinder 129 130 VFA ALL AMERICAN DRIVERS HANDBOOK Warning Devices amp Signs Lubricate Destination Sign Hinges Every 6 Months or 6000 Miles Lubricate Destination Sign Roller Gears Lightweight grease such as White Lube Axle amp Suspension Rear Inspect amp Tighten Com
131. rbon Monoxide 44 Heater Operation 75 Diesel Fuel 44 Diesel Engine Starting Procedure 45 Starting With Boost Cables 45 Using The Engine As A Brake 46 Engine Warning System 46 Exhaust System 47 DPF Regeneration In Blue Bird Buses 48 Levels of Notification 49 Stationary Regeneration Precautions 52 COMPRESSED NATUAL GAS Owner Operator Responsibilities 54 Control Panel Outlet Locations 75 Defrosting 76 Heater Defroster Location 76 Driver Passenger Comfort 76 Standard Heater Cut Off Valves 77 National Fire Protection 54 Fuel System Description 55 Safety Cautions And Warnings 56 Compressed Natural Gas Fuel 58 Compressed Natural Gas Filters 58 Refueling 59 Specific Gravity 60 Fuel Toxicity And Safety 60 Flammability 60 Antiknock Properties 61 Energy Conversions 61 Vehicle Performance And Emissions 61 Starting Procedure 61 Cold Start 62 Operation And Maintenance OfCNG Vehicle Components 62 TRANSMISSIONS Allison Automatic Transmission 64 Allison Model 3000 Bus Series Transmission 64 Allison Model 2000 Bus Series Transmission 65 Range Inhibited Light 67 Check Transmission Light 67 Allison Automatic Transmission Driving Tips 68 Electric Retarder If Equipped 69 Transmission Indicators 70 CARE amp MAINTENANCE ELECTRICAL Interior Lights 82 Exterior Lights 82 Doran Warning Light Monitor 83 Circuit Breakers 85 DOOR A
132. rease Inspect amp Tighten Driveshafts U Joint Bolts Tighten to 45 50 ft Ib Electrical Inspect Alternator Connections Inspect for loose wires damaged terminals damaged insulators Inspect Battery Ground Strap Check for solid connection tight fasteners and absense of corrosion Fuel System Inspect Fuel Lines Inspect for leaks or signs of abrasion Lubricate Fuel Stop Solenoid Inspect Fuel Tank Vent Inspect for obstruction Intake System Inspect Air Cleaner Filter Element Inspect for proper seating secure lid Replace if soiled wet or damaged Inspect Intake Tract All Fasteners Inspect for signs of contaminate infiltration loose clamps wear spots holes in piping Inspect Intake Tract Charged Air Tubing Inspect for signs of contaminate infiltration loose clamps wear spots holes in piping Inspect amp Tighten Intake Tract Hose Clamps Tighten to 10 in Ib Inspect amp Tighten Intake Tract Spring Loaded Clamps Tighten to near full spring compression Inspect Intake Tract Support Bracket Visual inspection Repair damaged parts immediately Inspect amp Tighten Intake Tract T Bolt Tighten to 50 in Ib Clamps Inspect amp Tighten Intake Tract Worm Gear Tighten to 38 42 in lb Clamps Steering Lubricate Axle Steering Linkage Drag Link NLGI 2 EP multipurpose grease rated GC LB or equivalent Lubri
133. reed switch kit Neither the bus running lights nor the Doran Warning Light Monitor operate properly e The running light bulb may be burned out Replace the light bulb 2 The overload thermistor has protected the circuit from overload Remove the overload condition A short e Incorrect light bulb s e Extra lights i e trailer lights etc Do not attempt to check a light emitting diode LED with an ohmmeter Some digital volt meters DVM have a diode checking position which is acceptable to test LEDs Any repair of the Doran Warning Light Monitor should be referred to a qualified technician Circuit Breakers The electrical system is protected by circuit breakers located in a side mounted elec trical box below the driver s window If a current overload or short should occur in any body circuit it will trip the circuit breaker If a short occurs and the circuit breaker breaks the circuit breaker will reset when the element cools usually in about 15 seconds A short may be indicated by blinking lights or fluctuating gauges The shorted circuit should be corrected immediately Refer to body or chassis master wir ing diagrams A complete wiring diagram is available from Blue Bird Body Company Technical Publications To access the electrical panel open the access door located outside the bus be low the driver s window Use of appropriate amperage circuit breakers is required ACCESSORIES AND ADDED COMPONENTS Wh
134. ressure may occasionally require adjust ment to ensure proper opening and closing of the stop arm The air regulator is accessible through the outside electrical panel door under the driver s window To regulate the air pressure remove the wire retaining clip below the regulator knob and pull the red lock ring Turn the knob counterclockwise to decrease the pressure and then slowly increase the pressure turn knob clockwise until the stop arm hinge is extended to approximately 90 Lock the knob into position by pushing in the red lock ring and installing the wire retaining clip Electrically operated stop arms may be activated by a manual switch or option ally by the warning lamp system The STOP sign must extend and if equipped with lights the lights must be op erating any time the red lights of the warning light system are flashing For state designed warning light stop arm systems which allow the stop arm to withdraw while warning lights are operating an audible alarm sounds to alert the driver of the condition Monthly Maintenance e Oil the dual action breakaway hinge at its pivot points with a high perfor mance penetrating lubricant Tri Flow duPont with Teflon is recom mended e Check that the breakaway portion of hinge is freely movable e Check that fasteners are secure Quarterly Maintenance Perform the Monthly procedures above Remove front and rear covers of base and check that fasteners ar
135. ribed for the right side mirrors Refer Outside of bumper Outside of bumper Centerline of bus to Steps 2 and 3 above Adi he elliptical A P 12 ft from 5 just the elliptical cross view mirrors front bumper QQ zag B3 ie Q by positioning each mirror head so that l the center of its field of view is aimed at 6 ft from front the eyes of the driver bumper 6 Make a final adjustment to the mir ror system so that the seated driver can view the areas required by Fed eral Motor Vehicle Safety Standard 111 including the entire top surface of cylinders M and N when located as illus trated and rearward a minimum of 200 feet measured from the mirror surface Test cylinders A 0 are using the outside rearview driving 1 ft tall x 1 ft diameter Cylinder P is 3 ft tall x 1 ft diameter mirrors The elliptical cross view mirrors should be adjusted to provide the seat ed driver a view of the entire surface of any cylinder A thru P when located as illustrated not visible by direct view of the driver The view provided by the el liptical cross view mirrors must overlap the view provided by the outside rear view driving mirror system All mirrors should be cleaned once a week or more if needed preferably with an ammonia solution Keep the mounting fasteners tight so that mirrors will not vibrate Check weekly 6 ft from outside body 1 ft from outside body
136. ributor will answer your questions or put you in contact with the proper factory personnel Throughout this manual are precautions labeled Warnings and Cautions and set in the style shown here CEN The Warning designation is generally used for precautions which if not properly observed while performing the related procedures or handling materials could result in serious personal injury or death COND The Caution designation is generally used for precautions which if not properly observed while performing the related procedures or handling materials could result in damage to the bus or its equipment Blue Bird Corporation offers many items as standard and optional equipment to meet federal state and local specifications and individual customer requirements This includes but is not necessarily limited to stop arms crossing guards warning lights warning light monitors mirrors first aid kits fire extinguishers warning reflectors fuses directional and brake lights warning buzzers security vandal locks emergency exits and seat belts Emergency equipment must be checked for proper operation daily It is the driver s responsibility to report any damage to qualified service technicians and that the condition be corrected before transporting passengers so A CA ALL AMERICAN DRIVERS HANDBOOK CEN Vehicle alterations which may cause non conformance with the Emission Control and or Federal Motor Vehicle Safety Standards FMVSS
137. rs Clean adjust mirrors Inspect All Windows Clean Windshield door glass driver s window rear vision windows rear door windows Brakes Inspect Air Brakes Air Lines amp Fittings Inspect for leaks or physical damage Drain Air Brakes Air Tanks Drain daily in cold weather weekly in warm weather Inspect Air Brakes Brake Chambers See Air Brakes Chapter for inspection criteria Inspect Air Brakes Brake Shoes Wear depends upon application environment See Meritor Cam Brakes Appendix in Air Brakes Chapter for guidelines Cooling System Inspect Coolant Level Top off with premixed coolant of same type as installed Never mix coolants of different colors types or brands See engine Operator s Manual for details Inspect Entire Cooling System Visually inspect for any signs of leakage Electrical Inspect All Lights Check all running stop marker hazard and warning lights for proper operation Engine Inspect Oil Level See Engine operators manual for oil specifications Fuel System Inspect Fuel Cap Inspect Water Separator Petcock Drain Check for water contamination Intake System Inspect Intake Tract Duct amp Elbow Visually inspect for proper fit and sealing cuts abarsions signs of dirt contamination Inspect Intake Tract Restriction Indicator Replace filter element if indicator is red Steering Inspect Power Steering Fluid Level
138. s with a high delivery nozzle to prevent spillage Fuel spray can cause serious injury vent slowly Do not fill to more than 95 capacity In 2007 diesel en gines use only diesel fuel labeled Ultra Low Sulfer per the engine manufacturer s specifications In Caterpillar use oils meeting API CJ 4 or Caterpillar ECF 3 compliant See Caterpillar Opera tion and Maintenance Manual SEBU8083 08 for details In Cummins use oils meeting API CJ 4 SL and Cummins Engine Standard CES 20081 See Cum mins Owners Manual ISB 6 7L CM2150 for details ROUTINE OPERATION e gt Diesel Engine Starting Procedure See the appropriate engine manufacturers operating manual for proper starting procedures Starting procedures vary from different engine manufacturers and also varies with temperature 1 Apply the parking brake 2 Place the transmission shift lever in the neutral position 3 Insert the ignition key and turn it to the ON position All the instrument panel lights will come on momentarily Depending upon conditions the Wait To Start light may remain on If so wait until it goes off before trying to start the engine This gives the engine grid heaters enough time to warm the combus tion chambers for efficient starting 4 After the engine starts turn on the high idle switch 1 000 1 200 rpm until the engine is fully warmed up CoAT Le Do not engage the starter longer than 30 seconds without allow ing the engine 120 seconds rest
139. serve weather and road con ditions and drive accordingly Be physically and mentally alert When backing up near pedestrians or in congested areas use someone outside to monitor or direct your movements Look around before driving away from where you are parked and observe all traffic rules and regulations Weekly Inspection Perform all the Daily Inspection procedures e Drain air tanks e Check tires Look for weather checks worn areas and tread Check the air pres sure Inspect seat cushion attachments for tightness Inspect seat belts and buckles Inspect outside lights for proper operation 43 44 so A CA ALL AMERICAN DRIVERS HANDBOOK Engine Exhaust Caution Carbon Monoxide CANNA Never idle the engine in a confined area Never sit in a parked or stopped vehicle with the engine running Exhaust gases particularly carbon monoxide can build up These gases are harmful and potentially lethal Carbon monoxide is colorless and odorless but can be present with all other exhaust fumes Do not drive with exhaust fumes present If you suspect exhaust fumes are entering the bus have the system inspected to determine the source and make the appropriate corrections immediately The best protection from carbon monoxide entry into the bus is a properly main tained engine exhaust system body and body ventilation system It is recommend ed that the exhaust system and body be inspected by a competent mechanic e Each tim
140. ssenger loads stay on board for extended periods of time such as on a charter or over the road activity trip Travel ing at highway road speeds causes heat to dissipate through the windshield glass and each passenger s breath continually adds to the air s moisture content To reduce fogging open the forward driver s window slightly to let the moist air escape Heater Defroster Location The blower in the front main heater contributes to keeping the driver s area glass clear of fog and frost See OUTLET LOCATION diagram For best results fresh air should be flowing into the heater To inspect the fresh air intake and make sure it is working properly open the front access panel on the driver s side of bus Driver Passenger Comfort When the windows are defrosted the other openings can be set as necessary for comfort The adjustable diffusers on the dash can be directed toward the driver and or passengers as desired The auxiliary unit under the driver s seat has a two speed electrical switch and it directs air upward for the driver s left side and forward around the steering column area 6 ROUTINE OPERATION e gt Standard Heater Cut Off Valves Valves are provided in the heater piping to permit isolation of the heating circuit from the engine coolant circuit This is useful in case a leak occurs within the system or to restrict the flow of hot water through the bus during warm weather When Valves No 1 and No 2 in the diagrams belo
141. st engagement pressure at the lever to achieve 120 125lbs at break over center Electrical Inspect Battery Battery Posts Clean and apply anti corrosion agent Exhaust System Inspect Exhaust Pipe Joints Inspect for loose clamps leaks damage Fuel System Replace Fuel Filter Filter Element Clean Fuel Filter Inlet Screen Clean Replace if damaged Steering Lubricate Steering Gear Pitman Arm Pivot NLGI 2 EP multipurpose grease rated GC LB or equivalent Use hand operated grease gun Every 6 Months or 10 000 Miles Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Air Spring Anchor Bolts Tighten to 20 30 ft Ib Inspect amp Tighten Comfort Air Suspension Air Spring Fasteners Torque to 30 35 ft Ib Inspect amp Tighten Comfort Air Suspension Leveling Valve Mount Bolt Tighten to 60 85 in Ib Inspect amp Tighten Comfort Air Suspension Lever Linkage Locknut Tighten to 100 150 in Ib Inspect amp Tighten Comfort Air Suspension Lower Shock Mount Tighten to 260 320 ft Ib Inspect amp Tighten Comfort Air Suspension Quick Align Bolts Tighten to 525 575 ft Ib Brakes Lubricate Air Brakes Cam Shaft Housing NLGI 2 EP multipurpose grease rated GC LB or equivalent Use hand operated grease gun Lubricate Air Brakes Haldex Slack Adjusters See Haldex lubricant specs in Air Brakes chapter Lubricate Air Brakes Meritor
142. stalled Never mix coolants of different colors types or brands See engine Operator s Manual for details Inspect Entire Cooling System Visually inspect for any signs of leakage Electrical Inspect All Lights Check all running stop marker hazard and warning lights for proper operation Engine Inspect Oil Level See Engine operators manual for oil specifications Fuel System Inspect Fuel Cap Inspect Water Separator Petcock Drain Check for water contamination Intake System Inspect Intake Tract Duct amp Elbow Visually inspect for proper fit and sealing cuts abarsions signs of dirt contamination Inspect Intake Tract Restriction Indicator Replace filter element if indicator is red Steering Inspect Power Steering Fluid Level Replinish to full mark Dextron III Tires amp Wheels Inspect All Tires amp Wheels Check air pressure Visually inspect tires tread wear lug nuts including spare Transmission Inspect Transmission Fluid Level Check production order for proper type of fluid to be added Every Week Seats Inspect amp Tighten Passenger Seats Cusion Screws Inspect for loose cushions clips Inspect Passenger Seats Seat Belts Lubricate buckles clean webbing as required Replace any damaged webbing straps Inspect Passenger Seats Upholstery Inspect for cuts tears wear and soiled areas Brakes Inspect Hydraulic Brak
143. stem will prevent the restriction indicator from operating properly Always look at the piping to ensure there are no leaks John Deere 8 1L Inspect the air intake system every 12 months or 25 000 miles whichever comes first Replace the air cleaner if it is damaged or torn or when air the restriction indicator shows restriction of 15 inches of water Do not reply completely on the air restriction indicator A leak in the air intake piping could cause a false indi cation Always visually inspect the system to ensure there are no leaks If the vehicle is operated in extremely dusty conditions more frequent air cleaner maintenance may be necessary Air Intake Piping Inspect the intake piping daily for wear points and damage to piping loose clamps or punctures that can cause damage the engine Replace damaged pipes and tight en loose clamps replace if necessary to prevent the air system from leaking Check for corrosion under the clamps and hoses of the intake system piping Corrosion can allow corrosive products and dirt to enter the intake system Disassemble and clean as required ChargeAir Piping Inspect the chargeair piping and hoses daily for holes cracks or loose connections Tighten the hose clamps as necessary Charge Air Cooler CAC Maintenance Check this system every 3 months or 7 500 miles Inspect the charge air cooler CAC for dirt and debris blocking the fins Check for cracks holes or other damage If dam age is fou
144. steners for evidence of loosening due to tampering and regular cleaning with mild soap and water Although there are more powerful cleaning solutions available some of them contain solvents and other chemicals that can attack the high strength materials used in the production of safety vents It is the customer s responsibility to ensure that cleaning solutions are compatible with the materials used on safety vents Graffiti removing cleaners often contain acetone ether lacquer thinner or other solvents known to destroy the high strength properties of many engineering plas tics and use of these cleaners must be avoided Graffiti resisting coatings often leave a sticky residue that interferes with the operation of the ventilator mechanism Use of these types of chemicals should be avoided Roof Hatch Pop up front or rear or raise for additional ventilation 30 ENROUTE EMERGENCIES e gt EMERGENCY EXIT SEE INSTRUCTIONS BELOW EMERGENCY EXIT EMERGENCY EXT TO OPEN PULL HANDLE PUSH OUT VANDOW Rear Emergency Door SEE INSTRUCTIONS BELOW Split Sash Pushout Window EMERGENCY EXIT ps EMERGENCY EXIT TO OPEN PULL UP HANDLE RUSH OUT DOOR EWERGENCY EXIT TOOPEN PULL HANDLE PUSH OUT WNDOW 000000 poa Transit Sliding Pushout Window Side Emergency Door
145. t Cooling system Engine Test Engine Starting Aid Block Heater Steering Inspect Hydraulic Pump Body amp Seals Inspect for leaks Inspect Steering Gear Body amp Seals Inspect for leaks Every 12 Months or 24 000 Miles Brakes Clean Air Brakes Pop Off Valves Steering Replace Hydraulic Reservoir Filter Element Replace element and fluid Replace more frequently in severe operating conditions Dextron III Transmission Replace Transmission Fluid Use Dextron III fluid Inspect Transmission Shift Cable Inspect Transmission Vent Clear vent hose of debris or obstruction Every 12 Months or 50 000 Miles Axle amp Suspension Rear Replace Rear Axle Petroleum Based Hypoid Gear Oil Viscosity depends upon operating climate Lubricant See Viscosity Temperature chart Every 12 Months or 100 000 Miles Axle amp Suspension Rear Replace Rear Axle Synthetic Lubricant Viscosity depends upon operating climate See Viscosity Temperature chart 133 VA ALL AMERICAN DRIVERS HANDBOOK Every 18 Months or 20 000 Miles Cooling System Lubricate Shutters Pivots Use Never Seize spray lubricant Every 24 Months or 24 000 Miles Brakes Clean Air Brakes Parking Brake Valve See Bendix Appendixes in Air Brakes Chapter Clean Air Brakes Quick Release Valves See Bendix Appendixes in Air Brakes Chapter Clean Air Brakes Relay Valves See Bendix Appendixes in Air Brakes Chapter
146. the door closes too hard and does not open far enough 2 3 Move the rod end bracket forward if the door does not close against the seal and does not open far enough 2 4 Move the rod end bracket rearward if the door opens and closes too far 3 Attach the roller bracket to the rear door and adjust Ifthe rear door hangs in the track when starting to close the door move the bracket to the rear e If the rear door does not open to the front enough move the roller forward 4 Perform the following adjustments and main tenance for ease of operation The top of door should be approximately inch below the door header 4 1 Move the door upwards so that the rubber door sweeps do not drag on the stepwell treads Adjust door height by loosening the bolts and nuts that attach the front door panel to the front hinge Holes in the hinge are slotted This permits vertical adjustment of the door Roller Bracket 4 2 Ensure that the top edge of the door nos ing rubber does not drag on the doorstop header rubber Remove the first three upper screws in the inner and outer nosing rubber retainer strips and force the nosing rubber downwards Replace the screws after the rubber nosing has been adjusted 4 3 The rear upper corner of the rear door panel should not drag on the rubber door stop on the header To provide the required clear ance move the door roller bracket towards Rod End Bracket 87 So A
147. ther wheel assembly on the vehicle e Let the air out of the tire by taking out the valve core If you have a way to put air back into a tire note that it is good safety practice to let the air out of both tires of a dual assembly before taking off the damaged tire and rim assembly from the vehicle After letting out the air take off the tire and rim assembly and put on the spare wheel and tire assembly Ifyou are not fully expert on the procedures to follow and or are not equipped with the proper tools and equipment do not attempt to raise the vehicle or remove or install the tire and wheel assembly Obtain expert tire service help Donot inflate a tire that has been run flat or is seriously low on air with out first having the tire taken off the wheel and the tire and tube checked for damage Note that work on bus wheels requires proper tools safety equipment and special training You can be badly injured and or damage can result from using the wrong service methods Only trained people using the proper equipment should service bus tires and wheels When putting air into a tire on the vehicle stand to the side and use a clip on chuck and hose extension Never add to your tires unless an accurate pressure gauge is also used In choosing the right tire pressure be careful not to go past the maximum pressure capacity shown on the tire CENNA Tire inflation pressure must not exceed the specifications of the tire and or wheel r
148. these important instructions may result in an explosive separation and could cause serious bodily injury or death It is very important to determine the size of each component before beginning any assembly operations When replacing tires use the same size load range and construction type as originally installed on the vehicle When replacing wheels use original equip ment manufacturer s wheels or equivalent available from your dealer with equivalent capacity width offset and mounting configuration as those origi nally installed on your vehicle Use of improper replacement wheels and tires may adversely affect ride handling load carrying capacity bearing life the clearance to body and chassis components vehicle ground clearance vehicle width and brake cooling Do not mix rim lock ring and wheel components from different manufacturers 36 ENROUTE EMERGENCIES e Jacking Instructions CEN Proper jacking procedures and basic safety measures must be observed to ensure safety of personnel while working under the bus Always check the serviceability of any lifting equipment prior to use Ensure that the lifting device is of sufficient strength to handle the bus and that the surface provides the necessary firmness to support the weight of the bus concentrated on the footprint of the jack Never move under a bus supported only by a hydraulic jack 1 Park the bus on flat level concrete or a comparable surface capable of supporti
149. to occur only when the bus is moving at a minimum speed and it stops when the vehicle slows or stops With Caterpillar engine if the exhaust is still unusually hot from recent regenera tion when the bus slows or stops the HEST indicator appears to remind the driver of the high temperature condition With Cummins engine the HEST indicator appears whenever the high tempera ture condition exists When performing a Stationary Regeneration the entire process occurs for an extended period while the bus is stopped It is therefore critical that prudent human safety and fire hazard precautions are followed Those precautions include e Read understand and abide by all the precautions pertaining to regeneration procedures in the engine manufacturer s Operator s Manual e If at all possible the Stationary Regeneration procedure should be conducted at a service facility by trained technicians The Driver s first priority is the safety of the passengers If a Stationary Regen eration must unavoidably be done by the Driver under a qualified technician s direction alternate transportation should be arranged first or passengers should be removed under proper supervision to a location away from the bus e Select an appropriate location to park the vehicle e Choose a surface that will not burn or melt under high temperature such as clean concrete or gravel not grass or asphalt e Ensure that nothing that can burn melt or explode gasoli
150. trol Set Resume At the desired cruise speed set speed by depressing the SET switch When the brake pedal is depressed the cruise returns to standby mode To reactivate to preset speed depress the RESUME switch after reaching at least 30 mph Exhaust Brake Activates the exhaust brake to help slow the bus during decelleration Warning Bank Cluster of indicator lamps See next page Message Display Center Displays additional informa tion to the vehicle operator 19 C IAPA ALL AMERICAN DRIVERS HANDBOOK Warning Bank 15 Engine Warn The engine needs service 1 Left Turn Flashes with left turn signal 16 HEST High Exhaust System Temperature 2 Brake System Indicates a brake system failure Stop 17 MIL Maintenance Indicator Light the vehicle and call for assistance 18 Wait to Start Indicates engine preheating Wait until 3 ABS Indicates fault in the anti lock brakes system Ser indicator goes off before starting engine vice as soon as possible 4 High Beam Headlights are in high beam 5 Stop Engine The engine ECU has detected a problem which can lead to engine damage Stop the engine and call for assistance 6 Right Turn Flashes with right turn signal Check Trans The transmission needs service 8 Trans Temp The transmission temperature is beyond normal operating range 9 Hydraulic Fluid Temperature The hydraulic fluid tem perature is beyond normal operating range 10 Engine Retard The eng
151. ue Bird Service Manual 79 so A CA ALL AMERICAN DRIVERS HANDBOOK CATIN Repair and or modification of the electrical system including adding components should be referred to a trained experienced technician The following guideline must be observed when working on the vehicle electrical system Be particularly cautious when adding components that they do not exceed the ability of the electrical system as designed and manufactured 1 Disconnect the battery before beginning any repair or modification to the electrical system CEN Always disconnect the battery negative NEG terminal first to avoid sparks arcing 2 Use only the proper gauge wiring with high temperature insulation compli ant with SAE J 1128 150 C 3 Be certain any added component is fitted with an adequate fuse and that it does not exceed the capability of the electrical system as designed and manufactured 4 Any push on type connectors must be insulated When installing or repairing wiring always observe the following precau tions Install clamps and ties to prevent chafing and contact with sharp edges Support wiring with insulated clamps at least every 30 inches 76 cm e When the wiring must flex i e when connected to moving parts like the engine be certain to provide adequate slack loops e Be certain to provide adequate length to prevent tension on the wires or connectors e Be certain wiring is secured at least 4 inches 1
152. ule TCM may de termine that it is necessary to restrict gear selection to protect the transmission from damage and provide safer operating conditions When this happens the RANGE INHIBITED warning light will activate and the transmission may not respond to the operator s commands Please see the Range Inhibited Light and Shift Inhibits section of the Allison Transmission operator s manual for more information Check Transmission Light The CHECK TRANSMISSION light is located in the instrument panel The electronic control system is programmed to inform you if operating parameters have been ex ceeded and to automatically take action to protect the transmission A diagnostic code will be registered when the CHECK TRANSMISSION light is on When the engine is started the CHECK TRANSMISSION light turns on for a few seconds This momentary indication shows that the lighting circuit is working prop erly If the light illuminates after startup a problem has been detected A diagnostic code will be recorded and shifts may be restricted Depending on the problem s se verity the operator may continue driving to reach service assistance The TCM may restrict upshifts and downshifts Please see your Allison Transmission operator s manual for more details on how shifts may be inhibited ROUTINE OPERATION e gt If the transmission will not shift into D drive or R reverse it may be because of an adverse operati
153. ummins engines in Blue Bird buses are aftertreatment systems which incorporate Diesel Particulate Fil ters DPF instead of ordinary mufflers These sophisticated exhaust systems reduce emissions by trapping exhaust borne particulates soot in a filter built into the DPF Over time soot accumulates in the DPF and must be removed by a process re ferred to as regeneration Regeneration is conceptually similar to the cleaning mode of a self cleaning oven in that heat is required to remove the soot The rate at which soot accumulates is dependent upon multiple conditions in cluding the quality of the diesel fuel type of engine oil and ambient temperature engine load and other factors Regeneration occurs in three ways Some regeneration occurs naturally whenever operating conditions speed engine load etc result in exhaust system temperatures high enough to oxi dize accumulated soot This unassisted regeneration process can generically be referred to as passive regeneration Regeneration can be caused by raising the temperature of the exhaust system Both Caterpillar and Cummins engines are equipped with systems designed to increase exhaust temperature when the ECM senses that regeneration is needed and when certain requirements including a minimum travel speed are met This automatic heat assisted mode can be generically referred to as active regeneration Regeneration can be manually activated by means of
154. urn clock wise disengage the ratchet 3 Slowly lower the tire by turning counter clockwise CEN Hold the wrench securely while lowering the tire the weight of the tire can cause the lug wrench handle to slip 4 Remove the lifting platform from the tire 5 To raise tire reverse procedures making certain to engage ratchet before cranking clockwise CZE Never move under a vehicle supported only by hydraulic jacks Always chock the wheels that are not being raised in both directions Do not get under the tire wheel while replacing a flat If your unit is equipped with a spare tire compartment follow this procedure to remove and replace spare 1 Unlatch the tire compartment door and secure in the open position with the chain and hook 2 Pull out the rack 3 Remove the wheel hold down clamp and lift off the wheel Reverse the procedure above to replace the wheel 34 ENROUTE EMERGENCIES e gt Damaged Tires CEN An inflated tire and rim can be very dangerous when misused or worn out Many accidents some fatal have resulted from improper handling and operation of bus rims and wheels To help avoid personal injury and or property damage get expert tire service help if you can If you must remove the wheel and change the tire without such help take the following precau tions e Ifthe tire seems to contain air under pressure stand to the side and check whether the wheel assembly appears normal by comparing it to ano
155. ut disassembly Loosen the lock nut turn the tube and retighten the nut when satisfactorily adjusted The geometry of the mechanical link between the doors causes the rear door to close well ahead of the front door so that the front nosing seal rubber always overlaps the rear Oil impregnated bronze bearings in the lower corners of the framework serve as pivots not supports All controls and mechanisms and the complete lower step tread are sealed inside the bus and out of the weather when the door is closed Outward Opening Air Powered Adjustment The pneumatic actuator is a cylinder connected to a lever on each door located in side the header cover An interconnecting link between the doors controls the opera tion sequence A safety release valve is located over the door Air switches inside the header cover operate Stepwell lights A two way manually operated valve manages the driver s door control Air pressure holds the door either open or closed depend ing upon the position of that valve The operation speed is adjustable by use of flow control valves located on the actuator 86 Jackknife Door Adjustment 1 Loosen the roller bracket at the top of the rear door 2 Adjust the length of rod between the door control and the door and the location of the rod end bracket on the door for proper open and closed posi tion 2 1 Lengthen the rod if the door opens too far and does not close against the top seal 2 2 Shorten the rod if
156. w are closed engine coolant is pre vented from circulating through the heaters This does not restrict circulation of the engine cooling circuit so it is safe to opeartate the engine with the valves closed Engine Caterpillar 7 VALVE NO LOCATION 1 AT THERMOSTAT HOUSING 2 AT TRANSMISSION OIL COOLER All American Rear Engine All American Forward Engine pit HTR DRIVER S HEATER FRT T DRIVER S HEATER mj f REAR HEATER REAR HEATER TRANSMISSION OIL COOLER 2 UNDER FLOOR A3FE PRESSURE LINES a RETURN LINES VALVES A3RE 77 78 CARE amp MAINTENANCE A though in most transportation operations maintenance tasks will be performed by service technicians familiarity with the basic tech nical data in this section will enhance the Drivers overall understand ing of the vehicle and may serve as a convenient reference for service technicians rendering roadside assistance This section also contains general cleaning and care guidelines For thorough service information and procedures refer to the All American Service Manual Actual operating conditions must be considered and maintenance intervals adjusted accordingly If at any time a system does not perform satisfactorily corrective service should be performed at once It is important that personnel attempting the repair or maintenance of this vehicle have access to and a thorough knowledge of the appropriate Bl
157. ward to increase or rearward to decrease the support in the lumbar area CAEN Do not attempt to adjust the driver s seat while the vehicle is in motion Do not adjust height while sitting in the driver s seat Keep feet and other items away from height adjustment handles and pedals while vehicle is in motion Alea TIE fel 1 2 3 4 LUMBAR ADJUSTMENT CUSHION TILT ADJUSTMENT HEIGHT BACK ANGLE ADJUSTMENT ADJUSTMENT FORE amp AFT ADJUSTMENT Driver s Seat Belt Operation The driver s seat belt should be worn at all times when the vehicle is being driven Blue Bird driver s seat belts feature automatic locking retractors which are self ad justing They feature an anti cinch device which helps prevent uncomfortable tight ening of the belt as you drive To use withdraw an adequate length of belt from the retractor or retractors to allow the buckle to connect After engaging the buckle allow the retractor to withdraw the belt to a snug fit Verify that the automatic lock ing mechanism is working properly by pulling the belt sharply against the retractor which should resist The buckle is released by pushing the button in its center Driver s Seat Belt With Shoulder Harness Optional The driver s seat belt should be worn at all times when the vehicle is being driven The driver s shoulder harness locks during emergency stops the lap belt may be ei th
158. which could cause a crash or could cause injury or death you should immediately informthe National Highway Traffic Safety Administration NHTSA in addition to notifying Blue Bird If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems be tween you your dealer or Blue Bird Corporation To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 or go to http www safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov Noise Emissions Warranty Blue Bird Body Company warrants to the first person who purchases this vehicle for purposes other than resale and to each subsequent purchaser that this vehicle as manufactured by Blue Bird was designed built and equipped to conform to all ap plicable United States Environmental Protection Agency Noise Control Regulations This warranty covers the vehicle as it was designed built and equipped by Blue Bird and is not limited to any particular part component or system of the vehicle manufactured by Blue Bird Defects in design or in assembly or in any part compo nent or system of the vehicle as manufactured by Blue Bird whic
159. y Doors Test Wheelchair Lift Follow the manufacturers recommendations Emergency Equipment Inspect Fire Extinguisher Charge Ensure that Extinguisher Charge is not expired Inspect Fire Extinguisher Mounting Bracket Ensure that Extinguisher bracket is secure and operates correctly Inspect First Aid Kit Contents Ensure that kit supplies are fully replenished clean and not expired Inspect First Aid Kit Mounting Bracket Ensure that mounting bracket is secure and operates correctly Emergency Exits Inspect All Emergency Exits Test all emergency exits for proper operation including warning buzzer Warning Devices amp Signs Test Stop Arms amp Crossing Arms Windows Inspect All Mirrors Clean adjust mirrors Inspect All Windows Clean Windshield door glass driver s window rear vision windows rear door windows Brakes Inspect Air Brakes Air Lines amp Fittings Inspect for leaks or physical damage Drain Air Brakes Air Tanks Drain daily in cold weather weekly in warm weather Inspect Air Brakes Brake Chambers See Air Brakes Chapter for inspection criteria Inspect Air Brakes Brake Shoes Wear depends upon application environment See Meritor Cam Brakes Appendix in Air Brakes Chapter for guidelines 123 oo ACA ALL AMERICAN DRIVERS HANDBOOK Cooling System Inspect Coolant Level Top off with premixed coolant of same type as in
160. y power is lost or disconnected A WARNING Serious injury or death can occur if these instructions are not followed Opening vehicle service door causes brakes to be applied Vehicle equipped with Door Brake Inter lock Operator must read and understand oper ating instructions before using vehicle Brakes will release if ignition is turned off when Door Brake is remotely activated Do not use Door Brake for overnight or prolonged parking Close vehicle service door before moving vehicle Door Brake and warning circuit are dis abled if battery power is lost or discon nected 73 so ACA ALL AMERICAN DRIVERS HANDBOOK Air Brakes All Americans equipped with air brakes employ separate systems for the front and rear service brakes A separate reservoir and air gauge is provided for each of these systems A dual treadle valve is provided for operating the service brake system In the event there is a failure in the air reserve for the front brakes the rear service brakes can still be applied using the treadle valve since the two service brake sys O Yo tems operate independently If there is a failure in the air reserve for the rear ser NA gs vice brake system the front service brakes and the rear spring brakes can be ap PA R KI N G plied through the treadle valve This allows the operator to use a normal method gt amp of braking even though part of the system is malfunctioning However in the case of an air
161. y wheel chocks or tow vehicle Failure to do so may result in bodily injury or property damage 1 Remove the release stud tool and nut from the carrying pocket on the brake chamber assembly 2 Remove the access plug from the end of the spring chamber 3 Insert the release stud through the opening in the chamber and into the spring pressure plate 4 Turn the release stud one quarter turn to engage the stud tangs with the slot in the pressure plate 5 Keep the stud engaged and install the nut on the release stud 6 Tighten the nut until the spring is fully caged and the brakes are released Do not loosen or remove the release stud and nut unless the brake chamber is completely assembled and is securely clamped 8 When air pressure is restored remove the release stud and install in carrying pocket SPRING CHAMBER BRAKE RELEASE RELEASE STUD Q B CARRYING POCKET 39 40 Towing Or Pushing Never tow or push a vehicle equipped with an Allison automatic transmission unless the drive shaft has been removed or the rear wheels have been raised off the ground Do not tow by the front axle or any frame cross member Damage to the wiring and or the air lines can result Optional tow hooks are located at the front and or rear of the vehicle under the bumper Tow hooks are designed to tow or pull with both hooks simultaneously Do not pull or tow with an individual
162. ystem _ OOO Inspect Charge Air Cooler Inspect for clogging debris As Specified by Engine Manufacturer _Cooling System _ _ _ _ O UOO Replace Coolant See your Engine Ooperator s Manual Use only premixed coolant s approved by the engine manufacturer Never mix different types or brands of coolant Engine Replace Oil amp Filter See Engine operators manual for oil and filter specifications and maintenance interval Adjust Valves See Engine manufacturer s Service Manual for interval 107 108 VA ALL AMERICAN DRIVERS HANDBOOK As Specified by Transmission Manufacturer Transmission Adjust Transmission Shift Cable See Transmission Chapter Every Day Doors Test Wheelchair Lift Follow the manufacturers recommendations Emergency Equipment Inspect Fire Extinguisher Charge Ensure that Extinguisher Charge is not expired Inspect Fire Extinguisher Mounting Bracket Ensure that Extinguisher bracket is secure and operates correctly Inspect First Aid Kit Contents Ensure that kit supplies are fully replenished clean and not expired Inspect First Aid Kit Mounting Bracket Ensure that mounting bracket is secure and operates correctly Emergency Exits Inspect All Emergency Exits Test all emergency exits for proper operation including warning buzzer Warning Devices amp Signs Test Stop Arms amp Crossing Arms Windows Inspect All Mirro
163. zed in the fuel line and warmed in the heat exchanger generally located under the hood The pressure regulator re duces pressure before the vapors are transported to the mixer carburetor TAND Do not use CNG pressure lines or vent lines to clamp hang con nect or attach any items including harnesses hoses power steering hose refrigerant hoses or any other item 62 63 so A CA ALL AMERICAN DRIVERS HANDBOOK Allison Automatic Transmission Important Allison supplies far more detailed information about your particular transmission than space allows in this manual Although we try to cover the most im portant points here it is imperative that you read and understand the Allison Trans mission Operator s Manual for more details about operation care and maintenance If you did not receive this manual with your bus please contact the transmission supplier Both Blue Bird Body Company and Allison Transmissions continually strive to improve the quality and performance of their respective products For this reason information and instructions in the Allison Transmission Operator s Manual supplied with the bus will take precedence over the general information in this publication Allison Model 3000 Bus Series Transmission The Allison electronic transmission provides five forward speeds and one reverse Fourth gear is a 1 to 1 ratio while the fifth gear is an overdrive with a 0 75 to 1 ratio The push button shift selector

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