Blue Bird TC/2000 Owner'S Manual Download | Manualshive

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49

LOWER SIDE PANEL REPAIR PROCEDURE

1. Remove the lower portion of the side panel by carefully drilling out the vertical rows of rivets on each

side of the panel from the bottom of the floor line rub rail to the bottom of the skirt and the rivets
attaching the bottom rub rail to the panel to be removed. Cut the panel not less than one inch below
the floor line rub rail and remove.

2. Clean to bare metal the one-inch wide section of panel left below the floor line rub rail and apply a

one-inch wide bead of Amicon two-component epoxy, TX-4009 or equivalent, following directions
and recommendations of the adhesive manufacturer.

3. Insert the replacement panel between the rub rail and the original side panel far enough to insure a

minimum of 1/2 inch of the replacement panel is under the rub rail. Install Cherry SSPV 86 blind
rivets, Blue Bird P/N 0888222 on 3 1/2 inch centers through the rub rail lower flange and the new and
old side panel.

4. Replace the vertical rows of rivets and the rivets attaching the bottom rub rail with the same type, size,

and quantity of fasteners as was used in the original construction or with Cherry SSPV 86 blind rivets,
Blue Bird P/N 0888222, as necessary.

5. Allow the adhesive to cure the proper amount of time (fourteen days at room temperature for the

Amicon TX-4009) before returning the vehicle to service.

SPARE TIRE LOCATION & REMOVAL

If your unit is equipped with a frame

mounted spare tire carrier, the following pro-
cedure should be used to remove and replace
spare:

1. Remove the two securing nuts and ro-

tate tire out of holes.

2. Open access door, if equipped, through

access hole, insert lug wrench, placing
socket over hex head on shaft and turn
clockwise and disengage ratchet.

3. Slowly lower tire by turning counter-

clockwise.

WARNING: Hold wrench securely while
lowering tire to prevent weight of tire from
causing lug wrench handle to slip out of
operator’s hand.

4. Remove lifting platform from tire.
5. To raise tire, reverse procedures, making certain to engage ratchet before cranking clockwise.

WARNING: At all times stay from beneath tire.

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Summary of Contents for TC/2000

Page 1: ...Owner s Manual TC 2000 ...

Page 2: ... 52 Engine Operating Instructions 52 Gasoline Engine Maintenance Instructions 56 1997 Emission Control Systems Warranty for Gasoline Engines 59 Noise Emissions Warranty 61 Fuel Lubricant Requirements 61 Compressed Natural Gas 62 Manual Five Speed Transmission 69 Allison Automatic Transmission 69 Hydraulic Brakes 74 Air Brakes 76 Hydraulic System Troubleshooting 78 Shutters 79 Cooling System 79 Cor...

Page 3: ...2 ...

Page 4: ...dingly Anytime a system does not perform satisfactorily corrective service should be performed at once Familiarity with automobile operation and controls is not a prerequisite but is assumed to be common knowledge to all who will be operating this coach Basically control and operation of both are the same but some distinct differences must be recognized before operation of the coach is attempted R...

Page 5: ...e checked for operation on a daily basis Safety equipment may vary due to state and federal specifications and individual customer requirements In addition the driver operator must insure 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 REPORTING SAFETY DEFECTS If you believe your vehic...

Page 6: ...ion procedures be followed on a daily basis Any malfunctions or defects should be corrected before the next trip Report needed services to respon sible maintenance personnel Check fuel level Drain air tanks cold weather Check engine oil level Check coolant level Check automatic transmission fluid level Look outside the bus Windshield mirrors front windows head tail directional and stop lights wipe...

Page 7: ...arking brake release reset Outside checks required before you drive away Turn signals right left front rear clean flashing Flasher warning lights front rear clean flashing Stop arm if used clean working Headlights hi lo beams Stoplights taillights clean working Hazard flasher working Final check as you move the bus Seat belt fastened Brakes Stop hold Steering feel OK Unusual noises Bus under contr...

Page 8: ...e lock as a means of cruise control Always release throttle lock before putting vehicle into motion 16 Driver s fresh air vent control 17 Hazard light flasher switch NOT ILLUSTRATED Door control Wig Wag low air pressure warning Warning light monitor indicates whether warning light are working Inside mirror Fusee canister Reflector flares and flags High idle switch TCRE Only TILT TELESCOPING STEERI...

Page 9: ...FE only WARNING Do not use throttle lock as a means of cruise control Always release throttle lock before putting vehicle into motion 15 Voltmeter indicates electrical system voltage 16 High beam indicator glows when headlight hi beam is on 17 Odometer records miles on vehicle 18 Oil pressure gauge indicates engine oil pressure 19 Parking brake valve prevents unit from rolling when parked 20 Water...

Page 10: ... Mounted on outside of rear roof cap manually changed from outside Periodically lubricate hinges with lightweight lubricating oil One Station Lighted Curtain Replace bulbs as needed May occasionally loosen and cause slack in the curtain due to vibration To tighten curtain loosen bolts pull curtain tight retighten bolts Roller Destination Sign with Lighted Curtain Replace bulbs as needed May occasi...

Page 11: ...y applied A com mon 10W30 or 10W40 motor oil will provide good lubrication Remember that all moving part joints tilt piv ots slide forward back adjustment and vertical motion pivots 4 total require lubrication This should be done every six months or 6 000 miles whichever occurs first with a lithium based grease in aerosol form DRIVER S SEAT BELT OPERATION Driver s seat belt should be worn at all t...

Page 12: ...d be checked for compliance with federal standards SEAT CARE AND CLEANING It is imperative that the interior of the bus be kept clean and seats are an important part of this mainte nance Regular cleaning and care will prolong the life of the seats and improve the general appearance Everyday dirt and soil Most everyday soil and dirt may be removed with a soap and water solution If the stain is pers...

Page 13: ...l 2 Lower the rear edge to the frame and rotate the swivel clamps so they engage the square tube crossmember 3 Tighten screws in front and rear clamps with phillips tip screwdriver until clamps do not rotate TRACK MOUNTED PASSENGER SEATS If your bus is equipped track mounted passenger seats and you relocate the seats or remove the seats to accommodate wheelchairs you must follow rules of spacing a...

Page 14: ...t or a restraining barrier of the same width in front of them with the proper seat spacing Seat to seat spacing must be 27 minimum to 31 maximum as measured from common points on the seats NOTE State or local regulations may be more restrictive Seat to restraining barrier spacing must be 12 minimum to 15 maximum measured from the barri ers front mounting hole on the aisle side leg to the front mou...

Page 15: ...s components are shielded F Use rubber grommets whenever wires must pass through holes G Cover all full time hot or accessory and ignition hot wires with approved loom H Avoid routing wires in contact with fuel lines or plastic components 6 Always be sure ground straps are replaced when any work is done on engine components The alternator must have at least a six 6 gauge strap The engine must have...

Page 16: ...1156 Stop Weldon 1010 Red 1156 Arrow 438 1157 Signal Stat 1605 1156 KD 772 9105 1156 Destination Sign 89 School Bus Sign TS93 DORAN WARNING LIGHT MONITOR The Doran monitor is a current monitoring device therefore if current is flowing through one of the bus lamp circuits the monitor senses this and lights the corresponding monitor bulb If the bus lamp burns out current ceases and the corresponding...

Page 17: ...be replaced by referring to Diagram of Coils and Reed Switches on Page 16 Locate the solder points for these components Step 8 Replace the inoperative coil reed switch assembly as follows a With wire clippers cut the reed switch leads 2 and the coil leads 2 as close to the board surface as possible If a tail lamp monitor is to be replaced pull the protective shield loose and retain for reuse later...

Page 18: ...an at the LED however if an LED itself is known to be inoperative contact your usual Blue Bird service parts source for special handling of replacement LED s Condition C If a monitor light stays on even when the exterior light of the bus is turned off the reed switch located inside of the monitor coil is not operating properly This can be repaired in the field by replacing the coil and reed switch...

Page 19: ...RNING LAMP LEFT REAR OUTPUT X X 3C TURN SIGNAL LAMP RIGHT REAR OUTPUT X X X 4C TURN SIGNAL LAMP RIGHT REAR INPUT X X X 2D TURN SIGNAL LAMP LEFT REAR INPUT X X X 3D TURN SIGNAL LAMP LEFT REAR OUTPUT X X X 1C STOP LAMP INPUT X X X 2C STOP LAMP RIGHT OUTPUT X X X 1D STOP LAMP LEFT OUTPUT X X X 7D TAIL LAMP INPUT X X X 7C TAIL LAMP RIGHT OUTPUT X X X 8D TAIL LAMP LEFT OUTPUT X X X 6C BACK UP LAMP INPU...

Page 20: ...itute for proper driver training and the exercise of driver care in operating the vehicle and loading and unloading of passengers Do not move the bus until you have accounted for each passenger that has disembarked and have confirmed that the pas senger is clear of the bus Failure to follow these procedures could cause serious injury or death Right front convex crossview and right and left front c...

Page 21: ...TERIOR REARVIEW Standard equipment on all school buses is comprised of 4 outside rearview driving mirrors 2 per side and 2 elliptical crossview mirrors 1 per side The outside rearview driving mirrors include 1 6 5 x 10 flat mirror and 1 6 5 x10 convex mirror each side The outside rearview driving mirrors are designed to pro vide the seated driver a view of the roadway to the rear and to the sides ...

Page 22: ...ounting fasteners are kept tight so that mirrors will not vibrate Check weekly and retighten if necessary EMERGENCY EQUIPMENT FIRST AID KIT The first aid kit is mounted in the front of the bus body just above the right windshield The contents of the kit should be inspected weekly or as required by local regulation to be sure that all contents comply with state specifications FIRE EXTINGUISHER The ...

Page 23: ...rear seat Inspect contents of the kit every 30 days or as required by local code to insure proper operation In units with optional locking emergency equipment in the front upper panel above the windshield all equipment is located behind the access door which is labeled with a list of the equipment To meet state specifications the door locking mechanism is connected to a buzzer system The buzzer so...

Page 24: ...e inspected and operated daily to in sure they are labeled and operate properly per the instructions pro vided Also see Transpec Safety Vent Split Sash Pushout Window EMERGENCYEXIT SEE INSTRUCTIONS BELOW EMERGENCY EXIT TO OPEN PULL HANDLE PUSH OUT WINDOW Transit Sliding Pushout Window EMERGENCY EXIT SEE INSTRUCTIONS BELOW EMERGENCY EXIT TO OPEN PULL HANDLE PUSH OUT WINDOW MERGENCY EXIT TO OPEN PUL...

Page 25: ...ble with the materials used on safety vents Graffiti removing cleaners often contain acetone ether lacquer thinner or other solvents known to de stroy the high strength properties of many engineering plastics and use of these cleaners must be avoided Graffiti resisting coatings often leave a sticky residue that interferes with smooth up down movement of the ventilator mechanism Some of these coati...

Page 26: ... On units equipped with air stop arms the air pressure may occasionally require adjustment to insure proper opening and closing of the stop arm Air regulator is accessible by opening the electrical panel door outside under the driver s window Regulator is identified as shown To regulate the air pressure remove the wire retaining clip below the regulator knob and pull the red lock ring out Turn the...

Page 27: ...and ground are avail able where required B Remove the rear cover of the base C Remove the red wire from the relay wires lead to terminal on motor D Remove red wire from the limit switch E Replace the red wire on the limit switch with the red wire from the motor F With a battery charger or any other 12V source ground the motor terminal black wire and attach the positive 12V to the red wire terminal...

Page 28: ...he labor savings and cost efficiency Approximate cost of replace ment blades on a steel blade is 8 10 depending on the quality 2 Aluminum reflective signs have improved in technology to the point where blades in southern expo sures are now lasting five to seven years This is due to ink improvements where the pigmentation in the inks actually darkens over the life of the sign Replacement now is due...

Page 29: ... voir and etc After closing press in the larger portion of the latch until it snaps to lock into position ACCESS DOORS In order to prolong the life of access door latches locks and hinges periodic maintenance should be performed as follows Once per week clean and inspect the door hinges and latch mechanisms Clean with a nonabrasive degreaser or cleanser as required Every three months lubricate wit...

Page 30: ...paration of the body and chassis thereby causing possible personal injury or death TOWING OR PUSHING CAUTION Never tow or push a vehicle equipped with Allison automatic transmission until the rear drive shaft has been removed or unless the rear wheels have been raised off the ground Do not tow by front axle Bus may be towed using front or rear bumper brackets Optional tow hooks are located at the ...

Page 31: ...ball screw drive It is connected to a lever off the front door Mechanically operated switches control automatic stop positions as well as stepwell and warning lights JACKKNIFE DOOR If so equipped 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...

Page 32: ... will operate quietly if properly lubricated ROLLER BRACKET ROD END BRACKET POWER JACKKNIFE DOOR NOTE For air diagram see drawing 0867606 supplied with vendor maintenance documents The following adjustments and lubrications should be performed on the power jackknife door Options 0233 0467 and 0468 to insure its proper operation 1 Lubricate center hinge with LPS No 1 type lubricant 2 Adjust cylinde...

Page 33: ...There is a keyed switch on the outside of the body on the cowl panel by the door that parallels the operation of the interior switch Emergency Release With the door in the fully closed position pull the release lever in the header panel rearward as far as pos sible You will feel the linkage release and then feel the lever snap into a park position so it will not return forward when released Push t...

Page 34: ... in the lock the coach cannot be started To complete the ignition circuit the lock cylinder must be removed from the lock and placed in the receptacle at the side of the door When this is done the circuit is completed and the coach can then be started No lubrication is required with this system SLIDING BOLT VANDAL LOCK The sliding bolt vandal lock for the rear center emergency door is an interior ...

Page 35: ... oil and grease quickly deteriorate the floorcovering These type products should be removed as soon as possible Continuous care must be exercised in the step well area where foreign objects can create a safety hazard Soil and debris cannot be permitted to build up as this not only creates a hazard for passengers but hinders door operation and door sweeps Insure that screws for floor trims and aisl...

Page 36: ... picks up heat from the engine coolant and transfers it into the body Satisfactory performance of the body heaters is basically dependent upon 1 Adequate engine coolant temperature this can be altered by thermostat rating which should never be higher than recommended by the engine manufacturer and or shutters 2 Adequate coolant flow this varies with engine speed and can be increased if necessary b...

Page 37: ...in heater has a three speed control switch for manual low or high speed operation and an additional maximum output position for flash defrosting or the most extreme of conditions All the air from the main heater blower can be used for defrosting by leaving the main outlet and foot warmer outlet closed HEATER ACCESS The front heater can be accessed from two different places From the outside RH side...

Page 38: ...e forward driver s window allowing the moist air to escape into the low pressure area outside the bus at that location CARE AND CLEANING OF DEFROSTER FANS Defroster fan motor bearings are lifetime lubricated and do not require maintenance Occasional cleaning of the blade and guard with a soft bristle brush and a vacuum cleaner or compressed air will help to maintain efficiency As with any other fa...

Page 39: ...0535 Fan is located on the upper inner panel 6 to the left of center Opt 0541 Defroster fan is located on the dash cover DRIVER PASSENGER COMFORT When defrosting requirements have been satisfied the other openings can be set as necessary for comfort The adjustable outlets on the rear surface of the dash can be directed toward the driver and or passengers as desired The auxiliary unit under the dri...

Page 40: ...gine off shut all engine heater gate valves 2 Fill cooling system completely including surge tank with coolant and run engine for a few minutes to bleed air from cylinder block and heads 3 Open the heater hose supply line gate valve Refer to following pages for heater cutoff valve loca tions Turn on optional heater water pump if so equipped 4 Run engine between 1200 and 1500 RPM loosen bleeder val...

Page 41: ...umes Therefore if you ever smell exhaust fumes of any kind inside your vehicle have it inspected immediately by your dealer and have the condition corrected Do not drive with exhaust fumes present REMOVAL OF UNDERSEAT FAN AND MOTOR ASSEMBLY 1 Remove screws securing outlet to heater front and rear 2 Lower outlet panel and move it toward aisle to clear end of heater 3 Rotate outlet panel toward rear...

Page 42: ...for repair to a system ENGINE Cummins 5 9TA Valve No Location 1 Rear LH Corner of Engine Block 2 At Transmission Oil Cooler FRT HTR 1 2 DRIVER S HEATER ENGINE FRT HTR 1 2 ENGINE DRIVER S HEATER REAR HEATER TCFE FRT HTR DRIVER S HEATER REAR HEATER TRANSMISSION OIL COOLER UNDER FLOOR 1 2 FRT HTR DRIVER S HEATER TRANSMISSION OIL COOLER UNDER FLOOR 1 2 TCRE PRESSURE LINES RETURN LINES VALVES 1 ...

Page 43: ...t excessive vibra tion caused by damaged blower wheels or fans can cause motor damage Check wheels and fans for obstruc tions or damage by running each fan alone then listening and feeling for irregularity Replace damaged wheels or fans to prevent vibratory damage to surrounding and supportive housing parts and fasteners as well as motors Switches are also maintenance free but loose wiring connect...

Page 44: ... this clamp is 1056050 Torque clamps to 45 inch lbs new and 34 inch lbs for retorque 50 OR 80 UNDERSEAT HEATER REAR WITH R H REAR HEATER 50 OR 80 UNDERSEAT HEATER FRONT WITH REAR HEATER HEATER CLAMP TRIM CLAMP ACCESS OPENING WALL VIEW FROM TOP TYPICAL CLAMP ORIENTATION AT HEATER CORE CONNECTION 50 OR 80 UNDERSEAT HEATER R H REAR 50 OR 80 UNDERSEAT HEATER R H FRONT 50 OR 80 UNDERSEAT HEATER REAR 50...

Page 45: ... 25 Front Heater Std 3 19 50 Front Underseat Opt 1325 1 56 80 Rear Underseat Opt 1342 2 34 76 Ft of Heater Pipe with 0 17 quarts per foot 12 92 20 26 in Heating System Capacity of engine coolant system 24 60 qts in Engine 44 86 qts Total Cap 11 22 Gal ENGINE BLOCK HEATER S The engine block heater s are designed to help maintain a warm engine block for easier starting and faster warm up If the bus ...

Page 46: ...ss into glazing rubber 5 Seal glass to glazing rubber from outside of the bus with an adhe sive sealant such as Silastic 732 RTV Adhesive Sealant 6 Apply soapy solution to filler strip channel on glazing rubber to act as a lubricant for easier installation of filler strip 7 Using filler strip tool insert fillet strip into channel on glazing rubber SPLIT SASH WINDOW GLASS REPLACEMENT NOTE The glass...

Page 47: ...ctive equipment such as gloves and safety goggles WINDOW LATCH REPLACEMENT 1 Remove screw and block located in side channel directly above stationary glass 2 Lower sliding sash so that latch enters large notch covered by block removed in Step 1 3 With latch in large notch push finger holds outward until inside edge is exposed Pull latch out of finger hole opening 4 Finger latch is pried off attach...

Page 48: ...S REPLACEMENT 1 Remove filler strip from channel in glazing rubber 2 Apply pressure against glass from the outside of the bus starting at a corner and push glass and glazing rubber off of metal flange 3 Remove glazing rubber from glass 4 Put glazing rubber on new glass 5 Apply a soapy solution to the flange on the bus body and to the filler strip channel on glazing rubber This acts as a lubricant ...

Page 49: ...Be sure there is an adequate supply of fluid at all times The solution used is a 50 50 mixture of methanol alcohol and water WIPER ASSEMBLY REPLACEMENT To replace wiper assembly Blue Bird No 0348144 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 ...

Page 50: ...de panel 4 Replace the vertical rows of rivets and the rivets attaching the bottom rub rail with the same type size and quantity of fasteners as was used in the original construction or with Cherry SSPV 86 blind rivets Blue Bird P N 0888222 as necessary 5 Allow the adhesive to cure the proper amount of time fourteen days at room temperature for the Amicon TX 4009 before returning the vehicle to se...

Page 51: ...ck whether the wheel assembly appears normal by comparing it to another wheel assembly on the vehicle Check whether the side ring and lock ring around the wheel rim if so equipped are seated properly for duals look between the tires to check this If they look as if they are not seated properly or if you cannot be sure stay away from the tire and wheel and do not attempt further repair without expe...

Page 52: ...el must always be properly matched Do not mount a 20 inch tire on a 22 1 2 inch wheel Failure to strictly adhere to these important instructions will result in an explosive separation and will cause serious bodily injury or death It is very important to determine the size of each component before any assem bly operations commence When replacing tires use the same size load range and construction t...

Page 53: ...the jack manu facturer s recommended procedure place jack securely under axle at spring or suspension beam and lift to required height for servicing Be sure any lock ing device on the jack is in place and operating and solidly support the ve hicle under the main frame rails with jack stands or blocks before working under or around the bus 5 After servicing is complete reverse above procedure ENGIN...

Page 54: ...eramic material coated with noble metal catalysts To prevent contamination and loss of effectiveness of the catalysts unleaded fuel must be used Unleaded fuel also reduces spark plug fouling exhaust system corrosion and engine oil deterioration Leaded fuel will also damage the oxygen sensor in the Computer Command Control system which could affect emission control The following precautions should ...

Page 55: ...hicle for any extended amount of time with the engine running Exhaust gases particularly carbon monoxide may build up These gases are harmful and potentially lethal Carbon monoxide is colorless and odorless but can be present with all other exhaust fumes Therefore if you ever smell exhaust fumes of any kind inside your vehicle have it inspected immediately by your dealer and have the condition cor...

Page 56: ...e and Positive to Positive Do not reverse the battery cables The alternator can be damaged Attach ground cable last and remove 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 3 Start the engine 4 After the engine starts disconnect the negative boost cable from the battery 5 D...

Page 57: ...ge ANTIFREEZE The unit is equipped with a 50 50 solution of antifreeze and water This mixture protects to 30 degrees F The driver should check antifreeze before taking unit into cold climate For protection to 92 degrees F below zero the mixture should be 68 percent antifreeze and 32 percent water Never have more than 68 percent antifreeze CAUTION Cold water should never be poured into the cooling ...

Page 58: ...Inspect cab areas near the exhaust system Look for broken damaged missing or out of position parts Also inspect for open seams holes loose connections or other conditions which could let exhaust fumes seep into the driver and passenger compartments Needed repairs should be made at once To help maintain system integrity replace the exhaust pipes whenever a new muffler is put on Be alert to any chan...

Page 59: ...ion Replace the PCV valve and blow out PCV valve hose with compressed air Replace hoses when necessary S SPARK PLUG WIRE SERVICE Clean the wires and inspect for burns cracks or other damage Check the wire boot fit at distributor and at spark plugs Replace wires as needed Insure that boot heat shields are properly grounded to engine T EGR SYSTEM SERVICE Conduct EGR system check as referenced in the...

Page 60: ...n and if the emissions failure is caused by the failure or malfunction of an emissions warranted part Blue Bird Body Company will correct the part failure or malfunction WHAT IS COVERED Listed below are most of the systems that affect emissions of your engine if so equipped These compo nents are covered by the above warranty Emission control components of these systems are covered by the emissions...

Page 61: ... for maintenance replacements or for the repair of compo nents affecting emission control the owner should assure himself herself that such parts are warranted by their manufacturer to be equivalent to genuine General Motors parts in performance and durability MAINTENANCE AND REPAIRS MAINTENANCE AND REPAIRS CAN BE PERFORMED BY ANY QUALIFIED SERVICE OUTLET HOWEVER WARRANTY SERVICE MUST BE PERFORMED...

Page 62: ...should meet specifications ASTM D4814 in the U S and CGSB 3 5 M87 in Canada These fuels should have the proper additives so you should not have to add anything to the fuel In the U S and Canada it s easy to be sure that you get the right kind of gasoline unleaded You ll see UNLEADED right on the pump Only unleaded nozzles will fit into your vehicle s filler neck Be sure that the posted octane is a...

Page 63: ...find Do not use leaded gasoline Even one tankful will seriously degrade your emission controls With con tinuous use spark plugs can get fouled the exhaust system can corrode the engine oil can deteriorate quickly and the vehicle s oxygen sensor will be damaged All of that means costly repairs that wouldn t be covered by warranty To check on fuel availability ask an auto club or contact a major oil...

Page 64: ...ted marked and tested in accordance with the rules for construction of unfired pressure vessels Section VIII Division 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 con tainer shall be replaced or removed inspected and retested in accordance with the document under which it was originally manufactured before bein...

Page 65: ...a narrower range of flammability than gasoline as well as a higher ignition temperature Despite these relative safety advantages fire potential does exist CNG is lighter than air therefore it can collect in the higher regions of a room and possibly go undetec ted creating fire potential Since the fuel system is a very high pressure system employing a flammable gas all safety issues nor mally consi...

Page 66: ...aused 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 which are not tolerant to contaminants Vehicle performance is dependent upon clean fuel and regular scheduled vehicle maintenance Compressed natural gas is expected to be delivered from the compressor station ...

Page 67: ... has recommended guidelines for CNG refueling systems State and local regulation regarding NGV refueling may preclude economic feasibility of indoor refueling such as in New York City However the significance 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 fa...

Page 68: ...ow 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 become lighter than air and rapidly dissipate FUEL TOXICITY AND SAFETY Natural gas is a nontoxic gas It is flammable under proper conditions Additionally it can cause suffoca tion if enough oxygen is displaced LNG has the added safe...

Page 69: ...Substantial improvements in performance and emissions can be obtained using natural gas conversion kits that are 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 Chec...

Page 70: ...an in gasoline engines Spark Plugs Spark plugs should be replaced as recommended by the vehicle manufacturer CAUTION Do not use CNG pressure or vent lines to clamp hang connect or attach any items including harnesses hoses power steering hose refrigerant hoses or any other item MANUAL FIVE SPEED TRANSMISSION The standard transmission used in the TCFE is a five speed Synchro Mesh trans mission Refe...

Page 71: ...e fuel control lever Install and secure the pin 4 Check accelerator linkage for the proper return to the idle position 5 Check to be certain there is between 1 3 16 and 1 9 16 travel in modulator cable 6 If the throttle linkage is readjusted for any reason the mechanical modulator must be readjusted as above MD3060 WORLD TRANSMISSION The Allison electronic world transmission provides five forward ...

Page 72: ...ear As the vehicle slows down the transmission will downshift auto matically The SELECT indicator will display the highest gear available and the Monitor will display the current 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 2 3 4 5 provide progressively greater engine bra...

Page 73: ...e vehicle control system is functioning properly Consult the retarder manufacturer s owner operator manual for additional information USING THE ELECTRIC RETARDER TCFE The electric retarder control switch is mounted on the vertical panel to the left of the driver It has five positions one off and four retard positions Each higher number increases the amount of retardation to slow the vehicle Rememb...

Page 74: ... slow the vehicle to an acceptable speed where the transmission may be downshifted safely An automatic compared to a manual shift transmission has a longer coast down time Until you are accustomed to this characteristic you may need to manually downshift to reduce speed With a little experience in driving the automatic you will learn to decelerate a bit sooner or brake until automatic downshifts o...

Page 75: ...re should be exercised to avoid plugging this breather with paint undercoating or any other material The breather provides a passage for normal expansion and contraction of air and fluid within the transmission 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 HYDRAULIC BRAKES Bendix hyd...

Page 76: ...power steering pump 3 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 4 Engine is not running brakes 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...

Page 77: ...f there is a failure in the air reserve for the rear service brake system the front service brakes and the rear spring brakes can be applied through the treadle valve This allows the operator to use a normal method of braking during an emergency situation However in the case of an air reserve failure the low air pressure warning buzzer will sound and warning light illuminated giving an indication ...

Page 78: ...with an inoperable air compressor or without cranking the engine and should only be used for moving the coach while servicing or in case of emergency MGM SERVICE AND PARKING BRAKE Releasing Spring Brake Manually If air pressure fails in the piston chamber the power spring applies the brakes and unless pressure can be re established the service brakes must be released as follows in order to move th...

Page 79: ...justment screw clockwise to increase pressure If the pressure comes up to specifica tions and the fan speed doesn t the fan motor has excessive internal leakage and is at fault Repair or replace fan motor If specified pressure is obtained the relief valve is at fault Repair or replace relief valve F If after adjusting the pressure relief screw the pressure does not come up to specification the pum...

Page 80: ...vertighten clamps as this can damage the hose or distort the tubing connector When replacing a hose the clamp should be torqued to 45 inch lbs When checking a hose clamp clamps should be torqued to a minimum of 34 inch lbs CORSAIR EM 300 FAN CLUTCH OPERATION The Corsair Electromagnetic Fan Clutch is activated by 12 VDC from the vehicle electrical system Bolted to the front of the engine the fan ge...

Page 81: ...ss must be spread in order to loosen the pitman arm for removal from the shaft Spreading the boss may be accomplished by using the correct size Allen wrench a chisel or a pitman arm spreader 5 When the boss is spread slide the pitman arm off the steering gear shaft 6 If vendor supplied mark does not line up with mark on the steering gear output shaft cross out vendor supplied mark on pitman arm wi...

Page 82: ...omatically for the increased turning radius If it becomes necessary to shorten the turning radius the steering gear poppets must be adjusted manu ally by doing the following Read the section on special poppet valve manual readjustment in the TAS65 Service Manual before proceeding 1 Set axle stops for correct turn 2 Turn new adjusting poppet screw 1469261 into jam nut until flush with end of screw ...

Page 83: ...olts to 11 13 ft lbs REAR AXLE SPICER REAR AXLE F170 S J190 S J210 S AND J230 SB 1 Assemble the bearings and hub onto the axle spindle 2 Install the dowelled wheel bearing adjustment nut Torque the adjusting nut to 50 ft lbs while rotat ing wheel in both directions so all bearing surfaces are in contact then back off 1 6 to 1 4 turn to allow wheel to rotate freely 3 Install the nut lock NOTE Rotat...

Page 84: ...EAR SUSPENSION FRONT SPRING HANGER BRACKET 125 125 REAR SPRING REAR SCHEDULED MAINTENANCE MONTHLY OR 1 000 MILES Grease safety barrier latch on Braun wheelchair lift Lubricate roof hatch weatherseals lock mechanisms Inspect all emergency equipment mounting fasteners Lubricate window latches and slides Lubricate hinge pin on entrance doors Lubricate pivot points on outward opening door Check adjust...

Page 85: ...ir lift Check fluid level in Collins wheelchair lift Lubricate hinge and latch mechanisms on access doors Check internal fasteners on electric stop arms Lubricate entrance door vandal lock Inspect heater valves to verify proper function Change engine oil and oil filter Inspect fuel cap tank and fuel lines Inspect engine fuel tank vents Inspect engine air filter replace if required Inspect drivesha...

Page 86: ...tery cleaner and reinstall on a rotating basis Adjust door control rod and closing mechanism to entrance doors Bleed all air from heaters Tighten all heater hose clamps Check cylinder chains hoses and wires on the Braun Wheelchair lift Check heater hoses motor wheels and fans on heaters Clean heater core Tighten heater hose clamps Inspect power steering pump Inspect steering gear Lubricate steerin...

Page 87: ...spect and clean Cyclo Gard air dryer Change coolant These check lists are suggested They do not replace or supersede local or state required driver inspection procedure MAINTENANCE SERVICE KEYS 11 13 10 9 2 1 12 1 4 5 6 7 12 12 1 10 9 1 6 4 5 1 10 9 1 11 8 1 3 10 9 1 12 TCFE MAINTENANCE SERVICE KEY TCRE MAINTENANCE SERVICE KEY 11 13 10 9 2 1 1 4 5 6 7 12 1 10 9 1 6 4 5 1 10 9 1 11 1 3 10 9 1 12 ...

Page 88: ...the gasket surface of filter head Replace O rings Fill new filters and lube O ring seals Service FF5018 Cummins 3903640 Follow instructions on filter for changing Racor S3211 30 Micron Loosen self venting drain at bottom of bowl to drain water See Cummins Book Avoid using contaminated fuel No 2 D recommended fuel blended for expected temperature range See Cummins Book Remove fuel tank sump drain p...

Page 89: ...ook See PowerTech 6081 CNG Engine Book Grasp with both hands and attempt to turn in both directions If rotation is felt damper should be replaced See PowerTech 6081 CNG Engine Book Inspect for loose fittings leaks cuts abrasions etc See PowerTech 6081 CNG Engine Book Pressure test system to 10 psi including radiator cap See PowerTech 6081 CNG Engine Book See PowerTech 6081 CNG Engine Book Adjust g...

Page 90: ... Torque to 600 625 ft lbs Torque to 100 125 ft lbs 1 2 Torque to 30 35 ft lbs 3 4 Torque to 30 35 ft lbs Inspect for leaks 4 875 inches between bottom of frame rail and top of axle Torque to 260 280 ft lbs Torque to 460 480 ft lbs Torque to 100 125 ft lbs 1 2 Torque to 30 35 ft lbs 3 4 Torque to 30 35 ft lbs Inspect for leaks 9 25 inches from top of axle pad to bottom of frame rail SPRING SUSPENSI...

Page 91: ... shaft or housing If leak is evident fluid oozing out it should be corrected immediately Check for leakage around the shaft or housing If leak is evident fluid oozing out it should be corrected immediately See key No 7 page 86 See page 80 Lubricate the slide Access to slide is obtained by removing rubber boot Use NLGI Grade No 2 Grease See page 81 See page 81 See TRW Ross Steering Gear Manual Grea...

Page 92: ...ubricate at 100 000 miles See Rockwell Field Maintenance Manual No 4 or See Eaton EB 31 Service Manual or See Eaton EB 32 Service Manual Also see page 76 4 Fittings See page 76 See key No 8 page 86 Use NLGI Grade No 2 Grease See page 77 4 Fittings Use NLGI Grade No 2 Grease See key No 9 page 86 4 Fittings Use NLGI Grade No 1 Grease Special Stopmaster Grease See key No 10 See page 74 Replenish if n...

Page 93: ...lied with vendor maintenance documents for schematic of air throttle See Williams Control Service Bulletin SB388UIC3D Use distilled water to fill Clean more often if corrosion appears Use heavy grease to help prevent corrosion See Delco Remy Service Bulletin1G 266 Check system for proper operation Check wiring and tubing for proper connection and deterioration Replace parts as necessary Check wiri...

Page 94: ...pening and closing of stop arm Lubricate breakaway hinge at four 4 pivot points Use Tri Flow Dupont lubricant Check outer fasteners for tightness Check inner fasteners for tightness Lubricate bushing shaft in center at base of lock handle See page 33 Use Apply lubricant Spray lubricant into key lock Use Apply lubricant Lubricate sliding bolt mechanism Use LPS No 1 lubricant No lubrication and adju...

Page 95: ...er As required Weekly Weekly Weekly As Required As Required HEATERS Check Heater Hoses Clean Heater Coil RH Front Heater Air Filter Check Motor Wheels Fans Check Heater Panels Housing Tighten Heater Hose Clamps BODY MOUNTING Inspect Mounting Bolts MIRRORS Adjust Mirrors SEATS Inspect Mounting Fasteners Inspect Cushion Attachments Inspect Upholstery Lubricate Driver s Seat Inspect Seat Belts Inspec...

Page 96: ... 6BTA5 9 17 qts 15 qts 24 6 qts 20 qts 23 6 qts 6 5 qts Cummins 8 3 C 24 qts 20 qts 38 qts 19 qts John Deere 8 1 32 qts 30 qts 42 qts 20 qts REAR AXLE FLUID CAPACITIES Spicer F 170 S 23 pts Single Speed Spicer J 190 S 31 5 pts Single Speed Spicer J 210 S 31 5 pts Single Speed Spicer J 230 SB 31 5 pts Single Speed Spicer M 190 T 35 0 pts Two Speed ENGINE OIL PRESSURE Cummins 5 9TA 40 60 PSI 2500 RP...

Page 97: ...IPTION The electric vehicle is different from any other vehicle you have ever driven When driving this vehicle you will notice the absence of noise typical of an internal combustion engine whether it is gasoline diesel or natural gas powered There will also be an absence of the distinct shifting of gears that you can feel when driving a combustion engine vehicle equipped with an automatic transmis...

Page 98: ...r 5 hp Battery Pack Brake Accelerator Speed Position Direction Traction Battery Pack Control Commands Status Oil Radiator Fans 4 Air Torque Current Motor Pump 2 hp 12 Volts to Vehicle 12 Volts to Radiator Fan Steering Brake Hydraulics BATTERY POWER The electric vehicle is operated solely by electric power The power is provided by batteries as follows Traction Batteries The battery packs provided t...

Page 99: ... CONTROLLER The motor controller is located in the right side rear compartment behind the rear tires The motor con troller contains five 5 printed circuit boards and numerous chassis mounted components It provides vari able voltage variable frequency 3 phase AC output power forward and reverse phase sequences and vector torque control When powered by a 336 volt DC Traction Battery Pack the motor c...

Page 100: ...hat is returned to the Traction Battery Packs The energy that is returned to the Traction Battery by the regenerative braking will increase the range of the bus This increase can be as much as 20 as compared to a system without regenerative braking The first movement of the brake pedal applies the regenerative braking by responding to a small rise in hydraulic brake fluid pressure The regenerative...

Page 101: ...y and to check for obstructions in any direction When walking around the vehicle it is also important to check the ground under the vehicle for fluid leaks from the power steering brakes diesel heater or the oil cooling system If you observe any leaks immediately notify the appropriate department DO NOT start the vehicle if you think it is leaking The following fluids are used in the operation of ...

Page 102: ...uccessfully engaged the D selector will illuminate Or you may press R Reverse When reverse is successfully engaged the R selector will illuminate To select Drive or Reverse the bus must be at zero speed not even the slightest roll and the brake pedal depressed The driver cannot change from one selection D R if the vehicle is moving You cannot move the bus until the D or R selector is fully illumin...

Page 103: ...of bus behind driver s wiper Check Motor Controller fuses in right side rear compartment Check F1 F2 on Relay Box in right side rear compartment Operating modes selector panel lights do not come on at second ignition position This indicates electric drive start failure 12 volt battery is dead jump start as indicated below Possible blown fuses inside fuse panel System battery connections disconnect...

Page 104: ...l non aggressive manner the regenerative brakes will absorb almost all of the mechanical energy of the moving bus and the life of the friction brakes will be greatly extended Always maintain a safe distance between your and those around you WARNING When starting from a standing stop on a hill the vehicle will behave much like a manual transmission equipped vehicle As such it may drift backward bef...

Page 105: ...ng any maintenance or repair Screens and covers must be maintained in place when unit is in operation Motors for use in hazard ous locations Class I II installation Repairs of these motors must be made by the manufacturer or autho rized service station approved by the manufacturer and U L to maintain the U L listing The U L listing applies to the electrical motor only and not to the belt or gear t...

Page 106: ...105 NOTES ...

Page 107: ...rd Opening Door 93 Power Jackknife Door 93 Seats 94 Vandal Locks 93 Windows 93 Body Tie Down 29 Brake Maintenance Chart 91 Air Brake System 91 Hydraulic Brakes Disc 91 Shoe Type Brakes Air 91 Chassis Component Maintenance Chart 92 Accelerator System 92 Automatic Transmission 92 Drivelines 92 Electrical System 92 Circuit Breakers 19 Coach Identification 4 Axle Record Chassis Service Number 5 Body S...

Page 108: ...3 Engine Access 34 Hood Removal for Mechanics Access 34 Rear Side Engine Compartment Doors 35 TCFE 34 TCRE 35 Engine Block Heaters 44 Engine Operating Instructions 52 Antifreeze 56 Catalytic Converter 53 Cold Start Aid 55 Computer Command Control System 54 Diesel Engine Starting Procedure 55 Engine Exhaust Gas Caution 54 Engine High Idle Switch 56 Engine Warning System 56 Exhaust System Gas Engine...

Page 109: ... Introduction 3 Jacking Instructions 52 John Deere 8 1 CNG Engine Maint Chart 88 Keeping Your Vehicle Looking New 33 Finish Damage 34 Floors Floorcovering 34 Foreign Material Deposits 34 Polishing Waxing Your Vehicle 33 Washing Your Vehicle 33 Light Bulb Data 15 Exterior Lights 15 Interior Lights 15 Lower Side Panel Repair Procedure 49 Maintenance Service Keys 86 Manual Five Speed Transmission 69 ...

Page 110: ... Safety 51 Towing or Pushing 29 Transpec Safety Vent 24 Maintenance Cautions 24 Service Repairs 24 Vandal Locks 33 Emergency Door 33 Entrance Door 33 Sliding Bolt 33 Wheelbearing Adjustments 82 Spicer Front Axle 82 Spicer Rear Axle 82 Wheelchair Lift Maintenance Chart 94 Braun Lift 94 Collins Lift 94 Wheelchair Lifts 24 Windows Windshields 45 Entrance Door Glass Replacement 47 Rear Vision Glass Re...

Page 111: ...Part Number 1919331 Blue Bird Corporation P O Box 937 Fort Valley GA 31030 ...

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