Grech Motors EG40 Owner'S Manual Download Page 5

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GRECH MOTORS

TA B L E O F C O N T E N T S

CAUTION-ADVISORY Regarding Customer Vehicle Alterations

General Vehicle Dimensional Specifications

Vehicle ID Labels

Customer Assistance

Wheels and Tires

Load Carrying Capacities

Ultra Ride Air Suspension

Firestone Ride Rite Air Spring

Kelderman Suspension

Preventative Maintenance

Basic Troubleshooting

E450 Vehicle Circuit Board Assembly

F550 Vehicle Circuit Board Assembly

Freightliner Vehicle Circuit Board Assembly

Vehicle Wiring Diagrams Online @

WWW.GRECHMOTORS.COM

Parts - Service - Warranty

Vendor Reference Listing

GRECH MOTORS

Warranty

Statement

Summary of Contents for EG40

Page 1: ...his label contains vital information used to identify your specific vehicle and the safety features that must be understood and followed in order to operate this vehicle safely Your Grech Vehicle ID N...

Page 2: ......

Page 3: ...r vehicle This edition covers all Chassis models and is designed to be used in conjunction with the original chassis manufacturer s owner s literature as well as all other component manufacturers lite...

Page 4: ...gency Roof Hatch Exit 16 Dual Overhead Parcel Rack 18 OPERATION Drivers Overhead Control Panel for F 550 Freightliner 19 Drivers Dash Control Panel for E 450 20 PROAIR Control Panel 21 Audio Video PA...

Page 5: ...istance Wheels and Tires Load Carrying Capacities Ultra Ride Air Suspension Firestone Ride Rite Air Spring Kelderman Suspension Preventative Maintenance Basic Troubleshooting E450 Vehicle Circuit Boar...

Page 6: ...ion of dash indicator lights with key on engine not started then again with engine started 10 Check operation of ventilation system heating defrosters fans and air conditioning 11 Check horn wipers wa...

Page 7: ...ansmission fluid level 23 Check engine coolant level 24 Check power steering fluid level 25 Check brake fluid level 26 Check belts for tension and wear 27 Check operation of cameras if applicable 28 C...

Page 8: ...WHILE VEHICLE IS IN MOTION IF A DOOR AJAR WARNING LIGHT IS LIT CHECK ALL DOORS FOR PROPER CLOSURE NEVER OPERATE THIS VEHICLE UNTIL THE PROBLEM HAS BEEN RESOLVED THIS BUS IS NOT DESIGNED TO TOW ANOTHE...

Page 9: ...eopen the door if it detects an obstruction again If the System detects an obstruction on its third attempt to close the door it will stop with the door coming to rest in the open position Pressing th...

Page 10: ...once it makes contact call the Grech Motors Service Department at 1 855 994 7324 and do not operate the vehicle 5 If the passenger door stops and re opens without seeming to contact an obstruction ca...

Page 11: ...Lever is in the left position the door can be opened with hand pressure applied to push the door out and away from the bus Electric Door Auxiliary Door Switch door operation This vehicle is equipped w...

Page 12: ...left to the right See Photo No 2 on page 13 5 Confirm that the red handle moves from the right to the left and from the left to the right without obstruction If the red handle does not move smoothly a...

Page 13: ...ever Decal Electric Door Release Lever Closed Position EMERGENCY USE ONLY CAUTION LEVER MUST BE CHECKED DAILY PRIOR TO VEHICLE OPERATION Electric Door Release Lever Exit Position Electric Door Emergen...

Page 14: ...plemental exit points in the event of an emergency The vehicle has multiple Emergency Egress Windows on the passenger side and the driver s side of the vehicle The Emergency Egress Windows are a vital...

Page 15: ...ed open 3 When Emergency Egress Window Latch is released the user can open the window by pushing on the bottom of the window frame The Emergency Egress Window should swing out and away from the vehicl...

Page 16: ...surface with a mild soap and water CAUTION When removing graffiti it is the customers responsibility to ensure cleaning solutions are compatible with the materials used on Safety Vents Solutions conta...

Page 17: ...atch Exit is missing the Emergency Exit designation sticker call the Grech Motors Service Department at 1 855 994 7324 and do not operate the vehicle 2 Each Emergency Roof Hatch is secured by one latc...

Page 18: ...d Parcel Rack CAUTION Do not overload Parcel Racks Do not fasten parcels to retainer bars Note Maximum loading specification for both model parcel racks is either 20 Lbs per foot or 5 Lbs per passenge...

Page 19: ...hts optional Note Cool mode A C on both front rear Heat mode Heat from front unit only on early models 4 Rear Door Ajar WARNING DEVICE 10 Climate Control Temperature Setting Point 5 Interior Lights 11...

Page 20: ...l Temperature Adjustment Up or Down 2 Reading Lights optional 9 Climate Control Switch Auto Mode On or Off 3 Interior Lights Note Cool mode A C on both front rear Heat mode Heat from front unit only o...

Page 21: ...temperature for two or three seconds then display will show actual temperature To switch between Fahrenheit and Celsius press both temperature up and down buttons at the same time for three seconds A...

Page 22: ...Tap to scan through currently stored Presets Press and hold to scan and store strongest stations in your area PLEASE SEE THE MANUFACTURERS LITERATURE FOR ADDITIONAL OPERATING INFORMATION 10 PROGRAM TY...

Page 23: ...ute or next waypoint 10 SETTINGS Tap to change your preferences for route calculation sound settings warnings and more 11 USEFUL INFO Tap to find information about current location nearby help country...

Page 24: ...h LED lights below the fuel gauge on Freightliner only and replenish the DEF fluid as needed It is never acceptable to run the vehicle out of DEF Engine Brake The new mid size Freightliner bus is equi...

Page 25: ...off water Note When you are done filling the tank replace the cap and close the Water Hose compartment Door Water for the Lavatory The lavatory water pump switch must be in the ON position in order f...

Page 26: ...ose in an approved sewer drain Then hook the hose to the dump valve which is located under the bus behind the right drive tire Now it is OK to open the valve Step 3 Step on the toilet flush and allow...

Page 27: ...his system will only operate when the ignition in the on position Note The suspension will automatically raise to vehicle ride height when the rear luggage door is closed CAUTION Only in emergency sit...

Page 28: ...dicates approximate location of Auxiliary Batteries on the drivers side of the vehicle On the F 550 the Charge Isolator Solenoid is located under the vehicle next to the battery This page references t...

Page 29: ...witch includes a center toggle switch that allows the operator to switch from right to left mirror The center posi tion of the toggle defeats all mirror operations When either the left or right mirror...

Page 30: ...able or disable step operation When the step is enabled opening the rear door automatically extends the step Note See Manufacturers literature regarding periodic lubrication requirements SEE MANUFACTU...

Page 31: ...LY PROHIBITED WITHOUT THE AUTHORIZATION OF GRECH MOTORS ENGINEERING DEPARTMENT MODIFYING THE SEATING ARRANGEMENT OF YOUR VEHICLE WITHOUT PROPER ENGINEERING SPECIFICATIONS CAN CHANGE THE WEIGHT DISTRIB...

Page 32: ...t 40 4 ft 44 ft 50 9 ft Ground Clearance 11 in 11 in 11 in 9 in 9 in 9 in Clear Door Opening Entry Door 881 4 x 323 4 91 x 32 in 91 x 32 in 881 4 x 323 4 881 4 x 323 4 881 4 x 323 4 Clear Door Opening...

Page 33: ...This is the Gross Axle Weight Rating Date Incomplete Vehicle Manufactured This is the date the chassis was produced by OEM manufacturer Date Of Manufacture by GRECH This is the date the vehicle was co...

Page 34: ...ealer A reasonable time must be allowed to perform a repair after taking your vehicle to the authorized dealer Repairs will be made using Grech Motors parts or remanufactured or other parts that are a...

Page 35: ...s under your state s warranty laws Grech Motors is also allowed a final repair attempt in some states In the United States a warranty dispute must be submitted to the BBB AUTO LINE before taking actio...

Page 36: ...Southeast Washington D C 20590 You can also obtain other information about motor vehicle safety from http www safercar gov REPORTING SAFETY DEFECTS CANADA ONLY If you believe that your vehicle has a...

Page 37: ...res space saver or temporary use spare tires light truck or LT type tires tires with nominal rim diameters of 10 to 12 inches or limited production tires as defined in Title 49 Code of Federal Regulat...

Page 38: ...rature A B C WARNING The temperature grade for this tire is established for a tire that is properly inflated and not overloaded Excessive speed under inflation or excessive loading either separately o...

Page 39: ...signed to carry a maximum load at 35 psi 37 psi 2 5 bar for Metric tires Increasing the inflation pressure beyond this pressure will not increase the tire s load carrying capability Extra load A class...

Page 40: ...he tread Tread area of the tire Area of the perimeter of the tire that contacts the road when mounted on the vehicle Tread area of the tire Area of the perimeter of the tire that contacts the road whe...

Page 41: ...on or the Japan Tire Manufacturing Association B 215 Indicates the nominal width of the tire in millimeters from sidewall edge to sidewall edge In general the larger the number the wider the tire C 65...

Page 42: ...acturers always use the letters ZR H U S DOT Tire Identification Number This begins with the letters DOT and indicates that the tire meets all federal standards The next two numbers or letters are the...

Page 43: ...the government course as a tire graded 100 Traction The traction grades from highest to lowest are AA A B and C The grades represent the tire s ability to stop on wet pavement as measured under contr...

Page 44: ...res These differences are described below A LT Indicates a tire designated by the Tire and Rim Association that is intended for service on light trucks B Load Range and Load Inflation Limits Indicates...

Page 45: ...d for temporary service on cars sport utility vehicles minivans and light trucks B 145 Indicates the nominal width of the tire in millimeters from sidewall edge to sidewall edge In general the larger...

Page 46: ...nded by Grech Motors You are strongly urged to buy a reliable tire pressure gauge as automatic service station gauges may be inaccurate Grech Motors recommends the use of a digital or dial type tire p...

Page 47: ...ng wheel after the vehicle travels over a bump or dip in the road that does not dampen out by itself Shimmy may result from significant under inflation of the tires improper tires load range size or t...

Page 48: ...commended cold pressures A hot tire at or below recommended cold inflation pressure could be significantly under inflated Note If you have to drive a distance to get air for your tire s check and reco...

Page 49: ...educe the risk of serious injury never attempt to re inflate a tire which has been run flat or seriously under inflated without first removing the tire from the wheel assembly for inspection Do not at...

Page 50: ...ems for holes cracks or cuts that may permit air leakage and repair or replace the tire and replace the valve stem Inspect the tire sidewalls for cracking cuts bruises and other signs of damage or exc...

Page 51: ...s these wear bars the tire is worn out and must be replaced Damage Periodically inspect the tire treads and sidewalls for damage such as bulges in the tread or sidewalls cracks in the tread groove and...

Page 52: ...mean the 31st week of 1997 After 2000 the numbers go to four digits For example 2501 means the 25th week of 2001 The numbers in between are identification codes used for traceability This information...

Page 53: ...he following precautions must be taken to protect the person mounting the tire 1 Make sure that you have the correct tire and wheel size 2 Lubricate the tire bead and wheel bead seat area again 3 Stan...

Page 54: ...y Drive slowly to the closest safe area out of traffic This may further damage the flat tire but your safety is more important If you feel a sudden vibration or ride disturbance while driving or you s...

Page 55: ...pped with a dissimilar spare wheel and tire assembly A dissimilar spare wheel and tire assembly is defined as a spare wheel and tire assembly that is different in brand size or appearance from the roa...

Page 56: ...oss of vehicle control vehicle rollover personal injury and death Additionally the use of non recommended tires and wheels could cause steering suspension axle transfer case or power transfer unit fai...

Page 57: ...vehicle stop and retighten the chains If this does not work remove the chains to prevent damage to your vehicle Remove the tire chains when they are no longer needed Do not use tire chains on dry road...

Page 58: ...e vehicle including a full tank of fuel and all standard equipment It does not include passengers cargo or optional equipment Vehicle Curb Weight is the weight of your new vehicle when you picked it u...

Page 59: ...can be limited either by volume capacity how much space is available or by payload capacity how much weight the vehicle should carry Once you have reached the maximum payload of your vehicle do not ad...

Page 60: ...uctural damage serious damage to the vehicle loss of control and personal injury WARNINGS Do not exceed the GVWR or the GAWR specified on the Safety Compliance Certification Label Do not use replaceme...

Page 61: ...d capacity Suppose your vehicle has a 1400 pound 635 kilogram cargo and luggage capacity You decide to go golfing Is there enough load capacity to carry you four of your friends and all the golf bags...

Page 62: ...lation would be 1400 2 x 220 9 x 100 1400 440 900 60 pounds Now you have the load capacity to transport the cement and your friend home In metric units the calculation would be 635 kilograms 2 x 99 ki...

Page 63: ...22 x 2 5 nuts 830 N m Lateral Control Rod Pass M22 x 2 5 nuts 830 N m Lateral Control Rod Driver 5 8 unc nuts 200 Ft lbs Magnet Mounting Plate 1 4 unc Nyloc nuts 8 10 Ft lbs Maintenance Schedule Check...

Page 64: ...east monthly intervals during the continuous operation of the vehicle see above When the vehicle is removed from long term storage Refer to original manufacturer owner s manual for greater detailed in...

Page 65: ...lar importance is the re torque of fasteners including axle bolts four link bolts and pan hard bar bolts This re torque must be performed within 90 days of the suspension be ing put into service Owner...

Page 66: ...of service must be considered when establishing maintenance intervals Therefore any such intervals noted in the following schedule must be adjusted according to the type of operation in which your spe...

Page 67: ...luid leaks from transmission engine power steering engine coolant gear oil fuel check all seatbelts for proper function and damage CHECK EVERY MONTH door linkage and pivot arm lubrication and worn or...

Page 68: ...nals check the torque of all door hardware on Vapor door systems AT 25 000 MILES 3000 HOURS DO THE FOLLOWING inspect tires for wear and inspect tread depth rotate tires inspect engine air filter clean...

Page 69: ...ls with silicon spray check for proper sealing re inspect torque settings on Ultra Ride Suspension System if equipped check the torque of all door hardware on Vapor door systems AT 90 000 MILES 10800...

Page 70: ...good If the rear A C is still not work ing call the Service Department at GRECH MOTORS EXTERIOR LIGHTING One or all exterior clearance lights inoperative please refer to the FORD owner s manual for fu...

Page 71: ...h is in the on position NOTE Always be sure to turn the water pump switch off when not in use Failure to do so could cause a steady drain on the auxiliary battery or could cause damage to the water pu...

Page 72: ...GRECH MOTORS 72 Basic Troubleshooting Guide PROBLEM POSSIBLE SOLUTIONS...

Page 73: ...GRECH MOTORS 73 E 450 Vehicle Circuit Board Assembly The Circuit Board Assembly above is shown horizontal for the purpose of this manual...

Page 74: ...d Diagram 1 Solenoid 250A 12V DC 2 Relay Block 3 Relay Sockets 4 Fuse Blocks 5 PAC Video Amplifier 6 A C Thermostat Relay Board 7 Electrical Panel Board 8 Timer 5 Min Lights 9 Mounting Bracket Solenoi...

Page 75: ...GRECH MOTORS 75 The Circuit Board Assembly above is shown horizontal for the purpose of this manual F 550 Vehicle Circuit Board Assembly...

Page 76: ...Vehicle Circuit Board Diagram Fuse Legend enlarged 1 Solenoid 250A 12V DC 2 Relay Block 3 Relay Sockets 4 Fuse Blocks 5 PAC Video Amplifier 6 Mounting Bracket Solenoid 7 Electrical Panel Board 8 Mega...

Page 77: ...GRECH MOTORS 77 Freightliner Vehicle Circuit Board Assembly The Circuit Board Assembly above is shown horizontal for the purpose of this manual...

Page 78: ...Freightliner Vehicle Circuit Board Diagram Fuse Legend enlarged 1 Solenoid 250A 12V DC 2 Relay Block 3 Relay Sockets 4 Fuse Blocks 5 PAC Video Amplifier 7 Electrical Panel Board 8 Timer 5 Min Lights 9...

Page 79: ...GRECH MOTORS 79 Main Wiring Diagrams All Vehicle Main Wiring Diagrams can be found online at WWW GRECHMOTORS COM diagrams wiring...

Page 80: ...our vehicles UNDERSTANDING WARRANTY POLICY read the following sections carefully Should your bus require service related to the converted areas of the vehicle read this section first before taking any...

Page 81: ...d then it can either be repaired at our Riverside California facility or by a shop that we recommend in your area or by a shop of your choice This procedure is true of both warranty and non warranty r...

Page 82: ...ger has determined that the repair is not covered or you are sure that it is not covered we would be happy to recommend a shop in your area or schedule an appointment with the Grech Motors Service Dep...

Page 83: ...s Service Department at 1 855 994 7324 If method 3 is used simply pay for the work and mail a copy of the invoice along with the Grech Motors repair authorization number R A N and include your Grech M...

Page 84: ...37 8900 1 Year or 12 000 Miles whichever occurs first SHURFLOW WATER PUMPS 1 800 854 3218 2 Years Unlimited Miles TRANSPEC WORLDWIDE 1 810 274 9400 Roof Hatch 1 Year Unlimited Miles VELVAC MIRRORS 1 8...

Page 85: ...nd workmanship under normal use and service for ve 5 years or 100 000 miles whichever comes rst from the date of purchase by the original retail customer In the event of a Warranty claim Grech Motors...

Page 86: ...Motors or for any parts or paint which have been subject to misuse neglect or accidents or have been subject to external mechanical or chemical influences especially stone chips airborne rust or indu...

Page 87: ...nges on previously sold products Additionally the information and specifications contained within this manual are current at time of printing Subsequently all information contained in this manual is s...

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