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IC Bus Gasoline CE Series, Operation And Maintenance Manual

The IC Bus Gasoline CE Series offers efficient and reliable transportation solutions. Ensure proper usage and upkeep with our comprehensive Operation And Maintenance Manual, available for download completely free. Access it easily on our website and find the essential information you need to maximize the performance and longevity of your IC Bus.

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Operation

NOTE: The traction control braking (ATC action) to limit
wheel spin does not occur at vehicle speeds above
approximately 31 mph (50 km/h).

Therefore, at speeds

above 31 mph (50 km/h), all ATC events are controlled only
by Engine Power Limiting.

The Traction Control switch for Hydraulic Brake
equipped vehicles.

With the Traction Control switch

in the TRAC CTRL position, the system operates as
described above. The MUD / SNOW position of the
Traction Control switch provides modified system
performance for deep mud or snow conditions. If the
optional Traction Control switch is in this position,
the instrument panel gauge cluster TRAC CTRL
indicator will flash.

The OFF Road switch for Air Brake equipped
vehicles.

With the Traction Control switch in the

TRAC CTRL position,

the system operates as

described above. The OFF ROAD position provides
modified system performance for off-road conditions.
If the optional Off Road switch is in this position, the
instrument panel gauge cluster TRAC CTRL indicator
will flash.

Driver Assist Systems

There are various driver assist systems that could be configured
on your bus. The driver assist systems are safety features that
assist the driver in various driving conditions.

Bendix

®

Wingman

®

Advanced

™

Collision Warning

System

WARNING

Tprevent personal injury and / or death, or
property

damage,

the

Bendix

®

Wingman

®

Advanced

™

Collision Warning System is not to

be used or relied upon to operate a vehicle.
The system should be used in conjunction with
rear view mirrors and other instrumentation to
maintain safe operation.

A vehicle equipped

with the Bendix

®

Wingman

®

Advanced

™

Collision

Warning System should be operated in the same
safe manner as if the system were not installed.
The system is not a substitute for normal safe
driving procedures. It will not compensate for
any driver impairment, such as drugs, alcohol,
or fatigue.

The Bendix

®

Wingman

®

Advanced

™

Collision Warning System is intended solely as
an aid for an alert and conscientious professional
driver.

WARNING

To prevent personal injury and / or death, or
property damage, before using this feature,
read and thoroughly understand the Bendix

®

Wingman

®

Advanced

™

Collision

Warning

System's Driver Instruction Manual, and obtain
proper training on the system.

129

Summary of Contents for Gasoline CE Series

Page 1: ...536R3 EPA 17 2017 HD OBD US Canada April 2020 IC Bus Gasoline CE Series Operation and Maintenance Manual IC Bus LLC 2701 Navistar Drive Lisle IL 60532 USA 2020 IC Bus LLC All rights reserved All marks are trademarks of their respective owners ...

Page 2: ...gistered owner e g IC Bus dealer who may need this data or information to properly service or diagnose this vehicle for repair or following an accident Any access to this information without the owner s consent may be in violation of law and may subject that person or entity to criminal penalties CALIFORNIA Proposition 65 Warning WARNING Breathing diesel engine exhaust exposes you to chemicals kno...

Page 3: ... engine VEHICLE IDENTIFICATION NUMBER VIN ENGINE Feature Code Serial Number FRONT AXLE Feature Code Serial Number REAR AXLE Feature Code Serial Number TRANSMISSION Feature Code Serial Number TRANSFER CASE Feature Code Serial Number CUSTOMER ASSISTANCE CENTER 1 800 44 TRUCK 1 800 448 7825 Navistar Inc 2701 Navistar Drive Lisle IL 60532 USA www navistar com IC Bus LLC 2701 Navistar Drive Lisle IL 60...

Page 4: ......

Page 5: ...tation Updated Text and Warning Messages 2 Section 14 Maintenance Intervals Rear Axle Interval Update 2 Emergency Exit Information Section 6 Passenger Controls Vandal Lock Information 3 Section 4 Driver Controls Pedal Adjustment Switch 3 Section 13 Maintenance Instructions Parking Brake Burnish Procedure 3 ...

Page 6: ......

Page 7: ...pment 19 Gasoline System Inspection 20 Section 3 Instrumentation Instrument Panel Gauge Cluster 21 Warning Indicators 22 Instrument Panel Gauge Cluster 24 Direct Drive Warning Indicators 25 Integral Digital Display 26 Integral Digital Display Detailed Information 28 Quadrant 3 Outside Temperature and Compass Displays If Equipped 34 Outside Temperature Reading 35 Optional Instrument Panel Gauge Clu...

Page 8: ...Three Position Door Switch 62 Opening the Entrance Door 63 Opening the Entrance Door Manually 63 Electric Actuated Door 63 Air Actuated Door 63 Traffic Warning System 63 Electronic Safety Messages 64 Eight Lamp AMBER and RED Warning Lights 64 Rocker Switches If Equipped 64 WIG WAG Warning System 65 Flashing Stop Arm 66 Crossing Gate 66 Driver Visual Warning Lights and Indicators 67 Audible Warning...

Page 9: ...se of Tether Anchors SafeGuard XChange Bus Seats 92 Cushion Release Latch 93 Track Seat Mounting Seat Type Specific 94 Section 8 Wheelchair Instructions and Information Introduction 99 Wheelchair Lift Operation 99 Wheelchair Lift Interlocks Extending 99 Wheelchair Lift Interlocks Retracting and Stowing 100 Wheelchair Lift Alarm 100 Parking Brake Wheelchair Lift Interlock and Alarm 100 Wheelchair L...

Page 10: ...ing the Air Parking Brake 124 Parking Brake Indicator Light 126 Antilock Braking System ABS 126 Antilock Driving Tips 127 ABS Self Check 127 Pedal Adjustment Switch If Equipped 128 Traction Control If Equipped 128 Driver Assist Systems 129 Bendix Wingman Advanced Collision Warning System 129 Bendix Wingman Fusion System 130 Stability Control Systems Bendix Electronic Stability Program ESP If Equip...

Page 11: ...on 159 Engine Compartment Fluid Check Points 160 Air Operated Passenger Door Adjustments 161 Door Opening and Closing Speed Adjustment Points 161 Pressure Regulator Adjustment 161 Opening Speed Adjustment 162 Closing Speed Adjustment 162 Electrically Actuated Entrance Door Adjustment 162 Axles 162 Front Axle Inspection and Lubrication 162 Front Axle Normal Maintenance 163 Front Axle Alignment 163 ...

Page 12: ...ng IC Air System 180 Drive Shaft 180 Suspension Air and Steel Springs 180 Frame and Tow Hooks If Equipped 181 Steering 181 General 181 Tightening Steering Intermediate Shaft Joint Bolts 182 Lubrication Points 182 Power Steering 182 Transmission 183 Transmission Fluid Level 183 Tires 183 Tire Warnings 183 Tire Maintenance 185 Checking Inflation 185 Underinflation 186 Inspection 186 Loads 186 Dual T...

Page 13: ...uid 202 Rear Axle 203 Power Steering System 203 Transmission 203 Tire and Rim Combinations 203 Lubricant and Sealer Specifications 204 Torque Specification Charts 210 Filter List 212 Section 15 Customer Assistance Service Information 213 Navistar Inc Warranty Program 213 Section 16 Index Index 215 vii ...

Page 14: ...Table of Contents viii ...

Page 15: ...erence If you sell the bus make sure this manual stays with it Optional Features This manual describes many optional features that may not be installed in this vehicle Cautions Warnings Notes Cautions Warnings and Notes are included throughout this manual CAUTION Cautions advise you of the proper care to be taken to prevent damage to your vehicle or property WARNING Warnings advise you of hazards ...

Page 16: ...one 1 800 44 TRUCK 87825 for assistance Component Code Numbers Code numbers are the basis for identifying the components used on your IC Bus bus They are used by sales personnel to order the bus by manufacturing to build it and by parts to service the bus Many items in this manual are identified by codes Code numbers are a combination of numbers and or letters These codes are listed on the Vehicle...

Page 17: ...f the windshield and windows to shade the interior and prevent fading of the interior trim 2 Inspect painted surfaces touch up all exposed primed or raw metal areas to prevent rust 3 Apply a thick coat of wax to prevent discoloration from the elements wax all chrome and stainless steel metal parts 4 Check the radiator coolant for proper level and adequate freeze protection 20 F 29 C is standard fo...

Page 18: ...U S Registered Vehicles If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying IC Bus 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...

Page 19: ...HD OBD system operates similarly to previous power train control systems by storing fault codes and turning on the MIL If the problem that caused the fault goes away the code will clear and the MIL will go out after certain operating conditions have been met This may take several times operating the vehicle Supplemental Federal Emission Control System Warranty The United States Environmental Prote...

Page 20: ...nnovative technologies The GHG emission related warranty covers components certified as innovative technologies which are part of the certified emission controls Please contact your authorized IC Bus or International Dealer for further information Supplemental Federal Emission Control System Maintenance Repair And Replacement Your vehicle may comply with the Greenhouse Gas GHG regulations adopted ...

Page 21: ...paired before operating the vehicle After returning from your daily routes you must complete a written inspection report in accordance with CDL regulations Report any faults that you find or any problems that occurred during your trip to the service department so that they can be repaired before the next trip NOTE Make sure your bus is in proper operating condition to keep the passengers safe NOTE...

Page 22: ... 2 5 Turn signal 2 6 Crossing gate 1 7 Headlight 2 8 Rearview mirror 1 9 RED warning light 2 CE Bus Rear View 1 Identification lamp 3 2 Amber warning light 2 3 Clearance lamp 2 4 Turn signal with or without arrows 2 5 Backup light 2 6 Stop lights tail light 2 7 Emergency door handle 1 8 RED warning light 2 9 Reflex reflector 2 8 ...

Page 23: ...spection Guide CE Bus Right Side View 1 Emergency roof vent hatch 2 Emergency exit window 3 Intermediate side marker lamp 4 Static vent 5 Hood latch 6 Reflex reflector 7 Side mounted turn sign lamp 8 Fuel door 9 ...

Page 24: ...ft Side View 1 Emergency exit window 2 Emergency roof vent hatch 3 Stop arm 4 Battery compartment 5 Electrical compartment access panel 6 Static vent 7 Side mounted turn signal lamp 8 Intermediate side marker lamp 9 Reflex reflector 10 ...

Page 25: ...hat all requested repairs have been made Leaks Check for signs of fluid leaks in the engine compartment Also check for signs of drips on the ground under the engine Outside Mirrors Make sure the outside view is not obstructed Check the cross view and rear view mirrors for cleanliness Also make sure the mirrors are intact and properly adjusted Battery WARNING To prevent personal injury and or death...

Page 26: ...injury and or death or property damage if wheels or tires must be changed obtain expert tire service help Mounting and dismounting of tires should only be performed by qualified personnel using necessary safety procedures and equipment Wheels and Tires Inspect all wheels and tires for any obvious defects damage or excessive tread wear Check tires for the proper inflation Check wheel or rim nuts fo...

Page 27: ...the Torque Charts in the Maintenance section Shock Absorbers Check for cracks leaks and missing or broken mounting bolts or bushings Brakes Location Description Drum or Rotor and Brake Linings Check to see that there are no cracks dents or holes and no loose or missing bolts Check to see that the brake linings where visible are not worn thin or contaminated by lubricant Hoses Check for secure coup...

Page 28: ...al injury and or death from hot coolant or steam scalding use the following procedure to remove the pressure cap from the de aeration tank A Allow the engine to cool B Wrap a thick cloth around pressure cap C Partially unscrew pressure cap slowly while firmly holding cap down then pause to allow pressure to release D When system pressure is released fully unscrew pressure cap while continuing to h...

Page 29: ...remove the pressure cap until the coolant has cooled failure to do so may result in personal injury If additional fluid is necessary see the Maintenance section of this manual to find the correct fluid type before filling Windshield Washer System Fluid Inspect the fluid level through the plastic reservoir If additional fluid is necessary see the Maintenance section of this manual to find the corre...

Page 30: ...ne running Instrumentation With engine running check gauges for oil pressure temperature alternator and fuel levels Wiper Blades Look through the windshield to inspect both wipers for signs of wear damage or signs of aging on the rubber blades Check wiper operation Passenger Entry Make sure the door opens and closes completely Make sure the entry steps are clear and the treads are secure and are i...

Page 31: ... kPa Restart engine shift into a low gear and gently pull against service and parking brakes separately to make sure they will hold Hydraulic Brake Check Pump the brake pedal three times Then apply firm pressure to the pedal and hold for 5 seconds The pedal should not move and the brake pressure indicator should not illuminate Accelerator Pedal Check for smooth non binding pedal action Shift Selec...

Page 32: ...ocation Description Compressor Belts Check for tension and wear Inspect for properly tensioned belt This ensures maximum compressor performance and belt life Evaporator Filters Check for cleanliness A properly maintained filter maximizes air flow and system performance Hoses Check that hoses are secured and protected Prevents the possibility of refrigerant leaks Wiring Harnesses Check that harness...

Page 33: ...e lights use the Exterior Lamp Check procedure in the Lights section of this manual Verify the Stop Arm and Crossing Gate are working properly and extend completely Verify the entrance door is opening and closing properly Verify the flasher warning lights and stop arm are working properly with the flasher switches and entrance door operations Check to see that the AMBER Warning Lights are flashing...

Page 34: ...th the gasoline system Location Description Fuel Tank Inspect fuel tank for dents scratches gouges abrasions and other signs of damage Check that fuel tank is secured to mounting brackets and hardware is secured to frame Fuel Lines Inspect fuel lines and connections for any leaks crimping or other signs of damage Fuel Door Fueling Port Verify that fuel door is securely closed and the fueling port ...

Page 35: ...display that provide odometer transmission gear indication and compass heading and outside temperature displays This instrument panel gauge cluster displays the crucial operational functions of the vehicle The following are descriptions and illustrations of the gauges warning indicators and integral digital display options NOTE See tables below for descriptions of callouts 26 54 21 ...

Page 36: ...e needs to be serviced at the first available opportunity 5 RSL The Red Stop Lamp illuminates RED when a serious problem has occurred This lamp is accompanied by a message on the odometer display and an AUDIBLE ALARM If the Red Stop Lamp illuminates immediately pull the vehicle safely off the roadway turn on the flashers set the parking brake place warning devices and stop the engine The engine sh...

Page 37: ... The Malfunction Indicator Lamp MIL illuminates when the On Board Diagnostics OBD detects a malfunction related to the emissions control system The illuminated MIL indicates that the vehicle needs to be serviced at the first convenient opportunity Lamp may remain active after repair until system operation confirms repair 16 Illuminates RED when a parking brake system malfunction has been detected ...

Page 38: ...fines Instrument Panel Gauge Cluster WARNING To prevent personal injury and or death or property damage never operate the vehicle when insufficient air pressure less than 70 psi 483 kPa is indicated for either the primary or secondary air system The volume of air required to stop the vehicle may be greater than that available Have the brake system checked and repaired before returning the vehicle ...

Page 39: ...itch is in the ON position 33 Provides indication of air pressure available for the primary air brakes in pounds per square inch psi 34 Indicates the approximate fuel level in the fuel tank 35 Provides indication of air pressure available for the secondary air brakes in pounds per square inch psi Direct Drive Warning Indicators The instrument panel gauge cluster also houses eight direct drive warn...

Page 40: ...t is arranged in four quadrants that display vehicle information The four quadrants can be individually selected by using the display control button Display Control The display control is used to scroll to a quadrant and to select the various modes within a quadrant To navigate between quadrants turn and release the control either clockwise or counterclockwise To select the screens within a quadra...

Page 41: ...ators see list of messages in the Instrument Panel Gauge Cluster Integral Digital Display Detailed Information section in Controls Features 44 Quadrant 1 Informational Messages Informational Display Screens Odometer Trip Odometer Total Engine Hours Trip Hours Instantaneous Fuel Economy Trip Average Fuel Economy Trip Idle Fuel Used 45 Quadrant 4 Transmission Gear Indication Transmission gears for t...

Page 42: ...ed Display Format 100 000 0 TRIP MILES TRIP KM Trip Odometer The trip odometer displays a record of the elapsed distance traveled since the last reset NOTE The trip hours and trip miles are independently reset Display Format 100 000 0 TRIP MILES TRIP KM Total Engine Hours The Engine Hour display provides a record of accumulated engine hours and will not show any increase unless the engine is runni...

Page 43: ...s fuel economy sent from the engine The display will indicate in miles per gallon or liters per 100 kilometers corresponding to the units selected while in the odometer mode Display Format 30 0 INST MPG INST L 100KM Trip Average Fuel Economy The display value will indicate the average fuel economy value since the last reset of the trip odometer The display indicates in miles per gallon or liters p...

Page 44: ...rox 45 0 FT LBSX1000 FT KGX1000 RR LBSX1000 RR KGX1000 Quadrant 2 Text and Warning Messages These messages inform the driver of vehicle conditions If the message flashes it will flash for 3 5 seconds and then will be displayed for an additional 3 5 seconds If more than one message is viewable the displayed message will be followed by an asterisk indicating multiple messages To view additional mess...

Page 45: ... Check Active Message displayed indicates Exterior Lamp Check is in progress Yes No HVAC Temp Setting Bar graph displayed show temperature setting in low to high increments No No Activate HVAC Front Blower Bar graph displayed show blower speed setting in OFF and low to high increments No No Cruise Indicates that the Cruise Control System is turned ON No No Check Brake Switch Check the brake switch...

Page 46: ...sage is displayed when when EGC requests the Amber Warning Lamp Yes 1 Red Stop Lamp 2 Amber Warning Lamp Check Trans Message is displayed when transmission needs to be serviced Yes Amber Warning Lamp Trans Temp Message is displayed when transmission turns on the Amber Warning Lamp Not available with all transmissions Yes Amber Warning Lamp Gen Trns Flt Message is displayed when transmission turns ...

Page 47: ...MS Exhaust Module Telematics AGSP 2 SIC 2 AGSP 3 SIC 1 PAM Service Tool Global Message is displayed when a module other than the engine requests the Amber Warning Lamp Yes Amber Warning Lamp VSL Ovrd Active Vehicle speed limit override active No No VSL Ovrd Expiring Vehicle speed limit override expiring No No Blank screen available only when engine rpm less than or equal to 325 rpm or vehicle spee...

Page 48: ... Red Stop Lamp indicator STOP ENGINE message The following chart provides the warning messages that are displayed along with corresponding Instrument panel gauge cluster indicators Warning indicator Warning Message Red Stop Lamp STOP ENGINE Amber Warning Lamp WARN ENGINE Quadrant 3 Outside Temperature and Compass Displays If Equipped The optional Outside Temperature and Compass Heading is displaye...

Page 49: ...st below the outdoor temperature reading Text messages necessary to calibrate the compass can be found in the instrument panel gauge cluster display in the lower right quadrant quadrant 2 of the display Twist the instrument panel gauge cluster display knob until the cursor is flashing in the lower right quadrant Press the instrument panel gauge cluster display knob until the desired text message i...

Page 50: ...oose a Declination Zone in the geographic center of the vehicle s operating area or change the Declination Zone daily to match the present Declination Zone To begin the Declination Zone set procedure the vehicle must be stopped with ignition key ON Refer to Zone Map for determining the proper Declination Zone number 36 ...

Page 51: ...Instrumentation Declination Zone Map 37 ...

Page 52: ...ne number is displayed Refer to Declination Zone Map to determine the proper number for the current geographic location NOTE If no Declination Zone number is selected within 15 seconds the display will return to the Compass Declination message NOTE If the compass is being calibrated recalibrated the Declination Zone must be set to the Zone number for the location where the compass calibration reca...

Page 53: ...e display control knob until this message appears 3 Press and hold the display control knob until the End Calibration command is displayed NOTE IF the End Calibration command will not show up turn OFF the vehicle restart it and return to Step 1 NOTE The following steps 4 through 6 must be completed within 3 minutes to lock in the new calibration Do not press the display control knob or turn the ke...

Page 54: ...he compass calibration Turn the vehicle ignition key OFF and then restart the vehicle Wait 10 seconds for the compass to complete its self test Drive the vehicle in a circle and note the compass readings If the lower left side quadrant of the Instrument Panel Gauge Cluster Display shows the correct compass vehicle heading the compass calibration is now complete If the compass readings are incorrec...

Page 55: ...gurations Item No Item Description Switch Indicator Status Left Side Optional Push Button Switches 49 Configured by customer request 50 Configured by customer request 51 Headlight Park Lamp Switch Go to Lights section 52 Instrument Panel Gauge Cluster Dimmer Switch Go to Lights section Right Side Optional Switches Indicators 53 Configured by customer request 54 Configured by customer request 41 ...

Page 56: ...ditional Comments Fuel Level Gauge low only alarms on each time the key is turned ON 5 beeps Gauge warning indicator illuminates Voltmeter Gauge out of range reading 5 beeps Gauge warning indicator illuminates Engine Oil Pressure Gauge out of range reading 5 beeps Gauge warning indicator illuminates Engine Coolant Temperature Gauge out of range reading 5 beeps Gauge warning indicator illuminates T...

Page 57: ...ergency exit Post Trip Inspection Repeated single beep lights flashing then horn honking Complete the Post Trip Inspection Turn Signal Alarm Continuous tone Alarm sounds if either turn signal is on for more than one mile Will not activate when hazard flashers are on Low Coolant Alarm Repeating single beep Gauge warning indicator illuminates Seat Belt Reminder With Seat Belt Monitoring Repeating si...

Page 58: ...Instrumentation 44 ...

Page 59: ... Washer WARNING To prevent personal injury and or death or property damage do not use the washers in freezing weather without first warming the windshield with the defrosters otherwise the washer solution may freeze on the windshield and obscure your vision which could cause an accident WARNING To prevent personal injury and or death or property damage do not use radiator coolant or antifreeze in ...

Page 60: ...urn Signal Multi Function Switch refer to the Lights section Steering Wheel and Column Steering Wheel Controls NOTE The location for the entry door and warning flasher switches is the steering wheel and the left side right side console switch panel OPEN CLOSE DOOR button is located on the steering wheel in the left side button position FLASHERS ON OFF and RED OVERRIDE button is located on the stee...

Page 61: ...vent personal injury and or death or property damage do not adjust the steering column while the vehicle is moving It could suddenly or unexpectedly move causing the driver to lose control of vehicle CAUTION To prevent property vehicle and or engine component damage do not lubricate the tilting mechanism The optional adjustable tilt steering column allows you to pull the tilt steering control towa...

Page 62: ...tches are installed in the same location unless precluded by state regulations Before reading this section of the manual sit in driver s seat and become familiar with the location of the controls and switches in this bus NOTE Your bus may not be equipped with all switches listed The left side console switch panel contains the controls for bus heaters and defrosters destination sign and other stand...

Page 63: ...e defog fan above windshield DRIVER DOME Turns ON OFF driver side lights DOME LIGHTS Turns ON OFF interior side lights NOISE SUPP Disconnects power to all noise generating devices LIFT SWITCH Turns wheelchair lift power ON or OFF MIDSHIP HEATER Turns heater blower motor to HIGH LOW OFF STEPWELL HEATER Turns the Stepwell Heater ON OFF POWER VENT Turns ON OFF power to exhaust vent 49 ...

Page 64: ...LAST DOME Turns ON OFF last dome light REAR DOME Turns ON OFF rear half dome lights REAR ROW DOME Turns ON OFF rear row lights MASTER FLASHER Turns ON OFF system power for the warning indicator system CROSSING GATE CANCEL Switch that blocks extension of crossing gate STOP ARM CANCEL Momentary switch retracts Stop Arm Crossing Gate turns on chime while RED warning flashers are on 50 ...

Page 65: ... cellular phones and two way radios Transmission Parking Brake and Ignition Switch Panel Before reading this section of the manual sit in driver s seat and become familiar with the location of these controls The Transmission Parking Brake Ignition Switch Panel provides the mounting for the automatic transmission shifter the knob to engage disengage the parking brake and the ignition switch For ins...

Page 66: ...ngements of the controls and switches on the console switch panels may be different Some switch positions may be empty while other rows may have only one switch Switches are installed in the same location unless precluded by state regulations Before reading this section of the manual sit in driver s seat and become familiar with the location of the controls and switches in this bus NOTE Your bus m...

Page 67: ...em ON and OFF SET COAST RESUME ACCEL SWITCH sets and controls the engine speed FOG LAMP SWITCH Turns the fog lamps ON and OFF ECON ON SWITCH Turns transmission Economy mode ON and OFF If Equipped DISAB TRAC ENAB Switch Turns Traction Control system ON or OFF Air Brake chassis 53 ...

Page 68: ...compression brake ON OFF PEDAL ADJ FWD BACK If Equipped Allows forward upward and back downward repositioning of power adjustable pedals when key is in the ON position the parking brake is set and the transmission is in Neutral or Park Cruise Control Operation WARNING To prevent personal injury and or death or property damage do not use the cruise control system when unpredictable driving conditio...

Page 69: ...ESUME ACCEL position switch 5 Push the OFF position on the switch to cancel the previous speed setting The previous speed setting is also cancelled when the vehicle is turned off Mirror Adjustment WARNING To prevent personal injury and or death or property damage use patience and always check the overall field of vision when unloading as some children could be outside the field of vision Do not mo...

Page 70: ...and at least four bus lengths behind the bus Use the following steps to adjust the mirrors before you operate the bus 1 Adjust the driver s seat to the desired position and observe the view through all outside mirrors to enhance visibility in all directions 2 Look through the right side flat driving mirror and make sure that the top of the side windows are visible in the upper edge of the mirror a...

Page 71: ...uzzer Feature This optional buzzer sounds when headlight switch is ON and ignition switch is in the OFF position Daytime Running Lights Feature This feature provides for vehicle headlights to be turned on when engine is running and headlight switch is in OFF position Optional Headlight Feature 08WPY Provides for headlights tail lights park marker lights and instrument panel gauge cluster lights to...

Page 72: ...ow or is operating at a reduced speed The hazard warning lights can be operated with the ignition in any key switch position Press the button to activate all hazard flashers simultaneously Press the button again to turn the flashers OFF Turn Signal Switch The turn signal switch is mounted on the left side of the steering column below the steering wheel The green directional indicator lights which ...

Page 73: ...ght The optional strobe light comes on automatically unless operated by a separate switch Check your state regulations on strobe light use Exterior Lamp Check Switch Location The switch to activate and deactivate the exterior lamp check system is one of the right side user switches located below the instrument panel gauge cluster Function The exterior lamp check is a feature that allows the driver...

Page 74: ...p position The exterior lamp switch ON indicator will then illuminate GREEN Deactivation To deactivate the system do any one of the following Press the exterior lamp switch to the OFF down position Move the ignition switch to the OFF or ACC Accessory position Manually turn on lamps being checked with this feature Release the parking brake When the exterior lamp check system is deactivated the GREE...

Page 75: ... the bus operated Consult with local and state authorities for specific procedures that may apply for children entering or exiting buses NOTE Due to various state and local requirements the location of the entrance door OPEN CLOSE switches shown may be different from your vehicle The entrance door OPEN CLOSE button is located on the steering wheel in the left side button position Press the top of ...

Page 76: ...witch to the CLOSE position Three Position Door Switch The optional three position door switch is located on the left side or right side console switch panel With the ignition ON the entrance door can be opened by moving the switch to the OPEN position With the ignition ON the entrance door can be closed by moving the switch to the CLOSE position Moving the switch to the RED OVER position will sta...

Page 77: ...ted behind the access panel over the entrance door To release the electrically actuated door grasp the handle and move forward left Air Actuated Door The emergency release for the air actuated door is located on the right side of the instrument panel To release the air actuated door move the toggle switch from NORMAL to EMERGENCY Traffic Warning System The traffic warning system alerts both oncomi...

Page 78: ...and RED warning lights below Eight Lamp AMBER and RED Warning Lights The eight lamp AMBER and RED warning system is made up of four AMBER two front and two rear and four RED two front and two rear flashing lights and is part of the warning flasher system The AMBER warning lights alert the public of the intent to stop and load unload students onto from the bus The RED warning lights and the stop ar...

Page 79: ...ile traveling at a speed lower than the preset road speed parameter with the door closed Non Sequential System With the master flasher switch in the ON position press the FLASHER ON OFF button to engage the AMBER warning lights If the master switch is not turned on there will be no activation of the lights or stop arm The AMBER warning lights change automatically to the RED warning lights when the...

Page 80: ... or leaving the bus Crossing Gate The crossing gate extends when the RED warning lights are on to make sure that students do not cross too close to the front of the bus and out of the view of the driver NOTE The illustration is for reference only and may differ from the actual vehicle 66 ...

Page 81: ...iver s responsibility to check for children who may be left on the bus at the end of every trip The Post Trip Inspection No Student Left Behind System is intended to be an aid to the driver to ensure that this responsibility is not inadvertently omitted The system provides audible and visual alerts when the bus ignition is turned off at the end of a trip SYSTEM FUNCTION Any time the ignition key i...

Page 82: ...ear of the bus lift then lower the rear emergency door lever If this bus is equipped with the post trip inspection RESET BUTTON located above the last window on the driver side press and release the reset button 3 The system is now deactivated and the instrument panel gauge cluster beep headlights and horn should now be off 4 Move the key to the OFF position Remove the key if exiting the bus SNOOZ...

Page 83: ...nt Left Behind system will be reactivated Emergency Exits Opening any emergency exit will trigger an alarm to alert the driver when the key is in the on or accessory position NOTE A label stating DO NOT BLOCK is required by each emergency door and side emergency exit window This label is a warning to the user of the bus not to block the emergency exits with wheelchair child restraint systems or ot...

Page 84: ...per operation Pull up on the release handle to unlatch the Vertical Emergency Exit Window and push the window outward to open 0000433122 2 1 1 Slide lubrication point 2 Release handle lubrication point Make sure windows are free of dirt fog condensation and snow Make sure the windows can open and close completely Once a year pull up on the release handle to open the emergency windows and lubricate...

Page 85: ... to the bus while not in use Vandal locks can be provided on front entrance doors side emergency door rear emergency window roof hatches and lift doors On the side emergency door the vandal lock is a dead bolt lock that the driver slides in place to secure the bus from unwanted vehicle access On the rear emergency window the driver uses the vandal lock handle to slide the lock in place The vandal ...

Page 86: ...ated as long as the door is locked Entrance Door Lock If Equipped 0000431525 1 1 Latch As an extra measure of security the bus may be equipped with a entrance door lock This lock mechanism is used to lock the entrance door to the bus in order to prevent unauthorized access to the bus while not in use or attended To lock the entrance door lock feature rotate the latch clockwise To unlock rotate the...

Page 87: ...ission in Park if available or Neutral prior to exiting the driver seat WARNING To prevent personal injury and or death or property damage use caution and reduce speed when operating this vehicle over rough roads or surfaces as this can cause loss of vehicle control Use caution and reduce speed Properly adjusted seats and seating systems may not compensate completely for severe road conditions Ens...

Page 88: ...t height lever while raising or lowering the seat to the desired height then release the lever While adjusting the seat height the seat height lever may remain in the up position The location and orientation of the height adjustment lever may vary 3 When at the desired position move the seat slightly up or down until the seat height lever snaps to its height engaged down position 4 After the desir...

Page 89: ...b The seatback adjustment knob is located on the left side of the seat at the intersection of the seatback and the lower seat cushion Turn the seatback adjustment knob clockwise to tilt the seatback forward and rotate the knob counterclockwise to tilt the seatback rearward Lumbar Support Pull the left side switch lumbar support switch upward or push downward to adjust the lumbar support to your pr...

Page 90: ...le is in motion to avoid personal injury Before fastening the seat belt adjust the seat to the desirable driving position Driver s lap and shoulder three point seat belt with retractor is standard Driver s Adjustable Lap and Shoulder Three Point Belt WARNING To prevent personal injury and or death or property damage position the safety belt height adjusters so that the belt rests across the middle...

Page 91: ...tton to disconnect the seat belt Seat Belt Tether NOTE The majority of the driver seats have nonadjustable tethers Driver seats with adjustable tethers must follow the Tether Adjuster Procedure Tether Adjuster Procedure 1 Tether adjuster NOTE The seat belt tether must be checked for proper adjustment prior to vehicle operation 1 Adjust the driver seat fore and aft to accommodate driver comfort 2 A...

Page 92: ... webbing Bleaching or re dyeing may cause a weakening premature deterioration of the webbing WARNING To prevent personal injury and or death or property damage to property use caution when cleaning seat belts Disinfectant products can contain solvent based chemicals that can adversely affect seat belt components NOTE Do not use a 70 isopropyl solution as a wash solution Do not use a 70 isopropyl s...

Page 93: ... cut through a seat belt the seat belt cutter is located inside of the driver s compartment lid NOTE Location of seat belt cutter may vary according to state regulations Passenger Seat Belts Buses may be equipped with optional passenger seat belts WARNING To prevent personal injury and or death or property damage properly inspect and maintain seat belts every 10 000 miles or sooner during heavy us...

Page 94: ...webbing is below the passenger s waist not over the stomach or abdomen area The lap portion of the belt must be low and snug over the bony structure of the passenger s hips Passenger Three Point Seat Belts If Equipped Buckling Up 1 The passenger should sit as flat against the seat back as possible to achieve the best possible fit of the lap shoulder belt on the passenger s upper and lower torso 2 ...

Page 95: ...n of the lap shoulder belt 6 Position the lap portion of the belt so that the webbing is below the passenger s waist not over the stomach or abdomen area The lap portion of the belt must be low and snug over the bony structure of the passenger s hips 7 Pull up on the shoulder portion of the lap shoulder belt to tighten the lap portion This step is important and must be done to ensure proper fit of...

Page 96: ...nd lies flat against the passenger There should be no twisting of the webbing Unbuckling 1 Push the RED buckle release button and remove the latch plate from the buckle The buckle has a release mechanism that separates the latch plate from the buckle 2 Allow the shoulder belt to retract and stow in the upper seat back 3 As a courtesy to the next passenger move the shoulder height adjuster up to th...

Page 97: ...the way right to create three seating positions Integrated Child Restraint Seats If Equipped WARNING To prevent personal injury and or death or property damage observe the following Follow all instructions on the child restraint and in this manual It is important to use an approved rearward facing infant restraint for a full year to allow the neck and spine to develop enough to support the weight ...

Page 98: ... damaged such as a bent buckle or 5 point connector or torn webbing Similarly the child restraint equipped bench or bucket seat must be replaced after a collision if it is damaged such as a bent or broken seat frame Indiana Mills and Manufacturing Inc IMMI Integrated Child Restraint Seats If Equipped WARNING To prevent personal injury and or death or property damage observe the following Use only ...

Page 99: ...en chest clip by squeezing middle tabs and pulling chest clip apart Unbuckle harness buckle by pressing down on RED release button To loosen harness lift metal at top of seat and pull down on shoulder strap to loosen strap Repeat with second shoulder strap 1 Metal tabs 2 Shoulder straps 3 Harness buckle Place the child in the restraint with the child s back flat against the back of the bus seat cu...

Page 100: ...est at armpit level Position each shoulder height adjuster at or just above the child s shoulder Be sure harness is snug and tight on child s thighs and chest IC Bus WHITE Integrated Child Restraint Seats If Equipped WARNING To prevent personal injury and or death or property damage observe the following This integrated child seat is designed for use only by children who weigh between 20 and 85 lb...

Page 101: ... Seat belt latch plates 3 Adjustment 4 Shoulder belt strap 5 Removable pad 6 Folded down leg rest pad 7 Buckle 1 Shoulder belt clip 2 Seat belt latch plates To open the child restraint grasp the upper portion leg rest pad and lower the child seat cushion 87 ...

Page 102: ... the forward facing position Ensure that the seat chosen is able to be installed in the forward facing position and is designed to be used with the child restraint anchorage system Passenger seats with optional child restraint anchorage systems for attaching add on child seats are usually located in the first few rows of passenger seats behind the operator and or entrance door To determine the loc...

Page 103: ...ctions on the child restraint and in this manual Follow the manufacturer s warnings for proper use of the child restraint system and Latch attachments Follow the manufacturer s warnings for proper use of the child restraint system and Latch attachments Location and Use of Lower Latch Anchors 1 Anchorage symbols 2 Lower latch anchors 89 ...

Page 104: ...o the seat belt bar and are visible under the rear of the seat back For the attachment of an add on child seat tether wrap the tether over the seat as shown then connect the snap hook to the tether anchor Adjust the tether to a snug and tight fit by pulling on the free end of the strap at the adjuster IMMI Seats Tether Installation 1 Child seat tether All base three point and integrated child rest...

Page 105: ...t rear edge Installing Tether 1 Strap free end 2 Tether anchor To attach an add on child seat tether route the tether on the child seat over the top of the belted BTI bus seat Extend the tether and connect the snap hook to the nearest tether anchor provision at the lower rear of the seat Adjust the tether to a snug and tight fit by pulling on the free end of the strap at the adjuster 91 ...

Page 106: ...e side rear pedestal and on the seat wall mount bracket rear edge 1 Strap Free End 2 Tether anchor To attach an add on child seat tether route the tether on the child seat over the top of the SafeGuard XChange bus seat Extend the tether and connect the snap hook to the nearest tether anchor provision at the lower rear of the seat Adjust the tether to a snug and tight fit by pulling on the free end...

Page 107: ...owering the cushion to seated position Keep hands and feet clear while lowering the seat cushion Rear Latching 1 Latch 2 Seat bottom Optional release latches may vary based on seat style Seats automatically latch when sat upon Pull up on seat cushion to confirm cushion is latched For both rear and side latching designs pull the latch to release Side Latching 1 Latch 2 Seat bottom 93 ...

Page 108: ...ce requirement are met Original seat layout for a specific unit can be obtained by contacting your IC Bus dealer The standard track seat label is found on the front bulkhead of all buses with track seating Minimum spacing with standard barrier to track barrier and track barrier to track barrier Minimum spacing with stanchion to track barrier track seat to track barrier and track seat to standard b...

Page 109: ...n 82 60 cm Track CEW QSCR11 Track Seat with 3 point belts with Integrated Child Seat 29 35 in 74 55 cm 32 35 in 82 17 cm Standard CEW QS11 Track Seat with 3 point belts without Integrated Child Seat 28 53 in 72 47 cm 32 56 in 82 70 cm Track CEW QS11 Track Seat with 3 point belts without Integrated Child Seat 29 36 in 74 57 cm 32 36 in 82 19 cm Standard IMMI Track Seat without Integrated Child Seat...

Page 110: ... 73 99 cm 34 13 in 86 69 cm IMMI ICS Track Seat with Integrated Child Seat IC Track 26 32 in 66 85 cm 30 32 in 77 01 cm CEW CR11 Track Seat with or without lap belts with Integrated Child Seat CEW CR11 Track Seat with or without lap belts with Integrated Child Seat 28 00 in 71 12 cm 31 00 in 78 74 cm CEW QSCR11 Track Seat with 3 point belts with Integrated Child Seat CEW QSCR11 Track Seat with 3 p...

Page 111: ...ith Integrated Child Seat 28 00 in 71 12 cm 31 00 in 78 74 cm IMMI Track Seat without Integrated Child Seat IMMI Track Seat without Integrated Child Seat 27 00 in 68 58 cm 31 00 in 78 74 cm IMMI ICS Track Seat with Integrated Child Seat IMMI ICS Track Seat with Integrated Child Seat 27 00 in 68 58 cm 32 00 in 81 28 cm IMMI Track Seat without Integrated Child Seat IMMI ICS Track Seat with Integrate...

Page 112: ...Seating and Safety Restraints 98 ...

Page 113: ... system for these buses are designed with interlocks that require the vehicle to be completely stopped with the transmission out of gear and the parking brake applied before the wheelchair lift system can be fully utilized Power will not be supplied to the wheelchair lift mechanism unless all of the following steps have been performed this is true even with the optional Lift switch in the ON posit...

Page 114: ...he manufacturer s Operation Manual instructions 2 Then close the wheelchair lift door according to the manufacturer s Operation Manual instructions The LIFT DOOR instrument panel gauge cluster indicator will then turn OFF Wheelchair Lift Alarm The instrument panel gauge cluster alarm a continuous beeping will be triggered if 1 The wheelchair lift door is extended and 2 a The parking brake is not a...

Page 115: ...akes set the foot operated parking brake Park indicator on instrument panel gauge cluster will turn ON 5 Open the wheelchair lift door The wheelchair lift can now be operated according to the manufacturer s Operation Manual instructions The LIFT DOOR instrument panel gauge cluster indicator will turn ON and will remain ON as long as the wheelchair lift door is opened PARKING BRAKE WHEELCHAIR LIFT ...

Page 116: ...ir lift mechanism and therefore the wheelchair lift cannot be operated until the previous steps have been completed WHEELCHAIR LIFT EXTENSION OPERATION After the bus has been safely parked see previous steps 1 Open the wheelchair lift door LIFT DOOR instrument panel gauge cluster indicator should be turned ON 2 Extend the wheelchair lift according to the manufacturer s Operation Manual instruction...

Page 117: ...hair lift has been safely stowed according to the wheelchair lift manufacturer s Operation Manual instructions the bus can be safely moved as follows Depress the service brake pedal and press and hold the button on the gearshift lever handle and move the gearshift lever from Park P to Reverse R or Drive D position and then release the button Release the parking brake push and release the parking b...

Page 118: ...Wheelchair Instructions and Information 104 ...

Page 119: ...ould cause an accident To improve defroster efficiency remove ice and or snow by hand from the windshield and windows with a non metallic scraper Driver Heater The driver heater console is located below the left side switch panel Three heater control knobs provide air flow direction fresh air or recirculation control and temperature selection Adjust the AIR knob to provide outside air into the dri...

Page 120: ... outlets utilizing the defrost climate control heat selector Use this mode at maximum fan speed and temperature setting for best windshield and side window defrosting If equipped the optional step well heater may be turned on for added air flow to the defroster vents Integrated Air Conditioning System IC Air This vehicle may be equipped with an optional skirt or roof mounted factory installed Inte...

Page 121: ... personal injury and or death or property damage wait until the motor cools off before repositioning the fan motor It can become extremely hot when operated in normal ambient temperatures for long periods of time Some buses are equipped with circulation fans The controls are labeled RIGHT FAN and LEFT FAN and are located on the left side switch panel driver console Each fan has OFF LO HI speed con...

Page 122: ...oster pump unless the heater cut off valve is manually opened Heater Cutoff Valve NOTE The illustration is for reference only and may differ from the actual vehicle Typical Heater Cutoff Valve The heater cutoff valve for the coolant supply is under the hood Turn the heater cutoff valves ON counterclockwise whenever the heater is used Turn the heater cutoff valves OFF clockwise to stop hot coolant ...

Page 123: ...the engine air inlet Operation of the components such as starter alternator electric motors and static electricity could also ignite flammable vapors Do not operate the bus in the possible presence of flammable vapors unless both a complete hazard analysis is performed and necessary additional safety processes and or equipment such as vapor testing air intake shutoff devices and ventilation are ut...

Page 124: ...areas without abundant forced ventilation with garage doors and windows wide open Maintain exhaust system in good operating condition WARNING To prevent personal injury and or death or property damage pay strict attention to the following Care should be taken to prevent sudden accelerations when both drive wheels are on a slippery surface This could cause both drive wheels to spin and allow the ve...

Page 125: ... to allow the starter motor to cool Automatic Transmission Starter Interlock Automatic transmissions must be in Neutral or Park before the starter will engage Starting the Engine NOTE Use of the cupholder during operation of the vehicle should be in accordance with state regulations school district guidelines and bus provider s operating policies NOTE Before starting a gasoline powered vehicle ref...

Page 126: ...he low oil pressure lamp will illuminate if minimum oil pressure is not met If the lamp remains illuminated for an extended period of time a derate may occur NOTE If the engine starts and then stops repeat engine starting procedure If more than three attempts are required contact your nearest service center to schedule service Clear Flooded Engine If the engine does not start normally It could be ...

Page 127: ...lamp is illuminated a Diagnostic Trouble Code DTC will be generated Take the vehicle to a service center as soon as possible as some optional features and or engine power may be lost while the indicator is lit Fuel NOTE For specific fuel system information refer to the vehicle Engine Operation and Maintenance Manual This vehicle is equipped with a PSI 8 8L gasoline engine which is fitted with a El...

Page 128: ...tem free from build up and deposits To view a list of brands that carry TOP TIER Detergent Gasoline visit www toptiergas com Acceptable Fuel And Blends Regular unleaded 87 octane minimum Fuel that contains less than 10 Ethanol Unacceptable Fuel And Blends Any octane rating lower then 87 octane 85 Ethanol 15 gasoline E85 Diesel Methanol Fuels containing additive methylcyclopentadienyl manganese tri...

Page 129: ...in a fire explosion hazard CAUTION To prevent vehicle and or engine damage do not mix diesel fuel or liquid propane with gasoline Warranty claims will not be honored against engines that have used mixed fuels CAUTION To prevent vehicle damage in the event the fuel filler cap needs to be replaced replace it with a genuine IC Bus fuel filler cap Failure to do so could lead to fuel system component d...

Page 130: ...the tank could cause fuel spillage and or increased pressure inside the fuel tank Pressure in an overfilled tank may cause leakage in the fuel system which could result in a potential fire explosive hazard 1 Turn OFF the vehicle and set the parking brake Follow all fueling site Personal Protective Equipment PPE requirements 2 Open the fuel door 3 Remove the fuel cap slowly from the vehicle 4 Check...

Page 131: ... OFF the dispenser 2 Immediately evacuate the area a Everyone in the affected area should move to a safe distance from the spill or leak Do not re enter area 3 Call for help a After you are at a safe distance from the affected area call 911 or the local fire department Restarting After Running Out of Fuel In the event the vehicle runs out of fuel perform the following 1 Refuel vehicle using the sp...

Page 132: ...old weather engine oil and that it is at its proper level At temperatures of 4 F 20 C or below it is recommended that you use a crankcase mounted coolant heater to improve cold engine starting Consult your IC Bus dealer for information about special cold weather equipment and precautions if operating in arctic temperatures of 20 F 29 C or lower Hot Weather Operation Keep the engine cooling system ...

Page 133: ...t available vehicle retardation When descending long grades requiring use of the brakes short applications 5 10 seconds duration should be made rather than long lighter continuous applications This minimizes temperature brake fade Warning Indicators Electronic gauge cluster indicators identify brake system fault conditions Certain faults may also result in cluster alarms The following lists some o...

Page 134: ...rtTrac hydraulic booster has a backup pump which will provide hydraulic boost at a reduced rate if the normal source of fluid is interrupted The signal for operation of the backup pump comes from the fluid flow switch or differential pressure switch If normal flow is interrupted the flow switch will close and activate the backup pump relay which will turn on the backup pump If braking performance ...

Page 135: ...rcuit the driver may experience a longer pedal stroke to attain desired stopping If a brake system failure occurs one of the instrument panel gauge cluster warning indicators should illuminate Manual Foot Operated Parking Brake System with Hydraulic Brakes WARNING To prevent personal injury and or death or property damage when parking your vehicle always use the parking brake When parking on a gra...

Page 136: ...l The PARKING BRAKE indicator will illuminate in the instrument panel gauge cluster To Manually Release The Parking Brake 1 Turn ignition switch to the ON position 2 Depress and hold the brake pedal 3 With the brake pedal held pull the brake release lever until the parking brake indicator goes out then release NOTE Wheelchair lift interlocks will prevent release of the parking brake until all cond...

Page 137: ... be sure all wheels are rolling free brakes are not frozen when starting out Always clean accumulated ice and snow from brake linkage If air pressure in either section of the split air brake system is reduced to 57 psi 393 kPa the warning buzzer will sound and a RED Air Pressure indicator on the instrument panel gauge cluster glows In addition the air gauge s will indicate low air pressure in at l...

Page 138: ...pplied pulled position Failure to do so could allow the vehicle to roll The purpose of the parking brake is to hold the vehicle in the parked position It should NOT be used to brake the vehicle during normal driving It may be used to assist in making an emergency stop in the event of service brake failure Parking Brake Wheelchair Lift Interlock If Equipped On vehicles equipped with an optional whe...

Page 139: ...nob Air Brake Gauge The air operated parking brake has an air gauge and warning buzzer When pressure in the parking brake air reservoir has been reduced to about 57 psi 393 kPa the buzzer sounds A loss of pressure in the control circuit prevents normal operation of the parking brake CAUTION To prevent property vehicle damage if air system pressure falls below 70 psi 483 kPa pull off the roadway se...

Page 140: ...s WARNING To prevent personal injury and or death or property damage do not rely on the Antilock Brake System ABS to interrupt vehicle engine brake on slippery road surfaces Turn these devices OFF during hazardous driving conditions Failure to follow this warning may cause wheel slippage and or loss of vehicle control WARNING To prevent personal injury and or death or property damage if the Antilo...

Page 141: ...er Each time the ignition is turned on the ABS performs a self check The ABS warning indicator will illuminate and if the ABS passes the self check the indicator will turn OFF a few seconds after the ignition is turned on ABS fault codes will be electronically stored in the ABS Antilock Driving Tips Use controlled even pressure to stop the vehicle being careful not to skid Most effective stopping ...

Page 142: ...o perform this operation Traction Control If Equipped WARNING To prevent personal injury and or death or property damage drivers operating a Traction Control equipped vehicle should employ safe driving practices and assume no additional driving risks Traction Control systems are designed to enhance overall vehicle safety when a vehicle is driven within its safe operating limits Traction Control ca...

Page 143: ...Assist Systems There are various driver assist systems that could be configured on your bus The driver assist systems are safety features that assist the driver in various driving conditions Bendix Wingman Advanced Collision Warning System WARNING Tprevent personal injury and or death or property damage the Bendix Wingman Advanced Collision Warning System is not to be used or relied upon to operat...

Page 144: ...raking When cruise control is on with the speed set the adaptive cruise control helps the driver maintain a set following distance behind a forward vehicle by automatically utilizing the engine retarder and foundation brakes Collision Mitigation Provides audible and visual alerts to the driver and applies the foundation brakes when the system determines a collision with a forward moving vehicle is...

Page 145: ...face Unit located in the instrument panel where it is easily visible and accessible Refer to the Manufacturer Instruction Manual for complete operating instructions This system utilizes a camera and radar in the front of the vehicle to detect other vehicles and hazardous situations In order for the system to operate effectively it must be free and clear of debris such as snow and ice Ensure that t...

Page 146: ...curs Vehicle Stability Control Speed Reduction In the case of a potential roll event the stability system will remove the throttle and quickly apply brake pressure to slow the vehicle combination below the threshold Steering Angle Sensor This sensor enables the advanced stability system to capture the driver s steering input and intervene if a yaw correction is needed The sensor also provides the ...

Page 147: ...eight The system allows for ease of vehicle loading and provides improved vehicle ride and increased driver comfort The system is completely automatic Automatic Transmission Operation Standard Allison 2000 PTS Transmission WARNING To prevent personal injury and or death or property damage check to see that area behind vehicle is clear of people animals and objects before backing up Use a spotter w...

Page 148: ... lever to Reverse R or Drive D position and then release the button For Air Brakes push in on the parking brake knob Park indicator on instrument panel gauge cluster will turn OFF For Hydraulic Brakes depress and hold the parking brake pedal with the brake pedal held pull the brake release lever until the Park brake indicator goes out then release the foot pedal 3 Lift foot from the brake pedal an...

Page 149: ...Vehicle 1 Use your service brake pedal to bring the vehicle to a complete stop 2 Make sure the engine is at low idle 3 Move the transmission shifter to the Parking Brake PB Park P or Neutral N With the Push Button shifter press the Neutral N button 4 For Air Brakes pull the parking brake knob Park indicator on instrument panel gauge cluster will turn ON 5 For Hydraulic Brakes set the foot operated...

Page 150: ...everse R The backup alarm will sound as long as the transmission shift selector is in the Reverse R position Roll Back Alarm Option Release the parking brake and then take your foot off the service brake pedal allowing the bus to drift backward The backup alarm will sound as soon as the bus begins to roll backward NOTE This optional backup alarm is activated every time the vehicle moves backwards ...

Page 151: ... light switch 1 Use the hazard warning light switch in an emergency to warn traffic of vehicle breakdown approaching danger the vehicle is in tow or is operating at a reduced speed 2 Press the button to activate all hazard flashers simultaneously 3 Press the button again to turn OFF the flashers Emergency Equipment Recommended On Board Fire Extinguisher Inspect the fire extinguisher monthly to mak...

Page 152: ...t Use this whenever any type of body fluid comes in contact with the bus When items are used they should be immediately replaced Reflective Triangle Use the triangle whenever the bus is pulled over to the side of the road The reflective triangle kit is usually located behind the driver s seat After opening the kit unfold the triangle and make sure it locks in place 138 ...

Page 153: ...nce from the spill or leak Do not re enter area 4 After you are at a safe distance from the affected area call 911 or the local fire department Fuse Circuit Breaker Charts NOTE To gain access to the fuse and circuit breakers reference page 10 for the location of the Electrical Compartment Access Panel The following fuse illustrations represent typical fuse panel layouts The actual vehicle fuse pan...

Page 154: ...m Controller Ignition Feed F17 5A Engine Electronics Ignition Feed F18 5A Accelerator Pedal Ignition Feed Location Size Description F19 5A Auto Drain Valve Relay Ignition Feed F20 10A Backup Light Ignition Feed F21 10A Transmission Control Module Ignition Feed 12V Crank Relay F22 5A Transmission Shifter LCT Eaton Hybrid HCM2 F23 10A Fuel Heater Air Dryer Drain Valve Park Regen Switch Ignition Feed...

Page 155: ...gnition Feed NOTE Locations marked with a must use fuse only NOTE Descriptions marked with a indicate fuses used with Eaton Hybrid equipped vehicles Power Relays Location Description R1 Wiper Power Relay R2 Wiper Speed Relay R3 Stop Light Relay R4 Back Up Light Relay R5 Ignition 1 Relay R6 Ignition 2 Relay 141 ...

Page 156: ...Roadside Emergencies Body Fuse Circuit Breaker Panel 142 ...

Page 157: ...wer Vent F9 5A Air Conditioning F10 25A Right Side Rear Wall Heater Switch 2 Right Side Rear Heater F11 7 5A Rear Power Vent Location Size Description 7 5A Defog Fan Left Side Switch 15A Defog Fan x3 Left Side Switch F12 20A Center Blower Left Side Switch F13 25A Step Warmer F14 15A Booster Pump F15 20A Two Way Radio Terminal Strip F16 3A Air Horn F17 15A Dome Lights 7 5A Direct to Disk Recording ...

Page 158: ...Recording DDR Digital Video Recorder DVR System F37 25A Spare Tire Winch F38 7 5A Stop Arm Crossing Gate Location Size Description F39 7 5A Backup B U Lights Act By Rear Emergency Exit 3A PTI Bus Scan PTI Checkmate F40 10A PTI CRS 3A PTI Checkmate Deactivate F41 15A PTI CRS Headlights F42 10A Fire Suppression System F43 3A Starter Interlock F44 7 5A Alternate Entrance Door F45 3A Entrance Door Dum...

Page 159: ...ent Behind F66 3A Battery Isolator F67 Rear Door Options F68 See Circuit Diagram F69 See Circuit Diagram Location Size Description F70 Backup B U Lights Activated By Rear Emergency Exit F71 3A Locking Compartment F72 3A Buzzer Isolation Relay F73 PTI CRS With Enter Door Activated Dome Light PTI Leave No Student Behind F74 See Circuit Diagram F75 See Circuit Diagram F76 PTI CRS With Enter Door Acti...

Page 160: ...pression Relay 2 NS3 Noise Suppression Relay 3 NS4 Noise Suppression Relay 4 MD1 Master Disconnect Relay 1 MD2 Master Disconnect Relay 2 MD3 Master Disconnect Relay 3 IGN Ignition Relay ACC1 Accessory Relay 1 ACC2 Accessory Relay 2 Fuse Description Chart Amps Color 5 TAN 10 RED 15 LIGHT BLUE Fuse Description Chart cont Amps Color 20 YELLOW 25 CLEAR 30 LIGHT GREEN Tilt Hood Raising the Hood 146 ...

Page 161: ...s a handle Mirror damage and misadjustment can occur Use the hood handle and pull the hood forward over center and allow it to settle into the raised position Lowering the Hood NOTE Make sure that the hood has no tools parts people in its path of motion Use the hood handle and push the hood backward over center and allow it to settle into lowered position 147 ...

Page 162: ... to prevent shorting of the electrical system 2 Place transmission in Neutral and set parking brake in both vehicles 3 Turn OFF lights heater air conditioner and any other electrical loads in both vehicles 4 Eye protection should be worn if available If not available shield eyes when near either vehicle s batteries 5 Make sure the vehicle bodies or bumpers are not touching 6 Connect one end of the...

Page 163: ...urpose of releasing the parking brake WARNING To prevent personal injury and or death or property damage always use both tow hooks to prevent possible overloading and breaking of individual hooks This vehicle may be equipped with optional dual tow hooks for recovery purposes only CAUTION To prevent property damage observe the following Due to many variables that exist in towing positioning and lif...

Page 164: ... a slow steady pull do not jerk on hooks Tow hooks are not designed for towing but for retrieval only Before moving the towed vehicle check for adequate road clearance of vehicle components IC Bus recommends unloading the towed vehicle prior to towing to reduce any abnormal loads to the vehicle components resulting from the towing procedures Before towing be sure to fully release the parking brake...

Page 165: ...els Suspended Whenever possible it is preferable to tow a disabled vehicle from the rear by raising the rear of the chassis When towing a vehicle with the rear of the chassis suspended the front wheels must be locked in the straight ahead position 151 ...

Page 166: ...Roadside Emergencies 152 ...

Page 167: ...hemicals used to clean or disinfect your IC Bus vehicle can adversely affect materials used to build the vehicle Many common cleaning chemicals can damage or ruin the appearance of materials like ABS plastic vinyl rubber aluminum glass and painted surfaces As with the cleaning chemicals used the cleaning process or the lack of a cleaning process can also affect the life and appearance of the vehic...

Page 168: ...ge glass Use a soft cloth and glass cleaner only Interior The best method to preserve the appearance and extend the life of the interior components of your IC Bus vehicle is frequent and thorough cleaning of the components A cleaning schedule and the cleaning requirements should be determined based on the type of service conditions in which the unit is operated Interior Light Bar Cleaning All Inte...

Page 169: ...en with warm or cold water to remove dirt and preserve the original luster of the paint Never wash the vehicle in the direct rays of the sun or when the sheet metal is hot to the touch as this may cause streaks in the finish Do not use hot water strong soaps or detergents Never wipe dirt off a dry surface as the dirt will scratch the paint Always make certain that steps and grab handles or any ext...

Page 170: ...or polish Use a high quality paste wax and follow the wax manufacturer s instructions to help prevent bus paint from fading Crossing Arm Cleaning The crossing arm is only to be cleaned with a mild detergent and warm water No other cleaners are to be used as they may damage the surface 156 ...

Page 171: ...e sure the vehicle receives proper care and maintenance IC Bus service parts are available through your IC Bus dealer If IC Bus service parts are not used the owner must make sure the parts used are an equivalent As with any machine take care to avoid being injured when performing maintenance repairs or inspections Improper or incomplete service could result in the vehicle not working properly whi...

Page 172: ...rly ventilated area WARNING To prevent personal injury and or death or property damage do not make modifications to any part component or system of the vehicle as that can adversely affect the quality and reliability of your vehicle WARNING To prevent personal injury and or death or property damage use only genuine IC Bus service parts The use of inferior parts can adversely affect the quality and...

Page 173: ...t trip inspection can be even more valuable since it may reveal problems in time for service work to be performed prior to the next trip This can help to minimize unwelcome surprises and unscheduled downtime A convenient checklist of items to include in Pre Post Trip inspections are identified in Section 2 Vehicle Inspection Guide as well as Commercial Driver s License CDL Manuals Chassis Lubricat...

Page 174: ...cation and Maintenance Intervals Chart at the end of this section for further details Engine Compartment Fluid Check Points NOTE Location of deaeration tank power steering reservoir transmission dipstick air cleaner and oil dipstick may vary depending on model year and engine type PSI 8 8L Gasoline Engine Left Side View 1 Power steering fluid level 2 Transmission fluid level 160 ...

Page 175: ...e adjustment of the pressure regulator To perform these adjustments open access panel door and use the procedures below Door Opening and Closing Speed Adjustment Points 1 Opening speed screw 2 Closing speed screw 3 Pressure regulator adjustment knob 4 Lock nuts 5 Air filter Pressure Regulator Adjustment WARNING To prevent personal injury and or death or property damage do not replace the air door ...

Page 176: ...osing speed screw 2 clockwise to slow the door closing speed or counterclockwise to increase the door closing speed Tighten the locknut 4 Electrically Actuated Entrance Door Adjustment Electrically actuated doors are set to operate in 2 to 2 seconds There is no adjustment for electrically actuated door opening and closing speed Axles Typical Axle Tire and Rim Specifications Vehicle Identification ...

Page 177: ...ndow is clean on the outside but discolored on the inside check the lube level by removing the rubber fill vent plug and insert a finger into the hole The specified lube level for clear window type hubcaps is from the minimum line to 5 16 in 8 mm above the minimum line If the lube level suddenly drops dramatically below the minimum level see the Service Manual for diagnostic procedure Front Axle A...

Page 178: ...e linings However exposure to excessive amounts of brake material dust may be a health hazard WARNING To prevent personal injury and or death or property damage pay strict attention to the following if your vehicle is equipped with Automatic Traction Control or any type of locking or limited slip differential power will be transmitted to the opposite wheel should one of the wheels slip Both wheels...

Page 179: ... with a rag soaked with water and wrung until nearly dry NEVER use compressed air or dry sweeping to clean the work area Use an industrial vacuum cleaner with a HEPA filter system and rags soaked in water and wrung until nearly dry Carefully dispose of used rags to avoid getting dust into the air Use an approved respirator when emptying vacuum cleaners and handling used rags Wash your hands before...

Page 180: ...travel or brake adjustment Check the push rod travel every service interval to determine if adjustment is necessary Brake chamber push rods on original equipment chambers have a stroke indicator an ORANGE RED paint marker rib near the base of the push rod to aid adjustment checks If the push rod is clean and the brakes require adjustment the ORANGE RED marker can be seen protruding from the chambe...

Page 181: ...cular installation then the interval should be increased or reduced accordingly Air Dryer Purge Valve Check that the purge valve opens and expels moisture when the air governor shuts off the air compressor Air should escape rapidly and then quickly stop If the purge valve does not open or you can hear a slight audible air leakage past the valve for longer than 30 seconds the valve may be sticking ...

Page 182: ...ions and conditions Refer to the Lubrication and Maintenance Intervals Chart later in this section for recommendations On a periodic basis of at least once per year inspect the entire brake system for The proper operation of the service and parking brakes The condition of the discs calipers and ABS exciter teeth Hydraulic fluid leaks Hose or pipe damage The condition of the ABS wheel speed sensors...

Page 183: ...s and add fluids only to the following locations Brake fluid to the brake master cylinder Power steering fluid to the power steering fluid pump reservoir Hydraulic Brakes Brake Fluid Level SmartTrac System NOTE If brake fluid is added frequently to maintain the proper level in the master cylinder it means that there is either rapid pad wear or a fluid system leak A more frequent and thorough brake...

Page 184: ...ng the parking brake foot pedal bring the vehicle to a gradual and complete stop using only the parking brake 4 Repeat the above steps nine times at two mile intervals Parking brake adjustment should only be performed by qualified service personnel and in accordance with instructions provided in the IC Bus CE Series Service Manual Chassis Inspection Regular maintenance and replacement of worn loos...

Page 185: ...ll not allow air to escape from the connection and this compressed air will push the connection apart Accessory Feed Connections WARNING To prevent personal injury and or death or property damage do not increase size of fuse or circuit breaker or change type of breaker supplied with your truck as this could cause wiring to overheat and possibly burn Electrical circuits are designed with a particul...

Page 186: ...ration and maintenance information pertaining to your PSI 8 8L gasoline engine refer to the Engine Operation and Maintenance Manual provided with the vehicle Scheduled Maintenance For information regarding routine scheduled maintenance such as replacement of oil filters coolant belts belt tensioners etc as well as inspection and adjustment of items such as valve lash etc refer to the Engine Operat...

Page 187: ...t to be sure that the rubber dust unloader valve at bottom of housing is in place free of debris and not cracked 4 Inspect the new air filter element for a damaged or nonresilient rubber gasket Inspect the air filter element body for dents or excessive pleat bunching If any of the mentioned conditions exist obtain and install an alternate new air filter element from your IC Bus or International de...

Page 188: ...eturn unless line or fitting is plugged A slow return is normal due to safety filter in fitting Leak in vacuum line Apply vacuum to gauge until locked up at RED zone Reconnect gauge and close end of line air tight Hold in reset button Indicator will drop slightly and then not move unless vacuum line has a leak Leak in gauge Repeat above except close gauge connection airtight Air cleaner element sp...

Page 189: ...ments are damaged from high vacuum If gauge is locked up at RED zone check elements for damage Radiator Core Inspection and Cleaning With the engine OFF visually inspect the radiator core assembly for debris and clogging of external fins Prior to engine operation remove any debris blocking the core Cooling System WARNING To prevent personal injury and or death or property damage do the following w...

Page 190: ...s on the deaeration tank when engine is cold Gravity Fill Coolant Method PSI 8 8L gasoline Engine Filling Instructions NOTE Using the KL5007NAV Coolant Management Tool is the recommended procedure to fill the cooling system however in some cases this tool may not be available and the following gravity fill procedure may be used instead Contact an IC Bus or International dealer for special instruct...

Page 191: ...here applicable on the top radiator pipe 3 Fill the deaeration tank with the proper coolant to the top of tank 4 Close cooling system vent valve when air is purged and coolant is seen flowing from valve 5 To purge air from the cooling system start engine and run at an elevated idle 1 500 rpm for approximately 10 minutes 6 Verify coolant concentration and adjust coolant level to the COLD MAX level ...

Page 192: ...rs capacities and other antifreeze information refer to the Engine Operation and Maintenance Manual Fan Clutch Inspect for proper operation secure electrical connections or air supply as appropriate See the applicable Service Manual for details Heater and Coolant Hose Inspection and Replacement Guide Proper maintenance and inspection of the heater and coolant distribution system is required to max...

Page 193: ... is recommended after 5 years of service In the event a hose failure is experienced prior to the recommended replacement time frame age and condition of remaining hoses should be considered to determine if all engine and body hoses should be replaced to reduce the potential for additional failures Engine Oil NOTE Use only recommended viscosity engine oil Refer to the Engine Operation and Maintenan...

Page 194: ... Under seat heaters may have an optional filter on the top surface of each heater box Heater booster pumps should not be run dry for more than 30 seconds This may cause the seals to fail Integrated Air Conditioning IC Air System The following conditions require the immediate attention of your nearest authorized IC Air Service Center Vibration and or noise from engine compartment Oil around refrige...

Page 195: ...sis are manufactured with frame rails of High Strength Low Alloy HSLA steel and must be handled in a specific manner to ensure maximum service life Specific instructions are published concerning proper repair of frame rails Before attempting frame repair or modification consult the service manager of your IC Bus dealer Inspect front and rear tow hooks for damage or loose mountings Steering General...

Page 196: ...ghten Lubrication Points Typical Steering Shaft 1 Lubrication points The steering shaft is lubricated at the three points shown above For the correct maintenance interval refer to the Lubrication and Maintenance Interval Chart at the end of this section Power Steering 1 Filter access cap 2 Fluid level 3 Internal power steering fluid filter Periodically replace the power steering fluid Whenever the...

Page 197: ...d fall within the COLD run band When the transmission fluid is hot the fluid level should fall within the HOT run band Add fluid as required Do not overfill or the transmission will overheat Check the shift linkage for proper operation Check operation of transmission neutral safety switch Try to start the vehicle in all shift selector positions The starter should ONLY operate when the shift select...

Page 198: ...roperty damage always follow these instructions when mounting tires on wheels Only personnel who have had proper training and experience should mount or remove tires from rims or wheels Use only heavy duty rims or rims approved for radial tires It may be necessary to contact your wheel and rim distributor to determine if your rims are approved for radial tires If a tube is to be used make sure spe...

Page 199: ... pressure is a very important maintenance practice to ensure safe vehicle operation and long life for the tires Failure to maintain correct inflation pressure may result in sudden tire destruction improper vehicle handling and may cause rapid and irregular tire wear Therefore inflation pressures should be checked daily and always before long distance trips Follow the tire manufacturer s recommende...

Page 200: ...arts Inspection Check condition of tires for abnormal wear patterns and proper inflation pressures Cut or broken tire casing must be repaired or replaced Tires should be inspected for the following conditions If any are present the tire should be removed and repaired retreaded or scrapped as the condition indicates Any blister bump or raised portion anywhere on the surface of the tire tread or sid...

Page 201: ...er mix different tire sizes or constructions on the same axle Rotation Steer tires that have developed some type of irregular wear pattern can be rotated to drive axles if rib tires are being used on all wheel positions Applying steer tires to a drive position will often wear off the irregularities and they can be moved back to the steer axles or run out to retread stage on the rear axle Another r...

Page 202: ...lly balanced and reinspected while spinning for an out of round condition Wear Radial tires can exhibit three types of normal wear patterns even erosion or chamfer Even Wear is a sign that the tire is being properly used and maintained Erosion Wear has also been called rolling wear channel or river wear Erosion wear is found more often at free rolling tires This is an indication that the tire is b...

Page 203: ...orrect tire chain usage installation and removal Wheels Wheel and Wheel Nut Maintenance and Installation WARNING To prevent personal injury and or death or property damage always follow these instructions when mounting tires on wheels Only personnel who have had proper training and experience should mount or remove tires from rims or wheels Use only heavy duty rims or rims approved for radial tire...

Page 204: ...wheel or fastener failures WARNING To prevent personal injury and or death or property damage when installing the tire and rim assembly on disc brake equipped axles make sure the tire valve stem clears the brake caliper The use of either an IC Bus or International truck valve stem retainer or a tire manufacturer s stem forming tool is the only acceptable method of obtaining clearance when necessar...

Page 205: ... inner wheel if duals or steer wheel over the wheel studs and onto the pilot pads of the hub Care must be taken to avoid damage to the stud threads while positioning the wheel Ensure that the wheel is resting on the pilot pads and is against the brake drum 6 Hand start all wheel nuts to avoid cross threading 7 Starting with the nut at the 12 o clock position and using the appropriate star or criss...

Page 206: ... pre trip inspection look for loose or missing wheel nuts Also look for rust streaks extending outward from the wheel nuts this can be an indicator that one or more wheel nuts are loose even if they cannot be turned by hand Normal periodic maintenance should also include checking the wheel nut torque with a torque wrench Windshield Wiper Wiper Blade Assembly Replacement 1 Press the plastic lever a...

Page 207: ...ovided in this manual are for normal highway and environmental service conditions These intervals may be expressed in miles kilometers hours of operation and or months of operation It is important to note that in high duty cycle types of operation and or where operating conditions are extremely severe such as in deep water mud or unusually dusty conditions the vehicle may require lubrication much ...

Page 208: ...s are performed at Special Intervals or in addition to A or B Service when the interval dictates Lubrication and Maintenance Interval Bus Gasoline CE Bus System Item Intervals Special Interval 3 miles km hours months Pre Trip Inspection Pre trip inspection Items listed in Section 2 Check All Axle U bolts Retorque At first 1 000 miles 1 600 km then every 36 000 miles 58 000 km thereafter Drag Link ...

Page 209: ...r Check A B Electrical Sensors Reseat A B Power Steering Filter Replace 40 000 64 000 12 Power Steering Fluid Change 40 000 64 000 12 Power Steering Fluid Check Level A B Steering System Check Tightness A B Steering Gear Lubricate A B ATTN Install grease slowly at low pressure Power grease guns may blow out seals Steering Intermediate Shaft U Joints Slip Joint Lubricate A B Steering Steering Inter...

Page 210: ...e Check AD IP 12 AD 9 24 Air Compressor Discharge Line Check blockage 50 000 80 000 1 500 24 Air Tanks all Drain Water A B Air Wet Tank Drain Water A B Brake Chamber Rod Travel Check A B Governor Cut in Cut out Pressure Check A B Low Air Pressure Warning Alarm Check A B Parking Brake Operation Check A B Rotors Drums Calipers Chambers Hoses etc Check for wear damage A B S Cam Bushings Lubricate A B...

Page 211: ...luid Change Every 2 years from the date of manufacturing Master Cylinder Cap Check Vent for Obstruction NOTE If obstruction is observed replace cap A B Master Cylinder Check Fluid Level A B Parking Brake Cable Check condition A B Parking Brake Operation Check A B Brakes Hydraulic Service Brakes Operation Check A B Coolant Check Level A B Fan Blade Shroud Check Damage Contact A B Fan Clutch Check A...

Page 212: ...ion indication on air restriction gauge Air Induction System Check looseness leaks Engine Oil and Filter s Replace Engine Oil Level Inspect Fan Belt Auto Tensioner Inspect Fan Belt Inspect Engine Fuel Filter Replace Refer to Engine Operation and Maintenance Manual Fuel Tank Fuel Tank Inspect for chips cracks damage or signs of impact 12 months Exhaust System Pipes Muffler Inspect for leakage loose...

Page 213: ...entional or Conventional Synthetic Mixed Automatic Trans Fluid Replace Allison 2000 50 000 80 000 24 Factory filled Synthetic Non Mixed Automatic Trans Fluid Replace Allison 2000 100 000 160 000 48 Neutral Start Switch Check Function A B Transmission Shift Selector Linkage Check Function A B Axle Flange Nuts Retorque B Axle U bolts Retorque At first 1 000 miles 1 600 km then every 36 000 miles 58 ...

Page 214: ... to 0 005 in specification or lube condition is contaminated or low then perform a full wheel end tear down Inspect bearings spindle and spindle nuts for excessive wear and replace as necessary Rear Axle With Synthetic Oil Change Dana Spicer 180 000 288 000 36 Meritor 250 000 400 000 36 Rear Axle Cont Rear Axle Wheel Ends Full tear down inspection of all wheel end components regardless of conditio...

Page 215: ...maged missing parts A B Entry Door Check Operation A B Emergency Doors Exits and Buzzers Check A B Fluid Leaks Check A B Headlights Bright Dim Daytime Check A B Heater Hoses and Connections Check Condition 12 months NOTE See Heater and Coolant Hose Inspection and Replacement Guide in this section for additional information Inspect and Clean Step Well and All Other Heater Cores and Blower Areas A B...

Page 216: ...top Arm s Crossing Gate Entrance Door Warning lights Interaction Check A B Unit Refill Capacities Air Conditioner Refrigerant See air conditioner manufacturer s Service Operation Manual for aftermarket bus A C system specifications Cooling System Refill Capacities Cooling system capacities vary greatly due to variations in bus length number of heaters and engine model Total capacity may range from...

Page 217: ...ransmission Model Transmission Fluid Volumes Pints Liters Allison 5 Speed Automatic 2100 PTS 38 18 Allison Automatic 2200 PTS 38 18 Allison Automatic 2500 PTS 38 18 Allison Automatic 2550 PTS 38 18 Approximate refill quantity less than initial fill since a portion of the used fluid remains in external circuits and transmission cavities Check at operating temperature and top off as required Tire an...

Page 218: ... and above 40 C and above 80W 90 26 C to 38 C 15 F to 100 F 80W 140 15 F and above 26 C and above 85W 140 10 F and above 12 C and above Front axle wheel bearing oil Dana axle multipurpose EP gear lube of API GL 5 quality meeting MIL PRF 2105E specs including synthetic lubricants Do Not Mix conventional lube with Synthetic lube 75W 40 F to 32 F 40 C to 0 C 75W 90 40 F to 100 F 40 C to 38 C 75W 140 ...

Page 219: ...above 12 C and above 80W 90 15 F and above 26 C and above 75W 90 40 F and above 40 C and above 75W 40 C to 2 C 40 F to 36 F SAE 40 or 50 10 F and above 12 C and above SAE 30 15 F and above 26 C and above Front axle wheel bearing grease tie rod ends drag link kingpin and bushing Dana axle Meritor axle Fleetrite NLGI 2 Lithium Complex Based Moly grease P N 991044C2 or equivalent GC LB NLGI 2 Multi p...

Page 220: ...ype Viscosity Ambient Temperature Notes Engine Engine Lubricating Oil Refer to Engine Operation and Maintenance Manual Electrical Terminals Lubricant Sealing Grease TriboTuff Premium Grease and or RED dielectric paint Connectors Dielectric Grease NYOGEL 760 G 206 ...

Page 221: ...PI CK 4 15W 40 Motor Oil 18 F to 108 F 10 C to 43 C NOTE Must not be used with Hydraulic Brake Booster System NOTE The power steering system is filled with ATF fluid at the factory CAUTION To prevent component system property damage ONLY use fluid types listed NOTE Certain fluid types may be better suited for use in your vehicle dependant on geographic location and temperature It is recommended to...

Page 222: ...te NLGI 2 Lithium Complex Based Moly grease P N 991044C2 or equivalent GC LB NLGI 2 Multi purpose Lithium Complex grease Drive Shaft U Joint Lubricate Fleetrite NLGI 2 Lithium Complex Based Moly grease P N 991044C2 or equivalent GC LB NLGI 2 Multi purpose Lithium Complex grease Clutch Release Bearing Shafts Fork Lubricate Fleetrite NLGI 2 Lithium Complex Based Moly grease P N 991044C2 or equivalen...

Page 223: ... speed Gear oil meeting MIL PRF 2105E API MT 1 GL 5 75W 40 F to 15 F 40 C to 26 C 75W 80 40 F to 80 F 40 C to 27 C 75W 90 40 F to 100 F 40 C to 38 C 75W 140 40 F and above 40 C and above 80W 90 15 F to 100 F 26 C to 38 C 80W 140 15 F and above 26 C and above 85W 140 10 F and above 12 C and above Single speed Continued International axle multipurpose EP gear lube of API GL 5 quality meeting MIL PRF...

Page 224: ...il 0 76 L Hypoid Gear Oil GL 5 SAE 85W 140 Above 10 F 12 C GL 5 SAE 85W 140 Above 15 F 26 C GL 5 SAE 80W 90 Above 15 F 26 C GL 5 SAE 75W Max outside temp 35 F 2 C Above 40 F 40 C GL 5 SAE 75W 140 Above 40 F 40 C Torque Specification Charts Disc Wheels Torque Chart Specified Torque Stud Size Nut Size lb ft N m 22 mm Flange Nut 33 mm Across Flats 450 500 610 678 NOTE Do not use lubrication on dry th...

Page 225: ...y V Rate with 4 500 lb Auxiliary Spring 260 300 353 407 15 500 lb Capacity International Air Suspension IROS for axles 14ADN 14ADP 14AJC 14AJE 14ATP and 14ATR 260 300 353 407 14TBH 15 500 lb Capacity International Air Suspension IROS for all other axles 370 400 502 542 14TBS 21 000 lb Capacity International Air Suspension IROS 260 300 353 407 23 000 lb Capacity International Air Suspension IROS fo...

Page 226: ...que Chart Specified Torque lb ft N m Wiper Pivot M20 Hex Nut 21 28 Seat Base Bolts Specified Torque lb ft N m All Seat Base Bolts 16 to 20 21 7 to 27 Filter List Filter part numbers and or specifications may change during the life cycle of this vehicle Current information on the appropriate chassis and engine filters for your vehicle can be obtained by contacting your local IC Bus or International...

Page 227: ...al subscription to the International Service PortalSM Website or via the OnCommand Service Information USB For Information on the International Service Portal website s content availability and fee structure contact your local International Truck Dealer or in the case of a National Account your International Fleet Service Manager The OnCommand Service Information USB contains International and IC ...

Page 228: ... Optional Service Contracts Custom Service Contracts and Performance PM designed to ensure the lowest possible cost of ownership are also available Published Service Contracts Performance PM Service designed to ensure the lowest possible cost of ownership are also available Optional Service Contracts have been pre packaged to fit most common applications HOW TO OBTAIN Navistar Inc Warranties Stand...

Page 229: ...ter 167 Air Dryer Purge Valve 167 Air Induction System 172 Air Reservoir Tanks Moisture Draining 167 Air Restriction Gauge Service 173 High Restriction Reading Table 175 No Restriction Reading Table 174 Troubleshooting 174 Air Suspension Seat If Equipped 75 Air Actuated Door 63 Air Operated Passenger Door Adjustments 161 Door Opening and Closing Speed Adjustment Points 161 Closing Speed Adjustment...

Page 230: ...46 Brake Fluid Level SmartTrac System 169 Brake Inspection and Adjustment 165 168 Brake Lines Hoses and Fittings 168 Brakes 13 164 B CONT Brakes cont ABS Self Check 127 Air Brakes 165 Air Disc Brakes 0004JBZ 0004JCC 0004WEY 0004WEZ 123 Air Dryer 167 Air Dryer Desiccant Replacement 167 Air Dryer Heater 167 Air Dryer Purge Valve 167 Air Reservoir Tanks Moisture Draining 167 Brake Inspection and Adju...

Page 231: ...d 88 Location and Use of Lower Latch Anchors 89 Circulation Fans 107 Clear Flooded Engine 112 C CONT Closing Speed Adjustment 162 Cold Weather Operation 117 Compass Declination Zone Set Procedure 35 Compass Directional Calibration Procedure 39 Component Code Numbers 2 Contamination of Coolant 178 Coolant Concentration 178 Cooling System 175 Cooling System Refill Capacities 202 Crossing Arm Cleanin...

Page 232: ... Adjustment 162 Electronic Safety Messages 64 Emergencies While Filling With Gasoline 117 Emergency Door 69 E CONT Emergency Equipment Recommended On Board 137 Body Fluid Cleanup Kit 138 Fire Extinguisher 137 First Aid Kit 138 Reflective Triangle 138 Emergency Exit Window 70 Emergency Exit Windows 70 Emergency Exit Window 70 Emergency Exits 69 Emergency Door 69 Emergency Exit Windows 70 Emergency ...

Page 233: ...ures 113 HD OBD Overview 113 Self Diagnostics 113 Engine Oil 179 Entrance Door Lock If Equipped 72 Exterior 155 Crossing Arm Cleaning 156 Waxing or Polishing Vehicles 156 Exterior Checks 11 Exterior Lamp Check 59 E CONT Exterior Lamp Check cont Activation 60 Deactivation 60 Function 59 Switch Location 59 F Fan Clutch 178 Filling Instructions 176 Filter List 212 Fire Extinguisher 137 First Aid Kit ...

Page 234: ...t Switch and Panel Lighting Control 57 Automatic Headlights 57 H CONT Headlight Switch and Panel Lighting Control cont Headlight Switch 57 Panel Lighting Control 58 Heater and Coolant Hose Inspection and Replacement Guide 178 Heater Booster Pump 108 Heater Cutoff Valve 108 Heater System 105 180 Auxiliary Heaters 106 Driver Heater 105 HIGH LOW Beam 59 High Restriction Reading Table 175 Horn 47 Hot ...

Page 235: ...re Reading 35 Quadrant 4 Transmission Gear Displays 35 Quadrant 3 Outside Temperature and Compass Displays If Equipped 34 User Switches 41 Warning Indicators 22 I CONT Integral Digital Display 26 Integral Digital Display Detailed Information 28 Quadrant 1 Informational Displays 28 Quadrant 2 Text and Warning Messages 30 Warning Messages 34 Integrated Air Conditioning IC Air System 180 Integrated A...

Page 236: ... 213 No Restriction Reading Table 174 O Opening Closing 61 Opening Speed Adjustment 162 Opening the Entrance Door 63 Air Actuated Door 63 Electric Actuated Door 63 Opening the Entrance Door Manually 63 Opening the Entrance Door Manually 63 Operation 54 Optional Instrument Panel Gauge Cluster Compass Calibration Procedure 35 Compass Declination Zone Set Procedure 35 Compass Directional Calibration ...

Page 237: ...Switch If Equipped 128 Manual Pedal Adjustment 128 Post Trip Inspection No Student Left Behind 67 Snooze Mode 68 System Activation 68 System Deactivation 68 System Function 67 P CONT Post Trip Inspection No Student Left Behind cont System Purpose 67 Power Outlet 51 Power Relays Table 141 146 Power Steering 182 Power Steering System 203 Pre Trip and Post Trip Inspections 159 Preface 1 157 Preparing...

Page 238: ...ped 120 SmartTrac Hydraulic Brakes If Equipped 168 S CONT SmartTrac Hydraulic Brakes If Equipped cont Brake Inspection and Adjustment 168 Brake Lines Hoses and Fittings 168 Fluid Precautions 168 Hydraulic Brakes Fluid Precautions 169 Snooze Mode 68 Split System Feature 121 Stability Control Systems Bendix Electronic Stability Program ESP If Equipped 131 Standard Allison 2000 PTS Transmission 133 S...

Page 239: ...aft Joint Bolts 182 Tilt Hood 146 Lowering the Hood 147 Raising the Hood 146 Tire and Rim Combinations 203 Approved Tire and Wheel Combinations Table 203 Tire Maintenance 185 T CONT Tire Maintenance cont Checking Inflation 185 Underinflation 186 Tire Replacement 188 Tire Warnings 183 Tires 183 Dual Tires Matching 187 Dual Tires Mixing 187 Inspection 186 Loads 186 Rotation 187 Rotation Is Advisable...

Page 240: ...n 186 Unit Refill Capacities 202 Air Conditioner Refrigerant 202 Cooling System Refill Capacities 202 Engine Crankcase 202 U CONT Unit Refill Capacities cont Power Steering System 203 Rear Axle 203 SmartTrac Brakes Brake Fluid 202 Transmission 203 Upholstery Care 154 Use of Tire Chains 189 User Switches 41 Using Air Brakes 124 Using the Air Parking Brake 124 V Vandal Locks If Equipped 71 Entrance ...

Page 241: ...l Installation Procedures 190 Wheel Nut Torque Maintenance 190 WIG WAG Warning System 65 Windshield Washer 45 Windshield Wiper 192 W CONT Windshield Wiper cont Wiper Blade Assembly Replacement 192 Windshield Wiper Washer System 45 Windshield Washer 45 Windshield Wiper Speed Control 45 Wiper Blade Speed 45 Windshield Wiper Speed Control 45 Wiper Arm Torque Chart 212 Wiper Blade Assembly Replacement...

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