IC Bus CE Series Operation And Maintenance Manual Download

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0000634530

4328291R1

Bus

™

Propane

Autogas

Series

US,

Canada,

Mexico

May

2015

IC Bus

™

Propane Autogas CE Series

Operation and Maintenance Manual

IC Bus, LLC

2701 Navistar Drive, Lisle, IL 60532 USA

Summary of Contents for CE Series

Page 1: ...CE Series US Canada Mexico May 2015 IC Bus Propane Autogas CE Series Operation and Maintenance Manual IC Bus LLC 2701 Navistar Drive Lisle IL 60532 USA 2015 Navistar Inc All rights reserved All marks...

Page 2: ...y be neither downloaded nor retrieved except by the vehicle s registered owner or in the alternative by another individual or entity authorized by the registered owner e g IC Bus Dealer who may need t...

Page 3: ...for this vehicle or 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 Ser...

Page 4: ......

Page 5: ...ystem Inspection 22 Section 3 Instrumentation Instrument Panel Gauge Cluster 23 Warning Indicators 24 Instrument Panel Gauge Cluster 26 Direct Drive Warning Indicators 27 Integral Digital Display 28 I...

Page 6: ...or 69 Opening the Entrance Door Manually 69 Electric Actuated Door 69 Air Actuated Door 69 Traffic Warning System 69 Electronic Safety Messages 69 Eight Lamp AMBER and RED Warning Lights 70 Optional R...

Page 7: ...er 96 Location and Use of Tether Anchors SafeGuard XChange Bus Seats 97 Cushion Release Latch 98 Track Seat Mounting Seat Type Specific 99 Section 8 Climate Controls Heater System 103 Driver Heater 10...

Page 8: ...ir Lift Interlocks 129 Wheelchair Lift Extension Operation 129 Starting Bus in Motion 130 Starting Bus in Motion With Transmission Shift Wheelchair Lift Interlocks 130 Retracting and Stowing Operation...

Page 9: ...ion 160 Air Brakes 161 Brake Inspection and Adjustment 161 Air Dryer 163 Air Dryer Desiccant Replacement 163 Air Dryer Purge Valve 163 Air Dryer Heater 163 Air Reservoir Tanks Moisture Draining 163 AB...

Page 10: ...n 183 Rotation Is Advisable 183 Tire Replacement 183 Wheel and Tire Balancing 184 Wear 184 Irregular Wear 184 Use of Tire Chains 184 Wheels 185 Wheel and Wheel Nut Maintenance and Installation 185 Whe...

Page 11: ...Table of Contents Section 14 Index Index 215 vii...

Page 12: ...Table of Contents viii...

Page 13: ...rence 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...

Page 14: ...phone 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...

Page 15: ...waxing to prevent deterioration Determining washing frequency is the customer s responsibility NOTE For vehicles exposed to ultraviolet rays of the sun apply a coating of Bon Ami soap or similar prod...

Page 16: ...shops smoky industrial areas and locations of possible road splash contact 5 If a vehicle is parked on an incline install wheel chocks Reporting Safety Defects U S Registered Vehicles If you believe t...

Page 17: ...BD 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 g...

Page 18: ...novative 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 o...

Page 19: ...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 probl...

Page 20: ...Mirrors 5 Turn Signals 6 Crossing Gate 7 Headlights 8 Rearview Mirrors 9 RED Warning Lights CE Bus Rear View 1 Identification Lamps 2 AMBER Warning Lights 3 Clearance Lamps 4 Turn Signals With or With...

Page 21: ...nspection Guide CE Bus Right 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 Signal Lamp 8 Fu...

Page 22: ...ft View 1 Emergency Kickout 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...

Page 23: ...l Cap The propane autogas fuel cap is on the right side of the bus located behind the right rear tire Typical Propane Autogas Fuel Tank Configuration The propane autogas fuel tanks are located on the...

Page 24: ...a manual shutoff valve to be used in the case of an emergency The valve is located underneath the bus on the front side of the propane autogas tank 1 4 Turn Fuel Safety Shutoff Valve To operate the v...

Page 25: ...s you walk up to the bus Check for vandalism and loose items under the vehicle Check the fuel door and the fuel tank cap Review the results of the previous post trip inspection with your supervisor or...

Page 26: ...xterior strobe light test it as well Inspect all reflectors headlights turn signals and emergency flashers Make certain they are clean firmly attached and without cracks or breaks Wheels and Tires WAR...

Page 27: ...the torque charts in the Maintenance section Shock Absorbers Check for cracks leaks and missing or broken mounting bolts or bushings Brakes Table 3 Brakes Drum or Rotor and Brake Linings Check to see...

Page 28: ...al injury 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 c...

Page 29: ...ure 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 fi...

Page 30: ...erformed with the engine running Instrumentation With engine running check gauges for oil pressure temperature alternator and fuel levels Wiper Blades Look through the windshield to inspect both wiper...

Page 31: ...psi 138 to 310 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 3 times The...

Page 32: ...6 Integrated Air Conditioning System IC Air Compressor Belts Check for tension and wear Inspect for properly tensioned belt This ensures maximum compressor performance and belt life Evaporator Filter...

Page 33: ...use the Exterior Lamp Check procedure in the Lights section of this manual Make sure the Stop Arm and Crossing Gate are working properly and extend completely Also make sure the entrance door is open...

Page 34: ...ct fuel tanks for dents scratches gouges abrasions and other signs of damage Check that fuel tanks are secured to mounting brackets and hardware is secured to frame Fuel Lines Inspect fuel lines and c...

Page 35: ...rs and an Integral Digital Display that provide odometer transmission gear indication and compass heading and outside temperature displays This instrument panel gauge cluster displays the crucial oper...

Page 36: ...ER Warning Lamp AWL illuminates when the vehicle 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 accomp...

Page 37: ...he 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...

Page 38: ...WARNING To prevent property damage personal injury and or death never operate the vehicle when insufficient air pressure less than 70 psi 483 kPa is indicated for either the primary or secondary air s...

Page 39: ...ndication of air pressure available for the primary air brakes in pounds per square inch PSI 34 Indicates the approximate fuel level in the fuel tanks 35 Provides indication of air pressure available...

Page 40: ...ly 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...

Page 41: ...tors 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 Sc...

Page 42: ...d 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 independent...

Page 43: ...aneous fuel economy sent from the engine The display shall be in miles per gallon or liters per 100 kilometers corresponding to the units selected while in the odometer mode Display Format 30 0 INST M...

Page 44: ...prox 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...

Page 45: ...ayed indicates restricted air flow to the engine Yes No Exterior Lamp Check Active Message displayed indicates Exterior Lamp Check is in progress Yes No HVAC Temp Setting Bar graph displayed show temp...

Page 46: ...arning 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 tu...

Page 47: ...veline EGC Compass Module ESC VSM SD AGSP TPMS 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 W...

Page 48: ...Indicator Association Calibration Ended Message is displayed when vehicle speed is less than 3 km h and the operator has requested Calibrate Compass in the current ignition cycle No No Declination Zo...

Page 49: ...r indicators Warning indicator Warning Message RED Stop Lamp STOP ENGINE AMBER Warning Lamp WARN ENGINE Outside Temperature and Compass Displays Optional The optional Outside Temperature and Compass H...

Page 50: ...near the front bumper Due to its location the sensor readings can be affected by road or engine heat during idling or prevailing driving conditions extended slow movement The display will be in F or C...

Page 51: ...ss Compass Declination Declination Zone and End Calibration NOTE The Declination Zone for the location where the Compass Calibration procedure is being performed must be set first and thereafter the C...

Page 52: ...Instrumentation Declination Zone Map 40...

Page 53: ...e 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...

Page 54: ...he 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 OF...

Page 55: ...pass 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...

Page 56: ...urations 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 t...

Page 57: ...dditional Comments Fuel Level Gauge low only alarms on each key switch turn on 5 BEEPS Gauge warning indicator illuminates Voltmeter Gauge out of range reading 5 BEEPS Gauge warning indicator illumina...

Page 58: ...rgency 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...

Page 59: ...ld Washer WARNING To prevent property damage personal injury and or death do not use the washers in freezing weather without first warming the windshield with the defrosters otherwise the washer solut...

Page 60: ...bout the Turn 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 steeri...

Page 61: ...se of the cruise control switches in this location refer to the cruise control procedure later in this section Horn The horn is a standard electric automotive type and is located in the center of the...

Page 62: ...ve 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...

Page 63: ...ositions 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 drive...

Page 64: ...TED MIRROR Turns heating element behind outside mirror glass ON OFF LEFT FAN Turns HI LO OFF driver s defog fan above windshield DRIVER DOME Turns ON OFF driver side lights DOME LIGHTS Turns ON OFF in...

Page 65: ...windshield defog fan HI LO OFF DESTINATION Turns ON OFF illumination for destination window STROBE LIGHT Turns ON OFF top strobe light LAST DOME Turns ON OFF last dome light REAR DOME Turns ON OFF rea...

Page 66: ...located inside the storage compartment The power outlet supplies a 12 volt power supply for driver accessories such as cellular phones and two way radios Transmission Parking Brake and Ignition Switc...

Page 67: ...Driver Controls 55...

Page 68: ...Driver Controls 56...

Page 69: ...nsole 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 Befo...

Page 70: ...s Traction Control system ON or OFF Air Brake chassis Optional MUD SNOW TRAC CTRL Switch Controls amount of ATC action of the Traction Control system Hydraulic Brake chassis ON LAMP CHECK Initiates ex...

Page 71: ...Driver Controls 59...

Page 72: ...e the cruise control feature 2 Press the SET position on the rocker switch after reaching a speed of at least 56 km h 35 mph to set the cruise speed 3 Push and hold the RESUME ACCEL to increase your s...

Page 73: ...necessary ask for assistance when moving vehicle Backup alarms are available through your IC Bus dealer However they are never a substitute for the above procedures 1 Left Right Side Flat Mirror Adjus...

Page 74: ...make sure that the top of the side windows are visible in the upper edge of the mirror and that the right side of the bus body is visible in the inside edge of the right flat mirror 3 Look through the...

Page 75: ...zzer 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...

Page 76: ...w 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 bu...

Page 77: ...ing the switch into the full turn position Move the turn signal lever up or down to the point where resistance to movement is felt The turn signal lever returns to the OFF position when released HI LO...

Page 78: ...e driver can exit the bus and visually inspect all lights on the exterior of the vehicle for proper operation Activation To activate the exterior lamp check Turn the key to the ON or Accessory ignitio...

Page 79: ...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 o...

Page 80: ...itch to the CLOSE position Three Position Door Switch The optional three position door switch is located on the left or right console switch panel With the ignition ON the entrance door can be opened...

Page 81: ...r 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...

Page 82: ...he 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 arm are intended to warn the pu...

Page 83: ...r 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...

Page 84: ...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 drive...

Page 85: ...rts when the bus ignition is turned off at the end of a trip System Function Any time the ignition key is in the RUN position AND the RED flashers have been turned on AND the door is opened or is alre...

Page 86: ...oze Mode NOTE The Snooze function can be turned Off before the snooze time out period by placing the ignition switch to the OFF position This function allows the driver to temporarily disable the No S...

Page 87: ...Lift switch in the ON position See Driver Controls section for the switch description Also refer to the Brake and Transmission sections for wheelchair lift interlocks 1 Ensure that the ignition switch...

Page 88: ...e Wheelchair lift door according to the manufacturer s Operator Manual instructions The LIFT DOOR Instrument Panel Gauge Cluster indicator will then turn Off Wheelchair Lift Alarm The Instrument Panel...

Page 89: ...red by NHTSA no later than 21 April 2004 This label is a warning to the user of the bus not to block the emergency exits with wheelchair child restraint systems or other items for example trash contai...

Page 90: ...present and visible at all times Inspect every emergency exit every day for proper operation Roof Vent Hatch When using the vent push upward at the locations marked on the hatch Open the hatch by turn...

Page 91: ...ting 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 seve...

Page 92: ...e Seat 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...

Page 93: ...Knob The seatback adjustment knob is located on the left of the seat at the intersection of the seatback and the lower seat cushion Turn the seatback adjustment knob clockwise to tilt the seatback for...

Page 94: ...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 Drive...

Page 95: ...ton 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...

Page 96: ...damage personal injury and or death do not bleach or re dye seat belt webbing Bleaching or re dyeing may cause a weakening premature deterioration of the webbing WARNING To prevent property damage pe...

Page 97: ...2 Seat Belt Cutter 3 Lid If it becomes necessary to 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...

Page 98: ...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 Optional Buckling Up 1 The passenger...

Page 99: ...S IMPORTANT AND MUST BE DONE TO ENSURE PROPER FIT OF LAP SHOULDER BELT TO PASSENGER The shoulder portion of the belt must be snug across the chest and in the center of the passenger s shoulder 8 Posit...

Page 100: ...l the way right to create three seating positions Integrated Child Restraint Seats Optional WARNING To prevent property damage personal injury and or death observe the following Follow all instruction...

Page 101: ...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 br...

Page 102: ...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...

Page 103: ...ne without sagging It does not press on the child s flesh or push the child s body into an unnatural position 1 Shoulder Height Adjuster 2 Chest Clip Fasten chest clip by pushing both sides together t...

Page 104: ...who weigh between 20 and 85 lb 9 and 39 kg Refer to the following illustration to become familiar with the parts of the child seat and five point seat belts This child restraint system conforms to U S...

Page 105: ...r and put it 2 3 in 5 7 6 cm below the child s chin The purpose of the clip is to keep the shoulder belts positioned correctly on the shoulders To remove the child reverse steps 1 3 Child Restraint An...

Page 106: ...ent in the same passenger seat and only one add on child seat is going to be installed it is recommended to use the system closest to the wall to improve the mobility of the passenger in the open seat...

Page 107: ...he 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 Ins...

Page 108: ...rap 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...

Page 109: ...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...

Page 110: ...ering 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 automatic...

Page 111: ...e 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 sea...

Page 112: ...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...

Page 113: ...3 99 cm 34 13 in 86 69 cm IMMI ICS Track Seat with Integrated Child Seat IC Track 30 54 in 77 57 cm 36 44 in 92 56 cm CEW CR11 Track Seat with or without lap belts with Integrated Child Seat CEW CR11...

Page 114: ...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 Se...

Page 115: ...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 bel...

Page 116: ...ilizing 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 ma...

Page 117: ...ent property damage personal injury and or death wait until the motor cools off before repositioning the fan motor It can become extremely hot when operated in normal ambient temperatures for long per...

Page 118: ...ooster pump unless the heater cut off valve is manually opened Heater Cut Off Valve NOTE The illustration is for reference only and may differ from the actual vehicle Typical Heater Cut Off Valve The...

Page 119: ...ng aids such as ether propane or gasoline in the engine air intake system WARNING To prevent property damage personal injury and or death never add gasoline gasohol and or alcohol to diesel fuel This...

Page 120: ...materials according to applicable regulations The following steps should be completed prior to starting the vehicle 1 Roll the key on as you would to start the vehicle normally 2 The WAIT TO START la...

Page 121: ...the key 6 Monitor idle speed Low idle speed is 750 850 rpm Check all gauges during warm up 7 For minimum oil pressure at idle refer to the Engine Operation and Maintenance Manual If oil pressure is to...

Page 122: ...ropane Electronic Fuel Injection LPEFI fuel system This system utilizes liquid propane fuel injection to improve power efficiency and operating characteristics The LPEFI system works the same as a gas...

Page 123: ...ict attention to all propane autogas fueling site instructions and cautions when refueling your vehicle WARNING To prevent property damage personal injury and or death do not vent or release propane i...

Page 124: ...e fuel door is left open after fueling the engine will not start 1 Turn off the vehicle and follow all fueling site Personal Protective Equipment PPE requirements 2 Open the fuel door 3 Unscrew the du...

Page 125: ...ter Running Out of Fuel If the vehicle runs out of fuel during operation refer to the Engine Operation and Maintenance Manual supplied with your vehicle Cold Weather Operation INSTRUCTIONS WARNING To...

Page 126: ...dirt buildup Fill fuel tank at end of daily operation to prevent condensation in tank Above normal coolant temperature could be temporarily decreased by downshifting into the next lower gear This incr...

Page 127: ...or death always check and maintain brakes in proper condition and adjustment Out of adjustment brakes could cause reduced braking ability The Full Power Brake System incorporates standard braking Ant...

Page 128: ...uster alarms The following lists some of the common faults See fault indicators in Instrumentation section NOTE Whenever a brake system warning indicator is lit do not operate the vehicle until the fa...

Page 129: ...in The switch is spring loaded to return to the neutral center position after being pushed or pulled There is no visual indication at the knob that the parking brake is applied or released Always obse...

Page 130: ...sounding and a warning indicator is illuminated 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 vehicl...

Page 131: ...ressure created activates the system causing the brake pads to contact the rotor When braking is released the air pressure in the brake chamber is released exhausting the pressure on the diaphragm cau...

Page 132: ...sion in Neutral position 4 Pull the parking brake control knob to apply the parking brake To release Air Parking Brake 1 Have the engine running and your foot on the service brake pedal 2 Push in the...

Page 133: ...lift manufacturer s Operator Manual before operating the Wheelchair lift Power will not be supplied to the wheelchair lift mechanism unless all of the following steps have been performed Wheelchair L...

Page 134: ...e Cluster alarm will beep continuously if the Wheelchair lift door is extended AND The Parking Brake is released NOTE When either the Powered Parking Brake is applied or the Wheelchair Lift door is cl...

Page 135: ...ckup of controlled wheels if you over brake for existing road conditions The wheel hubs carry exciter rings used by the axle mounted sensors to transmit wheel speed information to the ABS electronic c...

Page 136: ...standard brake system operation is maintained The brake system is still operational but the antilock system does not operate to prevent wheel lockup if you over apply the brakes for existing conditio...

Page 137: ...uces engine power and or selectively applies the rear brakes The system allows your vehicle to make better use of available traction in these conditions by also limiting the engine rpm when you push f...

Page 138: ...Control system is disabled International Ride Optimized Suspension IROS If Equipped CAUTION To prevent vehicle and or component damage do not operate a vehicle without air in the suspension springs O...

Page 139: ...and always keep that person in sight If so desired backup alarms are available through your IC Bus or International dealer However they are never a substitute for the above procedures WARNING To preve...

Page 140: ...ydraulic Brakes push and hold the Parking Brake knob Park indicator on Instrument Panel Gauge Cluster will turn off 3 Lift foot from the brake pedal and then slowly press the accelerator pedal Allison...

Page 141: ...sion Shift Wheelchair Lift Interlocks WARNING To prevent property damage personal injury and or death always set the parking brake when operating the wheelchair lift or unexpected and sudden vehicle m...

Page 142: ...ark position retract and stow the Wheelchair lift and then close the lift door LIFT DOOR gauge luster indicator should be turned off When the Wheelchair Lift has been safely stowed according to the Wh...

Page 143: ...ht switch panel to the ON position When in the ON position the switch indicator will be turned on Automatic Transmission Operating Temperatures Your vehicle may be equipped with a warning indicator or...

Page 144: ...Operation 132...

Page 145: ...ight 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...

Page 146: ...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...

Page 147: ...s fuel system emergency perform the following 1 Stop the vehicle place it in park and apply the parking brake 2 Immediately evacuate the area Everyone in the affected area should move to a safe distan...

Page 148: ...d F5 10A Stop Light Relay Battery Feed F6 30A Air Conditioner Blower Motor F7 10A Key Switch Battery Feed F8 3A Ignition 1 Relay F9 10A Diagnostic Connector Battery Feed F10 30A Ignition 2 Relayd F11...

Page 149: ...ABCO Air Antilock Brake System F26 5A Panel Light System F27 10A Brake Monitor Ignition Feed F28 5A Air Conditioner Clutch F29 5A Change Transmission Filter Ignition Feed Location Size Description F30...

Page 150: ...Roadside Emergencies Table 11 Fuse Description Chart Amps Color 5 TAN 10 RED 15 LIGHT BLUE 20 YELLOW 25 CLEAR 30 LIGHT GREEN 138...

Page 151: ...Roadside Emergencies Body Fuse Circuit Breaker Panel 139...

Page 152: ...eater F11 7 5A Rear Power Vent 7 5A Defog Fan Left Switch 15A Defog Fan x3 Left Switch F12 20A Center Blower Left Switch F13 25A Step Warmer F14 15A Booster Pump F15 20A Two Way Radio Terminal Strip F...

Page 153: ...lternate Entrance Door F45 3A Entrance Door Dump Valve F46 3A Fuel Fired Heater Timer F47 3A Stop Arm Crossing Gate Cancel F48 5A Dome Light Timer Relay F49 7 5A Emergency Exit Alarms F50 7 5A Front C...

Page 154: ...ency Exit F80 See Circuit Diagram F81 3A Electrical Panel Compartment Light F82 Rear Door Options F83 7 5A Emergency Exit Alarms Battery F84 10A AED Vandal Lock Switch Table 13 Power Relays Location D...

Page 155: ...e the latches on both sides of the cowl 1 Hood Handle NOTE Never use the crossview mirrors as a handle Mirror damage and misadjustment can occur Use the hood handle and pull the hood forward over cent...

Page 156: ...revent damage to vehicle electronic components voltage supplied to a vehicle s electrical system must never exceed 16 0 volts This voltage must not be exceeded when the ignition switch is in the OFF A...

Page 157: ...normally present around the battery 8 Reverse above procedure when removing the jumper cables Towing Instructions WARNING To prevent property damage personal injury and or death always install wheel...

Page 158: ...s becoming unintentionally detached from the vehicle CAUTION To prevent transmission damage vehicles should not be towed even short distances without suspending rear wheels or removing the axle shafts...

Page 159: ...d the Parking Brake knob to release the parking brake If battery power has been lost the Parking Brake cable will have to be disconnected by following the steps below see illustration CAUTION To preve...

Page 160: ...he differential and the transmission If axle shaft is not disconnected remove the rear axle shafts from the axle assembly Cover the wheel hub ends to prevent loss of axle lubricant and entrance of con...

Page 161: ...emicals used to clean or disinfect your IC Bus can adversely affect materials used to build the vehicle Many common cleaning chemicals can damage or ruin the appearance of materials like ABS plastic v...

Page 162: ...damage 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 is frequent and thorough cleaning...

Page 163: ...n 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 caus...

Page 164: ...r 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 dete...

Page 165: ...e 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 w...

Page 166: ...ulate in low spots creating a fire hazard Propane can also displace oxygen creating a suffocation hazard Propane systems should be serviced in a properly ventilated area WARNING To prevent property da...

Page 167: ...T use bumper as a lifting point 5 Support vehicle with floor stands under axle s If axle or suspension components are to be serviced support vehicle with floor stands under frame side members Pre Trip...

Page 168: ...ds the use of Fleetrite lubricants and IC Bus original equipment parts The lubrication intervals specified should be performed at whatever interval occurs first whether it is kilometers miles hours or...

Page 169: ...ined by the 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...

Page 170: ...eed 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 d...

Page 171: ...window as intended In situations where the window 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...

Page 172: ...ion All new IC Buses are manufactured with non asbestos brake linings However exposure to excessive amounts of brake material dust may be a health hazard WARNING To prevent vehicle damage personal inj...

Page 173: ...ith 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...

Page 174: ...ush 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 bas...

Page 175: ...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...

Page 176: ...e an exact maintenance interval time or mileage since vehicles are used in a variety of applications and conditions Refer to the LUBRICATION AND MAINTENANCE INTERVAL CHART later in this section for re...

Page 177: ...rake Fluid Accumulators WARNING To prevent property damage personal injury and or death since the brake system is under high pressure it should only be serviced by qualified personnel in accordance to...

Page 178: ...y Too much grease will not allow air to escape from the connection and this compressed air will push the connection apart Accessory Feed Connections WARNING To prevent property damage personal injury...

Page 179: ...L LPG 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 fil...

Page 180: ...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 a...

Page 181: ...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...

Page 182: ...or rain Temporary high restriction can occur during a rain or snow storm and it disappears after drying out COLD AIR MAY BE SO DENSE THAT HIGH RESTRICTION MAY NOT REDUCE ENGINE POWER BEFORE ELEMENTS...

Page 183: ...lant slowly with the engine running Adding cold coolant to a hot engine may crack the cylinder head or crankcase Never use water alone Make sure that coolant level is maintained between the COLD MIN a...

Page 184: ...ooling 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 7 Install the deaeration tan...

Page 185: ...ed to maximize hose life maintain performance of the system and avoid potential failures Poorly maintained coolant is cause for hose failure Coolant level and condition should be inspected on a regula...

Page 186: ...additional failures Engine Oil NOTE Use only recommended viscosity engine oil Refer to the Engine Operation and Maintenance Manual for specific engine oil specifications The PSI 8 8L LPG engine requi...

Page 187: ...priate cold warm months for greatest passenger comfort Maintain heat exchanger air filters if equipped The driver s heater filter is located behind the grille near the floor to the left of the driver...

Page 188: ...ght NOTE When retorque is required make sure the part is in like new condition If it can t be retorqued then the part needs to be replaced Suspension alignment must be maintained at all times Check th...

Page 189: ...ins and tightness of nuts at both ends of tie rod and drag link Check that pitman arm steering arm at steering gear mounting is tight and locked Check the power steering system for leaks or hose chafi...

Page 190: ...tem before returning the vehicle to service Failure to properly bleed the hydraulic system can result in shimmy complaints and or steering wheel oscillation when striking a bump Consult your IC Bus de...

Page 191: ...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 transmi...

Page 192: ...ways use experienced trained personnel with proper equipment and correct procedures to mount or remove tires and wheels WARNING To prevent property damage personal injury and or death always follow th...

Page 193: ...n 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 infla...

Page 194: ...by a repair These indicate the start of internal separation Any cut that reaches to the belt or ply cords or any cut that is large enough to grow in size and depth Any nail or puncturing object If an...

Page 195: ...tern Drive axle tires may be placed on the other end of the same axle so that direction of rotation is reversed This is often helpful if a heel and toe or alternate wheel nut wear pattern has develope...

Page 196: ...may be rotated to a drive axle Chamfer or Shoulder Wear with tires inflated properly is a normal tendency of most radial tire designs If both inside and outside shoulders are wearing evenly around the...

Page 197: ...bricant should be used as an aid for mounting tires Always inflate tires in a safety cage WARNING To prevent property damage personal injury and or death Do not mix stud piloted wheels or fasteners wi...

Page 198: ...to the wheel Tightening procedure for disc wheels with flange nuts hub piloted 1 Clean the mating surfaces of the hub drum and wheel s as well as the wheel studs and wheel nuts with a wire brush prior...

Page 199: ...uts To correct this condition operate the vehicle normally for approximately 80 km 50 miles then use a calibrated torque wrench to retorque the wheel nuts to specification using the appropriate patter...

Page 200: ...e wiper arm to the drive stud Remove the wiper arm from the drive stud by pulling the wiper arm outward Installation 1 Align the marks at the base of the wiper arm assembly and the drive stud boot 2 I...

Page 201: ...re 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...

Page 202: ...performed at Special Intervals or in addition to A or B Service when the interval dictates Lubrication and Maintenance Interval Bus Recommended Synchronized Intervals System Item Intervals Special Int...

Page 203: ...or worn Inspect B Electrical Power Distribution Center Corrosion throughout case and on pins of fuses and breakers Inspect B Power Steering Fluid Check Level A B Steering System Check Tightness A B S...

Page 204: ...heck A B Low Air Pressure Warning Alarm Check A B Air Tanks all Drain Water A B S Cam Bushings Lubricate A B Shoes Check for wear and drag A B Rotors Drums Calipers Chambers Hoses etc Check for wear d...

Page 205: ...Check A B Brake Pedal Holds Pressure Check A B Service Brakes Operation Check A B Parking Brake Operation Check A B Discs Calipers Lines etc Check for wear damage A B Parking Brake Cable Check condit...

Page 206: ...nance Manual Air Induction System Check looseness leaks Refer to Engine Operation and Maintenance Manual Air Filter Replace Refer to Engine Operation and Maintenance Manual Engine Oil and Filter s Rep...

Page 207: ...d Filter s Replace Allison 1000 PTS Spin On Control Main filter with any fluid first 8 000 5 000 _ With mixed conventional and Synthetic Trans fluid for Main or Lube Aux filter every 80 000 50 000 24...

Page 208: ...50 000 4 000 48 Conventional or Conventional Synthetic Mixed Automatic Trans Fluid Replace Allison MD 40 000 25 000 1 000 12 Allison 1000 PTS 80 000 50 000 24 Allison 2000 80 000 50 000 24 Transmissio...

Page 209: ...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...

Page 210: ...dal Check Function A B Entry Door Check Operation A B Emergency Doors Exits and Buzzers Check A B Roof Hatch es Check Operation A B Lights Interior Exterior Check A B Headlights Bright Dim Daytime Che...

Page 211: ...l and All Heater Core Air Filters Inspect Clean or Replace A B Air Conditioner Optional Check Performance B All Seat Base Bolts B Body Mounting Bolts Inspect Tightness At 1 600 km 1 000 miles then eve...

Page 212: ...ific engine crankcase capacities refer to separate Engine Operation and Maintenance Manual provided with vehicle Full Power Brakes Brake Fluid Approximately 6 Liters 1 6 Gallons Rear Axle Table 17 Axl...

Page 213: ...Automatic B 300d 14 29 Table 19 Transmission cont Transmission Model Transmission Fluid Volumes Liters Pints Allison Automatic 1000_PTS 18 38 Allison 5 Speed Automatic 2100 PTS 18 38 Allison Automatic...

Page 214: ...9R22 5 6 75 7 50 10R22 5 6 75 7 50 11R22 5 7 50 8 25 12R22 5 8 25 9 00 225 70R19 5 6 75 Table 20 Approved Tire and Wheel Combinations cont Tire Size Rim Width 235 80R22 5 6 75 7 50 245 70R19 5 6 75 7...

Page 215: ...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 Eaton Dana axle multipurpose EP gear lube of API GL 5 quality meeting MIL PRF 21...

Page 216: ...0 F and 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...

Page 217: ...te 472141 C1 Connectors Dielectric Grease NYOGEL 760 G Steering Power Steering fluid change Fleetrite P N CH990625C2 Strg Gear Ross TAS Output Seal Lubricate Fleetrite Lithium Complex Based Moly greas...

Page 218: ...te 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 B...

Page 219: ...trite P N 991884C1 SAE 50 All Temperatures Eaton Fuller UltraShift WetClutch Synthetic Castrol TranSynd or TES 295 Gear Box EmGard 2979 All Temperatures SAE 50 All Temperatures Eaton Dana Synchronized...

Page 220: ...s Recommended for highest transmission durability and lowest maintenance costs Allison Conventional Automatic Transmission Fluid ATF Fill Change Meets the requirements for Allison TES 389 specificatio...

Page 221: ...ve 26 C and above 90W 10 F to 100 F 12 C to 38 C 85W 140 10 F and above 12 C and above 140W 40 F and above 4 C and above Meritor Synthetic from factory with Cognis Emgard 75W 90 will have a tag attach...

Page 222: ...0 678 450 500 NOTE Do not use lubrication on dry threads Where excessive corrosion exists a light coat of lubricant on first three threads of stud bolt is permitted Keep lubricant away from Hex nut Fl...

Page 223: ...rnational Air Suspension IROS for all other axles 502 542 370 400 23 000 lb Capacity International Air Suspension IROS for axles 14ADN 14ADP 14AJC 14AJE 14ATP and 14ATR 353 407 260 300 14TBT 23 000 lb...

Page 224: ...Wiper Pivot M20 Hex Nut 28 21 Seat Base Bolts Specified Torque N m Lb ft All Seat Base Bolts 21 7 to 27 16 to 20 Filter List Filter part numbers and or specifications may change during the life cycle...

Page 225: ...e PortalSM Web site or via the OnCommand Service Information DVD Information on the Service PortalSM Web site s content availability and fee structure can be obtained by contacting your local Internat...

Page 226: ...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 de...

Page 227: ...engage Air Parking Brake 120 A CONT Air Brakes cont To release Air Parking Brake 120 Air Cleaner Element Service 168 Air Conditioner Refrigerant 200 Air Disc Brakes 0004JBZ 0004JCC 0004WEY 0004WEZ 119...

Page 228: ...rque Chart 211 Axles 158 Body 160 Front Axle Alignment 159 Front Axle Inspection and Lubrication 158 Front Axle Normal Maintenance 159 Rear Axle Inspection and Lubrication 159 B Backup Alarms 130 Body...

Page 229: ...Rear View 8 CE Bus Right View 9 CE White Integrated Child Restraint Seats Optional 92 Chassis Fuse Circuit Breaker Chart 136 C CONT Chassis Inspection 165 Chassis Lubrication 155 Chassis Mounted Char...

Page 230: ...e Door Adjustment 158 Electronic Safety Messages 69 Emergencies While Filling With Propane Autogas 113 Emergency Door 77 E CONT Emergency Equipment Recommended On Board 133 Body Fluid Cleanup Kit 134...

Page 231: ...rior Lamp Check 66 Activation 66 Deactivation 66 Function 66 Switch Location 66 F Fan Clutch 173 Filling Instructions 171 Filter List 212 Fire Extinguisher 133 First Aid Kit 134 First Respondent and O...

Page 232: ...Replacement Guide 173 Heater Booster Pump 106 H CONT Heater Cut Off Valve 106 Heater System 103 175 Auxiliary Heaters 104 Driver Heater 103 HI LO Beam 65 High Restriction Reading Table 170 Horn 49 Hot...

Page 233: ...ass Displays Optional 37 Outside Temperature Reading 38 User Switches 44 I CONT Instrument Panel Gauge Cluster cont Warning Indicators 24 Integral Digital Display 28 Integral Digital Display Detailed...

Page 234: ...d Maintenance Interval Bus Recommended Synchronized Intervals Table 190 Lubrication Points 177 M Maintenance Guidelines 153 M CONT Maintenance Intervals 189 Lubrication and Maintenance Interval Chart...

Page 235: ...nchor Optional 94 Passenger Three Point Seat Belts Optional 86 39 Inch Flex Seat 88 Buckling Up 86 Unbuckling 87 Passenger Two Point Seat Belt Lap Belts 86 Passenger Three Point Seat Belts Optional 86...

Page 236: ...le 183 Tire Replacement 183 Rotation Is Advisable 183 S SAE Oil Viscosity Grades 174 Safety Recalls and Authorized Field Changes 5 Scheduled Maintenance 167 Seat Base Bolts 212 Seat Belt Cutter 85 Sea...

Page 237: ...tem Function 73 System Purpose 73 T Terminal Inspection Cleaning Corrosion Protection 166 Tether Adjuster Procedure 83 Three Position Door Switch 68 Tightening Steering Intermediate Shaft Joint Bolts...

Page 238: ...Fluid Level 179 Transmission Table 201 Transmission Fluid Level 179 Transmission Table 201 Transmission Parking Brake and Ignition Switch Panel 54 Troubleshooting 169 Turn Signal 48 Turn Signal Switch...

Page 239: ...ft Interlocks Retracting and Stowing 75 Wheelchair Lift Operation 75 Wheelchair Lift Alarm 76 W CONT Wheelchair Lift Operation cont Wheelchair Lift Interlocks Extending 75 Wheelchair Lift Interlocks R...

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IC Bus CE Series, Operation And Maintenance Manual

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