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Engine

03

Engine/Transmission Installation

If any of the components mounted on the power plant were removed for maintenance, refer to the ap-

propriate chapter of this manual for installation instruction. Install all components on the engine and

transmission package at this time.

1. Adjust the bell housing cradle to center.

2. Adjust the rear adjustment screws so that the engine/transmission assembly is level from left to

right and tipped down toward the front by 3.5 degrees.

3. Center the engine/transmission assembly between the chassis frame rails and roll the dolly for

-

ward until the rear edge of the rear engine support is in line with the rear edge of the chassis rail.

4. Bolt the rear engine support to the engine mounting braces. Tighten the bolts to 110 - 125 ft-lb

(150 - 170 N-m). Move the engine dolly upper platform up or down as required.

5.  Install the bell housing bushing bolts. Tighten the bolts to 110 - 125 ft-lb (150 - 170 N-m).
6.  Install the transmission tail support if applicable.
7.  Install the bushing bolt and tighten. Tighten the bolts to 110 - 125 ft-lb (150 - 170 N-m).
8.  Lower the upper dolly platform and remove the dolly.

9. Tighten all mounting bolts in accordance with the Torque Chart in the Specifications Section of

this manual.

10. Connect or install all items removed or disconnected in steps 6 through 22 in the power plant

removal procedure above.

11. Refill the cooling system as instructed in this chapter.
12. Attach the ground cable to the battery and put the battery cutoff switch into the “ON” position.
13. Start the engine and check for leaks at all connections.

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Содержание LOW FLOOR

Страница 1: ...anual Hampton Roads Transit Chassis Numbers 77621 77660 Coach Numbers 2000 2039 Customer Name Click here to go to the Table of Contents Click here to go to the Index Click here to go to the Maintenanc...

Страница 2: ...ecifically for the coaches whose serial numbers are designated on the cover of the manual The customized services outlined may not be appropriate for other Gillig coaches which are not included in the...

Страница 3: ...eral Information 19 Introduction 19 Important Safety Information 19 Bus Operation 22 Jacking and Towing 29 Supporting the Coach on Jack Stands 30 Towing Instructions 31 Driveshaft Removal 34 Axle Shaf...

Страница 4: ...r 86 Surge Tank 89 Air Intake System 90 Exhaust System 93 Engine Removal Installation 98 Drive Belts 104 Engine Diagnostics 109 Chapter 4 Transmission Driveline Rear Axle 111 Transmission 111 Operatio...

Страница 5: ...End Alignment 168 Front Axle Troubleshooting 172 Steering Column 174 Chapter 6 Air System 183 Air System Operation 183 Suspension Air System Operation 186 Kneeling System Operation 188 Door Control O...

Страница 6: ...gular Scheduled Maintenance 247 Rebuilding the Air Dryer 249 Air Dryer Troubleshooting 254 Air System Condenser Separator 257 Chapter 7 Brakes Wheels 261 Hazardous Material Warning 261 Brake System 26...

Страница 7: ...it Valves 306 Spool Valve 306 PWM Fan Control System 308 Hydraulic Fan Motor 309 Troubleshooting the Fan Motor Circuit 310 Fan Motor Removal 312 Fan Motor Inspection and Repair 313 Hydraulic Pump 315...

Страница 8: ...e 352 Jump Starting with a Booster Battery 353 Battery Equalizer 356 Equalizer Troubleshooting 358 Equalizer Replacement 359 EM70D Electrical System Monitor 361 Charging System 363 Alternator 363 On V...

Страница 9: ...ing Air Conditioning 429 Passenger Heating and Air Conditioning 429 System Control 432 Driver s Heater and Defroster System 433 Booster Pump 433 Auxiliary Coolant Heater Optional 441 Chapter 11 Body a...

Страница 10: ...10 Table of Contents Windows 479 Windshield 479 Driver s Side Window 481 Window Removal 482 Emergency Egress Windows 483 Driver s Seat 485 Passenger Seating 496 Index 499...

Страница 11: ...to be sure that they have the most current in formation available before performing the job If there are any questions regarding the values supplied in this specifications listing contact the Gillig...

Страница 12: ...accompanying OEM manuals use the most up to date standard S A E torque values Always use bolts and nuts with the same torque values and strength made of the same material and treated plated with the s...

Страница 13: ...e the Gillig specified torque value by this sum Now multiply the result by Distance A The new torque which you will set on your torque wrench should be less than the Gillig specified torque For exampl...

Страница 14: ...man Arm Nut 200 250 271 339 Drag Link to Steering Arm Nut 200 250 271 339 Steering Gear Mounting Bolts 7 8 14 490 510 664 692 Steering Gear Mounting Bolts 3 4 16 290 310 393 420 Refer to the Meritor M...

Страница 15: ...Seize Torque Range ft lbs w o Anti Seize Upper and Lower Torque Rods to Chassis 5 8 18 Phos Oil 8 Cadmium TS w Wax C 115 5 145 5 Upper Torque Rods to Axle Bracket 5 8 18 Phos Oil 8 N A N A 200 5 265...

Страница 16: ...l 20 qt 19 L High 16 qt 15 L Low All Seasons above 14 F 15W 40 API Category CI 4 For winter and arctic conditions see Oil Viscosity in Chapter 3 Engine Engine Coolant 15 gal 57 L dry fill including ho...

Страница 17: ...proved Depends on viscosity Refer to the viscosity grades listed above Petroleum with Semi Synthetic Base Oils and EP additives 80W 90 O76 P Above 15 F 26 C Fully Synthetic Base Oil and EP additives 7...

Страница 18: ...Specifications 18...

Страница 19: ...damage to the equipment or unsafe operating conditions It is important to understand that these messages do not cover every possible situation Gillig Corporation could not possibly know and evaluate...

Страница 20: ...ransmission or attached components Disconnect all batteries before servicing the electrical system Stay clear of all moving parts and do not wear loose clothing or jewelry while servicing the bus Reli...

Страница 21: ...ostly failures For example a low cost switch could result in a high cost fire a low cost filter could result in a high cost transmission rebuild Please remember that parts of lesser quality often fail...

Страница 22: ...isor and when authorized follow these steps to reenter the bus 1 Be sure that the parking brake is applied If you can see the black band at the base of the park ing brake switch the parking brake is a...

Страница 23: ...the ignition select switch to the appropriate run position Press the Engine Start button 7 Check the indicator lamp strip to verify that the WARNING INTERLOCK DEACTIVATED indi cator is not illuminate...

Страница 24: ...t try to start the engine until this lamp goes out This should take about 25 seconds NEVER use starting fluid of any type on the Cummins ISL engine This engine has an intake air heating grid element w...

Страница 25: ...ine down immediately and begin troubleshooting If the oil pressure gauge reads zero after 15 seconds or Check Engine and or Stop Engine indicator lamps remain lit after startup shut the engine down im...

Страница 26: ...temperature it will automatically shut down the engine The Stop Engine indicator lamp Figure 1 4 along with an alarm sound will activate when the automatic shutdown sequence has started Other lamps su...

Страница 27: ...minutes before shutting it down This allows engine parts to cool properly The front doors will automatically close when the ignition is turned off with the DoorAir lever in the NORMAL position An ala...

Страница 28: ...l steps when this hap pens To avoid automatic door closure and its alarm put the Door Air lever in the RELEASE position before turning off the ignition This will ensure that the front doors stay open...

Страница 29: ...lat surface before jacking 2 Shift the transmission into Neutral apply the parking brake and shut down the engine 3 The floor jack must be located properly to prevent the possibility of the jack slidi...

Страница 30: ...it is inconvenient to use the rear suspension points on the H frame for example if you re working on the rear suspension use FOUR jack stands one at each of the following frame points two stands at G...

Страница 31: ...g lifted by the towing equipment unless the coach is properly blocked and supported The Gillig Low Floor should never be towed more than a few feet without first disconnecting the driveline An auxilia...

Страница 32: ...BRT Buses FORWARD Front Bumper Channel Figure 1 8 Gillig Fixed Tow Bar for Standard Low Floorsssss 32 2 47 5 max 3 7 19 5 6 9 Figure 1 11 BRT Tow Bar Ground Clearance and Towing Height Figure 1 10 Inc...

Страница 33: ...d the front axle must be securely chained so that the shock absorbers and air springs are not damaged Chain the front axle as follows 1 Support the frame securely with blocks or jack stands 2 Make sur...

Страница 34: ...STRAP BEARING CUP GREASE PLUG Driveshaft Removal The driveshaft is very heavy Be careful when removing it 1 Remove retaining screws and bearing straps on one U joint See Figure 1 13 2 Slide drive shaf...

Страница 35: ...he center of the flange with a lead hammer to loosen the flange and dowels from the studs Figure 1 14 An alternative method is to use a large hammer 5 to 6 pounds against a 1 5 brass drift or a 1 5 br...

Страница 36: ...ect the battery ground from the voltage equalizer 3 Disconnect the battery cables from the batteries 4 Disconnect the power connectors from the ECU s and electronic equipment ABS engine transmission I...

Страница 37: ...or extended coverage applicable to the vehicles in this build refer to the VIN s shown on the cover page may be different items covered and or durations For details of the actual coverage of these bus...

Страница 38: ...he attached GILLIG is obligated under this agreement and as an agent of those manufacturers to resolve any disputes and be responsible to ultimately ensure compliance with the terms stated herein Howe...

Страница 39: ...anufactured or assembled components and systems as well as some purchased assemblies Warranty and coverage provided by GILLIG Coverage Period 1 Months Miles COACH WARRANTY 2 3 7 12 50 000 BODY STRUCTU...

Страница 40: ...systems or special options 3 Fleet defect coverage is for a maximum of 12 months or 50 000 miles and includes all components and assem blies on the vehicle 4 Basic body structure warranty includes an...

Страница 41: ...s chapter of this manual for fluid and lubricant specifications fastener torque figures and other information Adjusting Maintenance Intervals The mileage figures given in the Maintenance Schedule are...

Страница 42: ...problem 3 Inspect the drive belts Look for cracking tears burns etc on the alternator and air condition ing belts Refer to the Engine chapter for complete belt inspection instructions 4 Inspect the t...

Страница 43: ...ts one slip shaft NLGI 2 EP Grease 8 000 2 Brake Camshaft Bushings Four fittings one at each wheel end NLGI 1 or 2 MP Grease 50 000 3 Slack Adjusters Four fittings one at each wheel end NLGI 1 or 2 MP...

Страница 44: ...to approved specification 4x year if equipped with grease fittings lube intermediate column u joints and slip joint At each lube cycle tighten hose clamps and inspect all hydraulic hoses and connectio...

Страница 45: ...000 miles Check coolant SCA concentration level Every 15 000 miles Replace coolant filter Every 15 000 miles Check charge air cooler for leaks Every 24 000 miles Replace standard secondary fuel filte...

Страница 46: ...t fasteners and straps Every 12 000 miles Transmission Voith Mineral Based Transmission Fluid Change transmission fluid and filter First at 2 500 miles Second at 11 500 miles Then every 36 000 miles S...

Страница 47: ...mtg plate Every 25 000 miles Test brake valve operation check for leaks Every 25 000 miles Inspect air compressor lines Every 42 000 miles Check compressor discharge and inlet for carbon Every 42 000...

Страница 48: ...or wear and damage Every 24 000 miles Check shocks and bushings for leaks and wear Every 24 000 miles Check for proper ride height Every 24 000 miles Check for loose or damaged mounting parts Every 24...

Страница 49: ...0 000 miles Drive Axle 71163 Check gear oil in drive axle Every 5 000 miles Change gear oil in drive axle City Service Every 25 000 miles or annually whichever comes first City Service with Synthetic...

Страница 50: ...heck for system error codes engine trans ABS com fault etc Daily Check interior lights and hazard lights operation Daily Check throttle and brake pedal for dirt debris corrosion and function Every 6 0...

Страница 51: ...k battery electrolyte level and connection torques Every 12 000 miles Test with Midtronic tester per manufacturer s procedures Every 12 000 miles Check voltage regulator settings Every 24 000 miles Se...

Страница 52: ...y 6 000 miles Inspect all electrical connections inside of return air Every 6 000 miles Remove cables reapply Kopr Shield and re torque cables and fuses Every 36 000 miles Remove cables reapply Kopr S...

Страница 53: ...torque cables Every 36 000 miles Front Main I O Panel Inside Inspect power and ground cables fuses and circuit breakers Every 6 000 miles Re torque cables Every 36 000 miles Exit Door I O Panel Inspec...

Страница 54: ...ur city county or state uses magnesium chloride as a de icer it is ESSENTIAL that the underbody and engine compartment be washed and inspected frequently Gillig does not warrant its vehicles structure...

Страница 55: ...s related bearings and spring pins Every 6 000 miles Check drive train sprockets and idler pulleys Every 6 000 miles Check stow latch mechanism and solenoid linkage Every 6 000 miles Check stow proxim...

Страница 56: ...ine Every 18 000 miles Check clutch air gap X426 X430 only Every 18 000 miles Check evap heater blower condensor fan motor speed voltage amps Every 24 000 miles Lubricate evaporator fan shaft bearings...

Страница 57: ...es Visually inspect engine coolant hose hose clamp on heater coil system Every 48 000 miles Clean condensor evaporator coils Every 48 000 miles Check engine coolant for antifreeze protection down to 3...

Страница 58: ...Preventive Maintenance 58...

Страница 59: ...king in the engine compartment always locate read and understand all warning decals Engine Oil Proper maintenance includes the use of proper oil checking the oil level daily and following the pre scri...

Страница 60: ...s The use of low viscosity oils can aid in starting the engine at ambient temperatures below 23 F 5 C However continuous use of low viscosity oils can decrease engine life due to wear Always use the h...

Страница 61: ...hange Intervals Refer to the Preventive Maintenance chapter for the recommended oil and oil filter change interval More frequent intervals are recommended if any of the following severe operating cond...

Страница 62: ...r element if necessary at this time Refer to the Replacing the Oil Filter section which follows this section 6 Add 20 quarts of oil through the engine oil fill tube in addition the filter should have...

Страница 63: ...6 Thread the new element onto the filter header and tighten it by hand until the seal touches the adaptor filter head Hand tighten one full turn after contact is made Do not use any tools to tighten...

Страница 64: ...tiometer to regulate the flow of fuel to the engine Whenever interlock is triggered by activation of coach doors fast idle the lift master power switch or the kneeling system the service brakes are au...

Страница 65: ...the coach has been in operation long enough to reach normal operating temperatures 180 F to 190 F use extreme caution when removing the engine pan drain plug and filters as serious burns can result 1...

Страница 66: ...he outer edge of the turbine base Slide a new centrifuge bowl K over the stem and seat uniformly over the bowl seal Install and tighten the knurled bowl nut H securely using finger pressure only 7 Ins...

Страница 67: ...sembly 73236 includes items H K L M N and U E Housing assembly 73233 S Repair kit idle cut out valve 7 053 T Seal idle cut out valve 7 054 G Control mechanism assembly 70675 Screw hex head cap control...

Страница 68: ...l depending on oil type oil change interval engine type and condi tion and operating conditions Oil additive package design will affect soot size and thus the amount of carbon and soot collected in th...

Страница 69: ...he oil inlet port on the left side Replace the seal and retighten bolts Continue from Step 3 above Oil Line Connections Disconnect leaking hose and remove hose adapter from port Clean threads in port...

Страница 70: ...is another danger to the fuel system of a diesel engine Algae can clog the fuel filters and injector nozzles Since algae must have water to survive it is important to keep water out of the fuel system...

Страница 71: ...d from the primary filter on a daily basis Drain no more than about 4 oz to avoid having to re prime the engine See Chapter 2 Preventive Maintenance for filter change intervals Primary Fuel Filter Ele...

Страница 72: ...n the high pressure fuel system with the engine running Engine operation causes high fuel pressure High pressure fuel spray can cause serious injury or death 1 Turn on the ignition switch which will c...

Страница 73: ...lter 3 Remove the fuel filter thread adaptor sealing ring 4 Clean the gasket surface of the filter head 5 Install the new thread adapter sealing ring supplied with the new filter 6 Do not add fuel to...

Страница 74: ...ection only enough to stop the leak On the engine flexible metal shielded Teflon lines are used between the fuel filter and the fuel pump to minimize damage caused by vibration Fuel Check Valve Depend...

Страница 75: ...ave warranty implications Please consult your Cummins service representative your fuel supplier and your local BPA before using biodiesel fuel Never mix gasoline gasohol or alcohol with diesel fuel Th...

Страница 76: ...REME CARE WHEN DOING ANY WORK ON THE FUEL SYSTEM Only qualified personnel should attempt to work on or repair the fuel system Figure 3 7 Fuel Tank 6 4 5 2 3 Emco Wheaton Fuel Fill Neck Pressure Relief...

Страница 77: ...ews securing the valve to the fuel tank 3 Remove the valve assembly and gasket 4 Clean old gasket material from the level control valve mounting surface on the fuel tank 5 Position a new level control...

Страница 78: ...k Installation 1 Install the drain plug in the bottom of the fuel tank and tighten it securely 2 If the control valve and or whistle were removed replace them as directed in the appropriate procedure...

Страница 79: ...river heater defroster and passenger heating systems Refer to the Climate Control chapter in this manual for information about heating system coolant circulation Coolant Specifications The proper cool...

Страница 80: ...emix the coolant solution in a container of sufficient size in the following order a Soft clean water b Antifreeze ethylene glycol or propylene glycol c Supplemental coolant additive Do not pour conte...

Страница 81: ...ter shutoff valves Figure 3 8 3 Remove the filter using a filter wrench strap Note The coolant filter header is equipped with check valves which prevent coolant from draining out of the engine when th...

Страница 82: ...it until boiling stops and the engine has cooled before pressing the relief valve 1 Press and hold the relief valve vent cock at the surge tank to relieve pressure from the system 2 When all pressure...

Страница 83: ...top off the water cleaner solution 4 Turn the heater temperature switch to HIGH to allow maximum coolant flow through the heater core The fan does not have to be on 5 Start and run the engine for the...

Страница 84: ...cifications Take into consideration the concentration of additive supplied by the coolant filter when determining how much liquid additive to add to the coolant mixture d Mix the water antifreeze and...

Страница 85: ...ion such as oleum and water to remove heavy dirt accumulations from the radiator and core Inspect and repair bent radiator fins Repair all cooling system leaks as soon as they are detected Refer to th...

Страница 86: ...through the upper piping circulates through the core and returns to the engine through the lower piping The radiator assembly consists of three components the engine coolant radiator the charge air co...

Страница 87: ...and mounting bolts 4 Lower the radiator to clear the top of the door opening and rotate it sideways enough to fit through the radiator access door Using a suitable lifting device the radiator may now...

Страница 88: ...road oils brake lining mud and tire rubber carbon black b Spray the core with solvent until the fin louvers are free of dirt c Wash and air dry Repaint if necessary 2 Waterside Cleaning interior of ra...

Страница 89: ...areful not to damage the threads on the edge of the glass Surge Tank Removal 1 Relieve system pressure using the manual pressure relief valve 2 Drain the cooling system to a level below the level of t...

Страница 90: ...lamps which are damaged or broken 4 Inspect the air induction hoses for holes or leaks 5 Check for loose broken or missing mounting brackets Air Cleaner Troubleshooting Attempt to determine the exact...

Страница 91: ...uld be checked daily with the engine run ning at FAST IDLE If the window in the indicator is RED the normal color is green the Air Filter Element requires replacement Do not replace the Air Fil ter El...

Страница 92: ...10 5 N m torque 5 Reset the air restriction indicator by depressing the button on the top of the indicator Verify that the color in the window of the indicator is GREEN Air Cleaner Assembly Removal 1...

Страница 93: ...of the engine turbocharger refer to the appropriate section of the engine manufacturer s service manual furnished with the coach Maintenance All joints and clamps in the exhaust system should be routi...

Страница 94: ...ve installation indicator matches the step on the exhaust clamp 1 Refer to Figure 3 13 Position the band clamp over the smallest tube The larger end of the clamp must be on the overlapping tube or fle...

Страница 95: ...vy Carefully remove the muffler from the coach through the muffler access door opening Muffler Installation 1 Position the muffler inside the rear cap with the lower mounting brackets aligned with the...

Страница 96: ...then remove the elbow 3 Remove the band clamp that attaches the pipe to the turbocharger outlet adapter 4 Remove the nuts from the U bolts that secure the pipe to the mounting brackets on the engine...

Страница 97: ...nded state Stretch tubing so that tape label is tight making sure arrows on the tape are pointing in the direction of exhaust flow see Figure 3 15 Remove the tape after installing clamps Figure 3 15 F...

Страница 98: ...ut the particular discon nects Identify and tag each item as it is disconnected to aid in identification at installation time Perform the following steps to remove the engine transmission 1 It is not...

Страница 99: ...switch and the neutral start leads at the transmission 19 Disconnect the oil pressure sending unit lines at the manifold block near the transmission 20 Remove the rear bumper and mounting brackets 21...

Страница 100: ...personnel If the engine transmission assembly is left on the dolly the upper platform must be lowered to its lowest position The following instructions are for the Gillig supplied dolly Refer to Figur...

Страница 101: ...emove the bell housing bushing bolts and chassis mounted support brackets 10 Remove the transmission tail support bushing bolt if installed 11 Remove the rear support angle from the chassis rails 12 R...

Страница 102: ...at may leak around the engine compartment This not only creates a fire danger see the Preventive Maintenance chapter for engine steam cleaning intervals but these fluids are also corrosive to the rubb...

Страница 103: ...rear engine support to the engine mounting braces Tighten the bolts to 110 125 ft lb 150 170 N m Move the engine dolly upper platform up or down as required 5 Install the bell housing bushing bolts Ti...

Страница 104: ...o excess use In any case the belt must be replaced and re tensioned This does not indicate any defect caused during manufacturing Belts may fail after three 3 or four 4 seasons of use due to fatigue S...

Страница 105: ...edge in a belt can be caused by a dam aged pulley or from interference with some part of the coach Check the condition of the pulleys Make sure the belt does not rub on any part of the vehicle while...

Страница 106: ...sing lumpy belts 20 100 x149 OK LUMPY BELTS Figure 3 25 Lumpy Belts OK 20 100 x144 INTERNAL CORD FAILURE Figure 3 26 Internal Cord Failure Improper Length It is possible that an improper length belt c...

Страница 107: ...loosely belts can slip heat burn grab or snap Many more belts fail from under tightening than from over tightening When operated too tightly belts can damage the engine by causing side loading on the...

Страница 108: ...A C compressor belt to between 200 300 lb The optimum setting for installing a new belt is close to 300 lb After installing a new belt run the engine for a few minutes The belt will loosen and the ten...

Страница 109: ...nition switch to the ON position 4 If no active fault codes are recorded both the CHECK ENGINE and the STOP ENGINE lamps will come on and stay on 5 If active fault codes are recorded both the CHECK EN...

Страница 110: ...Engine 110...

Страница 111: ...eneral Information chapter When replacing any component or attachment on the transmission or driveline use only replacement parts of the same or equivalent quality Using parts of lesser quality can re...

Страница 112: ...details Gear Selection Transmission gear selection is accomplished through the shifter control located in the driver console at the driver s left The control is a pushbutton pad with the gear range no...

Страница 113: ...onverter that also acts as a hydrodynamic brake retarder when the brakes are applied A three posi tion switch on the brake pedal operates a pump brake that slows the pump side of the converter This ca...

Страница 114: ...n Transmission fluid is an integral part of the unit and serves multiple purposes in the transmission The fluid transmits the driving force from the engine through the torque converter It also provide...

Страница 115: ...ace the clutch plates Glycol test kits can be used to detect antifreeze in the transmission fluid While generally reliable certain kits may produce positive test results because of additives used in s...

Страница 116: ...sections which follow before checking the fluid level of the transmission Always check the fluid level at least twice for each cold and hot check to ensure that an accurate dipstick reading is obtain...

Страница 117: ...e minute 3 Shift to D Drive and operate the engine for 5 10 seconds at idle 4 Shift to R Reverse and operate the engine for 5 10 seconds at idle 5 Repeat steps 3 and 4 twice 6 Shift to N Neutral and a...

Страница 118: ...00 800 RPM Do not allow dirt or foreign matter to enter the filler tube when checking fluid level or adding fluid to the transmission Before removing the dipstick clean around the end of the filler tu...

Страница 119: ...fluid the gauge is compensated for most accurate reading Note that the gauge will be fairly accurate with different fluids STAND BY When in standby mode top amber top green center green bottom green...

Страница 120: ...D Will illuminate when the oil level is above the top of the span of the top red LED bar or the oil level is below the bottom of the span of the bottom red LED bar for more than 32 seconds If the Chec...

Страница 121: ...red battery 24vdc b black ground c yellow Neutral 24vdc d Not used e white reset switch f brown Not used to rear run box wire harness to ft0650 transmission oil sensor interconnection cable FT2200 Po...

Страница 122: ...pproximately 180 F Because of this manual dipsticks will only give correct level readings when fluid temperature is close to either of these points The FT2200 is de signed to give temperature compensa...

Страница 123: ...nd shorter change intervals The transmission oil filter mounts in the transmission oil sump and there are no other external filters If there is evidence of engine coolant in the transmission fluid sys...

Страница 124: ...n the fluid The plug is accessible through the transmission pan drain hole 5 Examine the fluid for contamination A normal amount of condensation will appear in the fluid during opera tion 6 Inspect th...

Страница 125: ...he breather and the area around the breather at scheduled maintenance periods Transmission Fluid Cooler The transmission depends on an integral cooler also known as a heat exchanger to maintain a safe...

Страница 126: ...tions earlier in this chapter b Remove the transmission fill tube if it interferes with the transmission removal A significant amount of fluid may drain from the hydraulic lines when they are disconne...

Страница 127: ...engine output shaft for wear damage or burrs that could affect ease of installation 2 Inspect the engine to transmission mounting flange bell housing flange for raised metal burrs or gasket residue In...

Страница 128: ...engine Rotate the transmis sion to the left on a horizontal axis counterclockwise and then move it back toward the engine 4 Install the bolt to attach the transmission to the tail shaft support 5 Inst...

Страница 129: ...shifts and reverse ranges Stall Testing Stalling the Voith transmission more than 15 seconds will cause damage to the transmission and will limit warranties Stall Testing is defined by applying the se...

Страница 130: ...h end that transmits power from the transmission output shaft to the differential input shaft pinion shaft A slip joint permits the drive shaft to extend and retract in length as the differential asse...

Страница 131: ...p and down by hand to ensure the needle bearings are not worn to the extent that play is observed 3 Inspect the assembly to observe any wear torsion cracks or twisting damage to any component of the d...

Страница 132: ...uitable chassis grease Ensure that fresh grease is forced from the bearing caps 6 Reconnect the ground cable to the battery and unblock the coach Remove the Drive Shaft U Joint Refer to Figure 4 6 Whe...

Страница 133: ...match 2 Push the U joint into position in the yoke 3 Install the bearing straps locking tabs lock washers and capscrews Tighten the capscrews 3 8 24 to 38 48 lb ft 52 65 N m torque for full round yok...

Страница 134: ...anges Fill Meritor axles with Meritor specified lubricants only Lubricants and capacities are listed in the Specifications chapter Refer to Approved Rear Drive Axle Lubricants which you can access on...

Страница 135: ...also between the differential pinion gears and case The case halves are secured by cap screws and hardened washers The differential is supported in tapered roller bearings which accept both thrust and...

Страница 136: ...re for removal and installation of the axle shaft is applicable regardless of wheth er the axle assembly is removed or installed on the vehicle Axle Shaft Removal Wear safe eye protection Do not hit t...

Страница 137: ...ined end of the shaft into rear axle lubricant then insert the shaft into the housing guiding the splines into the side gear and at the same time align the flange holes with the hub studs When the stu...

Страница 138: ...Transmission Driveline Rear Axle 138...

Страница 139: ...em information is provided in the Air System chapter In Case of Suspension Failure The suspension system is designed for stability and will usually allow the coach to be driven even if spring failure...

Страница 140: ...y support the coach body by placing blocks or jacks under the frame rail The axle must also be supported either by the wheels or with a jack 2 Rear suspension only Place blocks or bottle jacks between...

Страница 141: ...ag for evidence of cracks punctures deterioration or chafing Replace the air bag if any damage is evident 2 Inspect the upper and lower retainers and the piston for cracks burrs or other damage All su...

Страница 142: ...height control valve link if disconnected Make sure the lever adjustment has not been changed For the rear connect the height control valve links the rear suspension uses two height control valves 7 B...

Страница 143: ...shing which are part of the shock absorber as sembly from the air spring mounting assembly Discard the upper mounting bushings and the remaining part of the lower mounting bushings Rear Suspension 1 S...

Страница 144: ...ing attachment Caused by incorrect application modification or mounting Warranty is void Problem Shock makes hissing noise but resistance is felt in both extension and compression This does not point...

Страница 145: ...er to allow insertion of the lower stud into the hole in the air spring mounting assembly Be sure to use a new rubber bushing on the mounting stud above the air spring mounting assembly 4 Place anothe...

Страница 146: ...m must have at least 80 psi in the accessory air tank Before adjusting the air spring height run the engine until the air gauge in the dash reads at least 110 psi or apply shop air until the gauge rea...

Страница 147: ...e is in the neutral position then tighten the link end clamp as described in Step 3 5 Check the air spring height at the rear suspension LH drivers side by repeating Step 4 above this time on the LH s...

Страница 148: ...up 45 for 10 seconds Air should flow to the air springs 4 Move control arm to neutral position The valve should shut off the air flow 5 Move the control arm down 45 for 10 seconds The air should exha...

Страница 149: ...rack in parallel lines when in operation This operation is performed at the factory and should not require service by the user The torque rods are also the means by which caster is adjusted Except for...

Страница 150: ...sure the old torque rod and adjust the new one to the same length Always perform a full suspension inspection and alignment after changing or adjusting torque rods including a check of caster wheelbas...

Страница 151: ...pension beams The suspension is connected to the chassis frame by four torque rods The air springs and shock absorbers form the other connecting points of the suspen sion and frame Two height control...

Страница 152: ...ommends that torque rods always be changed out in pairs Upper Torque Rod Removal 1 Support the axle in its present position 2 Remove the nuts and bolts that attach the rod end to the crossmember or fr...

Страница 153: ...emoving the suspension is hazardous Take all precautions to protect yourself from injury and the coach from damage Because no two shop environments are the same the instructions for removing and insta...

Страница 154: ...housing 10 Disconnect the four shock absorbers from the H frame as follows a Remove the nuts bolts and washers from the lower shock absorber mounts b Remove the shock absorbers from the H frame 11 Dis...

Страница 155: ...le to the H frame and tighten to the torque specified in Axle Suspension Torque Values in the Specifications chapter 2 Raise the coach a minimum of 4 feet as measured from the bottom of the wheels to...

Страница 156: ...ssis air system and check for proper ride height 15 Inspect all fasteners and axle alignment Rear Axle Alignment The rear axle must be kept perpendicular to the frame The rear axle alignment is set at...

Страница 157: ...suspension air system Listen for air leakage due to loose fit tings between air tank and air suspen sion or damaged air lines air springs or height control valve Apply a soapy solution to connections...

Страница 158: ...orber or shock absorber mounting bracket Reconnect loose parts and replace any defective parts Check the adjustment of the height control valves Air spring s worn out Replace Air spring s fail to full...

Страница 159: ...ble at www arvinmeritor com tech_library For technical support call 800 535 5560 Do not repair or recondition front axle components Damaged or out of specification components should be replaced All ma...

Страница 160: ...f the axle Excessive heat will weaken axle components Safety glasses should be worn to protect the eyes during axle replacement and repair Raise the front of the coach and block the frame securely to...

Страница 161: ...ed in Step 2 8 Disconnect the height control valve link from the mounting bracket Push the control arm of the valve down to let the air out of the air springs 9 Disconnect the air lines from the air s...

Страница 162: ...ecification adjust the ride height as explained in this chapter Make sure the lever adjusting nut is securely tightened when ride height adjustment is completed 11 Check for air leaks at the upper and...

Страница 163: ...y rattle or shimmy in any part of the steering system Make sure the steering column is properly aligned Steering Lubrication All lubrication fittings must be clean before applying lubri cant Ensure th...

Страница 164: ...ut shaft Use a proper puller if the arm will not come off of the sector shaft under hand pressure Pitman Arm Installation Axle and suspension fastener torque specifications are listed in the Specifica...

Страница 165: ...m and steering arm while tapping on the arm with a light hammer and using a heavy hammer as backing Push on the drag link to remove it Replace any drag link tube or end assemblies if they are damaged...

Страница 166: ...ront wheels or the pitman arm Use a torque wrench only DO NOT use an impact wrench 4 Make sure the threads on the stud and stud nut are clean and not damaged and are free from all foreign material on...

Страница 167: ...ter Box The TRW miter box on your coach is lubed for life with Dexron III No routine maintenance is neces sary Intermediate Shaft Maintenance The U joints and slip shaft of the steering intermediate s...

Страница 168: ...ing the equipment recommended in the Meritor manual Any variation from Meritor speci fications indicates a need for adjustment and or a replacement of any bad parts Consult the Meritor Maintenance Man...

Страница 169: ...m the end of the torque rod tube 3 Place the mouth of the clamp over a slot in the rod Always adjust the torque rods as a pair either upper or lower and in the same amount for each torque rod If you a...

Страница 170: ...a protractor with a level gauge against the bottom edge of a straight section of the frame rail near the chassis midpoint 3 Determine the angle at which the frame rail slopes from level Compute the ac...

Страница 171: ...m turning angle which is measured at the inner wheel during a turn is 45 degrees Use an accurate turning angle instrument to make correct angular measurements 1 Turn the steering wheel to the left unt...

Страница 172: ...rom turns Hydraulic system problems See Hydraulic System chapter No positive caster Check and adjust caster Steering column binding Check and repair U joints and support bearings Linkage ball sockets...

Страница 173: ...ring stops wrong See Hydraulic System chapter Worn king pins or bushings Worn missing seals and gaskets Replace seals and gaskets Incorrect lubricant Lubricate with specified lubri cant Axle not lubri...

Страница 174: ...gear input worm shaft and is connected by a second U joint secured by a clamp bolt and nut The steering column is mounted to a reinforcement bracket which is bolted to the steering column sup port bra...

Страница 175: ...Plate 27 Actuator Housing Bushing Asm 28 Spring Actuator Housing 29 Lock Pin Telescope 30 Spring Anti Rattle 31 Pivot Pin 32 Cam Actuator 33 Tilt Telescope Lever 34 Plate Disengaging 1 2 3 3 4 5 6 7...

Страница 176: ...such it is imperative that the instructions in this section are followed to the letter Failure to observe the procedures and instructions set out in this section may result in loss of steering All ca...

Страница 177: ...e lower spring cover 40 springs 41 42 and spring retaining rod 5 from lower bear ing housing 2 Remove button head stop screw 23 and internal lock washer 24 from main housing 18 assembly 8 Push wheel t...

Страница 178: ...the two pivot screws 19 loosely into the assembly Place a 1 2 inch dia by 3 inch long bolt and nut assembly between the support bracket flanges close to the bracket nuts as a tool to spread the suppo...

Страница 179: ...ole in the main housing assembly 18 and torque button head stop screw 23 and internal tooth lock washer 24 into stop screw hole to 15 20 ft lb 20 3 27 1 N m 6 Press in a new bearing 3 into each counte...

Страница 180: ...in housing assembly 18 with actuator cam ears over disengaging plate 34 raised tabs Use care that spring 30 does not eject from assembly 14 Assemble spring 28 into top of lock pin and assemble actuato...

Страница 181: ...33 is held in the up position the jacket and wheel tube assembly must be able to telescope to full up and full down position When tilt lever is held in the down position the jacket and wheel tube asse...

Страница 182: ...Suspension 182...

Страница 183: ...eaches 130 psi the air governor turns off the air compressor by supplying air pressure to the air compressor unloader system When the wet tank pressure drops to 110 psi the air governor turns the air...

Страница 184: ...personal injury resulting from contact with moving rotating leaking heated or electrically charged components 6 Never connect or disconnect a hose or line containing pressure it may whip Never remove...

Страница 185: ...ES STOP LIGHT SWITCH FRT AXLE SBM REAR VIEW DEL PORTS SUPPLY PORTS SUPPLY PORTS FRONT VIEW ABS PMV DCV QRV SERVICE RELAY VLV R 12DC ABS PMV ATC VLV optional GOVERNOR SCV FILTER REAR SHOP AIR FILL CONN...

Страница 186: ...The valves are actuated by the relative movement be tween the coach body and the axles Never get under the coach without first blocking the frame or placing the coach over a pit With the air springs d...

Страница 187: ...ng Brake Valve SR Interlock Solenoids Stop Light Switch Low Pressure Switches Double Check Valves Brake Valve Filter SCV Front Shop Air Connection Front Tow Connector Front Suspension Kneeling Valve M...

Страница 188: ...e switch in the KNEEL position the switch is spring loaded to return to the center OFF position When the switch returns to the center position the kneel ing system will stop exhausting air from the ai...

Страница 189: ...t the height control valve from refilling the suspen sion air bags Kneel or exhaust solenoid This solenoid when energized exhausts the air pressure in the suspen sion air bags which lowers the front s...

Страница 190: ...e close cylinder is evacuated At about 65 to 70 of the operating cycle the air flow is slowed to give a cushioning effect at the full open position of the door The open cylinder remains pressurized wh...

Страница 191: ...hield washer fill recess This pressurizes the large close cylinder of the door motor closing the doors Driver leaves the external valve in this position holding the doors closed with air pressure Driv...

Страница 192: ...Door Motor Close Spring Open Cylinder Solenoid Driver s Door Control Valve Optional External Door Open Valve located at windshield washer fill recess Accessory Air Tank Open Cylinder Close Cylinder En...

Страница 193: ...alfunction The swept volume dis placement of this compressor is 18 7 cubic feet per minute See Figure 6 5 to determine whether the air compressor is a through drive or non through drive version The th...

Страница 194: ...nduction Air flows from the engine to the compressor opening an inlet valve in the cylinder head of the compressor 2 Compression Air pressure is increased caus ing the compressor s discharge valve to...

Страница 195: ...als Cylinder Head Remove carbon deposits from the discharge cavity and rust and scale from the cooling passages of the cylinder head Clean carbon and dirt from the inlet and unloader passages Shop air...

Страница 196: ...ge 2 Check air inlet and discharge ports between compressor and the governor 3 Check under plate or at power steering pump for leakage 4 Check flanges for cracks or breaks 2 3 4 4 2 NON THROUGH DRIVE...

Страница 197: ...ven in this manual are general Depending on the configuration of your bus additional steps may be required 1 Set the spring parking brakes and block the wheels of the vehicle 2 Drain the air pressure...

Страница 198: ...ater and lines leading to the compressor Tighten per Gillig specifications 7 Through drive version air compressor only If necessary reinstall the power steering pump Refer to the manufacturer s mainte...

Страница 199: ...ed See air system leakage test proce dures which follow If the compressor fails to unload verify proper governor operation Air System Leakage Test 1 Park your bus on a level surface Leave engine on 2...

Страница 200: ...ents Excessive engine crankcase pressure Verify engine crankcase venting is to manufacturer s specification Compressor duty cycle too high Check system for leaks Make necessary repairs Compressor pass...

Страница 201: ...r manufacturer s service instructions Chafed or worn discharge line Replace faulty sections of discharge line Loose or leaking air line connections Verify all connections are secure Tighten to vehicle...

Страница 202: ...osity in unloader piston bore loose leaking seal at unloader piston bore Replace compressor Discharge line blocked due to freezing or carbon build up Check for trap low spots in lines Make necessary r...

Страница 203: ...ens the inlet passage Reservoir air pressure then flows around the inlet valve through the passage in the piston and out the unloader port to the compressor unloading mechanism Air also flows around t...

Страница 204: ...The pressure range between cut in and cut out is not adjustable 4 When proper adjustment is obtained tighten the adjusting screw locknut and replace the cover Leakage Tests Leakage tests should be pe...

Страница 205: ...ith a pair of retaining ring pliers remove the spring assembly retaining ring 1 and save 5 Pull the adjusting screw 4 and spring assembly out of the governor body 2 6 Gently tap the open end of the va...

Страница 206: ...are seated into piston 11 as far as possible Do not use a press or hammer to install the retaining ring Excessive force may damage the piston 3 Metallic piston only Install the inlet exhaust valve sp...

Страница 207: ...ng screw If provided cover is clear non metallic install O ring 20 and screw cover onto the adjusting screw Tighten until cover bottoms on governor body Note O ring 20 is used only on Hi Temp and wate...

Страница 208: ...yer and the wet supply reservoir All reservoirs however should be drained daily Drain valves are located inside the battery compartment door at the front driver s side of the coach see Figure 6 16 In...

Страница 209: ...ing system pressure and being sure that the contacts close when reservoir pressure is between 70 and 66 psi 483 455 kPa The contacts will be closed when the indicator light and buzzer operate The 66 p...

Страница 210: ...re protection valves the PPV will automatically block the flow to the leaking accessory system when the pressure in the accessory tank drops to around 70 psi This will protect the brake system by main...

Страница 211: ...the check ball or disc from its seat and the flow is unobstructed Flow in the reverse direction is prevented by the seating of the ball or disc which is caused by a drop in upstream air pressure and a...

Страница 212: ...are reversed Double check valves are designed so that the shuttle or disc can never impede the backflow of air in the exhaust mode Preventive Maintenance Every 100 000 miles 12 months or 3 600 operati...

Страница 213: ...se nylon air lines to replace existing nylon air lines only Do not route nylon lines where temperatures can exceed 200 F 93 C since these temperatures can cause the lines to soften and deteriorate 1 I...

Страница 214: ...n capped until its turn for connection 12 Tighten all fittings securely Be sure elbows are installed at the proper angle and are aimed in the correct direction Be sure the air lines and fittings are s...

Страница 215: ...ir supply is depleted Brake Valves Brake Valve Bendix E 10R The E 10R Retarder Control Brake Valve is used with retarder systems installed on automatic transmissions The retarder system is actuated ea...

Страница 216: ...a ry air to flow out the No 1 or primary delivery port Applying Normal Operation No 2 or Secondary Circuit When the primary inlet valve 29 is moved off its seat air is permitted to pass through the bl...

Страница 217: ...pressure When applications in the graduating range are made a balanced position in the primary circuit is reached as the air pressure on the delivery side of the primary piston 11 equals the effort e...

Страница 218: ...h as broken air lines and broken or missing parts Every 3 months or 25 000 miles or 900 operating hours Clean any accumulated dirt gravel or foreign material away from the heel of the treadle plunger...

Страница 219: ...ke system air pressure builds up Depress the treadle to several positions between the fully released and fully applied positions and check the delivered pressure on the test gauges to see that it vari...

Страница 220: ...ol assembly to the upper valve housing 6 Remove the boot from the plunger 7 Remove the three remaining cap screws 2 from the mounting plate Separate the mounting plate from the retarder control sectio...

Страница 221: ...nut 7 on the threaded end of the stem 22 Insert a screw driver to restrain the stem remove the lock nut 7 spring seat 8 and stem spring 9 9 Remove adapter 13 and O ring 14 Remove the primary piston 1...

Страница 222: ...relay piston 24 and install relay piston through primary inlet exhaust assembly 29 into under side of upper body 4 Install O ring 14 on adapter 13 and install adapter on upper body Install O ring 10...

Страница 223: ...n the mounting plate and the small diameter into the recess of the plunger 3 Connect all air supply and delivery lines to the brake valve that were previously removed 4 Plug the connector of the cable...

Страница 224: ...pproximately 1 4 move ment at the end of the treadle switch 1 should close and the volt ohm meter will respond with a reading of near 0 closed circuit 4 To check switch 2 leave the black lead of the v...

Страница 225: ...ews and tightening securely lAterAl AdJuster screws fiNe AdJustmeNt of switch Arm trAvel 2 2 1 3 4 4 3 1 d c b A course verticAl AdJustmeNt seQueNce cANNoN style coNNector Numbered pAcKArd style coNNe...

Страница 226: ...red to the primary service port enters the small cavity above the piston and moves it down The exhaust seat moves down with the piston and seats on the inner or exhaust portion of the inlet exhaust va...

Страница 227: ...lances the delivery pressure As delivered air pressure is changed the valve reacts instantly to that change holding the brake application at that level Exhaust or Release See Figure 6 33 When air pres...

Страница 228: ...g bolts and then the valve R 12DC Disassembly Callout numbers in this section refer to Figure 6 34 Before disassembly mark the location of the mounting bracket to the cover and of the cover to the bod...

Страница 229: ...piston 9 9 Depress and hold the exhaust cover assembly 16 and remove and discard the retaining ring 17 from the valve body 10 10 Slowly release the holding force on the exhaust cover assembly 16 to r...

Страница 230: ...ct the exhaust valve seat on the relay piston for nicks and scratches which could cause excessive leakage 4 Inspect the inlet valve seat in the body for scratches and nicks 5 Inspect the check valve s...

Страница 231: ...nstall retainer 12 on inlet exhaust valve 11 and insert both in the body 10 5 Install spring 13 in the body 10 6 Install exhaust cover assembly 16 in the body 10 Depress and hold the exhaust cover ass...

Страница 232: ...25 000 miles 3 months or 900 operating hours check for proper operation Every 100 000 miles 12 months or 3 600 operating hours disassemble and rebuild the valve R 12DC Installation 1 Clean air lines 2...

Страница 233: ...hange holding the brake application at that level Exhaust or Release When air pressure is released from the service port and air pressure in the cavity above the relay piston is exhausted air pressure...

Страница 234: ...ne from the balance port Release the parking brake and coat the balance port with a soap solution to check the diaphragm and its seat Leakage equivalent to a 1 bubble in 3 seconds is permitted If the...

Страница 235: ...er 10 Remove the service port cap nut and O ring from the R 14 11 Remove the diaphragm from the R 14 cover R 14 Cleaning and Inspection 1 Wash all metal parts in mineral spirits and dry them thoroughl...

Страница 236: ...install the cover on the valve body and the mounting bracket on the cover 6 Secure the mounting bracket and cover to the body using the 4 capscrews and lockwashers Torque to 80 120 in lb 7 Install th...

Страница 237: ...2 Inspect all lines and or hoses for damage and replace as necessary 3 Install valve and tighten mounting bolts 4 Connect air lines to valve plug any unused ports 5 Test the valve as outlined in the o...

Страница 238: ...phragm will seal against the body seat The exhaust port is still sealed by the center portion of the diaphragm when the brake valve application is released The air pressure above the diaphragm is rele...

Страница 239: ...with exhaust port pointing down and securely tighten mounting bolts 2 Connect air lines to valve brake application line to top port brake chamber line to side ports QR 1 Disassembly 1 Remove four scr...

Страница 240: ...wing from the primary air tank only enters the reservoir port of the SR 1 This air remains under piston A as system air pressure builds With primary tank pressure below about 55 psi the spring above p...

Страница 241: ...will apply the service section of the spring brake actuators Brake Application Loss of Primary Tank Refer to Figure 6 42 If air pressure in the primary air tank falls below about 55 psi the pressure b...

Страница 242: ...on Check First block the vehicle and hold by means other than the vehicle brakes Charge the air brake system to governor cut out pressure 130 5 psi 1 Pull up on the park brake valve to apply the parki...

Страница 243: ...the check valve 4 3 Remove the two Phillips head screws and remove the exhaust cover 5 4 Separate the exhaust diaphragm 6 from the cover 5 Remove the inlet and exhaust valve assembly 7 6 Remove the i...

Страница 244: ...torque 3 Install inlet and exhaust valve assembly 7 in valve body 4 Secure the exhaust cover 5 with two 10 24 Phillips screws and lockwashers Tighten to 20 30 in lb torque 5 Install exhaust diaphragm...

Страница 245: ...e operating button Secure with the roll pin 1 PP 1 Disassembly 1 Remove the two capscrews 3 which retain the lower cover and remove the cover Remove the sealing ring 4 2 Insert a small punch through t...

Страница 246: ...exhaust port to close A speed switch prevents interlock activation above 3 mph The coach operator must not use the interlock system to stop the bus Doing so may damage the brakes During normal vehicle...

Страница 247: ...brake system due to condensation Under these conditions the presence of small amounts of water should not be an indication that the dryer is not performing properly Note also that a small amount of o...

Страница 248: ...d limits proceed to the next step c Heater Element Inspection With the ignition switch in the Off position remove the thermostat cover Using an ohmmeter check the resistance between the metal end cove...

Страница 249: ...ir system is depressurized Drain all reservoirs of all air pressure 2 Identify tag and disconnect the three air lines from the end cover and note the position of the ports relative to the coach frame...

Страница 250: ...he sealing ring found at the base of the cartridge Figure 6 47 Air Dryer Components Cleaning and Inspection 1 Prior to assembly wash all metal parts thoroughly using a quality commercial solvent such...

Страница 251: ...e check valve assembly into the end cover making sure the holes in the metal stamping are facing up and the tang on the check valve assembly fits into the mating recess in the cover 10 Place the desic...

Страница 252: ...r and nut Tighten the nut to 20 30 in lb 2 3 3 4 N m torque Install the lock washer and nut finger tight to allow for reconnection of the electrical wire when rein stalled on the coach 6 Install the s...

Страница 253: ...of the front service brake and a controlled or modulated application of the rear spring brakes 12 With the spring brakes released refill the air system to governor cut out pressure 13 Check for the ap...

Страница 254: ...Compressor unloader leaking With compressor unloaded check for leakage Possible Cause Remedy Problem 2 Water in air tanks Replace desiccant cartridge B Improper discharge line length or material Minim...

Страница 255: ...purge valve B Defective air governor Test governor for proper cut in cut out settings and leakage C Purge control line connected to reservoir or exhaust port of governor Purge control line must be con...

Страница 256: ...Cause Remedy Problem 6 Desiccant material expelled from dryer purge valve exhaust may look like whitish liquid or paste or small beads See appropriate Problems Remedies B Dryer not securely mounted ex...

Страница 257: ...on via the unit s electroni cally controlled automatic drain valve Preventive Maintenance The air system condenser separator must be inspected periodically for proper operation The interval between in...

Страница 258: ...ve the shuttle valve 4 Clean and inspect all parts for damage contamination and corrosion Clean the automatic drain valve filter and blow dry with compressed air do not remove the filter from sump If...

Страница 259: ...412 77322 Kit 2 Contains Shuttle O rings mounting bolts and filter 412 90364 12 Volt Relay 411 76282 24 Volt Relay 411 76281 Figure 6 50 Haldex Consep Condenser Separator Exploded View Kit 2 Kit 2 Kit...

Страница 260: ...Air System 260...

Страница 261: ...dingly Meritor and Gillig recommend that workers use caution to avoid creating and breathing dust when servicing brakes Specific recommended work practices for reducing exposure to non asbes tos dust...

Страница 262: ...tting agents Cleaning Work Areas Clean work areas with a vacuum equipped with a HEPA filter or by wet wiping NEVER use compressed air or dry sweeping to clean work areas When you empty vacuum cleaners...

Страница 263: ...ated cam operated double shoe brakes with each shoe mounted on a separate anchor pin The brakes use automatic slack adjusters The parking emergency braking is accom plished by combination spring brake...

Страница 264: ...for wear at the anchor pin holes and roller slots 4 Check camshaft and camshaft bushing for wear 5 Replace brake shoe return springs 6 Examine brake linings for grease on the lining wear and loose ri...

Страница 265: ...ontainers Brake components should be stored in their original protective containers until time of installa tion Be careful not to contaminate or damage brake hoses or fittings during handling Do not d...

Страница 266: ...restricted or clogged air line If this condition is encountered disconnect both ends of the suspected line and blow through it to make sure the passage is clear Inspect the hose for a partial restric...

Страница 267: ...rake section of the combination rear brake chambers contains springs that are under extreme lethal pressure There are no user serviceable parts inside the spring brake chamber Never attempt to disasse...

Страница 268: ...Instal lation For Spring Brakes section Mounting Stud Nuts Check to ensure the mount ing stud nuts are tightened to the 100 115 ft lb clockwise and washers are in place between the nut and the bracke...

Страница 269: ...ure to exhaust all air pressure after step 7 5 Insert the release bolt into the center hole of the head and being sure that the formed end of the bolt has entered the hole in the piston inside the cha...

Страница 270: ...s Position the non pressure chamber end of the breather tube in the upper half of the chamber fac ing away from the road surface Failure to do so may void the MGM Brakes Warranty 5 Cut the service pus...

Страница 271: ...connector tube are engaged a minimum of 1 2 into each of the flexible elbows The tube must be glued to both of the elbows with a high quality rubber adhesive These units must be mounted with the breat...

Страница 272: ...k adjusters adjust the brake shoe to drum clearance automatically The function of slack adjusters is to maintain chamber stroke as the linings wear Automatic slack adjusters are self adjusting and do...

Страница 273: ...g the following procedure see Figure 7 3 1 Measure the length from the face of the air chamber to the end of the yoke pin while the brake is released 2 Have another person apply the brakes at 90 100 p...

Страница 274: ...evis pin from the clevis 3 Using a 7 16 wrench turn the adjusting nut counterclockwise until the slack adjuster clears the clevis 4 Remove the slack adjuster from the cam shaft For the rear slack adju...

Страница 275: ...e length of ad juster arm 5 and 5 1 2 adjuster arm lengths utilize the shorter hole location while 6 and 6 1 2 length adjusters utilize the longer hole locations Do not tighten anchor bracket fastener...

Страница 276: ...not move from its position while tightening fasteners 8 The adjuster must be manually adjusted at this time Rotate the adjusting hex clockwise until the lining lightly contacts the drum Then back off...

Страница 277: ...rque is less than 13 ft lb or no ratcheting sound occurs Unknown Perform automatic brake adjuster operational check see below Off Vehicle Inspection Component Cause Action Adjuster not func tioning pr...

Страница 278: ...ient time for brake to fully retract During the brake release observe rotation of the adjustment hex attaching a wrench on the hex or scribing the hex will make this rotation easier to see This rotati...

Страница 279: ...Adjust brakes E Grease or other contamination on E Clean or replace brake linings brake linings F Brake linings installed backward F Install brake shoes correctly G Brake linings installed in wrong p...

Страница 280: ...or replace air lines D Leaks in spring brake assembly D Repair or replace spring brake E Wheel bearings not adjusted correctly E Adjust wheel bearings F Drum has runout of more than 0 010 F Repair or...

Страница 281: ...wheels turning at the same speed to maintain the vehicle in a straight line When the wheel speed enters the stable region again the pressure is automatically increased There is an ABS warning lamp loc...

Страница 282: ...p turns off when the vehicle speed reaches approximately 4 mph If the warning lamp remains lit or comes on at any other time during vehicle operation it signals a malfunction of the ABS Diagnostics To...

Страница 283: ...r Block and secure the chassis 2 Release the slack adjusters so that the shoes retract and the drums will clear the linings The pro cedure for releasing the automatic slack adjusters is in this sectio...

Страница 284: ...blow the parts dry Inspection 1 Inspect bearing rollers for excessive wear nicks and burrs or other damage Slowly rotate the roller bearings around the cone to detect any flat or rough spots on the c...

Страница 285: ...b 5 Press the inner grease seal into the hub The lip of the seal must point toward the inside of the hub Coat the face of the seal with grease 6 Install the hub assembly on the front wheel spindle Be...

Страница 286: ...rake drum if installed Figure 7 13 7 Adjust the dial indicator so that the pointer is against the center of the knuckle Set the dial indicator on zero 8 Measure the end play while pushing pulling on b...

Страница 287: ...t Due to the unique design of the rear axle you should refer to the rear axle manufacture s manual Meritor see Notice below for the proper procedure For rear hub and wheel bearing service information...

Страница 288: ...wheel failures and accidents Make sure the rim ring is seated to the full depth of the groove fits tightly all around and is se curely locked Use a specially constructed safety cage while inflating ti...

Страница 289: ...stud nuts should be properly tightened Refer to instructions for wheel nut torque and tightening sequence in this section See that studs and nuts are free from oil and grease 2 Retighten the nuts eve...

Страница 290: ...overloading or hitting curbs at high speed or at a sharp angle may damage wheels The wheel stud nuts must be kept tight Check all stud nuts after every tire change Wheels Removed Do not heat wheels i...

Страница 291: ...t of the inner wheel on the hub The studs may have turned in the hub and worn the stud groove or the studs may have actual cracks or breaks resulting from the abuse The wheel may have worn ball seats...

Страница 292: ...ts can also cause wheel distortion or wheel runout These conditions can cause excessive tire wear Wheel nuts must be tightened to the torque values listed in this section These specifications have pro...

Страница 293: ...refer to the wheel manufacturer s manual supplied with your vehicle when installing removing or servicing wheel assemblies For Alcoa aluminum wheels consult the Alcoa Heavy Duty Wheel Service Manual...

Страница 294: ...30W oil at a point between the flange and hex see Figure 7 16 and 2 drops of SAE 30W oil on the last few threads of each stud 4 Snug up each of the flange nuts to about 50 ft lb in the sequence shown...

Страница 295: ...ssure If excessive pressure buildup occurs load under inflation high speed or a combination of these factors is responsible Use the size and type of tire which has the capacity to carry the load at th...

Страница 296: ...same gauge so the test will be consistent if there is any inaccuracy in the gauge Tire Inspection Nails small stones bits of metal or glass imbedded in the tread should be removed If loss of air resul...

Страница 297: ...ng and possible damage to the differential drive unit Match tires to within 1 2 13 mm of the same rolling radius or within 1 5 38 mm of the same rolling circumference The most accurate method of measu...

Страница 298: ...ot neces sarily go flat immediately when a fabric break occurs on the inside of the tire because it may take some time for the break to chafe completely through the tube The tube may become chafed at...

Страница 299: ...against the brake drum as excessive heat conducted from the drum by the valve stem may damage the valve and cause possible loss of air pressure Mounting Tires 1 Do not gouge or nick the wheel It is be...

Страница 300: ...f its position Static unbalance causes a hopping or pounding action up and down which frequently leads to wheel flutter or wheel tramp Dynamic Balance An out of round condition greater than 3 32 2 4 m...

Страница 301: ...ther case tires will re volve with a side motion and scrape tread off If the misalignment is severe rubber will be scraped off both tires If it is slight only one tire will be affected The scraping ac...

Страница 302: ...than in the rear When toe in is excessive tire wear shows feathered edges on the inside of the skid design Toe Out Wheels on the same axle are closer together in the rear than in the front Tire wear s...

Страница 303: ...ring gear to steer the front wheels and 2 furnishes hydraulic pressure to operate the fan motor The system consists of a fluid reservoir pump steering gear fan motor control assembly fluid cooler and...

Страница 304: ...ilot pressure on the fan motor s spool valve will be very low allowing the flow to go around the fan motor through the bypass tube This causes the fan speed to drop to a speed of zero to 500 RPM depen...

Страница 305: ...ering Return Return marked with t for tank return Fan Control Valve Fan Motor Hydraulic Reservoir Cooler Pump A C E D B F Bypass Relief Valve 00 PSI Cracking Pressure Pressure Port marked with p Inlet...

Страница 306: ...e and the control or thermostatic valve are open when the engine coolant is below 194 F This allows the oil to bypass the fan motor causing the fan to idle As the coolant get hotter both valves progre...

Страница 307: ...T FROM GEAR PUMP TO MOTOR FLUID FLOW FROM SWITCHING VALVE INLET TO FAN MOTOR INLET FLUID INLET FROM GEAR PUMP TO MOTOR DIVERTING TO TANK MOTOR MOUNTED SWITCHING VALVE ENGINE COOLANT HOT VALVE CLOSED M...

Страница 308: ...e PWM duty cycle decreases PWM signal is a 0 voltage for longer time the fan speed increases At a minimum duty cycle PWM signal at 0 volts the fan is at maximum speed The com mand fan speed is proport...

Страница 309: ...em The operation of the fan motor is basically just the opposite of that of the hydraulic pump Fluid under pressure is released through the two pump gears of the motor The pressure is dissipated while...

Страница 310: ...op the engine b Disconnect the pilot line to the fan control valve c Block the port in the fan control valve and the line to the control valve that was disconnected in the step above Blocking the pilo...

Страница 311: ...ngine in the cold condition run at governed speed Check the fan speed using the photo tach If the fan runs at maximum speed stop the engine and check the voltage supply to the fan control valve to ens...

Страница 312: ...otor Plug or cap all fluid system openings to preclude entry of foreign matter into the hydraulic system 5 Disconnect the Weather pak electrical connection from the valve Mark the wires to ensure that...

Страница 313: ...h the old isolators out of the bracket and install new isolators 3 Position the channel between the brackets and install the bolts washers and locknuts Tighten the locknuts to 40 45 ft lb 55 65 N m to...

Страница 314: ...d cable to ensure that the coach cannot be started while work on the hydraulic system is underway 2 Insert the fan motor and valve assembly into the mounting channel with the valve on top Install the...

Страница 315: ...4 0 GPM There is no pressure relief valve for the fan motor circuit in the pump Pressure relief for the fan motor circuit is provided by a relief valve at the motor The hydraulic fan motor is tempera...

Страница 316: ...are to ensure that the drive gear and key are removed with the pump 3 Remove the pump and adapter coupling from the engine Hydraulic Pump Installation 1 Position a new gasket on the gasket surface of...

Страница 317: ...familiarized with the specific details and techniques of the maintenance procedures on these units Failure to follow all proper procedures may result in damage to the equipment with the possibility of...

Страница 318: ...opening Check the fluid level by removing the dipstick attached to the filler cap Wipe the dipstick and reinsert it into the reservoir Remove the dipstick a second time and observe the level indicate...

Страница 319: ...Low Fluid Sensor Filter Clamp Plug Steering Gear Return Pump Supply Suction Line Case Drain Control Valve Return Note Shown is a 9 qt reservoir which uses one filter element If your bus has a 16 qt h...

Страница 320: ...eering power is available Back pressure is caused by restrictions to fluid flow Undersized replacement fittings and lines pinched lines and high flow rates are possible causes of back pressure High sy...

Страница 321: ...C Then close the valve in the pres sure gauge line and observe the pressure gauge reading The pressure reading should be 2175 50 PSI Do not leave the valve closed for more than 5 seconds 6 Open the v...

Страница 322: ...and spacer block during this test Make sure that the spacer block contacts the axle stop squarely which will prevent breaking the axle stops or dangerous ejection of the spacer block Leakage Test If t...

Страница 323: ...operation An ideal operating temperature should range between 140 and 160 F 60 to 71 C Normal operation in this range will allow for intermittently higher temperatures which will be encountered durin...

Страница 324: ...adding fluid to the system take care to use only the fluid recommended in the Fluid Specifica tions section of the Specifications chapter this manual and ensure that the fluid is clean It is recom men...

Страница 325: ...al times 7 Again check the fluid level in the reservoir 8 With the engine idling steer from full left turn to full right turn several times Stop steering with the wheels pointed straight ahead and loo...

Страница 326: ...s ton to allow pressure relief when the steered wheel approaches the axle stops The tripped valve reduces pressure in the gear box and thus helps to reduce heat generated by the pump and prolongs the...

Страница 327: ...teering com ponents Do not attempt to weld any broken steering component Replace the component with original equipment only Do not cold straighten hot straighten or bend any steering system component...

Страница 328: ...ocedure in Steering Column Re moval later in this chapter Do not pound the universal joint or input shaft coupling on or off the input shaft as internal damage to the steering gear can result A chisel...

Страница 329: ...eased 2 Use a suitable dolly to support the steering gear as you install it on the chassis mounting bracket 3 Install the five mounting bolts Tighten the four 3 4 bolts to 295 ft lb and the 7 8 bolt t...

Страница 330: ...Parts Manual This will ensure that the replacement hose will meet the required specification When replacing a hose assembly with a replacement not supplied by Gillig 1 The replacement hose must meet o...

Страница 331: ...ded placement of front and rear safety blocks Steering performance can be affected by misalignment anywhere in the overall steering system Other factors outside the steering system itself can also con...

Страница 332: ...ke piping joints or seal Possible Cause Remedy Problem Fluid leakage at actuating shaft of steering gear Replace seal A Worn or damaged seal Replace damaged parts Lubricate bearing cap more frequently...

Страница 333: ...C Coupling misalignment Leakage between manifold or reservoir at replenishing hole due to O ring damage Reser voir inlet tube to pump cover O ring should be carefully examined for damage and replaced...

Страница 334: ...A Fluid flow restriction Check maximum fluid flow B Fluid flow too high Possible Cause Remedy Problem Foaming hydraulic fluid in reservoir See pump servicing instructions A Air leak in suction side of...

Страница 335: ...Diagnosis section B Faulty steering geometry Align front end C High operating temperature Locate and correct cause of overheating D Bent or damaged king pins and tie rods Repair or replace king pins...

Страница 336: ...link sockets Check and repair replace parts as needed D Excessive wear or damage in steering gear or column G Front end alignment incorrect Align front end caster Possible Cause Remedy Problem Steerin...

Страница 337: ...t for wear and looseness Replace bracket if necessary and tighten to recommend ed torque rating A Worn universal joint E Rack on piston damaged Replace parts as required F Damaged pinion gear on outpu...

Страница 338: ...olumn binding Check and repair U joints and support bearings C Linkage ball sockets seized or binding Check and repair replace D King pins seized or binding Check and repair replace A No positive cast...

Страница 339: ...te wiring diagrams for each circuit Always turn off the battery disconnect switch see below before doing any work on any part of the electrical system Battery Battery Maintenance Today s buses make mo...

Страница 340: ...is diluted with water H2 O Keep batteries out of reach of children Batteries contain sulfuric acid Avoid contact with skin eyes or clothing Shield your eyes when working near the battery to protect ag...

Страница 341: ...n the OFF position before disconnecting cables from the batteries ON OFF ON OFF Battery Disconnect Microswitch is mounted within the Battery Disconnect Switch Figure 9 1 Battery Disconnect Switche Str...

Страница 342: ...een disconnected making possible a complete emergency engine shut down via the battery disconnect switch The electrical system is protected from spikes that might occur if the alternator continued to...

Страница 343: ...y Cable Removal Order of Battery Cable Installation 3 2 2 2 3 3 Replacing Batteries Always replace batteries in matched state of charge age and manufacturer P N pairs See torque val ues for battery nu...

Страница 344: ...r to the Battery Cleaning section below for the proper cleaning procedure Batteries that smell of sulfur like a rotten egg must be replaced 2 Any fluids on or around the battery may be an indication t...

Страница 345: ...he battery top with a cloth or brush and a solution of baking soda and water approximate ly 1 lb baking soda in one gallon of warm water When cleaning do not allow any cleaning solution or other forei...

Страница 346: ...e electrolyte when the battery is charged Water should be added to a battery when it is fully charged If it becomes necessary to add water to a dead battery add only enough water to cover the tops of...

Страница 347: ...cable 2 Connect a carbon pile load tester across the battery 3 Connect a voltmeter across the battery 4 If the carbon pile load tester does not have an accurate built in ammeter connect an ammeter in...

Страница 348: ...rming the hydrometer test procedures given on the next page observe the following guide lines 1 The hydrometer must be clean inside and out to obtain accurate readings 2 Hydrometer readings must never...

Страница 349: ...ometer reading according to the temperature of the electrolyte When the electro lyte temperature is above 80 F 27 C add 4 points 0 004 to the reading for each 10 above 80 F If electrolyte temperature...

Страница 350: ...ttery to full charge A fully charged condition is reached when the cells are gassing freely and three corrected spe cific gravity readings taken at hourly intervals show no increase Note you can deter...

Страница 351: ...low charging rate in amperes all cells are gassing freely and no change in specific gravity occurs 6 The full charge specific gravity is 1 260 1 280 corrected for electrolyte temperature with the ele...

Страница 352: ...high wiring resistance a faulty alternator slipping drive belts faulty regulator or a defective battery equalizer 3 Overloads caused by a defective starter or shorted circuits 4 Shorted or pinched wir...

Страница 353: ...en recently charged 4 Do not break live circuits at battery terminals because a spark usually occurs at the point where a live circuit is broken Care must always be taken when connecting or disconnect...

Страница 354: ...ter battery must be of the same voltage as the discharged battery and must have a nega tive ground 4 Do not route the cable on or near pulleys fans or other parts which will move when the engine start...

Страница 355: ...to ground an unpainted section of your bus If a large arc occurs when attempting to make the connection do not connect Check that jumper cables are not reversed 9 Be sure that cables are clear of fan...

Страница 356: ...qually from both batteries and that the voltages of the two batteries are kept equal When tapping into the battery system to obtain power for 12 volt loads a charge imbalance can result caus ing Batte...

Страница 357: ...ainst reverse polarity damage and therefore the DC connection sequence is not an issue The equalizer will not function properly unless all three battery connections are made Battery A and Battery B vo...

Страница 358: ...low voltage on the 12 volt supply Electrical testing reveals there is no 12 volt output from the equalizer while jump starting even though the equalizer separately tests OK Cause The 12 volt load whi...

Страница 359: ...ttery compartment to the OFF position Even with the battery disconnect switch OFF all connections from the battery to the equalizer remain live To prevent personal injury use extreme caution when work...

Страница 360: ...replacement equalizer aligning the holes in the mounting flange with the holes in the floor of the compartment Attach the equalizer to the compartment floor with four screws Tight en the screws firmly...

Страница 361: ...prevent overheating and fires in the event of major electrical malfunctions If the fuse blows the equalizer will cease functioning properly and all three of the indica tor lamps pictured above will c...

Страница 362: ...tery High 1 Battery voltage exceeds 30 VDC Check alternator output Check alternator regulator Check battery connections Battery Balance CHECK 12V SYSTEM lamp lights on the indicator lamp strip 1 Batte...

Страница 363: ...e circuits through a fuse in the engine compartment The positive field terminal F1 is connected to the voltage regulator The ground field terminal F2 is grounded to the diode end frame on the alternat...

Страница 364: ...endanger the alternator diodes and vehicle wiring The high current flow may result in a burned wiring harness and burned open diodes 2 Never operate the alternator on an open circuit field terminal co...

Страница 365: ...the terminals are clean and the clamps are tight Check to ensure the batteries are not bulging On Vehicle Voltage Adjustment Check or adjust the voltage regulator setting as follows 1 Connect a voltm...

Страница 366: ...lead to ground a Voltmeter should read 0 volts b If voltmeter reads a voltage even if very small a poor ground connection exists and must be corrected before the system will operate properly 5 Connec...

Страница 367: ...roblem in the wiring between the alternator POS terminal and the ignition relay b If voltmeter reads 0 volts proceed to next step 10 Connect voltmeter to ignition relay terminal 30 This is the 24 volt...

Страница 368: ...n pile 24 volt load tester across the batteries Figure 9 13 3 Connect an induction type ammeter over the positive cable at the alternator 4 Connect a voltmeter to the alternator positive cable and gro...

Страница 369: ...tive it should be replaced with a new or remanufactured unit If you want to rebuild the defective alternator contact the manufacturer Delco Remy for instructions Alternator Removal 1 Open the rear eng...

Страница 370: ...the oil line in the clip attached to the alterna tor drive end frame When replacing or connecting the oil line be sure to prevent foreign matter from entering the oil line or fittings 5 Connect the w...

Страница 371: ...ng alternator cables and fuses keep these important tips in mind Keep cables either vertical or horizontal to prevent interference with the fuse insulator Never install small wire rings between any la...

Страница 372: ...y 12v battery Alt HVAC Rear Panel Cables DETAIL A Copper Buss Bar Starter 24V Batt Jump Start 2V Batt Rear Panel Cables DETAIL B DETAIL C Copper Buss Bar Buss Bar Stud CRITICAL ELECTRICAL CONNECTIONS...

Страница 373: ...n the FRONT position in order to start the engine from the driver s area The starter can be cranked for no more than 15 seconds at a time This 15 second limit is programmed into the I O system to prot...

Страница 374: ...engaged until the starter solenoid circuit is interrupted If the pinion fails to engage the ring gear the motor will not be energized thus preventing damage to the pinion and gear teeth When the engin...

Страница 375: ...To determine the condition of the battery follow the test procedures described in Batteries in an earlier section of this chapter Be sure the batteries are fully charged The wiring switches and starti...

Страница 376: ...an Ohmmeter Starter Relay Contactor Test Perform the starter relay contactor test as fol lows 1 Connect the test setup shown in Figure 9 17 2 Turn on the carbon pile Voltmeter should read battery vol...

Страница 377: ...r Run Box You should hear the starter relay close If not proceed to next step 3 Connect the voltmeter to the battery cable ends at the starter voltmeter connection 1 4 Push the start button and measur...

Страница 378: ...om the solenoid 1 With the ignition rotary switch selected to IGNITION and the start button depressed measure the voltage loss in the following circuits If working from the engine compartment flip the...

Страница 379: ...ing the starter to operate again Starter Maintenance and Overhaul Other than periodic lubrication and keeping cable connections clean and tight the starter should require no periodic maintenance The s...

Страница 380: ...3 2 5 ft lb 1 8 3 4 Nm TORQUE Starter Installation 1 Use a suitable strap to raise the starter into position against the engine block 2 Secure the starter to the engine block with three bolts Figure...

Страница 381: ...r lead from the solenoid motor terminal to the solenoid frame or ground terminal The drive will now shift into the cranking position and remain so until the bat tery is disconnected Jumping for more t...

Страница 382: ...ntrols com Theory of Operation The multiplexing system consists of modules installed at various locations on the coach refer to Figure 9 23 for loca tions Clean power for the system is provided by a u...

Страница 383: ...cation Figure 9 24 Power Management Module Zone A B Indicator Lamp Strip light bar and Air Tank Compartment Located at the top of the driver s windshield s area the Indicator Lamp Strip B1 ID s 67 and...

Страница 384: ...oller for up to eight inputs and eight outputs There are several of these modules installed in the bus the number of modules depending upon bus design Each output circuit is individually fused inputs...

Страница 385: ...ule will take 32 inputs A green LED will light up if the module re ceive a input signal T2 48LED 06 GL Indicator Lamp Strip Module The Indicator Lamp Strip Module has been integrated into the Multiple...

Страница 386: ...formation for example that the doors are open the ramp is deployed or that a stop has been requested Figure 9 30 T2 GW 024 MVCM Module T2 DIO 4OUT K7 Module Optional The optional T2 DIO 4OUT K7 Module...

Страница 387: ...33 L2 RF NET R2 Wireless Communication Module Figure 9 32 T2 DIO PWM 888 K7 Headlight Control Pulse Width Modulation Module T2 DIO PWM 888 K7 Control Module with Pulse Width Modulation The T2 DIO PWM...

Страница 388: ...SA CA U S A CONTROLS CORP GILLIG P N 3 4 36 028 MODEL T2 DIO 888 K6 GL zONE A B AIR TANK COMPARTMENT IN RADIO BOx wAKe to mAster diode blocK bAtt ABOVE THE DRIVER ABOVE ExIT DOOR ABOVE HVAC GRILL zONE...

Страница 389: ...any electrical troubleshooting check the coach chassis numbers on the manual s front cover Ladder charts use logical symbols and connecting lines to show the relationships between the various inputs a...

Страница 390: ...iplexer system checks for the required conditions scanning from left to right If a path can be completed by meeting all the required conditions between the start of the circuit on the left and the out...

Страница 391: ...the output circuit is on or active On T2 DIO 888 T2 HCNC 888 and T2 DIO 808S modules output circuits and their corresponding red LED s are always numbered 1 through 8 T2 DIO 888 and T2 HCNC 888 module...

Страница 392: ...LED s on off If a red output LED is on this indicates that the processor has triggered the corresponding func tion If the red output LED is off this indicates that that this output is not active Red...

Страница 393: ...m Fault 7 Flashes Module B3 70 Comm Fault 8 Flashes Module C1 71 Comm Fault 9 Flashes Module D1 72 Comm Fault 10 Flashes Incorrect DINEX program or incorrect accessory Palm PC Note Module D2 73 is the...

Страница 394: ...e A B a Disconnect the A1 module s power connector AMP 207121 1 in zone A B b Disconnect the A2 module s power connector AMP 207121 1 in zone A B c Disconnect the B1 module s power connector AMP 64050...

Страница 395: ...or lights for most major func tions Air Tank Electrical Panel The Air Tank Electrical Panel Figure 9 40 is located on the ceiling above the driver s area It contains the following Components of the I...

Страница 396: ...ram in the Electrical Schematics Manual to ensure that the connections are properly accomplished Turn the battery disconnect switches to the ON position and test the circuit for proper functioning Rel...

Страница 397: ...r Locks Above Door Enclosure This enclosure is located in the interior above the passenger door It contains I O module C1 71 for the multiplexer system and the door closure mechanism on busses with re...

Страница 398: ...ems communicate through use of this SAE J1939 standard communication link This link receives operational information regarding the engine and other vehicle components which is needed for proper bus sy...

Страница 399: ...O A C B 939 939 COLOR yEL GRN 3 WAy PLUG 5 MPH VOLTS GND BUSS BAR GROUNDING ADAPTER T TEMP PART OF ENGINE HARN PRESS RR BOx HARN TERMINATION RESISTOR C 0J C 0J 2 C 0J 3 C 0J 8 C 0J 7 C 0J 6 PART OF BU...

Страница 400: ...rts by an employee inside the bus always keep this switch in the center Engine Kill Off position when working in the engine compartment Figure 9 44 Rear Run Box Switches Component Replacement 1 Turn t...

Страница 401: ...l for the circuit and connection affected If the horns do not operate quick checks may be made as follows 1 Connect a jumper lead from terminal 86 on the horn relay to ground If the horn operates the...

Страница 402: ...per The backup alarm beeper is mounted in the right rear corner panel between the taillights Figure 9 46 It is the same type of beeper as the kneeling wheelchair ramp beeper but has a different tone R...

Страница 403: ...hydraulic flow to the engine fan but the fan will still be free wheeling and light the Fire indicator on the light bar just as if the linear heat detection wire had been shorted out by heat in the eng...

Страница 404: ...hes to the engine exhaust components Do not allow the detection wires to be pinched or crimped Do not kink the detection wires by bending the wires in sharp turns of 3 radius or less Use enough tensio...

Страница 405: ...ly if it is properly maintained and serviced Adhere to the maintenance schedule in theAmerex manual supplied with the bus Installation Operation and Maintenance Manual No 13980 Rev F see the Inspectio...

Страница 406: ...OFF THE BATTERY DISCONNECT SWITCH before servicing fluorescent lighting If the lamp is not functioning it may be related to a bad connection and not end of life failure See Figure 9 51 The molded plas...

Страница 407: ...ting plate to the ceiling panel Pull the as sembly far enough out from the panel to gain access to the ballast 2 Disconnect the electrical connectors attaching the ballast to the ceiling wiring harnes...

Страница 408: ...recessed double contact RDC bays on the ends of the lamp tubes The molded plastic comprising the RDC is very brittle The RDC not only protects the pins from dam age but most importantly keeps the lam...

Страница 409: ...red LED on also indicates that ballast is in extinguish mode For more information call your Gillig Service representative or contact Pretoria at Pretoria Transit Interiors Inc 1975 Joe B Jackson Pkwy...

Страница 410: ...oors are opened The bulbs are replaced by removing the lamp lens which is attached to the lamp housing with two screws Engine Compartment Lights The engine compartment lamps are controlled by a switch...

Страница 411: ...he condition of the bulbs and wiring only It does not take the place of a thorough exterior lighting systems inspection with an observer outside the bus checking each lamp as it is activated Headlight...

Страница 412: ...be used at the inboard lamp positions while units with 2A molded into the top of the lens must be used at the outboard lamp positions 2 Position the retaining ring over the lens and secure it to the m...

Страница 413: ...stop light indicator light The rear stop light circuit is not routed through the multiplexer This is a safety measure in case of multiplexer failure Lamp Component Replacement Disposable Type The stop...

Страница 414: ...turn signal system The flasher function is provided by the processor in the multiplexer system Refer to the Turn Signal Lights wiring diagram in the Electrical Schematics Manual for fur ther informat...

Страница 415: ...and side mounted turn signal lights serve also as marker lights Marker clearance and identification lights turn on when the ignition rotary switch is in the or position Refer to the Exterior Lighting...

Страница 416: ...ter Gillig part number 51 49903 000 Cyberdyne part number 8303 whenever you change tire size or drive axle gear ratio First call Gillig s Engineering department and determine the frequency to order fo...

Страница 417: ...Manual Deploy Procedure If the ramp cannot be operated electrically a manual latch release handle is provided to allow the opera tor to manually deploy and or stow the ramp Once the release handle has...

Страница 418: ...2 Lift the outermost edge of the ramp up and slowly push the ramp up and into the coach Continue to push the ramp downward until the outermost edge of the ramp comes to rest nearly in the fully stowed...

Страница 419: ...ool Packard P N Crimping Hand Tool 20 14 Ga 1201 4254 Crimping Hand Tool 12 Ga 1208 5115 Removal Tool 1201 4012 AMP Mate N Lok Connectors The following table shows the tools needed to remove and repla...

Страница 420: ...Electrical System 420 Deutsch DT Series Connectors...

Страница 421: ...Electrical System 421...

Страница 422: ...Electrical System 422 Deutsch HD 10 Series Connectors...

Страница 423: ...Electrical System 423...

Страница 424: ...Electrical System 424 Deutsch HD 30 Series Connectors...

Страница 425: ...Electrical System 425...

Страница 426: ...ecking for electrical continuity Never splice into wiring even with shrink tubing to reseal Always use dielectric grease when opening and resealing plugs and junction boxes Wire Sizes and Colors Each...

Страница 427: ...s and switches on the dash panels and electrical control panels To remove a wire and terminal from the connector insert a thin blade screwdriver into the open end of the connector and push the tang do...

Страница 428: ...ns or cavities across the connector until the desired terminal or cavity is reached When connecting the harness connectors to the connector panel or to the mating connector the connec tor keyway and k...

Страница 429: ...of refrigerant to the coil Evaporator Coil picks up heat from bus interior In order for the air conditioning heating system to function all of these components must perform properly See Figure 10 1 Th...

Страница 430: ...will remain thoroughly lubricated by operating the system weekly for short intervals of at least 5 to 10 minutes This will also prevent the compressor shaft seal from leaking and will detect any loss...

Страница 431: ...cause painful lacerations Refrigerant Precaution Although Freon is a safe refrigerant certain precautions must be observed when handling or servic ing any system which uses this cooling medium If rel...

Страница 432: ...connected to the compressor and includes wires for the dash controls driver s A C stop light warning sensor cutout switches and other components necessary to the operation of the compressor In the eng...

Страница 433: ...ment as follows 1 Remove the filter retainer from the side slides 2 Remove and clean or replace the filter element 3 Reinstall the retainer into the slides to secure the filter element Hose Service Th...

Страница 434: ...attach the hoses to the pump Plug the openings of the hoses to prevent loss of coolant 5 Disconnect the electrical wires from the pump and label as necessary for easy reinstallation 6 Remove the four...

Страница 435: ...portion will need to be repaired or replaced depending on the extent of the damage c 7 0 amps or higher for a 24 VDC system The pump is being obstructed but not to the point of complete failure or the...

Страница 436: ...un but will operate properly when the polarity has been corrected Check the circuit breaker to verify that it is functioning properly 2 Check the motor connections with a voltmeter to verify that the...

Страница 437: ...Remove the plastic hole plug Using an Allen wrench loosen and remove the drive magnet as sembly 5 Remove the four flat head screws from the interface piece The motor is now ready to be repaired as nee...

Страница 438: ...der magnet on the end of the shaft 5 Remove the snap ring from the shaft but not remove any shims or the compression spring Re move bearings by sliding them off and discard them 6 Clean the bearing se...

Страница 439: ...With Ball Bearings Wave Washer Shim O Ring Electronics Housing Pan Head Screw Circuit Board Heat Sink Assembly Pan Head Screw Flat Washer Motor Lead Wires Heat Sink Tubing Stator Lead Wires Socket Hea...

Страница 440: ...n Figure 10 5 2 Run a bead of electronic compatible RTV such as Dow Corning 3145 around the electronics housing Place the electronics assembly at the approximate position of the old electronics noted...

Страница 441: ...el fuel and can be dangerous if used incorrectly Consult the OEM documentation included in the manual package for buses with this option and refer to the Preventive Maintenance chapter of this manual...

Страница 442: ...Heating Air Conditioning 442...

Страница 443: ...ied if necessary Pay special attention to the undercoating in the wheel arches and the area around and behind the rear wheels Corrosion will result from deteriorated undercoating Corrosion Protection...

Страница 444: ...orrosion should be cleaned off and undercoating or other protections sealers coating etc should be applied to the exposed surfaces We recommend di electric grease be reapplied to all electrical connec...

Страница 445: ...l position the plate must be able to turn freely Therefore the clearance between gusset and clamping plate must be at least 5mm see Figure 11 1 The screw must be screwed in by 1 to 1 1 2 turns into th...

Страница 446: ...after installation Noticed after more than 15 minutes Incorrect fastener torque too loose or too tight Dismount corner gusset Check the bores If damaged replace the gusset Check the threads If damage...

Страница 447: ...u have 15 minutes to make adjustments before the locking agent dries If installation must be redone ALWAYS use new Torx screws and new clamping plates In addition always check that the gusset is in pe...

Страница 448: ...nd the fixed type which cannot be opened Although skirt panels can be repaired following procedures provided in the Body Repair and Paint Section it is often more cost effective to replace the entire...

Страница 449: ...ing the process tap on the panel with a rubber mallet along a line near the top see Figure 11 8 being careful not to damage the finish To avoid damaging the bottom of the skirt panel when using a jack...

Страница 450: ...rough the holes in the skirt panel hinge and into the clamping plates Tighten the capscrews approximately one and a half turns into the clamp ing plates until a slight resistance is felt Ensure that t...

Страница 451: ...cted for evidence of loosening and retightened if necessary Cleaning should be done with a mild soap and water solution Other cleaning chemicals may damage the hatch surfaces Graffiti removal cleaners...

Страница 452: ...3 4 5 6 7 8 9 10 11 12 4 1 Outside release 2 Hinge pin 3 Handle base 4 Release handle 5 Release handle shield 6 Main hinge not serviceable 7 Release hinge 8 Mounting frame 9 Trim molding 10 Plunger s...

Страница 453: ...ide from window height to roof and curves at the top to overlap the roof along the rear and on each of the sides The cap encompasses the rear and side AC access door and the AC vents on each side At t...

Страница 454: ...rubber bumper pieces are con nected to the aluminum channel using fiber pins A steel reinforcement plate is bolted to the back of the aluminum channel at the center to help further stabilize and stren...

Страница 455: ...ndshield washer spray head see Figure 11 12 for a typical electrical wiper assembly Wiper speeds are infinitely variable between the minimum and maximum speeds Speed selection for each wiper is provid...

Страница 456: ...ered do not remain in the proper position Water should be sprayed on the windshield during wiper service to aid in wiper sweep adjustment Do not allow blades to drag on dry windshields Once the wiper...

Страница 457: ...to the splined surfaces and then install the arms snaprings spacers acorn nuts and set screws Check for proper operation If necessary remove the arms and repo sition both using an equal number of spli...

Страница 458: ...hat uses self generated air pressure to hold access doors in an upright posi tion The strut functions by drawing in air and trapping it in the air tight cylinder as the sliding shaft is extended Air i...

Страница 459: ...s maintained Replacement of a bent or damaged frame member will necessitate cutting out the old member and weld ing in a piece which has been cut to fit from tubing of the same dimensions and thicknes...

Страница 460: ...ames or intense heat When painting a repaired surface it may be easier to paint an entire section such as a door or panel than to try to match the paint color for a small portion of a surface To acqui...

Страница 461: ...astic cleaner applied in thin coats using light pressure Buffing with a clean soft cloth will add luster to the finish Product instructions and recommen dations should be followed Selected solvents ar...

Страница 462: ...No 2 1 and 3 denatured alcohol Freon TF and TE 35 Ethanol 10 Sol Ban Ami Dirtex 2 Sol Reg Joy Heptane White Kerosene Methyl isopropyl and isobutyl alcohols Lacryl PCL 2035 polycarbonate cleaner Petro...

Страница 463: ...moving the adjacent windows and then peeling the panel off of the post Refer to the Window section in this chapter for instructions on window removal and replacement To replace the panel apply wide do...

Страница 464: ...solution to completely dry on floor Pick up solution with a damp clean mop Rinse flooring with a mop using clean cool water to remove deter gent Matting Replacement For safety the flooring is covered...

Страница 465: ...rs or brake interlock could cause injury to passengers so it is essential that the doors are checked daily for proper operation and maintained through proper adjustment and repair Safety Features Brak...

Страница 466: ...he interlock function on your Low Floor bus When the switch is in the On position the brakes activate automatically and the throttle is disabled whenever the rear doors are opened the lift is activate...

Страница 467: ...ormed on a daily basis This is a simple test that requires very little time and should be performed before a bus leaves the depot for transit ser vice Before leaving the depot drivers should first aut...

Страница 468: ...making any adjustments check the air system pressure there must be at least 90 psi for correct adjustments 3 Exhaust the door engine by opening the manual air valve Doors can now be manually opened 4...

Страница 469: ...e leading edges when they meet at the center The rear 2 panel should lead the front 1 panel when closing If the rear panel does not lead lengthen the front panel connecting rod until the rear panel le...

Страница 470: ...e closing speed adjustment screw then turning the screw until door closing speed is satisfactory Backing the screw out counterclock wise increases closing speed 2 Adjust the opening speed by loosening...

Страница 471: ...r bottoms after actua tion Proximity switches see Figure 11 21 should be adjusted to provide a 4mm gap between the switch and the teeter plate at the closest point in the teeter plate s travel Front D...

Страница 472: ...j Screw 8 Connecting Rods 9 Open Speed Adj Screw 10 Emergency Release 11 LS3 Switch 12 Cam Lever Assembly 13 Closing Spring 1 2 3 4 5 6 7 8 9 10 8 11 13 12 Rear doors The rear doors on your bus operat...

Страница 473: ...rn the rod while watching the lock pawl cam notch gap Make sure that the gap is between 1 16 and 1 8 7 Lengthen the left hand connecting rod until the left hand door panel closes against the closed st...

Страница 474: ...s one which is normally open and another which is normally closed one or both of the switch circuits will be used depending on the options installed on your bus Refer to the Gillig Electrical Schemati...

Страница 475: ...switch has two separate circuits one which is normally open and another which is normally closed one or both of the switch circuits will be used depending on the options installed on your bus Refer to...

Страница 476: ...doors open or closed and manually extending the cylinder rod will determine the amount or remaining stroke Adjust the length as required Touchbars Each touchbar has two switches top and bottom Check...

Страница 477: ...the screw on the rear cap of the door motor refer to item 6 in Figure 11 22 and the circled area of Figure 11 27 The cushioning screw can be found behind the left end of the closing spring To adjust...

Страница 478: ...4 Replace door panel by reversing Steps 1 3 of this procedure Door Window Replacement To prevent personal injury wear gloves and eye protection when working with glass 1 Pop out broken glazing using c...

Страница 479: ...Gillig coaches are made of laminated glass or Lexan plexiglass both referred to as glazing Laminated glass is fabricated of two sheets of glass with plastic inserted between the panel and plastic bake...

Страница 480: ...g channel groove with a rubber gasket or silicone lubricant to prevent the rubber molding from hanging on the glazing Set the bottom of the glazing into the molding 3 With an assistant holding the gla...

Страница 481: ...aluminum frame with slide rails fabricated into the frame The inner frame around each window has a cen ter slot rimmed with brush trim on each side to facilitate sliding without lubrication The window...

Страница 482: ...zed aluminum frame The glazing can then be removed from the frame by cutting through the weld on the right side frame and removing the bolts which hold the frame together The frame can be then be spre...

Страница 483: ...ross the bottom also function as a retainer for the release bolts catch bars 2 Wedge Spacer Blocks With the window open wipe the egress frame seal with a vinyl cleaner solution and clear any debris be...

Страница 484: ...rt to open the window is to move the retention spring as far as possible towards the outside of the coach Retighten screws to 30 35 in lb 6 Testing Open and close each window and check for smooth oper...

Страница 485: ...cting USSC Group Inc at 610 834 7282 Seat Adjustment Refer to Figure 11 32 below The following seat control listing covers the basic features of a typical USSC seat Options such as heaters and ventila...

Страница 486: ...Body and Interior 486 Driver s Seat Troubleshooting Use the following chart to troubleshoot the USSC seat...

Страница 487: ...by foreign objects Weekly Check the following seat functions and adjustments and repair as required Fore aft Height Rake Back recline Lumbar Bolsters Air valve Seat belt Monthly Check fore aft slides...

Страница 488: ...the threaded rod itself Replacing Rubber Bellow 1 Remove the plastic pins item 3 400 on Figure 11 34 that secure the bellow to the top of the seat cushion 2 Remove the seat from the riser see the Remo...

Страница 489: ...s Locate the holes with a center punch and pierce the fabric before inserting the plastic pins 7 Replace the plastic bellow and reinsert the plastic pins Air Bag Replacement 1 Disconnect the source of...

Страница 490: ...valve and secure it with the two mounting screws 9 Reconnect the three air hoses 10 Replace the knob and backing nut 11 Reconnect the source of air pressure and test for leaks by filling and emptying...

Страница 491: ...the USSC seat illustrations on the following pages Item Description Item Description Replace Side Bolster Bags Refer to Figure 11 37 1 Remove seat back cover refer to the Seat Back Cover Replacement...

Страница 492: ...Body and Interior 492 Figure 11 33 USSC Seat Assembly...

Страница 493: ...Body and Interior 493 Figure 11 34 USSC Seat Suspension Assembly...

Страница 494: ...Body and Interior 494 Figure 11 36 Base Assembly With Manual Slider Release Figure 11 35 Base Assembly With Air Operated Slider Release...

Страница 495: ...Body and Interior 495 Figure 11 37 Seat Air Connections...

Страница 496: ...often as possible The construction of the cloth allows dust dirt and grit to fall to the base of the pile therefore presenting clean pile to the passenger The grit if not vacuumed out frequently will...

Страница 497: ...w g n i g n o p s y b t n e m t a e r t e t e l p m o c 2 r a T e n e z n e B h t i w n e t f o S 2 1 d i c A y r e t t a B l a r e v e s r o f e v a e l e t a n o b r a c i B m u i d o S f o n o i t...

Страница 498: ...three wheelers in a designated area of the coach The wheelchair securement systems are located in an area made vacant by folding seats The folding seats lock into position The only maintenance require...

Страница 499: ...n 183 Preventive Maintenance 47 Reservoirs 208 Suspension 186 Troubleshooting 254 Index Alignment Specs 168 Alternator Cable Fuse Installation 371 Description 363 Drive Belt 107 Mounting 364 Removal I...

Страница 500: ...109 Check Valve Air 211 212 Check Valve Fuel 74 Clamp Exhaust 94 Cleaning Exterior 461 Exterior Lights 462 Interior 463 Undercoating 443 Column Steering 174 Connectors Wiring Blade Type 427 Hinge Type...

Страница 501: ...Dolly 100 Fast Idle 64 Installation 103 Mounts 102 Oil Filter 62 65 Oil Specifications 59 Preventive Maintenance 45 Removal 98 Starting 24 Stop Engine Override 26 Throttle 64 Equalizer Battery Descri...

Страница 502: ...ifications 17 Hose Replacement 330 Pressure Test 321 Preventive Maintenance 46 Pump 315 Troubleshooting 332 I Inspection Daily 41 Interlock System Brake 64 246 466 Intermediate Shaft Steering 167 J J1...

Страница 503: ...79 Pump Heater Booster 433 Pump Hydraulic 315 Q QR 1 Brake Air Valve 238 Quick Release Brake Valve 238 R R 12DC Brake Valve 226 Radiator Cleaning 88 Inspection 87 Mounting 86 Removal Installation 87 R...

Страница 504: ...ce 48 Torque Values 14 Troubleshooting 157 Suspension Rear Air System Operation 186 Description 151 Preventive Maintenance 48 Removal Installation 153 Troubleshooting 157 SWAT Switch 190 467 Switch Ai...

Страница 505: ...4 Fuel Level Control 77 Fuel Pressure Relief 77 Interlock Solenoid 246 Park Brake 245 Pressure Protection 210 Pressure Safety 209 Quick Release 238 Relay 226 Spring Brake 240 Vanner EM70D 361 Vent Roo...

Страница 506: ...GILLIG CORPORATION 25800 Clawiter Road Hayward CA 94545 Phone 510 785 1500 Fax 510 785 6819 Printed November 2006...

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