GILLIG LOW FLOOR Service Manual Download

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Engine

Oil Change Procedure

1. When changing the oil, start the engine and let the coolant temperature reach at least 140° F.

Draining the oil while it is warm permits all the oil and suspended contaminates in the oil sump

to easily flow out of the oil sump.

2. Shut down the engine.

Use a heat resistant pan with a capacity of

at least

30 quarts to catch all

of the draining oil. After the oil has drained, deposit it at an authorized

oil reclamation center.

Engine oil being drained from a recently running engine can be extremely

hot, even if the engine has been running for a relatively short time. To

avoid hot oil contacting your hands or arms, use a socket wrench to

completely remove the oil pan drain plug.

3. Place a catch pan beneath the oil pan drain plug. Remove the plug and catch the used oil. Allow

time for all oil to drain.

4. Reinstall the drain plug.

Do not overtighten; proper torque for the drain plug is 50 lb-ft.

5. Replace the oil filter 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 been filled

with oil).

7. Check the oil level at the dipstick following the procedures given in the preceding “Checking the

Oil Level” section. Top off the oil as necessary. Do not overfill.

ENGINE OIL FILTER

The ISL engine is equipped with a spin-on oil filter (Fleetguard LF9009), mounted under the filter head,

just below the oil cooler on the street side of the coach (Figure 3-3

). This filter contains an internal ven

turi that provides filter bypass oil flow through a stacked disk section of the filter. Lubricating oil filters

must

be of the venturi style. Using an oil filter without a venturi will result in premature engine wear.

Use only the LF9009 filter. Do

not

use an LF3000 filter. The oil, supplied to the engine by the oil pump,

passes through the full flow filter before reaching the various moving parts of the engine. Refer to the

Cummins

Troubleshooting and Repair

manual for information about the filter bypass valve and oil flow

in general.

Summary of Contents for LOW FLOOR

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 18: ...Specifications 18...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 58: ...Preventive Maintenance 58...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 110: ...Engine 110...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 138: ...Transmission Driveline Rear Axle 138...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 182: ...Suspension 182...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 260: ...Air System 260...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 421: ...Electrical System 421...

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

Page 423: ...Electrical System 423...

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

Page 425: ...Electrical System 425...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 442: ...Heating Air Conditioning 442...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

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

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

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

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GILLIG LOW FLOOR, Service Manual

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