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IC Bus BE Series, Operation And Maintenance Manual

The Modena BE Series user manual is a comprehensive guide that enables users to effortlessly install, navigate, and maintain their Modena BE products. This essential manual can be easily accessed and downloaded for free from our website, ensuring a hassle-free user experience.

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Index

SECTION 14 — INDEX

Numerics/Symbols

1/4 Turn Fuel Safety Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1/4 Turn Fuel Safety Shutoff Valve Location. . . . . . . . . . . . . . . . . . . .12
39 Inch Flex Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

A

ABS / Plastic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
ABS Connections and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . .164–165
ABS Self-Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Additional Components Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Adjustable Tilt or Tilt / Telescoping Steering Column. . . . . . . . . . .50
Adjusting the Length of the Tether. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Air Brake Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118, 161

ABS Connections and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Air Disc Brakes (0004JBZ, 0004JCC, 0004WEY,

0004WEZ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Air Dryer Desiccant Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Air Dryer Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Air Dryer Purge Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Air Reservoir / Tanks Moisture Draining. . . . . . . . . . . . . . . . . . . . .163
Brake Inspection and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Parking Brake Indicator Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Using Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Using the Air Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Air Brake Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
To engage Air Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

A

(CONT.)

Air Brakes (cont.)

To release Air Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Air Cleaner Element Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Air Conditioner Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Air Disc Brakes (0004JBZ, 0004JCC, 0004WEY,

0004WEZ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Air Dryer Desiccant Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Air Dryer Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Air Dryer Purge Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Air Reservoir / Tanks Moisture Draining. . . . . . . . . . . . . . . . . . . . . . . .163
Air Restriction Gauge Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

High Restriction Reading Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
No Restriction Reading Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

Air-Actuated Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Air-Operated Passenger Door Adjustments. . . . . . . . . . . . . . . . . . .157

Door Opening and Closing Speed Adjustment Points. . . . .157

Closing Speed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Opening Speed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Pressure Regulator Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . .157

Electrically Actuated Entrance Door Adjustment. . . . . . . . . . .158

Allison Generation IV Push-Button Shift Selector. . . . . . . . . . . . .128
Allison Transmission Mechanical Lever Shifters. . . . . . . . . . . . . .128
Alternator–Starter–Battery Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Antilock Braking System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Antilock Driving Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Approved Tire and Wheel Combinations Table. . . . . . . . . . . . . . . .202

215

Summary of Contents for BE Series

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

Page 2: ...ay be neither downloaded nor retrieved except by the vehicle s registered owner or in the alternative by another individual or entity authorized by the registered owner e g IC Bus Dealer who may need this data or information to properly service or diagnose this vehicle for repair or following an accident Any access to this information without the owner s consent may be in violation of law and may ...

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

Page 4: ......

Page 5: ...System Inspection 22 Section 3 Instrumentation Instrument Panel Gauge Cluster 23 Warning Indicators 24 Instrument Panel Gauge Cluster 26 Direct Drive Warning Indicators 27 Integral Digital Display 28 Integral Digital Display Detailed Information 30 Outside Temperature and Compass Displays Optional 37 Outside Temperature Reading 38 Optional Instrument Panel Gauge Cluster Compass Calibration Procedu...

Page 6: ...oor 69 Opening the Entrance Door Manually 69 Electric Actuated Door 69 Air Actuated Door 69 Traffic Warning System 69 Electronic Safety Messages 69 Eight Lamp AMBER and RED Warning Lights 70 Optional Rocker Switches 70 WIG WAG Warning System 71 Flashing Stop Arm 72 Crossing Gate 72 Driver Visual Warning Lights and Indicators 73 Audible Warning Buzzer 73 Post Trip Inspection No Student Left Behind ...

Page 7: ...her 96 Location and Use of Tether Anchors SafeGuard XChange Bus Seats 97 Cushion Release Latch 98 Track Seat Mounting Seat Type Specific 99 Section 8 Climate Controls Heater System 103 Driver Heater 103 Auxiliary Heaters 104 Defrost Operating Instructions 104 Integrated Air Conditioning System IC Air 104 Circulation Fans 105 Heater Booster Pump 106 Heater Cut Off Valve 106 Section 9 Operation Star...

Page 8: ...air Lift Interlocks 129 Wheelchair Lift Extension Operation 129 Starting Bus in Motion 130 Starting Bus in Motion With Transmission Shift Wheelchair Lift Interlocks 130 Retracting and Stowing Operation 130 Backup Alarms 130 Economy Mode 131 Automatic Transmission Operating Temperatures 131 Section 10 Roadside Emergencies Hazard Warning Switch 133 Emergency Equipment Recommended On Board 133 Fire E...

Page 9: ...tion 160 Air Brakes 161 Brake Inspection and Adjustment 161 Air Dryer 163 Air Dryer Desiccant Replacement 163 Air Dryer Purge Valve 163 Air Dryer Heater 163 Air Reservoir Tanks Moisture Draining 163 ABS Connections and Sensors 164 Hydraulic Full Power Brakes 164 Brake Inspection and Adjustment 164 Brake Fluid Level 164 Fluid Precautions 165 Brake Lines Hoses and Fittings 165 Hydraulic Brake Fluid ...

Page 10: ...on 183 Rotation Is Advisable 183 Tire Replacement 183 Wheel and Tire Balancing 184 Wear 184 Irregular Wear 184 Use of Tire Chains 184 Wheels 185 Wheel and Wheel Nut Maintenance and Installation 185 Wheel Nut Torque Maintenance 186 Hub Piloted Wheel Installation Procedures 186 Windshield Wiper 187 Wiper Blade Assembly Replacement 187 Wiper Arm Removal Replacement 188 Removal 188 Installation 188 Ma...

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

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

Page 13: ...erence If you sell the bus make sure this manual stays with it Optional Features This manual describes many optional features that may not be installed in this vehicle Cautions Warnings Notes Cautions Warnings and Notes are included throughout this manual CAUTION Cautions advise you of the proper care to be taken to prevent damage to your vehicle or property WARNING Warnings advise you of hazards ...

Page 14: ...r phone 1 800 44 TRUCK 87825 for assistance Component Code Numbers Code numbers are the basis for identifying the components used on your IC Bus bus They are used by sales personnel to order the bus by manufacturing to build it and by parts to service the bus Many items in this manual are identified by codes Code numbers are a combination of numbers and or letters These codes are listed on the Veh...

Page 15: ...d waxing to prevent deterioration Determining washing frequency is the customer s responsibility NOTE For vehicles exposed to ultraviolet rays of the sun apply a coating of Bon Ami soap or similar product to the inside surfaces of the windshield and windows to shade the interior and prevent fading of the interior trim 2 Inspect painted surfaces touch up all exposed primed or raw metal areas to pre...

Page 16: ... shops smoky industrial areas and locations of possible road splash contact 5 If a vehicle is parked on an incline install wheel chocks Reporting Safety Defects U S Registered Vehicles If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying ...

Page 17: ...OBD system operates similarly to previous power train control systems by storing fault codes and turning on the MIL If the problem that caused the fault goes away the code will clear and the MIL will go out after certain operating conditions have been met This may take several times operating the vehicle Supplemental Federal Emission Control System Warranty The United States Environmental Protecti...

Page 18: ...nnovative technologies The GHG emission related warranty covers components certified as innovative technologies which are part of the certified emission controls Please contact your authorized IC Bus or International Dealer for further information Supplemental Federal Emission Control System Maintenance Repair And Replacement Your vehicle may comply with the Greenhouse Gas GHG regulations adopted ...

Page 19: ...epaired before operating the vehicle After returning from your daily routes you must complete a written inspection report in accordance with CDL regulations Report any faults that you find or any problems that occurred during your trip to the service department so that they can be repaired before the next trip NOTE Make sure your bus is in proper operating condition to keep the passengers safe NOT...

Page 20: ... Mirrors 5 Turn Signals 6 Crossing Gate 7 Headlights 8 Rearview Mirrors 9 RED Warning Lights CE Bus Rear View 1 Identification Lamps 2 AMBER Warning Lights 3 Clearance Lamps 4 Turn Signals With or Without Arrows 5 Back up Lights 6 Stop Lights Tail Lights 7 Emergency Door Handle 8 RED Warning Lights 9 Reflex Reflector 8 ...

Page 21: ...Inspection Guide CE Bus Right View 1 Emergency Roof Vent Hatch 2 Emergency Exit Window 3 Intermediate Side Marker Lamp 4 Static Vent 5 Hood Latch 6 Reflex Reflector 7 Side Mounted Turn Signal Lamp 8 Fuel Door 9 ...

Page 22: ...eft View 1 Emergency Kickout Window 2 Emergency Roof Vent Hatch 3 Stop Arm 4 Battery Compartment 5 Electrical Compartment Access Panel 6 Static Vent 7 Side Mounted Turn Signal Lamp 8 Intermediate Side Marker Lamp 9 Reflex Reflector 10 ...

Page 23: ...el Cap The propane autogas fuel cap is on the right side of the bus located behind the right rear tire Typical Propane Autogas Fuel Tank Configuration The propane autogas fuel tanks are located on the underside of the bus behind the rear axle 11 ...

Page 24: ...s a manual shutoff valve to be used in the case of an emergency The valve is located underneath the bus on the front side of the propane autogas tank 1 4 Turn Fuel Safety Shutoff Valve To operate the valve grab firmly and pull the valve down a 1 4 turn 90 until the tab on the lever contacts the dowel on the tank This will manually stop fuel flow from the tanks 12 ...

Page 25: ...as you walk up to the bus Check for vandalism and loose items under the vehicle Check the fuel door and the fuel tank cap Review the results of the previous post trip inspection with your supervisor or previous driver Check all previously noted items to make sure that all requested repairs have been made Leaks Check for signs of fluid leaks in the engine compartment Also check for signs of drips o...

Page 26: ...exterior strobe light test it as well Inspect all reflectors headlights turn signals and emergency flashers Make certain they are clean firmly attached and without cracks or breaks Wheels and Tires WARNING To prevent property damage personal injury and or death if wheels or tires must be changed obtain expert tire service help Mounting and dismounting of tires should only be performed by qualified...

Page 27: ...o the torque charts in the Maintenance section Shock Absorbers Check for cracks leaks and missing or broken mounting bolts or bushings Brakes Table 3 Brakes Drum or Rotor and Brake Linings Check to see that there are no cracks dents or holes and no loose or missing bolts Check to see that the brake linings where visible are not worn thin or contaminated by lubricant Hoses Check for secure coupling...

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

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

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

Page 31: ... psi 138 to 310 kPa Restart engine shift into a low gear and gently pull against service and parking brakes separately to make sure they will hold Hydraulic Brake Check Pump the brake pedal 3 times Then apply firm pressure to the pedal and hold for 5 seconds The pedal should not move and the brake pressure indicator should not illuminate Accelerator Pedal Check for smooth non binding pedal action ...

Page 32: ...e 6 Integrated Air Conditioning System IC Air Compressor Belts Check for tension and wear Inspect for properly tensioned belt This ensures maximum compressor performance and belt life Evaporator Filters Check for cleanliness A properly maintained filter maximizes air flow and system performance Hoses Check that hoses are secured and protected Prevents the possibility of refrigerant leaks Wiring Ha...

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

Page 34: ...ect fuel tanks for dents scratches gouges abrasions and other signs of damage Check that fuel tanks are secured to mounting brackets and hardware is secured to frame Fuel Lines Inspect fuel lines and connections for any leaks crimping or other signs of damage Decals and Labeling Verify that all required propane decals are present on tanks and vehicle Fuel Safety Shutoff Valve Check for signs of da...

Page 35: ...ors and an Integral Digital Display that provide odometer transmission gear indication and compass heading and outside temperature displays This instrument panel gauge cluster displays the crucial operational functions of the vehicle The following are descriptions and illustrations of the gauges warning indicators and integral digital display options 23 ...

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

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

Page 38: ... WARNING To prevent property damage personal injury and or death never operate the vehicle when insufficient air pressure less than 70 psi 483 kPa is indicated for either the primary or secondary air system The volume of air required to stop the vehicle may be greater than that available Have the brake system checked and repaired before returning the vehicle to service There are 10 gauges in the i...

Page 39: ...indication of air pressure available for the primary air brakes in pounds per square inch PSI 34 Indicates the approximate fuel level in the fuel tanks 35 Provides indication of air pressure available for the secondary air brakes in pounds per square inch PSI Direct Drive Warning Indicators The Instrument Panel Gauge Cluster also houses eight 8 direct drive warning indicators that alert the operat...

Page 40: ...lly selected by using the display control button Display Control The display control is used to scroll to a quadrant and to select the various modes within a quadrant To navigate between quadrants turn and release the control either clockwise or counterclockwise To select the screens within a quadrant press and release the control Press and hold the control for more than 3 seconds to reset the val...

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

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

Page 43: ...taneous fuel economy sent from the engine The display shall be in miles per gallon or liters per 100 kilometers corresponding to the units selected while in the odometer mode Display Format 30 0 INST MPG INST L 100KM Trip Average Fuel Economy The display value shall be the average fuel economy value since the last reset of the trip odometer The display shall be in miles per gallon or liters per 10...

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

Page 45: ...layed indicates restricted air flow to the engine Yes No Exterior Lamp Check Active Message displayed indicates Exterior Lamp Check is in progress Yes No HVAC Temp Setting Bar graph displayed show temperature setting in low to high increments No No Activate HVAC Front Blower Bar graph displayed show blower speed setting in Off and low to high increments No No Air Pressure Diagnostic Yes No Cruise ...

Page 46: ...Warning Lamp Yes 1 RED Stop Lamp 2 AMBER Warning Lamp Check Trans Message is displayed when transmission needs to be serviced Yes AMBER Warning Lamp Trans Temp Message is displayed when transmission turns on the AMBER Warning Lamp Not available with all transmissions Yes AMBER Warning Lamp Gen Trns Flt Message is displayed when transmission turns on RED Stop MIL or PROTECT or the YELLOW Warning in...

Page 47: ...iveline EGC Compass Module ESC VSM SD AGSP TPMS Exhaust Module Telematics AGSP 2 SIC 2 AGSP 3 SIC 1 PAM Service Tool Global Message is displayed when a module other than the engine requests the AMBER Warning Lamp Yes AMBER Warning Lamp VSL Ovrd Active No No VSL Ovrd Expiring No No Blank screen available only when engine rpm less than or equal to 325 rpm or vehicle speed less than 3 km h No No Cali...

Page 48: ...g Indicator Association Calibration Ended Message is displayed when vehicle speed is less than 3 km h and the operator has requested Calibrate Compass in the current ignition cycle No No Declination Zone Message is displayed only when vehicle speed is less than 3 km h No No 36 ...

Page 49: ...er indicators Warning indicator Warning Message RED Stop Lamp STOP ENGINE AMBER Warning Lamp WARN ENGINE Outside Temperature and Compass Displays Optional The optional Outside Temperature and Compass Heading is displayed in Quadrant 3 Typical displays for Temperature and Compass Heading are listed in the following table The display provides both the outside ambient temperature and the relative dir...

Page 50: ... near the front bumper Due to its location the sensor readings can be affected by road or engine heat during idling or prevailing driving conditions extended slow movement The display will be in F or C depending on the units selected while in the odometer mode Quadrant 4 Transmission Gear Displays Quadrant 4 Transmission Gear Indications Allison P R N D L gear display 38 ...

Page 51: ...ass Compass Declination Declination Zone and End Calibration NOTE The Declination Zone for the location where the Compass Calibration procedure is being performed must be set first and thereafter the Compass Directional Calibration procedure can be performed Both procedures are listed on the following pages and must be followed exactly to ensure proper calibration of the compass Compass Declinatio...

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

Page 53: ...ne number is displayed Refer to Declination Zone Map to determine the proper number for the current geographic location NOTE If no Declination Zone number is selected within 15 seconds the display will return to the Compass Declination message NOTE If the compass is being calibrated recalibrated the Declination Zone must be set to the Zone number for the location where the compass calibration reca...

Page 54: ...the display control knob until this message appears 3 Press and hold the display control knob until the End Calibration command is displayed NOTE IF the End Calibration command will not show up turn OFF the vehicle restart it and return to Step 1 NOTE The following steps 4 through 6 must be completed within 3 minutes to lock in the new calibration Do not press the display control knob or turn the ...

Page 55: ...mpass calibration Turn the vehicle ignition key OFF and then restart the vehicle Wait 10 seconds for the compass to complete its self test Drive the vehicle in a circle and note the compass readings If the lower left quadrant of the Instrument Panel Gauge Cluster Display shows the correct compass vehicle heading the compass calibration is now complete If the compass readings are incorrect inspect ...

Page 56: ...gurations Item No Item Description Switch Indicator Status Left Side Optional Push Button Switches 49 Configured by customer request 50 Configured by customer request 51 Headlight Park Lamp Switch Go to Lights section 52 Instrument Panel Gauge Cluster Dimmer Switch Go to Lights section Right Side Optional Switches Indicators 53 Configured by customer request 54 Configured by customer request 44 ...

Page 57: ...Additional Comments Fuel Level Gauge low only alarms on each key switch turn on 5 BEEPS Gauge warning indicator illuminates Voltmeter Gauge out of range reading 5 BEEPS Gauge warning indicator illuminates Engine Oil Pressure Gauge out of range reading 5 BEEPS Gauge warning indicator illuminates Engine Coolant Temperature Gauge out of range reading 5 BEEPS Gauge warning indicator illuminates Transm...

Page 58: ...ergency exit Post Trip Inspection REPEATED SINGLE BEEP LIGHTS FLASHING THEN HORN HONKING Complete the Post Trip Inspection Turn Signal Alarm CONTINUOUS TONE Alarm sounds if either turn signal is on for more than one mile Will not activate when hazard flashers are on Low Coolant Alarm REPEATING SINGLE BEEP Gauge warning indicator illuminates Seat Belt Reminder With Seat Belt Monitoring REPEATING SI...

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

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

Page 61: ...use of the cruise control switches in this location refer to the cruise control procedure later in this section Horn The horn is a standard electric automotive type and is located in the center of the steering wheel Push down the horn button to operate it 49 ...

Page 62: ...ove causing the driver to lose control of vehicle CAUTION To prevent property vehicle and or engine component damage do not lubricate the Tilting mechanism The optional adjustable tilt steering column allows you to pull the tilt steering control toward you and move the steering wheel up or down Hold the control while adjusting the wheel to the desired position Release the tilt steering control to ...

Page 63: ...positions may be empty while other rows may have only one switch Switches are installed in the same location unless precluded by state regulations Before reading this section of the manual sit in driver s seat and become familiar with the location of the controls and switches in this bus NOTE Your bus may not be equipped with all switches listed The left console switch panel contains the controls ...

Page 64: ...ATED MIRROR Turns heating element behind outside mirror glass ON OFF LEFT FAN Turns HI LO OFF driver s defog fan above windshield DRIVER DOME Turns ON OFF driver side lights DOME LIGHTS Turns ON OFF interior side lights NOISE SUPP Disconnects power to all noise generating devices LIFT SWITCH Turns Wheelchair lift power On or Off MIDSHIP HEATER Turns heater blower motor to HI LO OFF 52 ...

Page 65: ... windshield defog fan HI LO OFF DESTINATION Turns ON OFF illumination for destination window STROBE LIGHT Turns ON OFF top strobe light LAST DOME Turns ON OFF last dome light REAR DOME Turns ON OFF rear half dome lights REAR ROW DOME Turns ON OFF rear row lights MASTER FLASHER Turns ON OFF system power for the warning indicator system 53 ...

Page 66: ...s located inside the storage compartment The power outlet supplies a 12 volt power supply for driver accessories such as cellular phones and two way radios Transmission Parking Brake and Ignition Switch Panel Before reading this section of the manual sit in driver s seat and become familiar with the location of these controls The Transmission Parking Brake Ignition Switch Panel provides the mounti...

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

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

Page 69: ...onsole switch panels may be different Some switch positions may be empty while other rows may have only one switch Switches are installed in the same location unless precluded by state regulations Before reading this section of the manual sit in driver s seat and become familiar with the location of the controls and switches in this bus NOTE Your bus may not be equipped with all the switches liste...

Page 70: ...ns Traction Control system ON or OFF Air Brake chassis Optional MUD SNOW TRAC CTRL Switch Controls amount of ATC action of the Traction Control system Hydraulic Brake chassis ON LAMP CHECK Initiates exterior lamp test during Pre Trip inspection SNZ NO STDNT LEFT Initiates delay of Post Trip inspection system activation Optional Lift Door Indicator Green indicator flashes to indicate that Lift door...

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

Page 72: ...te the cruise control feature 2 Press the SET position on the rocker switch after reaching a speed of at least 56 km h 35 mph to set the cruise speed 3 Push and hold the RESUME ACCEL to increase your set speed or the SET COAST to decrease your set speed 4 A slight tap on the brake pedal deactivates the cruise To return to this speed press the RESUME ACCEL position switch 5 Push the OFF position on...

Page 73: ... necessary ask for assistance when moving vehicle Backup alarms are available through your IC Bus dealer However they are never a substitute for the above procedures 1 Left Right Side Flat Mirror Adjustment Switch 2 Left Right Side Convex Mirror Adjustment Switch The optional mirror adjustment controls are located on the left side console control panel The switches with the left and right directio...

Page 74: ... make sure that the top of the side windows are visible in the upper edge of the mirror and that the right side of the bus body is visible in the inside edge of the right flat mirror 3 Look through the right convex driving mirror and make sure that the view in the top of the convex mirror overlaps the view covered by the right hand flat driving mirror and that the right side of the bus body is vis...

Page 75: ...uzzer Feature This optional buzzer sounds when headlight switch is ON and ignition switch is in the OFF position Daytime Running Lights Feature This feature provides for vehicle headlights to be turned on when engine is running and headlight switch is in OFF position Optional Headlight Feature 08WPY Provides for headlights tail lights park marker lights and Instrument Panel Gauge Cluster lights to...

Page 76: ...ow or is operating at a reduced speed The hazard warning lights can be operated with the ignition in any key switch position Press the button to activate all hazard flashers simultaneously Press the button again to turn the flashers off Turn Signal Switch The turn signal switch is mounted on the left side of the steering column below the steering wheel The green directional indicator lights which ...

Page 77: ...king the switch into the full turn position Move the turn signal lever up or down to the point where resistance to movement is felt The turn signal lever returns to the OFF position when released HI LO Beam Pull the turn signal lever past the click position the lights switch to high beam position Pull again to return to low beam 65 ...

Page 78: ...he driver can exit the bus and visually inspect all lights on the exterior of the vehicle for proper operation Activation To activate the exterior lamp check Turn the key to the ON or Accessory ignition position All lights that will be checked must be turned OFF The parking brake must be applied Place the exterior lamp check switch in the ON up position The exterior lamp switch ON indicator will t...

Page 79: ...d the bus operated Consult with local and state authorities for specific procedures that may apply for children entering or exiting buses NOTE Due to various state and local requirements the location of the entrance door Open Close switches shown may be different from your vehicle The entrance door Open Close button is located on the steering wheel in the left button position Press the top of the ...

Page 80: ...witch to the CLOSE position Three Position Door Switch The optional three position door switch is located on the left or right console switch panel With the ignition ON the entrance door can be opened by moving the switch to the OPEN position With the ignition ON the entrance door can be closed by moving the switch to the CLOSE position Moving the switch to the RED OVER position will start the RED...

Page 81: ...or The emergency release for the air actuated door is located on the right side of the instrument panel To release the air actuated door move the toggle switch from NORMAL to EMERGENCY Traffic Warning System The Traffic Warning system alerts both oncoming and following drivers when the bus is preparing for safety stops such as railroad crossing stops or when loading and unloading passengers The sy...

Page 82: ...the warning flasher system The AMBER warning lights alert the public of the intent to stop and load unload students onto from the bus The RED warning lights and the stop arm are intended to warn the public that students are boarding or leaving the bus The warning indicator control is located on the right side of the steering wheel Optional Rocker Switches NOTE These switches can be located on the ...

Page 83: ...or closed Non Sequential System With the master flasher switch in the ON position press the FLASHER ON OFF button to engage the AMBER warning lights If the master switch is not turned on there will be no activation of the lights or stop arm The AMBER warning lights change automatically to the RED warning lights when the entrance door is opened The RED warning lights will deactivate when the doors ...

Page 84: ... or leaving the bus Crossing Gate The crossing gate extends when the RED warning lights are on to make sure that students do not cross too close to the front of the bus and out of the view of the driver NOTE The illustration is for reference only and may differ from the actual vehicle 72 ...

Page 85: ...erts when the bus ignition is turned off at the end of a trip System Function Any time the ignition key is in the RUN position AND the RED flashers have been turned on AND the door is opened or is already open the system will be automatically activated Once the system is activated it will trigger the vehicle alarm when the ignition is in the OFF position for greater than half a second At this time...

Page 86: ...ooze Mode NOTE The Snooze function can be turned Off before the snooze time out period by placing the ignition switch to the OFF position This function allows the driver to temporarily disable the No Student Left Behind system activation and is called the Snooze mode The purpose is to allow passengers to disembark the vehicle without the No student Left Behind system triggering the vehicle alarm T...

Page 87: ... Lift switch in the ON position See Driver Controls section for the switch description Also refer to the Brake and Transmission sections for wheelchair lift interlocks 1 Ensure that the ignition switch is in the OFF ON or ACCESSORY position 2 Place transmission shift lever in P Park or N Neutral position 3 Apply Parking Brake The Instrument Panel Gauge Cluster PARK indicator will turn On An Option...

Page 88: ...he Wheelchair lift door according to the manufacturer s Operator Manual instructions The LIFT DOOR Instrument Panel Gauge Cluster indicator will then turn Off Wheelchair Lift Alarm The Instrument Panel Gauge Cluster alarm a continuous beeping will be triggered if 1 The wheelchair lift door is extended AND 2 a The Parking Brake is not applied knob is not pulled and released OR b The transmission is...

Page 89: ...ired by NHTSA no later than 21 April 2004 This label is a warning to the user of the bus not to block the emergency exits with wheelchair child restraint systems or other items for example trash containers Pull up the RED lever to unlatch the emergency door After the door is unlatched push outward to open Make sure the printed operating instructions are present and visible at all times Inspect eve...

Page 90: ... present and visible at all times Inspect every emergency exit every day for proper operation Roof Vent Hatch When using the vent push upward at the locations marked on the hatch Open the hatch by turning the RED knob to the 2 position then push upward on the knob Make sure the printed operating instructions are present and visible at all times Inspect every emergency exit for proper operation eve...

Page 91: ...ating this vehicle over rough roads or surfaces as this can cause loss of vehicle control Use caution and reduce speed Properly adjusted seats and seating systems may not compensate completely for severe road conditions Ensure that head clearance will be maintained during all road conditions as the seat may move up and decrease the available space WARNING To prevent property damage personal injury...

Page 92: ...he Seat Height Lever while raising or lowering the seat to the desired height then release the lever While adjusting the seat height the Seat Height Lever may remain in the up position The location and orientation of the Height Adjustment Lever may vary 3 When at the desired position move the seat slightly up or down until the Seat Height Lever snaps to its height engaged down position 4 After the...

Page 93: ... Knob The seatback adjustment knob is located on the left of the seat at the intersection of the seatback and the lower seat cushion Turn the seatback adjustment knob clockwise to tilt the seatback forward and rotate the knob counterclockwise to tilt the seatback rearward Lumbar Support Pull the left switch Lumbar Support Switch upward or push downward to adjust the lumbar support to your preferen...

Page 94: ...e is in motion to avoid personal injury Before fastening the seat belt adjust the seat to the desirable driving position Driver s lap and shoulder three point seat belt with retractor is standard Driver s Adjustable Lap and Shoulder Three Point Belt WARNING To prevent property damage personal injury and or death position the safety belt height adjusters so that the belt rests across the middle of ...

Page 95: ...tton to disconnect the seat belt Seat Belt Tether NOTE The majority of the driver seats have nonadjustable tethers Driver seats with adjustable tethers must follow the Tether Adjuster Procedure Tether Adjuster Procedure 1 Tether Adjuster NOTE The seat belt tether must be checked for proper adjustment prior to vehicle operation 1 Adjust the driver seat fore and aft to accommodate driver comfort 2 A...

Page 96: ...y damage personal injury and or death do not bleach or re dye seat belt webbing Bleaching or re dyeing may cause a weakening premature deterioration of the webbing WARNING To prevent property damage personal injury and or death use caution when cleaning seat belts Disinfectant products can contain solvent based chemicals that can adversely affect seat belt components NOTE Do not use a 70 isopropyl...

Page 97: ... 2 Seat Belt Cutter 3 Lid If it becomes necessary to cut through a seat belt the seat belt cutter is located inside of the driver s compartment lid NOTE Location of seat belt cutter may vary according to state regulations Passenger Seat Belts Buses may be equipped with optional passenger seat belts WARNING To prevent property damage personal injury and or death properly inspect and maintain seat b...

Page 98: ...t over the stomach or abdomen area The lap portion of the belt must be low and snug over the bony structure of the passenger s hips Passenger Three Point Seat Belts Optional Buckling Up 1 The passenger should sit as flat against the seat back as possible to achieve the best possible fit of the lap shoulder belt on the passenger s upper and lower torso 2 Pull out the shoulder belt webbing from the ...

Page 99: ...IS IMPORTANT AND MUST BE DONE TO ENSURE PROPER FIT OF LAP SHOULDER BELT TO PASSENGER The shoulder portion of the belt must be snug across the chest and in the center of the passenger s shoulder 8 Position the shoulder height adjuster at or just above the passenger s shoulder The shoulder belt should not cross the passenger s face or neck 9 Make sure the lap shoulder belt is snug and lies flat agai...

Page 100: ...ll the way right to create three seating positions Integrated Child Restraint Seats Optional WARNING To prevent property damage personal injury and or death observe the following Follow all instructions on the child restraint and in this manual It is important to use an approved rearward facing infant restraint for a full year to allow the neck and spine to develop enough to support the weight of ...

Page 101: ...n damaged such as a bent buckle or 5 point connector or torn webbing Similarly the child restraint equipped bench or bucket seat must be replaced after a collision if it is damaged such as a bent or broken seat frame Indiana Mills and Manufacturing Inc IMMI Integrated Child Restraint Seats Optional WARNING To prevent property damage personal injury and or death observe the following Use only with ...

Page 102: ...pen chest clip by squeezing middle tabs and pulling chest clip apart Unbuckle harness buckle by pressing down on RED release button To loosen harness lift metal at top of seat and pull down on shoulder strap to loosen strap Repeat with second shoulder strap 1 Metal Tabs 2 Shoulder Staps 3 Harness Buckle Place the child in the restraint with the child s back flat against the back of the bus seat cu...

Page 103: ...ine without sagging It does not press on the child s flesh or push the child s body into an unnatural position 1 Shoulder Height Adjuster 2 Chest Clip Fasten chest clip by pushing both sides together then position chest clip at middle of the child s chest at armpit level Position each shoulder height adjuster at or just above the child s shoulder Be sure harness is snug and tight on child s thighs...

Page 104: ... who weigh between 20 and 85 lb 9 and 39 kg Refer to the following illustration to become familiar with the parts of the child seat and five point seat belts This child restraint system conforms to U S Federal Motor Vehicle Safety Standard 213 and Canada Motor Vehicle Safety Standard No 213 4 1 Buckle Release Button 2 Seat Belt Latch Plates 3 Adjustment 4 Shoulder Belt Strap 5 Removable Pad 6 Fold...

Page 105: ...er and put it 2 3 in 5 7 6 cm below the child s chin The purpose of the clip is to keep the shoulder belts positioned correctly on the shoulders To remove the child reverse steps 1 3 Child Restraint Anchorage Systems Optional The following provides information pertaining to attaching add on child seats to passenger seats with child restraint anchorage systems including tether anchors When installi...

Page 106: ...sent in the same passenger seat and only one add on child seat is going to be installed it is recommended to use the system closest to the wall to improve the mobility of the passenger in the open seat in case of an emergency WARNING To prevent property damage personal injury and or death observe the following Follow all instructions on the child restraint and in this manual Follow the manufacture...

Page 107: ...the tether over the seat as shown then connect the snap hook to the tether anchor Adjust the tether to a snug and tight fit by pulling on the free end of the strap at the adjuster IMMI Seats Tether Installation 1 Child Seat Tether All base three point and integrated child restraint BTI bus seats equipped with LATCH are also equipped with tether anchors for add on child seats Location and Use of Te...

Page 108: ...trap Free End 2 Tether Anchor To attach an add on child seat tether route the tether on the child seat over the top of the belted BTI bus seat Extend the tether and connect the snap hook to the nearest tether anchor provision at the lower rear of the seat Adjust the tether to a snug and tight fit by pulling on the free end of the strap at the adjuster 96 ...

Page 109: ...e side rear pedestal and on the seat wall mount bracket rear edge 1 Strap Free End 2 Tether Anchor To attach an add on child seat tether route the tether on the child seat over the top of the SafeGuard XChange bus seat Extend the tether and connect the snap hook to the nearest tether anchor provision at the lower rear of the seat Adjust the tether to a snug and tight fit by pulling on the free end...

Page 110: ...wering the cushion to seated position Keep hands and feet clear while lowering the seat cushion Rear Latching 1 Latch 2 Seat Bottom Optional release latches may vary based on seat style Seats automatically latch when sat upon Pull up on seat cushion to confirm cushion is latched For both rear and side latching designs pull the latch to release Side Latching 1 Latch 2 Seat Bottom 98 ...

Page 111: ...ce requirement are met Original seat layout for a specific unit can be obtained by contacting your IC Bus dealer The standard track seat label is found on the front bulkhead of all buses with track seating Minimum spacing with standard barrier to track barrier and track barrier to track barrier Minimum spacing with stanchion to track barrier track seat to track barrier and track seat to standard b...

Page 112: ...n 82 60 cm Track CEW QSCR11 Track Seat with 3 point belts with Integrated Child Seat 29 35 in 74 55 cm 32 35 in 82 17 cm Standard CEW QS11 Track Seat with 3 point belts without Integrated Child Seat 28 53 in 72 47 cm 32 56 in 82 70 cm Track CEW QS11 Track Seat with 3 point belts without Integrated Child Seat 29 36 in 74 57 cm 32 36 in 82 19 cm Standard IMMI Track Seat without Integrated Child Seat...

Page 113: ...73 99 cm 34 13 in 86 69 cm IMMI ICS Track Seat with Integrated Child Seat IC Track 30 54 in 77 57 cm 36 44 in 92 56 cm CEW CR11 Track Seat with or without lap belts with Integrated Child Seat CEW CR11 Track Seat with or without lap belts with Integrated Child Seat 28 00 in 71 12 cm 31 00 in 78 74 cm CEW QSCR11 Track Seat with 3 point belts with Integrated Child Seat CEW QSCR11 Track Seat with 3 po...

Page 114: ...n 71 12 cm 31 00 in 78 74 cm IMMI Track Seat without Integrated Child Seat IMMI Track Seat without Integrated Child Seat 27 00 in 68 58 cm 31 00 in 78 74 cm IMMI ICS Track Seat with Integrated Child Seat IMMI ICS Track Seat with Integrated Child Seat 27 00 in 68 58 cm 32 00 in 81 28 cm IMMI Track Seat without Integrated Child Seat IMMI ICS Track Seat with Integrated Child Seat 27 00 in 68 58 cm 32...

Page 115: ...could cause an accident To improve defroster efficiency remove ice and or snow by hand from the windshield and windows with a non metallic scraper Driver Heater The driver heater console is located below the left switch panel Three heater control knobs provide air flow direction fresh air or recirculation control and temperature selection Adjust the Air knob to provide outside air into the driver ...

Page 116: ...tilizing the Defrost Climate Control Heat selector Use this mode at maximum fan speed and temperature setting for best windshield and side window defrosting If equipped the optional step well heater may be turned on for added air flow to the defroster vents Integrated Air Conditioning System IC Air This vehicle may be equipped with an optional skirt or roof mounted factory installed Integrated Air...

Page 117: ...vent property damage personal injury and or death wait until the motor cools off before repositioning the fan motor It can become extremely hot when operated in normal ambient temperatures for long periods of time Some buses are equipped with circulation fans The controls are labeled RIGHT FAN and LEFT FAN and are located on the left switch panel driver console Each fan has OFF LO HI speed control...

Page 118: ...booster pump unless the heater cut off valve is manually opened Heater Cut Off Valve NOTE The illustration is for reference only and may differ from the actual vehicle Typical Heater Cut Off Valve The heater cut off valve for the coolant supply is under the hood Turn the heater cut off valves ON counterclockwise whenever the heater is used Turn the heater cut off valves OFF clockwise to stop hot c...

Page 119: ...ing aids such as ether propane or gasoline in the engine air intake system WARNING To prevent property damage personal injury and or death never add gasoline gasohol and or alcohol to diesel fuel This mixture creates an extreme fire and explosion hazard WARNING To prevent property damage personal injury and or death never start the engine unless you re sure the transmission selector is in Neutral ...

Page 120: ...d materials according to applicable regulations The following steps should be completed prior to starting the vehicle 1 Roll the key on as you would to start the vehicle normally 2 The WAIT TO START lamp will illuminate while the fuel system performs the purging procedure this may take 5 30 seconds depending on engine heat and engine off time 3 Once the fuel system purge is complete the WAIT TO ST...

Page 121: ... the key 6 Monitor idle speed Low idle speed is 750 850 rpm Check all gauges during warm up 7 For minimum oil pressure at idle refer to the Engine Operation and Maintenance Manual If oil pressure is too low the low oil pressure warning lamp may illuminate along with an AMBER lamp 8 During normal engine operation the low oil pressure lamp will illuminate if minimum oil pressures are not met If the ...

Page 122: ...Propane Electronic Fuel Injection LPEFI fuel system This system utilizes liquid propane fuel injection to improve power efficiency and operating characteristics The LPEFI system works the same as a gasoline fuel injected system with the only difference being that it injects liquid propane into each intake port The propane fuel system operates similar to a gasoline fuel system A typical gasoline fu...

Page 123: ...rict attention to all propane autogas fueling site instructions and cautions when refueling your vehicle WARNING To prevent property damage personal injury and or death do not vent or release propane indoors or near sewers pits or low lying areas Propane can accumulate in low spots creating a fire hazard Propane can also displace oxygen creating a suffocation hazard Propane autogas systems should ...

Page 124: ...he fuel door is left open after fueling the engine will not start 1 Turn off the vehicle and follow all fueling site Personal Protective Equipment PPE requirements 2 Open the fuel door 3 Unscrew the dust cap from the vehicle fill valve 4 Check the seal gasket or O ring for tears breaks or cuts If damaged missing do not dispense until replaced 5 Remove the nozzle from the dispenser 6 Screw the nozz...

Page 125: ...fter Running Out of Fuel If the vehicle runs out of fuel during operation refer to the Engine Operation and Maintenance Manual supplied with your vehicle Cold Weather Operation INSTRUCTIONS WARNING To prevent property damage personal injury and or death do not use the washers in freezing weather without first warming the windshield with the defrosters otherwise the washer solution may freeze on th...

Page 126: ... dirt buildup Fill fuel tank at end of daily operation to prevent condensation in tank Above normal coolant temperature could be temporarily decreased by downshifting into the next lower gear This increases engine RPMs which increases coolant flow and air flow through the radiator NOTE If above normal operating temperatures persist have vehicle serviced at first available opportunity Turning Off t...

Page 127: ...d or death always check and maintain brakes in proper condition and adjustment Out of adjustment brakes could cause reduced braking ability The Full Power Brake System incorporates standard braking Antilock Braking ABS Automatic Traction Control ATC and the Powered Parking brake into one fully integrated hydraulic brake system With the Full Power Brake system braking energy is stored similar to an...

Page 128: ...luster alarms The following lists some of the common faults See fault indicators in Instrumentation section NOTE Whenever a brake system warning indicator is lit do not operate the vehicle until the faulty condition has been corrected Brake Pressure ON STEADY when either front or rear brake system brake pressure is low Once the vehicle is stopped and the parking brake is set it will not release un...

Page 129: ... in The switch is spring loaded to return to the neutral center position after being pushed or pulled There is no visual indication at the knob that the parking brake is applied or released Always observe the gauge Instrument Panel Gauge Cluster PARKING BRAKE indicator to determine if the parking brake is applied or released The parking brake will be automatically applied when the ignition switch ...

Page 130: ... sounding and a warning indicator is illuminated The volume of air required to stop the vehicle may be greater than that available Have the brake system checked and repaired before returning the vehicle to service All air brake equipped vehicles have a split brake system A split system provides a way to stop the vehicle if a failure occurs in either the primary or secondary brake system If air pre...

Page 131: ...pressure created activates the system causing the brake pads to contact the rotor When braking is released the air pressure in the brake chamber is released exhausting the pressure on the diaphragm causing the brake pads to return to their neutral non braked position Using Air Brakes WARNING To prevent property damage personal injury and or death always check and maintain brakes in proper conditio...

Page 132: ...ssion in Neutral position 4 Pull the parking brake control knob to apply the parking brake To release Air Parking Brake 1 Have the engine running and your foot on the service brake pedal 2 Push in the control knob 3 Wait until system pressure has reached 70 psi NOTE DO NOT operate vehicle until system pressure has reached 70 psi NOTE To release the parking brake on vehicles with the Optional Wheel...

Page 133: ...r lift manufacturer s Operator Manual before operating the Wheelchair lift Power will not be supplied to the wheelchair lift mechanism unless all of the following steps have been performed Wheelchair Lift Extension Operation NOTE Some vehicles with wheelchair lift extensions are configured to operate with the ignition switch off This optional configuration requires the lift door to be open the tra...

Page 134: ...ge Cluster alarm will beep continuously if the Wheelchair lift door is extended AND The Parking Brake is released NOTE When either the Powered Parking Brake is applied or the Wheelchair Lift door is closed the Instrument Panel Gauge Cluster alarm will immediately stop beeping Antilock Braking System ABS WARNING To prevent property damage personal injury and or death Antilock Brake System s ABS are...

Page 135: ...ockup of controlled wheels if you over brake for existing road conditions The wheel hubs carry exciter rings used by the axle mounted sensors to transmit wheel speed information to the ABS electronic control unit located on the chassis frame The control unit monitors and compares all wheel speed inputs to determine if any wheel s are about to lock If wheel lockup is about to occur the control unit...

Page 136: ...s standard brake system operation is maintained The brake system is still operational but the antilock system does not operate to prevent wheel lockup if you over apply the brakes for existing conditions NOTE If the ABS indicator stays illuminated or continues to flash have the system serviced immediately A yellow warning indicator on the instrument panel indicates the status of the ABS Each time ...

Page 137: ...duces engine power and or selectively applies the rear brakes The system allows your vehicle to make better use of available traction in these conditions by also limiting the engine rpm when you push further on the accelerator which limits wheel spin The TRAC CTRL indicator in the Instrument Panel Gauge Cluster will illuminate during this Traction Control event The TRAC CTRL indicator will also il...

Page 138: ...n Control system is disabled International Ride Optimized Suspension IROS If Equipped CAUTION To prevent vehicle and or component damage do not operate a vehicle without air in the suspension springs Operating the vehicle without air in the air suspension springs will damage the suspension degrade ride performance and may cause transmission damage The suspension system automatically adjusts to dif...

Page 139: ... and always keep that person in sight If so desired backup alarms are available through your IC Bus or International dealer However they are never a substitute for the above procedures WARNING To prevent property damage personal injury and or death hold the brake pedal down while you move the gearshift from position to position to prevent unexpected vehicle movement NOTE For complete transmission ...

Page 140: ...Hydraulic Brakes push and hold the Parking Brake knob Park indicator on Instrument Panel Gauge Cluster will turn off 3 Lift foot from the brake pedal and then slowly press the accelerator pedal Allison Generation IV Push Button Shift Selector 1 Digital Display 2 Mode ID 3 Mode Button 4 Range Selector Buttons To shift the transmission into R Reverse or D Drive press the brake pedal then press R or ...

Page 141: ...ssion Shift Wheelchair Lift Interlocks WARNING To prevent property damage personal injury and or death always set the parking brake when operating the wheelchair lift or unexpected and sudden vehicle movement may occur Read and understand these paragraphs along with the Wheelchair lift manufacturer s Operator Manual before operating the Wheelchair lift On vehicles equipped with an optional Wheelch...

Page 142: ...Park position retract and stow the Wheelchair lift and then close the lift door LIFT DOOR gauge luster indicator should be turned off When the Wheelchair Lift has been safely stowed according to the Wheelchair lift manufacturer s Operator Manual instructions the bus can be safely moved as follows Depress the service brake pedal and press and hold the button on the gearshift lever handle and move t...

Page 143: ...ght switch panel to the ON position When in the ON position the switch indicator will be turned on Automatic Transmission Operating Temperatures Your vehicle may be equipped with a warning indicator or gauge that will indicate high transmission fluid temperatures The sump fluid reservoir temperatures of the Allison Transmissions should not exceed 250 F 120 C 131 ...

Page 144: ...Operation 132 ...

Page 145: ...light switch 1 Use the hazard warning light switch in an emergency to warn traffic of vehicle breakdown approaching danger the vehicle is in tow or is operating at a reduced speed 2 Press the button to activate all hazard flashers simultaneously 3 Press the button again to turn off the flashers Emergency Equipment Recommended On Board Fire Extinguisher Inspect the fire extinguisher monthly to make...

Page 146: ...t Use this whenever any type of body fluid comes in contact with the bus When items are used they should be immediately replaced Reflective Triangle Use the triangle whenever the bus is pulled over to the side of the road The reflective triangle kit is usually located behind the driver s seat After opening the kit unfold the triangle and make sure it locks in place 134 ...

Page 147: ...as fuel system emergency perform the following 1 Stop the vehicle place it in park and apply the parking brake 2 Immediately evacuate the area Everyone in the affected area should move to a safe distance from the spill or leak Do not re enter area 3 Call for help After you are at a safe distance from the affected area call 911 or the local fire department Fuse Circuit Breaker Charts NOTE To gain a...

Page 148: ...ed F5 10A Stop Light Relay Battery Feed F6 30A Air Conditioner Blower Motor F7 10A Key Switch Battery Feed F8 3A Ignition 1 Relay F9 10A Diagnostic Connector Battery Feed F10 30A Ignition 2 Relayd F11 5A Body Builder NEC GPS Prewire F12 5A System Controller Switch Pack Accessory Feed F13 5A Aware F14 5A Body Builder Ignition Feed F15 10A Compass Module Aware F16 10A System Controller Ignition Feed...

Page 149: ...WABCO Air Antilock Brake System F26 5A Panel Light System F27 10A Brake Monitor Ignition Feed F28 5A Air Conditioner Clutch F29 5A Change Transmission Filter Ignition Feed Location Size Description F30 5A WTEC Shift Selector Eaton Hybrid TECU F31 10A Fan Shutter F32 20A Coolant Heater F33 15A Fog Light Battery Feed F34 10A Windshield Washer Pump Ignition Feed NOTE Locations marked with a must use ...

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

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

Page 152: ...Heater F11 7 5A Rear Power Vent 7 5A Defog Fan Left Switch 15A Defog Fan x3 Left Switch F12 20A Center Blower Left Switch F13 25A Step Warmer F14 15A Booster Pump F15 20A Two Way Radio Terminal Strip F16 3A Air Horn F17 15A Dome Lights 7 5A Direct to Disk Recording DDR Digital Video Recording DVR System Camera System F18 20A Video System Terminal Strip F19 15A Heater Mirrors F20 15A Air Compressor...

Page 153: ...Alternate Entrance Door F45 3A Entrance Door Dump Valve F46 3A Fuel Fired Heater Timer F47 3A Stop Arm Crossing Gate Cancel F48 5A Dome Light Timer Relay F49 7 5A Emergency Exit Alarms F50 7 5A Front Cluster Light F51 7 5A Emergency Exit Lights F52 3A Traction Sanders F53 20A Pedestrian Lights 3A PTI Bus Scan PTI Check Mate F54 15A PTI CRS F55 7 5A Heated Wiper Blades F56 10A Motorized Mirrors F57...

Page 154: ...gency Exit F80 See Circuit Diagram F81 3A Electrical Panel Compartment Light F82 Rear Door Options F83 7 5A Emergency Exit Alarms Battery F84 10A AED Vandal Lock Switch Table 13 Power Relays Location Description NS1 Noise Suppression Relay 1 NS2 Noise Suppression Relay 2 NS3 Noise Suppression Relay 3 NS4 Noise Suppression Relay 4 MD1 Master Disconnect Relay 1 MD2 Master Disconnect Relay 2 MD3 Mast...

Page 155: ...se the latches on both sides of the cowl 1 Hood Handle NOTE Never use the crossview mirrors as a handle Mirror damage and misadjustment can occur Use the hood handle and pull the hood forward over center and allow it to settle into the raised position 143 ...

Page 156: ...prevent damage to vehicle electronic components voltage supplied to a vehicle s electrical system must never exceed 16 0 volts This voltage must not be exceeded when the ignition switch is in the OFF ACC or IGN position or during engine cranking The most reliable means for jump starting a vehicle is to use batteries connected so as to provide 12 volts Never use an electric welder 1 Remove metal ri...

Page 157: ...s normally present around the battery 8 Reverse above procedure when removing the jumper cables Towing Instructions WARNING To prevent property damage personal injury and or death always install wheel chocks when manually releasing the spring brakes For towing make sure the vehicle is securely connected to the tow vehicle and the tow vehicle parking brakes are applied before releasing the disabled...

Page 158: ...ks becoming unintentionally detached from the vehicle CAUTION To prevent transmission damage vehicles should not be towed even short distances without suspending rear wheels or removing the axle shafts or propeller shaft In the event the chassis is equipped with tandem axles and the vehicle is to be towed from the front the forward rear axle may be raised to clear the road surface and secured to t...

Page 159: ...ld the Parking Brake knob to release the parking brake If battery power has been lost the Parking Brake cable will have to be disconnected by following the steps below see illustration CAUTION To prevent vehicle and or component damage while removing the parking brake cable only the threaded rod should rotate If the cable is to be reused do not allow the cable to twist during removal Parking Brake...

Page 160: ...the differential and the transmission If axle shaft is not disconnected remove the rear axle shafts from the axle assembly Cover the wheel hub ends to prevent loss of axle lubricant and entrance of contaminants Towing Vehicles With Rear Wheels Suspended Whenever possible it is preferable to tow a disabled vehicle from the rear by raising the rear of the chassis When towing a vehicle with the rear ...

Page 161: ...hemicals used to clean or disinfect your IC Bus can adversely affect materials used to build the vehicle Many common cleaning chemicals can damage or ruin the appearance of materials like ABS plastic vinyl rubber aluminum glass and painted surfaces As with the cleaning chemicals used the cleaning process or the lack of a cleaning process can also affect the life and appearance of the vehicle Chemi...

Page 162: ... damage glass Use a soft cloth and glass cleaner only Interior The best method to preserve the appearance and extend the life of the interior components of your IC Bus is frequent and thorough cleaning of the components A cleaning schedule and the cleaning requirements should be determined based on the type of service conditions in which the unit is operated Interior Light Bar Cleaning All Interio...

Page 163: ...en with warm or cold water to remove dirt and preserve the original luster of the paint Never wash the vehicle in the direct rays of the sun or when the sheet metal is hot to the touch as this may cause streaks in the finish Do not use hot water strong soaps or detergents Never wipe dirt off a dry surface as the dirt will scratch the paint Always make certain that steps and grab handles or any ext...

Page 164: ...or polish Use a high quality paste wax and follow the wax manufacturer s instructions to help prevent bus paint from fading Crossing Arm Cleaning The Crossing Arm is only to be cleaned with a mild detergent and warm water No other cleaners are to be used as they may damage the surface 152 ...

Page 165: ...le receives proper care and maintenance IC Bus service parts are available through your IC Bus dealer If IC Bus service parts are not used the owner must make sure the parts used are an equivalent As with any machine take care to avoid being injured when performing maintenance repairs or inspections Improper or incomplete service could result in the vehicle not working properly which in turn may r...

Page 166: ...mulate in low spots creating a fire hazard Propane can also displace oxygen creating a suffocation hazard Propane systems should be serviced in a properly ventilated area WARNING To prevent property damage personal injury and or death do not make modifications to any part component or system of the vehicle as that can adversely affect the quality and reliability of your vehicle WARNING To prevent ...

Page 167: ...OT use bumper as a lifting point 5 Support vehicle with floor stands under axle s If axle or suspension components are to be serviced support vehicle with floor stands under frame side members Pre Trip and Post Trip Inspections Pre Trip inspections should be performed each day by the operator before operating this vehicle In many circumstances a Post Trip inspection can be even more valuable since...

Page 168: ...nds the use of Fleetrite lubricants and IC Bus original equipment parts The lubrication intervals specified should be performed at whatever interval occurs first whether it is kilometers miles hours or months Refer to the Lubrication and Maintenance Intervals Chart at the end of this section for further details Engine Compartment Fluid Check Points NOTE Location of deaeration tank power steering r...

Page 169: ...mined by the adjustment of the pressure regulator To perform these adjustments open access panel door and use the procedures below Door Opening and Closing Speed Adjustment Points 1 Opening Speed Screw 2 Closing Speed Screw 3 Pressure Regulator Adjustment Knob 4 Lock Nuts 5 Air Filter Pressure Regulator Adjustment WARNING To prevent property damage personal injury and or death do not replace the a...

Page 170: ...peed screw 2 clockwise to slow the door closing speed or counterclockwise to increase the door closing speed Tighten the locknut 4 Electrically Actuated Entrance Door Adjustment Electrically actuated doors are set to operate in 2 to 2 seconds There is no adjustment for electrically actuated door opening and closing speed Axles Typical Axle Tire and Rim Specifications Vehicle Identification Label F...

Page 171: ...r window as intended In situations where the window is clean on the outside but discolored on the inside check the lube level by removing the rubber fill vent plug and insert a finger into the hole The specified lube level for clear window type hubcaps is from the minimum line to 8 mm 5 16 in above the minimum line If the lube level suddenly drops dramatically below the minimum level see the Servi...

Page 172: ...tion All new IC Buses are manufactured with non asbestos brake linings However exposure to excessive amounts of brake material dust may be a health hazard WARNING To prevent vehicle damage personal injury and or death pay strict attention to the following if your vehicle is equipped with Automatic Traction Control or any type of locking or limited slip differential power will be transmitted to the...

Page 173: ...with water and wrung until nearly dry NEVER use compressed air or dry sweeping to clean the work area Use an industrial vacuum cleaner with a HEPA filter system and rags soaked in water and wrung until nearly dry Carefully dispose of used rags to avoid getting dust into the air Use an approved respirator when emptying vacuum cleaners and handling used rags Wash your hands before eating drinking or...

Page 174: ...push rod travel every service interval to determine if adjustment is necessary Brake chamber push rods on original equipment chambers have a stroke indicator an orange RED paint marker rib near the base of the push rod to aid adjustment checks If the push rod is clean and the brakes require adjustment the orange RED marker can be seen protruding from the chamber when the brakes are applied Check t...

Page 175: ...d accordingly Air Dryer Purge Valve Check that the purge valve opens and expels moisture when the air governor shuts off the air compressor Air should escape rapidly and then quickly stop If the purge valve does not open or you can hear a slight audible air leakage past the valve for longer than 30 seconds the valve may be sticking and should be rebuilt Purge valves may also stick if the air dryer...

Page 176: ...ne an exact maintenance interval time or mileage since vehicles are used in a variety of applications and conditions Refer to the LUBRICATION AND MAINTENANCE INTERVAL CHART later in this section for recommendations On a periodic basis of at least once per year inspect the entire brake system for The proper operation of the service and parking brakes The condition of the discs calipers and ABS exci...

Page 177: ...Brake Fluid Accumulators WARNING To prevent property damage personal injury and or death since the brake system is under high pressure it should only be serviced by qualified personnel in accordance to the instructions in the service manual The hydraulic brake fluid accumulators store fluid under pressure The pressure of the gas in the accumulator may gradually diminish over time The brake system ...

Page 178: ...ly Too much grease will not allow air to escape from the connection and this compressed air will push the connection apart Accessory Feed Connections WARNING To prevent property damage personal injury and or death do not increase size of fuse or circuit breaker or change type of breaker supplied with your truck as this could cause wiring to overheat and possibly burn Electrical circuits are design...

Page 179: ...8L LPG engine refer to the Engine Operation and Maintenance Manual provided with the vehicle Scheduled Maintenance For information regarding routine scheduled maintenance such as replacement of oil filters coolant belts belt tensioners etc as well as inspection and adjustment of items such as valve lash etc refer to the Engine Operation and Maintenance Manual supplied with the vehicle Air Inductio...

Page 180: ...e sure that the rubber dust unloader valve at bottom of housing is in place free of debris and not cracked 4 Inspect the new air filter element for a damaged or nonresilient rubber gasket Inspect the air filter element body for dents or excessive pleat bunching If any of the mentioned conditions exist obtain and install an alternate new air filter element from your IC Bus or International dealer 5...

Page 181: ... fitting Leak in vacuum line Apply vacuum to gauge until locked up at RED zone Reconnect gauge and close end of line air tight Hold in reset button Indicator will drop slightly and then not move unless vacuum line has a leak Leak in gauge Repeat above except close gauge connection airtight Engine air flow too low to generate a restriction reading Turbocharged engines must be full load to pull full...

Page 182: ...w or rain Temporary high restriction can occur during a rain or snow storm and it disappears after drying out COLD AIR MAY BE SO DENSE THAT HIGH RESTRICTION MAY NOT REDUCE ENGINE POWER BEFORE ELEMENTS ARE DAMAGED FROM HIGH VACUUM If gauge is locked up at RED zone check elements for damage Chassis Mounted Charge Air Cooler and Radiator Core Inspection and Cleaning With the engine off visually inspe...

Page 183: ...olant slowly with the engine running Adding cold coolant to a hot engine may crack the cylinder head or crankcase Never use water alone Make sure that coolant level is maintained between the COLD MIN and COLD MAX lines on the deaeration tank when engine is cold Gravity Fill Coolant Method PSI 8 8L LPG Engine Filling Instructions NOTE Using the KL5007NAV Coolant Management Tool is the recommended p...

Page 184: ...cooling system start engine and run at an elevated idle 1 500 rpm for approximately 10 minutes 6 Verify coolant concentration and adjust coolant level to the COLD MAX level 7 Install the deaeration tank cap once the coolant is stabilized at the COLD MAX level 8 Verify the coolant is at the correct level and concentration 9 Inspect and adjust the coolant level as necessary prior to daily operation ...

Page 185: ...red to maximize hose life maintain performance of the system and avoid potential failures Poorly maintained coolant is cause for hose failure Coolant level and condition should be inspected on a regular basis Check coolant level as part of the daily inspection Check coolant concentration per coolant manufacturer requirements Heater and coolant hose inspections should be performed on an annual basi...

Page 186: ...r additional failures Engine Oil NOTE Use only recommended viscosity engine oil Refer to the Engine Operation and Maintenance Manual for specific engine oil specifications The PSI 8 8L LPG engine requires the use of synthetic blend oil that meets Dexos1 standards This requirement will provide a reduction in volatility and oil consumption significant wear protection and improved piston cleanliness ...

Page 187: ...opriate cold warm months for greatest passenger comfort Maintain heat exchanger air filters if equipped The driver s heater filter is located behind the grille near the floor to the left of the driver s seat The optional step well heater filter is located behind the grille to the front of the step well Under seat heaters may have an optional filter on the top surface of each heater box Heater boos...

Page 188: ...ight NOTE When retorque is required make sure the part is in like new condition If it can t be retorqued then the part needs to be replaced Suspension alignment must be maintained at all times Check the U bolts as follows After the bus has been operating under load for 1 600 km 1 000 miles retorque the U Bolt nuts Thereafter retorque the U bolt nuts every 58 000 km 36 000 miles Clean and lubricate...

Page 189: ...pins and tightness of nuts at both ends of tie rod and drag link Check that pitman arm steering arm at steering gear mounting is tight and locked Check the power steering system for leaks or hose chafing Repair at once Maintain proper power steering fluid level Regularly inspect steering column joint bolts and steering linkage particularly for body to chassis clearance Tightening Steering Intermed...

Page 190: ...stem before returning the vehicle to service Failure to properly bleed the hydraulic system can result in shimmy complaints and or steering wheel oscillation when striking a bump Consult your IC Bus dealer or IC Bus Service Manual for the proper procedures for filling and bleeding the system The power steering fluid filter is located inside the power steering reservoir To remove the filter unscrew...

Page 191: ...s hot the fluid level should fall within the HOT run band Add fluid as required DO NOT OVERFILL or the transmission will overheat Check the shift linkage for proper operation Check operation of transmission neutral safety switch Try to start the vehicle in all shift selector positions The starter should ONLY operate when the shift selector is in Neutral or Park if supplied Refer to the LUBRICATION...

Page 192: ...lways use experienced trained personnel with proper equipment and correct procedures to mount or remove tires and wheels WARNING To prevent property damage personal injury and or death always follow these instructions when mounting tires on wheels Only personnel who have had proper training and experience should mount or remove tires from rims or wheels Use only heavy duty rims or rims approved fo...

Page 193: ...on and long life for the tires Failure to maintain correct inflation pressure may result in sudden tire destruction improper vehicle handling and may cause rapid and irregular tire wear Therefore inflation pressures should be checked daily and always before long distance trips Follow the tire manufacturer s recommended cold inflation pressure for the tire size type load range ply rating and axle l...

Page 194: ...e by a repair These indicate the start of internal separation Any cut that reaches to the belt or ply cords or any cut that is large enough to grow in size and depth Any nail or puncturing object If any stone or object is held by a tread groove and is starting to drill into the tread base remove the object Proper tire inflation toe in adjustment loads and road speeds are important factors governin...

Page 195: ...ttern Drive axle tires may be placed on the other end of the same axle so that direction of rotation is reversed This is often helpful if a heel and toe or alternate wheel nut wear pattern has developed Rotation Is Advisable 1 If front steering axle tires become irregularly worn move to rear position 2 In a dual assembly reverse the position of the tires if one tire wears much faster than its mate...

Page 196: ... may be rotated to a drive axle Chamfer or Shoulder Wear with tires inflated properly is a normal tendency of most radial tire designs If both inside and outside shoulders are wearing evenly around the tire no further action is required Overinflation is not effective in correcting this effect Irregular Wear If irregular wear is present check the axle alignment tire pressure wheel balance shock and...

Page 197: ...ubricant should be used as an aid for mounting tires Always inflate tires in a safety cage WARNING To prevent property damage personal injury and or death Do not mix stud piloted wheels or fasteners with hub piloted wheels or fasteners Mixing wheel types may cause premature wheel failure Do not change from steel wheels or a steel inner and aluminum outer wheel combination to aluminum wheels withou...

Page 198: ... to the wheel Tightening procedure for disc wheels with flange nuts hub piloted 1 Clean the mating surfaces of the hub drum and wheel s as well as the wheel studs and wheel nuts with a wire brush prior to assembly 2 Lubricate the two piece wheel nuts by putting two drops of oil in the slot between the nut and washer and spin the washer to spread the oil around the nut to washer contact surface 3 C...

Page 199: ...nuts To correct this condition operate the vehicle normally for approximately 80 km 50 miles then use a calibrated torque wrench to retorque the wheel nuts to specification using the appropriate pattern shown in the wheel nuts torque sequence diagram 10 As part of a daily pre trip inspection look for loose or missing wheel nuts Also look for rust streaks extending outward from the wheel nuts this ...

Page 200: ...he wiper arm to the drive stud Remove the wiper arm from the drive stud by pulling the wiper arm outward Installation 1 Align the marks at the base of the wiper arm assembly and the drive stud boot 2 Install the wiper arm on the drive stud Confirm the correct height of each wiper from the base of the windshield per the figure shown 3 Place the wiper arm retaining nut on the drive stud and tighten ...

Page 201: ...are for normal highway and environmental service conditions These intervals may be expressed in miles kilometers hours of operation and or months of operation It is important to note that in high duty cycle types of operation and or where operating conditions are extremely severe such as in deep water mud or unusually dusty conditions the vehicle may require lubrication much more frequently than s...

Page 202: ... performed at Special Intervals or in addition to A or B Service when the interval dictates Lubrication and Maintenance Interval Bus Recommended Synchronized Intervals System Item Intervals Special Interval 3 km miles hours months Pre Trip Inspection Pre trip Inspection Items listed in Section 2 Check All Wheel Bearing Oil Type Check Level A B Suspension Fasteners Components Check A B Tie Rod Ends...

Page 203: ...d or worn Inspect B Electrical Power Distribution Center Corrosion throughout case and on pins of fuses and breakers Inspect B Power Steering Fluid Check Level A B Steering System Check Tightness A B Steering Gear Lubricate A B ATTN Install grease slowly at low pressure Power grease guns may blow out seals Steering Intermediate Shaft U Joints Slip Joint Lubricate A B Power Steering Fluid Change 64...

Page 204: ...Check A B Low Air Pressure Warning Alarm Check A B Air Tanks all Drain Water A B S Cam Bushings Lubricate A B Shoes Check for wear and drag A B Rotors Drums Calipers Chambers Hoses etc Check for wear damage A B Brake Chamber Rod Travel Check A B Air Dryer Desiccant Replace AD 9 Model 400 000 km 250 000 miles 24 Other Models 200 000 km 125 000 miles 12 Air Dryer Heater Purge Valve Check AD IP 12 AD...

Page 205: ...e Check A B Brake Pedal Holds Pressure Check A B Service Brakes Operation Check A B Parking Brake Operation Check A B Discs Calipers Lines etc Check for wear damage A B Parking Brake Cable Check condition A B Hydraulic Full Power Brakes Accumulators Replace At Instrument Cluster Light Indication or 12 years Coolant Check Level A B Radiator CAC Fins Check for Blockage A B Fan Clutch Check A B Fan B...

Page 206: ...enance Manual Air Induction System Check looseness leaks Refer to Engine Operation and Maintenance Manual Air Filter Replace Refer to Engine Operation and Maintenance Manual Engine Oil and Filter s Replace Refer to Engine Operation and Maintenance Manual Fan Belt Auto Tensioner Inspect Refer to Engine Operation and Maintenance Manual Engine Fuel Filter Replace Refer to Engine Operation and Mainten...

Page 207: ...id Filter s Replace Allison 1000 PTS Spin On Control Main filter with any fluid first 8 000 5 000 _ With mixed conventional and Synthetic Trans fluid for Main or Lube Aux filter every 80 000 50 000 24 With Synthetic Trans fluid only for Main or Lube Aux filter every 80 000 50 000 24 Allison 2000 controls filter with any fluid type At first 8 000 5 000 200 and then every 80 000 50 000 24 thereafter...

Page 208: ...150 000 4 000 48 Conventional or Conventional Synthetic Mixed Automatic Trans Fluid Replace Allison MD 40 000 25 000 1 000 12 Allison 1000 PTS 80 000 50 000 24 Allison 2000 80 000 50 000 24 Transmission Cont Factory filled Synthetic Non Mixed Automatic Trans Fluid Replace Allison 1000 PTS 160 000 100 000 48 Allison 2000 160 000 100 000 48 Allison MD 240 000 150 000 4 000 48 Allison GOLD FILTERS re...

Page 209: ...o 0 005 in specification or lube condition is contaminated or low then perform a full wheel end tear down Inspect bearings spindle and spindle nuts for excessive wear and replace as necessary Rear Axle With Synthetic Oil Change Dana Spicer 288 000 180 000 3 years Meritor 400 000 250 000 3 years Rear Axle Cont Rear Axle Wheel Ends Full tear down inspection of all wheel end components regardless of ...

Page 210: ...edal Check Function A B Entry Door Check Operation A B Emergency Doors Exits and Buzzers Check A B Roof Hatch es Check Operation A B Lights Interior Exterior Check A B Headlights Bright Dim Daytime Check A B Seat Belt s Bolts Check Operation Condition A B Warning lights Stop Arm s Crossing Gate Entrance Door Warning lights Interaction Check A B Safety Equipment As Equipped Check A B Optional Compo...

Page 211: ...ll and All Heater Core Air Filters Inspect Clean or Replace A B Air Conditioner Optional Check Performance B All Seat Base Bolts B Body Mounting Bolts Inspect Tightness At 1 600 km 1 000 miles then every 4 800 km 3 000 miles Heater Hoses and Connections Check Condition 12 months NOTE See Heater and Coolant Hose Inspection and Replacement Guide in this section for additional information Body Compon...

Page 212: ...cific engine crankcase capacities refer to separate Engine Operation and Maintenance Manual provided with vehicle Full Power Brakes Brake Fluid Approximately 6 Liters 1 6 Gallons Rear Axle Table 17 Axle Axle Lube Capacities Liters Pints Dana Spicer S11 130 S14 130 S16 130 7 5 16 Dana Spicer 17060S 19060S 21060S 23060SH 13 2 28 Meritor MS 17 14X 3DFL MS 19 14X 3DFL MS 21 14X 3DFL 15 9 33 6 Meritor ...

Page 213: ... Automatic B 300d 14 29 Table 19 Transmission cont Transmission Model Transmission Fluid Volumes Liters Pints Allison Automatic 1000_PTS 18 38 Allison 5 Speed Automatic 2100 PTS 18 38 Allison Automatic 2200 PTS 18 38 Allison Automatic 2500 PTS 18 38 Allison Automatic 2550 PTS 18 38 Allison Automatic School and Shuttle Bus 3000 PTS 27 58 Approximate refill quantity less than initial fill since a po...

Page 214: ... 9R22 5 6 75 7 50 10R22 5 6 75 7 50 11R22 5 7 50 8 25 12R22 5 8 25 9 00 225 70R19 5 6 75 Table 20 Approved Tire and Wheel Combinations cont Tire Size Rim Width 235 80R22 5 6 75 7 50 245 70R19 5 6 75 7 50 255 70R22 5 6 75 7 50 8 25 265 70R19 5 6 75 7 50 8 25 275 80R22 5 7 50 8 25 295 75R22 5 8 25 9 00 202 ...

Page 215: ...C 15 F to 100 F 80W 140 15 F and above 26 C and above 85W 140 10 F and above 12 C and above Front axle wheel bearing oil Eaton Dana axle multipurpose EP gear lube of API GL 5 quality meeting MIL PRF 2105E specs including synthetic lubricants Do Not Mix conventional lube with Synthetic lube 75W 40 F to 32 F 40 C to 0 C 75W 90 40 F to 100 F 40 C to 38 C 75W 140 40 C and above 40 F and above 80W 15 F...

Page 216: ...10 F and above 12 C and above 80W 90 15 F and above 26 C and above 75W 90 40 F and above 40 C and above 75W 40 C to 2 C 40 F to 36 F SAE 40 or 50 10 F and above 12 C and above SAE 30 15 F and above 26 C and above Front axle wheel bearing grease tie rod ends drag link king pin and bushing Eaton Dana axle Meritor axle Fleetrite NLGI 2 Lithium Complex Based Moly grease P N 991044C2 or equivalent GC L...

Page 217: ...ite 472141 C1 Connectors Dielectric Grease NYOGEL 760 G Steering Power Steering fluid change Fleetrite P N CH990625C2 Strg Gear Ross TAS Output Seal Lubricate Fleetrite Lithium Complex Based Moly grease P N 991044C2 or equivalent GC LB NLGI 2 Multi purpose Lithium Complex grease Strg Intermediate Shaft U Joints Slip Joint Lubricate Fleetrite NLGI 2 Lithium Complex Based Moly grease P N 991044C2 or...

Page 218: ...ite NLGI 2 Lithium Complex Based Moly grease P N 991044C2 or equivalent GC LB NLGI 2 Multi purpose Lithium Complex grease Clutch Release Bearing Shafts Fork Lubricate Fleetrite NLGI 2 Lithium Complex Based Moly grease P N 991044C2 or equivalent GC LB NLGI 2 Multi purpose Lithium Complex grease Cooling System Coolant Refer To Engine Operation and Maintenance Manual 206 ...

Page 219: ...etrite P N 991884C1 SAE 50 All Temperatures Eaton Fuller UltraShift WetClutch Synthetic Castrol TranSynd or TES 295 Gear Box EmGard 2979 All Temperatures SAE 50 All Temperatures Eaton Dana Synchronized Fill Change Lubricants are listed in order of preference Mineral Gear Oil API GL 1 Rust and Oxidation Inhibited Fleetrite P N 991061C1 Petroleum Oil Engine Oil API CJ or CI SAE 90 Above 10 F 12 C SA...

Page 220: ...es Recommended for highest transmission durability and lowest maintenance costs Allison Conventional Automatic Transmission Fluid ATF Fill Change Meets the requirements for Allison TES 389 specification Approved Conventional ATF Suppliers website http www allisontransmission com service Below 13 F 25 C pre heat is required Rear Axle Single speed Gear oil meeting MIL PRF 2105E API MT 1 GL 5 75W 40 ...

Page 221: ...ove 26 C and above 90W 10 F to 100 F 12 C to 38 C 85W 140 10 F and above 12 C and above 140W 40 F and above 4 C and above Meritor Synthetic from factory with Cognis Emgard 75W 90 will have a tag attached to fill plug that reads as follows Filled with synthetic lube Do Not Mix Single speed Continued Meritor petroleum 0 76 A Hypoid Gear Oil 0 76 B Hypoid Gear Oil 0 76 D Hypoid Gear Oil 0 76 E Hypoid...

Page 222: ...10 678 450 500 NOTE Do not use lubrication on dry threads Where excessive corrosion exists a light coat of lubricant on first three threads of stud bolt is permitted Keep lubricant away from Hex nut Flange nut washer surface and flat on disc wheel Steering Column Pinch Bolts Torque Chart Specified Torque Bolt Type N m Lb ft 7 16 20 95 102 70 75 210 ...

Page 223: ...ernational Air Suspension IROS for all other axles 502 542 370 400 23 000 lb Capacity International Air Suspension IROS for axles 14ADN 14ADP 14AJC 14AJE 14ATP and 14ATR 353 407 260 300 14TBT 23 000 lb Capacity International Air Suspension IROS for all other axles 353 407 260 300 14VAB 13 500 lb Capacity RR Springs Vari Rate with 4 500 lb Auxiliary Rubber Spring 353 407 260 300 14VAC 15 500 lb Cap...

Page 224: ...t Wiper Pivot M20 Hex Nut 28 21 Seat Base Bolts Specified Torque N m Lb ft All Seat Base Bolts 21 7 to 27 16 to 20 Filter List Filter part numbers and or specifications may change during the life cycle of this vehicle Current information on the appropriate chassis and engine filters for your vehicle can be obtained by contacting your local IC Bus or International dealer parts department If you nee...

Page 225: ...ce PortalSM Web site or via the OnCommand Service Information DVD Information on the Service PortalSM Web site s content availability and fee structure can be obtained by contacting your local International Truck dealer or in the case of a National Account an International Fleet Service Manager The OnCommand Service Information DVD contains Navistar branded truck engine and bus information includi...

Page 226: ... Optional Service Contracts Custom Service Contracts and Performance PM designed to ensure the lowest possible cost of ownership are also available Published Service Contracts Performance PM Service designed to ensure the lowest possible cost of ownership are also available Optional Service Contracts have been pre packaged to fit most common applications HOW TO OBTAIN Navistar Inc Warranties Stand...

Page 227: ... engage Air Parking Brake 120 A CONT Air Brakes cont To release Air Parking Brake 120 Air Cleaner Element Service 168 Air Conditioner Refrigerant 200 Air Disc Brakes 0004JBZ 0004JCC 0004WEY 0004WEZ 119 Air Dryer 163 Air Dryer Desiccant Replacement 163 Air Dryer Heater 163 Air Dryer Purge Valve 163 Air Induction System 167 Air Reservoir Tanks Moisture Draining 163 Air Restriction Gauge Service 168 ...

Page 228: ...orque Chart 211 Axles 158 Body 160 Front Axle Alignment 159 Front Axle Inspection and Lubrication 158 Front Axle Normal Maintenance 159 Rear Axle Inspection and Lubrication 159 B Backup Alarms 130 Body 160 Body Fluid Cleanup Kit 134 Body Fuse Circuit Breaker Panel 139 Fuse Description Chart Table 142 Power Relays Table 142 Brake Fluid Level 164 Brake Inspection and Adjustment 161 164 Brake Lines H...

Page 229: ...s Rear View 8 CE Bus Right View 9 CE White Integrated Child Restraint Seats Optional 92 Chassis Fuse Circuit Breaker Chart 136 C CONT Chassis Inspection 165 Chassis Lubrication 155 Chassis Mounted Charge Air Cooler and Radiator Core Inspection and Cleaning 170 Checking Inflation 181 Child Restraint Anchorage Systems Optional 93 Location and Use of Lower LATCH Anchors 94 Circulation Fans 105 Closin...

Page 230: ...ce Door Adjustment 158 Electronic Safety Messages 69 Emergencies While Filling With Propane Autogas 113 Emergency Door 77 E CONT Emergency Equipment Recommended On Board 133 Body Fluid Cleanup Kit 134 Fire Extinguisher 133 First Aid Kit 134 Reflective Triangle 134 Emergency Exit Windows 78 Vertical Emergency Exit Window 78 Emergency Exits 77 Emergency Door 77 Emergency Exit Windows 78 Vertical Eme...

Page 231: ...erior Lamp Check 66 Activation 66 Deactivation 66 Function 66 Switch Location 66 F Fan Clutch 173 Filling Instructions 171 Filter List 212 Fire Extinguisher 133 First Aid Kit 134 First Respondent and Operator Warning 135 Chassis Fuse Circuit Breaker Chart 136 Fuse Description Chart Table 138 Power Relays Table 137 Flashing Stop Arm 72 Flooring 151 Fluid Precautions 165 Frame and Optional Tow Hooks...

Page 232: ... Replacement Guide 173 Heater Booster Pump 106 H CONT Heater Cut Off Valve 106 Heater System 103 175 Auxiliary Heaters 104 Driver Heater 103 HI LO Beam 65 High Restriction Reading Table 170 Horn 49 Hot Weather Operation 114 Hub Piloted Wheel Installation Procedures 186 Hydraulic Brake Fluid Accumulators 165 Hydraulic Brakes 115 Power Parking Brake System 117 To Manually Apply the Powered Parking B...

Page 233: ...pass Displays Optional 37 Outside Temperature Reading 38 User Switches 44 I CONT Instrument Panel Gauge Cluster cont Warning Indicators 24 Integral Digital Display 28 Integral Digital Display Detailed Information 30 Quadrant 1 Informational Displays 30 Quadrant 2 Text and Warning Messages 32 Warning Messages 37 Integrated Air Conditioning IC Air System 175 Integrated Air Conditioning System IC Air...

Page 234: ...nd Maintenance Interval Bus Recommended Synchronized Intervals Table 190 Lubrication Points 177 M Maintenance Guidelines 153 M CONT Maintenance Intervals 189 Lubrication and Maintenance Interval Chart Notes 190 Lubrication and Maintenance Interval Chart Symbols Key 190 Lubrication and Maintenance Interval Bus Recommended Synchronized Intervals Table 190 Mirror Adjustment 60 N Navistar Inc Warranty...

Page 235: ...Anchor Optional 94 Passenger Three Point Seat Belts Optional 86 39 Inch Flex Seat 88 Buckling Up 86 Unbuckling 87 Passenger Two Point Seat Belt Lap Belts 86 Passenger Three Point Seat Belts Optional 86 P CONT Passenger Three Point Seat Belts Optional cont 39 Inch Flex Seat 88 Buckling Up 86 Unbuckling 87 Passenger Two Point Seat Belt Lap Belts 86 Pedal Adjustment 125 Post Trip Inspection No Studen...

Page 236: ...ble 183 Tire Replacement 183 Rotation Is Advisable 183 S SAE Oil Viscosity Grades 174 Safety Recalls and Authorized Field Changes 5 Scheduled Maintenance 167 Seat Base Bolts 212 Seat Belt Cutter 85 Seat Belt Tether 83 Tether Adjuster Procedure 83 Seat Height Adjustment 80 Self Diagnostics 110 Service Information 213 Signaling for a Turn 64 Snooze Mode 74 Split System Feature 116 Standard Allison 1...

Page 237: ...stem Function 73 System Purpose 73 T Terminal Inspection Cleaning Corrosion Protection 166 Tether Adjuster Procedure 83 Three Position Door Switch 68 Tightening Steering Intermediate Shaft Joint Bolts 177 T CONT Tilt Hood 143 Lowering the Hood 144 Raising the Hood 143 Tire and Rim Combinations 202 Approved Tire and Wheel Combinations Table 202 Tire Maintenance 181 Checking Inflation 181 Underinfla...

Page 238: ... Fluid Level 179 Transmission Table 201 Transmission Fluid Level 179 Transmission Table 201 Transmission Parking Brake and Ignition Switch Panel 54 Troubleshooting 169 Turn Signal 48 Turn Signal Switch 64 HI LO Beam 65 T CONT Turn Signal Switch cont Lane Change 65 Signaling for a Turn 64 Turning Off the Engine 114 Two Position Door Switch 68 Typical Propane Autogas Fuel Tank Configuration 11 U U S...

Page 239: ...ift Interlocks Retracting and Stowing 75 Wheelchair Lift Operation 75 Wheelchair Lift Alarm 76 W CONT Wheelchair Lift Operation cont Wheelchair Lift Interlocks Extending 75 Wheelchair Lift Interlocks Retracting and Stowing 75 Wheels 185 Wheel and Wheel Nut Maintenance and Installation 185 Hub Piloted Wheel Installation Procedures 186 Wheel Nut Torque Maintenance 186 WIG WAG Warning System 71 Winds...

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