Saf-T-Liner C2 School Bus. Driver’s Manual (2012)

Pre- and Post-Trip Checklists

Pretrip and Post-Trip

Inspection General Information

Regulations in Canada and the U.S. clearly indicate

that it is the driver’s responsibility to perform an in-

spection, and ensure the complete road-worthiness

of a vehicle, before placing it into service. Commer-

cial vehicles may be subject to inspection by autho-

rized inspectors, and an unsafe vehicle can be taken

out of service until the driver or owner repairs it.

Use the following checklists to ensure that vehicle

components are in good working condition before

each trip. Careful inspections eliminate stops later to

fix overlooked or forgotten items.

Numbers within each of the checklists reference the

corresponding detailed instructions found under the

daily, weekly, or monthly inspection and maintenance

procedures in Chapter 12.

If any system or component does not pass this in-

spection, it must be corrected before operating the

vehicle. Whenever equipment requires adjustment,

replacement, repair, addition of lubricants, or a

change of lubricants, see the Saf-T-Liner C2 School

Bus Workshop Manual for procedures and specifica-

tions, or take the vehicle to an authorized Freightliner

dealer.

IMPORTANT: The pretrip and post-trip checklists

in this chapter, and the maintenance procedures

detailed in Chapter 12 and in the Saf-T-Liner

C2 School Bus Maintenance Manual are not all

inclusive. Also, refer to the inspection and

maintenance instructions of the major compo-

nent manufacturers.

11.1

Pre- and Post-Trip Checklists

See Table 11.1 for a checklist of the procedures that

Daily Pretrip Inspection and

should be performed daily, before the first trip.

Maintenance Checklist

IMPORTANT: Before performing any checks,

apply the parking brake and chock the tires.

Procedure Performed

Procedure

Daily Pretrip Inspections/Checks

(check off)

Reference

drain manually drained air reservoirs (that are not equipped with automatic drain

_______

valves)

Check

_______

surge tank coolant level

Inspect

_______

radiator and charge air cooler

Inspect

_______

engine for fuel, oil, or coolant leaks

Check

_______

intake-air restriction indicator and air intake system

Check

_______

engine oil level

Check

_______

automatic transmission fluid level, if equipped

Check

_______

fuel/water separator, if equipped

Inspect

_______

fuel tank(s), fuel lines, and connections

Check

_______

fuel level

Check

_______

clean diesel engine fuel cap vent area

Check

_______

front and rear suspension components

Check

_______

reset dash-mounted air intake restriction indicator

Check

_______

air-pressure warning system

Check

_______

horn

Check

_______

backup alarm, if equipped

Check

_______

exterior lights

Inspect

_______

air brake chambers and pushrods

Inspect

_______

slack adjusters

Check

_______

tire pressure

Inspect

_______

tire condition

Check

_______

rims and wheels

Check

_______

air brake system

Check

_______

parking brake

Inspect

_______

frame rails (missing bolts), crossmembers (bent or loose)

mud flaps (aren’t damaged, at least 10 inches above the ground, and brackets

Check

_______

are secure)

exhaust system (mounted securely, connected tightly, no signs of leaks such as

Check

_______

soot trails)

Inspect

_______

Bendix Hydro-Max® Power Booster , if equipped

Inspect

_______

engine and chassis wiring

Inspector___________________________________________________ Date ________________

Table 11.1, Daily Pretrip Inspection and Maintenance Checklist

11.2

Pre- and Post-Trip Checklists

See Table 11.2 for a checklist of the procedures that

Weekly Post-Trip Inspection

should be performed weekly, post-trip.

and Maintenance Checklist

IMPORTANT: Before performing any checks,

apply the parking brake and chock the tires.

Procedure Performed

Procedure

Weekly Post-Trip Inspections/Checks

(check off)

Reference

_______

manually drain air reservoirs that are equipped with automatic drain valves

—

Inspect

_______

batteries and battery cables

Check

_______

wheel bearing lubricant level

Inspect

_______

steering components

Check

_______

drive belt conditions

Check

_______

air restriction indicator

Inspect

_______

seat belts and tether belts

—

Inspector___________________________________________________ Date ________________

Table 11.2, Weekly Post-Trip Inspection and Maintenance Checklist

See Table 11.3 for a checklist of the procedures that

Monthly Post-Trip Inspection

should be performed monthly, post-trip.

and Maintenance Checklist

IMPORTANT: Before performing any checks,

apply the parking brake and chock the tires.

Procedure Performed

Procedure

Monthly Post-Trip Inspections/Checks

(check off)

Reference

_______

clean the battery terminals

Check

_______

fluid level in the hydraulic clutch reservoir, if equipped

Check

_______

steering wheel play

outer surfaces of the hood and body (for visible surface breaks and damage, as

Check

_______

—

well as corrosion and paint condition)

Inspect

_______

brake lining wear

Inspect

_______

driveshaft

—

Inspect

_______

condition of floor covering and upholstery

—

Check

_______

operation of roof hatches and warning buzzers

—

Check

_______

operation and locking of emergency doors

—

Inspect

_______

wiper blades

—

Inspect

_______

body mounting bolts and clips securely fastened

_______

clean the bus undercarriage

Inspector___________________________________________________ Date ________________

Table 11.3, Monthly Post-Trip Inspection and Maintenance Checklist

11.3

Pre- and Post-Trip Inspections and Maintenance

1.2

Exhaust the remaining air and moisture

Daily Pretrip Inspection and

from the system by opening the drain

Maintenance Procedures

cocks on the bottom of the remaining air

reservoirs. Block the valves open.

IMPORTANT: If any system or component does

not pass this inspection, it must be corrected

NOTICE

before operating the vehicle. Whenever equip-

ment requires adjustment, replacement, and/or

Coolant must be filled to the COLD MAX line of

repair, see the Saf-T-Liner C2 School Bus Work-

the surge tank. Low coolant could result in en-

shop Manual for procedures and specifications.

gine overheating, which could cause engine dam-

age.

Complete the following inspection and maintenance

procedures to ensure that vehicle components are in

2. Check the engine coolant level in the radiator

good working condition before each trip. A driver who

surge tank.

is familiar with the vehicle and drives it regularly can

perform the daily inspections, then add the weekly

If the coolant is low, fill the surge tank to the

and monthly post-trip inspections as scheduled.

MAX line with a 50/50 mixture of water and the

type of antifreeze currently installed in the ve-

If the driver does not operate the vehicle on a con-

hicle. See Fig. 12.1. For a list of approved cool-

sistent basis, all daily, weekly, and monthly inspec-

ants for both diesel and liquid propane gas

tion and maintenance procedures should be per-

(LPG) engines, see Table 12.1. If the surge tank

formed before the trip.

was empty, start the engine after refilling and

check the level again when the engine is at oper-

IMPORTANT: The pre- and post-trip checklists,

ating temperature.

inspections, and maintenance procedures de-

tailed in this chapter are not all-inclusive.

Refer to other component and body manufactur-

ers’ instructions for specific inspection and

maintenance instructions, as well as local, state,

and federal guidelines.

1. Drain the brake system air reservoirs (reservoirs

without automatic drain valves only).

Water and oil normally enter the air reservoir in

the form of vapor because of the heat generated

during compression. After the water and oil con-

dense, drain the resulting emulsion as follows:

1.1

Open the wet tank valve. The drain cock

or pull chain drain is located on the for-

ward end of the supply air reservoir, which

05/31/2007

f200705

is connected directly to the air compres-

sor. Block the valve open.

Fig. 12.1, Surge Tank Fill Cap

WARNING

When draining the air reservoir, do not look into

the air jets or direct them toward anyone. Dirt or

sludge particles may be in the airstream and

could cause injury.

12.1

Pre- and Post-Trip Inspections and Maintenance

3.6

Make sure the heater hoses are pliable

Approved Coolants

and are not cracking or ballooning.

Coolant

EngineType

Coolant Manufacturer

Designation*

3.7

Tighten hose clamps as necessary.

Old World Industries

Fleet Charge®

IMPORTANT: Do not overtighten hose

Shell HD/N

Shell

clamps, as hose life can be adversely af-

Antifreeze

Diesel

fected.

Texaco

JC04 Antifreeze

Van Waters and

Diesel Antifreeze

3.8

Ensure hose support brackets are se-

Rogers Ltd. (Canada)

No. 6038

curely fastened. Make sure hoses are not

Chevron Delo

located near sources of wear, abrasion, or

Propane

Chevron

Antifreeze No.

high heat.

275110^†

IMPORTANT: When replacing hoses, install

* Freightliner-approved antifreeze must meet one of the following condi-

tions: A. Ethylene glycol solution that meets GM 6038-M Engineering

service-type knitted or braided yarn-

Standards. B. Ethylene glycol solution that has less than 0.1% anhydrous

sodium metasilicate and meets either GM 1825-M or GM 1899-M Engi-

reinforced neoprene hose. Extended-service-

neering Standards.

life silicone hoses may also be used. See

†

Chevron Delo coolant is approved for use in LPG engines only.

the Alliance Parts Catalog at www.alliance-

Table 12.1, Approved Coolants

brandparts.com or contact a Freightliner

dealer.

Inspect the radiator and charge air cooler, includ-

4. Check the ground underneath the engine for fuel,

ing the radiator and heater hoses, clamps and

oil, or coolant leaks. Correct any leaks found.

support brackets.

5. Inspect the air intake system for leaks or dam-

3.1

Inspect the radiator and charge air cooler

age.

for clogged fins. Use compressed air or

water directed from the fan side of the

core to backflush any material restricting

NOTICE

airflow.

Failure to maintain a sealed air intake system

3.2

Inspect the radiator and charge air cooler

could allow the entry of dirt and contaminants

for damage and accumulated debris.

into the engine. This could adversely affect en-

Straighten bent or damaged fins to permit

gine performance and result in engine damage.

airflow across all areas of the cores.

5.1

Push the reset button on the air intake

NOTE: When traveling through areas of high

restriction indicator located on the air

insect concentration, it may be necessary to

cleaner, if equipped.

clean the exterior of the radiator or the

5.2

Check the air intake duct from the air

charge air cooler core as often as every 200

cleaner to the engine intake. Make sure

miles (322 km).

the duct components are secure and air-

3.3

Inspect and clean the condenser. If

tight.

clogged, the condenser can restrict airflow

through the radiator.

NOTICE

3.4

Check the radiator for leaks. If leaks are

Operating the engine with the oil level below the

found, have the radiator repaired or re-

minimum fill (or "add") mark or above the maxi-

placed. See Group 20 of the Saf-T-Liner

mum fill (or "full") mark could result in engine

C2 School Bus Workshop Manual for in-

damage.

structions, or take the vehicle to an autho-

rized Freightliner dealer for assistance.

IMPORTANT: On engines that comply with

3.5

Make sure the radiator inlet and outlet

EPA07 or newer regulations, use CJ-4 engine

hoses are pliable and are not cracking or

oil with less than 1% sulfated ash. Failure to

ballooning.

12.2

Pre- and Post-Trip Inspections and Maintenance

use CJ-4 oil may void the warranty on emission

aftertreatment components.

6. Check the engine oil level.

NOTICE

Operating the engine with the oil level below the

08/05/2010

f012186

minimum fill (or "add") mark or above the maxi-

Oil should be within the cross-hatched area of the

mum fill (or "full") mark could result in engine

dipstick.

damage.

Fig. 12.3, Oil Dipstick (propane engine)

6.1

Park the vehicle on a level surface. Allow

several minutes for the oil to drain back

NOTICE

into the oil pan to ensure an accurate

reading.

Failure to use the recommended oil can result in

NOTE: For diesel engines, follow the engine

engine or aftertreatment component damage and

manufacturer’s guidelines for engine shut-

will void the warranty.

down time requirements prior to checking

If the vehicle is equipped with an automatic

the oil level.

transmission, check the automatic transmission

fluid level.

6.2

Pull out the dipstick and clean it with a

paper towel or cloth, then push the dip-

NOTE: The fluid must be warm to ensure an

stick back in all the way. Remove it again,

accurate check. The fluid level rises as tem-

keeping the tip down, and check the oil

perature increases.

level.

7.1

Operate the transmission in a Drive (D)

6.3

If the oil is below the cross-hatched area,

range until normal operating temperature,

or the add mark, at the tip of the dipstick,

160 to 200°F (71 to 93°C), is reached.

add at least one quart (liter) of the recom-

mended oil. See Fig. 12.2 for diesel en-

7.2

With the parking brake applied, shift to

gines and Fig. 12.3 for propane engines.

Neutral (N). Let the engine run at idle.

For diesel engines that comply with

7.3

Wipe the dipstick clean and check the

EPA07 or newer regulations, use CJ-4

fluid level. A safe operating level is any

engine oil with less than 1% sulfated ash.

level within the HOT-run (upper) band on

the dipstick. See Fig. 12.4.

For liquid propane gas (LPG) engines, use

SAE 5W-30 oil that meets GM standard

7.4

If the fluid is not within this range, add or

GM6094M and has the American Petro-

drain fluid as needed to bring the level to

leum Institute (API) symbol. Do not use

the top of the HOT-run band.

SAE 10W-40 or 20W-50.

Check for water in the fuel/water separator, if

equipped.

FULL

ADD 2 QT

IMPORTANT: When draining fluid from a

fuel/water separator, drain the fluid into an

appropriate container and dispose of it prop-

10/26/2012

f012203

erly. Many jurisdictions now issue fines for

Fig. 12.2, Oil Dipstick (diesel engine)

draining fuel/water separators onto the

ground.

8.1

Place a suitable container under the fuel/

water separator.

12.3

Pre- and Post-Trip Inspections and Maintenance

02/27/2002

f270077

A. Hot-Run Band

B. Cold-Run Band

Fig. 12.4, Automatic Transmission Dipstick Markings

NOTE: A hose may be used to direct water

into the container. Use a hose with a 1/2-

inch pipe thread on DAVCO models.

8.2

If the engine is equipped with a built-in

02/03/2010

f470552

water separator, loosen the drain valve,

1. Washers (qty 2)

7. Mounting Head

and allow the water to run out. Close the

2. Nuts (qty 2)

8. Mounting Bolts (qty 2)

drain valve, taking care not to overtighten

3. Frame Rail

9. Filter Element

it.

4. Fuel Outlet Port

10. Sight Bowl

5. Fuel Inlet Port

11. Drain Plug

8.3

Alliance/Racor Models: Turn the drain plug

6. Priming Pump

counterclockwise to open it. See

Fig. 12.5.

Fig. 12.5, Alliance Fuel/Water Separator Assembly and

Installation

DAVCO Models: Remove the vent cap

and open the drain. See Fig. 12.6.

WARNING

8.4

Stop draining fluid when fuel begins to

drain out.

Never operate the engine with the fuel tank shut-

Alliance/Racor Models: Turn the drain plug

off valves partly closed. This could damage the

clockwise to close it.

fuel pump, causing sudden loss of engine power,

possibly resulting in serious personal injury due

DAVCO Models: Close the drain valve.

to reduced vehicle control.

Install and hand-tighten the vent cap.

9.4

If equipped with fuel tank shutoff valves,

Inspect the fuel tanks, fuel lines, and connec-

be sure the valves are fully open.

tions.

9.1

Ensure fuel tanks are secured to their

WARNING

mounting brackets and that the mounting

brackets are secured to the frame.

Never fill fuel tanks to more than 95 percent of

9.2

Replace leaking fuel tanks.

their liquid capacity. This could make them more

likely to rupture from impact, possibly causing

9.3

If lines or connections are leaking or

fire and resulting in serious personal injury or

chafed, have them repaired or replaced.

death by burning.

Do not mix gasoline or alcohol with diesel fuel.

This mixture could cause an explosion, possibly

12.4

Pre- and Post-Trip Inspections and Maintenance

resulting in serious personal injury or death. Do

not fill the fuel tanks in the presence of sparks,

open flames, or intense heat. These could ignite

the fuel, possibly causing severe burns.

IMPORTANT: On engines that comply with

EPA07 or newer regulations, use ultralow-sulfur

diesel (ULSD) with 15 ppm sulfur content or

less. Failure to use ULSD fuel may void the

warranty on emission components.

10. Check the fuel level in the fuel tank(s). To keep

condensation to a minimum, fuel tanks should be

filled at the end of each day.

On vehicles equipped with a diesel engine, be

sure that the fuel cap vent area is clean.

11. Inspect the front and rear suspension compo-

nents, including springs, spring hangers, shocks,

and suspension brackets.

11.1

Check for broken spring leaves, loose

U-bolts, cracks in the suspension

brackets, and loose fasteners in the spring

hangers and shackles.

11.2

Inspect the shock absorbers for loose fas-

teners and leaks.

11.3

Tighten all loose fasteners and have any

components replaced that are worn,

cracked, or otherwise damaged.

11.4

On vehicles with air suspensions, check

for leaks. Check air suspension compo-

nents for cuts and bulges.

WARNING

Do not replace individual leaves of a damaged

front or rear suspension leaf spring assembly;

replace the complete spring assembly. Visible

damage, such as cracks or breaks, to one leaf

05/05/2009

f470530

causes hidden damage to other leaves. Replace-

1. Inlet Port/Check Valve

Vent Cap O-Ring

ment of only the visibly damaged part(s) is no

2. Lower Housing

Vent Cap

assurance that the spring is safe. If cracks or

3. Bypass Valve

10. Collar

breaks exist on front spring assemblies in either

4. Filter Element

11.

120VAC Pre-Heater

of the two top leaves, a loss of vehicle control

5. Spring

12.

12VDC Pre-Heater

could occur. Failure to replace a damaged spring

6. Cover O-Ring

13. Drain Valve

assembly could cause an accident resulting in

7. Clear Cover

serious personal injury or property damage.

Fig. 12.6, DAVCO Fuel/Water Separator (Fuel Pro 482

12. Push the reset button on the dash-mounted air

shown)

intake restriction indicator, if equipped.

12.5

Pre- and Post-Trip Inspections and Maintenance

13.

With the ignition switch in the OFF position,

check the air-pressure warning system.

13.1

If not previously drained, drain the air res-

ervoirs using moderate brake applications

until pressure in both reservoirs is less

than 70 psi (483 kPa).

13.2

Turn the ignition switch to the ON/RUN

position. The ICU will complete a full

gauge sweep and bulb check, and an au-

dible warning will sound. Ensure the low

air pressure lamp (BRAKE AIR) remains

illuminated and an audible warning contin-

ues to sound after the gauge sweep is

complete.

14.

Make sure that the electric horn works.

05/27/2011

f545785

15.

Make sure all the exterior lights are working.

Fig.

12.7, Pretrip Light Inspection Switch

All exterior lights should be checked for proper

operation. Clean the windshield, side, and rear

•

stop arm

windows (if equipped) with a long-handled or

•

park lights (all)

telescoping window cleaning device and stan-

dard cleaning solutions.

•

turn signals

IMPORTANT: Stand only on the ground, on

•

left and right headlights (low- and

a stepladder, or an elevated walkway. The

high-beam)

vehicle entry/exit steps and handholds are

•

crossing arm (may partially retract

not designed for this purpose. The tires,

during flashing-off period)

fenders, engine, and other under-hood com-

•

taillights

ponents do not have adequate gripping sur-

faces and handholds.

•

brake lights

15.1

Turn the ignition switch to the ACCES-

•

back-up lights

SORY or ON/RUN position.

15.4

The pretrip light inspection can be stopped

15.2

Make certain the service brake is not ap-

by:

plied and the parking brake is set.

• turning the ignition switch to the

15.3

Press the pretrip inspection switch on the

OFF position;

dash, shown in Fig. 12.7, to begin the

• applying the service brake;

pretrip light inspection.

The instrument cluster will beep rapidly for

• releasing the parking brake.

five seconds, and then begin a 10-second

16.

Inspect the air brake chamber and the air brake

countdown, followed by a 2-second beep.

chamber pushrods.

The 10-second countdown period allows

the operator to exit the bus before the pre-

DANGER

trip light inspection begins. After the

2-second beep, the following exterior

Do not loosen or remove the parking brake clamp

lights will flash simultaneously:

ring for any purpose. See Fig. 12.8. The parking/

• amber warning lights (front and rear)

emergency brake section of the brake chamber is

not intended to be serviced. Serious injury or

• red warning lights (front and rear)

12.6

Pre- and Post-Trip Inspections and Maintenance

death may result from sudden release of the

power spring.

Before doing any repairs or adjustments on a

service/parking brake chamber, read the appli-

cable warnings and instructions in Group 42 of

the Saf-T-Liner C2 School Bus Workshop Manual.

17. Visually inspect slack adjuster components.

Inspect the slack adjuster boot for cuts or tears.

If the boot is damaged, have it replaced. See

Fig. 12.9.

06/17/2003

f421398

7/16-inch Adjusting

6. Clevis

Nut

1/2-inch Clevis Pin

2. Grease Fitting

1/4-inch Clevis Pin

3. Boot

Grease Relief

4. Link

Opening

5. Brake Chamber Piston

10. Slack Adjuster Spline

Rod

Fig. 12.9, Automatic Slack Adjuster (typical)

18.1

If a tire has been run flat or underinflated,

check for possible wheel or tire damage

before adding air.

Keep compressed air reservoirs and lines

02/22/2000

f421352

dry during tire inflation. Use well-

maintained inline moisture traps and ser-

A. Do not remove the clamp ring.

vice them regularly.

1. MGM TR-T (TR Series) Brake Chamber shown

Fig. 12.8, Parking Brake Chamber Clamp

NOTICE

18. Check tire inflation pressures.

A weekly pressure loss of 4 psi (28 kPa) or more

Tires should be checked when cool. For inflation

in a tire may indicate damage. The tire should be

pressures and maximum loads (per tire) see the

inspected and, if necessary, repaired or replaced

tire manufacturer’s guidelines.

by a qualified tire service facility.

18.2

Inflate the tires to the applicable pressures

WARNING

if needed.

IMPORTANT: The load and cold inflation

Do not operate the vehicle with underinflated or

overinflated tires. Incorrect inflation can stress

pressure must not exceed the wheel manu-

the tires and make the tires and wheels suscep-

facturer’s recommendations, even though

tible to damage, possibly leading to wheel or tire

the tire may be approved for a higher load

failure and loss of vehicle control, resulting in

inflation. Some wheels are stamped with a

serious personal injury or death.

maximum load and maximum cold inflation

rating. If they are not stamped, consult the

12.7

Pre- and Post-Trip Inspections and Maintenance

wheel manufacturer for the correct tire infla-

Otherwise a vehicle or workshop accident could

tion pressure for the vehicle load. If the load

occur, possibly resulting in serious personal in-

exceeds the maximum wheel capacity, the

jury or death.

load must be adjusted or reduced.

NOTICE

18.3

Be sure valve stem caps are on every tire

and that they are screwed on finger-tight.

Use the recommended torque values and follow

IMPORTANT: Low-rolling resistance (LRR) tires

the proper tightening sequence. Insufficient

wheel nut torque can cause wheel shimmy, re-

minimize wasted energy as a tire rolls, thereby

sulting in wheel damage, stud breakage, and ex-

decreasing rolling effort and improving fuel effi-

treme tire tread wear. Excessive wheel nut torque

ciency. If tire replacement is necessary, replace-

can break studs, damage threads, and crack

ment tires must meet or exceed the rolling resis-

discs in the stud hole area.

tance of the originally installed tires in order to

20.3

Make sure all wheel nuts are tightened. If

maintain compliance with greenhouse gas and

tightening is necessary, use the tightening

fuel efficiency regulations (GHG14).

pattern in Fig. 12.10 for 10-stud disc

Contact your tire manufacturer/supplier to deter-

wheels and Fig. 12.11 for 8-stud disc

mine the rolling resistance of the originally in-

wheels to initially tighten the flange nuts to

stalled tires. Visit www.epa.gov/smartway for

50 to 100 lbf·ft (68 to 136 N·m). Then

additional information and resources.

tighten the flange nuts to 450 to 500 lbf·ft

(610 to 678 N·m).

19. Inspect the condition of all tires.

19.1

Check the tire tread depth. If tread is less

than 4/32 inch (3 mm) on any front tire, or

less than 2/32 inch (1.5 mm) on any rear

tire, replace the tire.

19.2

Inspect each tire for bulges, cracks, cuts,

and penetrations.

19.3

Inspect each tire for oil contamination (pe-

troleum derivatives will soften the rubber

and destroy the tire).

20. Check the wheel nuts for indications of loose-

ness. Examine each wheel component.

08/23/93

f400081a

20.1

Remove all dirt and debris from the as-

sembly. Rust streaks or metal build-up

Fig. 12.10, Tightening Pattern, 10-Stud Disc Wheels

around stud holes, or out-of-round or worn

stud holes, may be caused by loose wheel

NOTE: Vehicles operating under severe or

nuts.

adverse conditions should be checked more

frequently.

20.2

Examine the wheel components (including

studs and nuts) for cracks or other dam-

21. Check the air brake system for proper operation.

age.

21.1

Check the air governor cut-in and cut-out

pressures. Start the engine and ensure

WARNING

the BRAKE AIR lamp goes out and the

buzzer silences when pressure reaches

Have any worn or damaged wheel components

approximately 70 psi (483 kPa) in both air

replaced by a qualified person using the wheel

reservoirs. The air governor should cut out

manufacturer’s instructions and the wheel indus-

at approximately 120 psi (827 kPa). For

try’s standard safety precautions and equipment.

vehicles with an optional dryer reservoir

12.8

Pre- and Post-Trip Inspections and Maintenance

21.4

Check the air leakage in the system.

With the parking brake applied, the trans-

mission out of gear, and the air system

fully charged, release the service brakes

and shut down the engine. Wait one min-

ute and note the air pressure drop in psi

(kPa) per minute from the primary air res-

ervoir.

If leakage exceeds the limits shown in

Table 12.2, repair all areas of leakage be-

fore driving the vehicle.

Maximum Allowable Service Brake Leakage

03/08/2012

f400052a

Brakes Released

Brakes Applied

2 psi/min. (14 kPa/min)

3 psi/min. (21 kPa/min)

Fig. 12.11, Tightening Pattern, 8-Stud Disc Wheels

Table 12.2, Maximum Allowable Service Brake

module (DRM), the cut-out pressure is

Leakage

approximately 130 psi (896 kPa).

22.

Test the parking brake on a 20 percent grade.

With the engine idling, apply the brake

pedal several times. The air governor

Apply the hand brake with the vehicle on a 20

should cut in when pressure in the primary

percent grade (or a steep grade that the vehicle

air reservoir (top air gauge) reaches ap-

may normally be parked on). If the parking brake

proximately 100 psi (690 kPa).

does not hold the vehicle, repair the parking

brake system.

21.2

Check the air pressure buildup time.

23.

Inspect the operation of the Hydro-Max® brake

With the air system fully charged, make

booster, as follows.

one full brake application and note the air

pressure reading on the primary air

23.1

With the engine off, depress the brake

gauge. Further reduce air pressure using

pedal. The warning light and buzzer

moderate brake applications, then run the

should come on, and the electric motor

engine at governed rpm. Note the time

should run.

that the pressure reaches the previously

noted reading on the primary air gauge,

23.2

Start the engine and allow the gauges to

then note the time that the air pressure

sweep. Depress the brake pedal. No

reaches cut-out pressure.

warning lights, buzzer, or electric motor

should come on.

If it takes longer than 30 seconds to reach

cut-out pressure after the primary air

24.

Inspect the engine and chassis wiring.

gauge passes the previously noted pres-

Check for loose wiring, chafed insulation, and

sure (noted after one full brake applica-

damaged or loose hold-down clamps. Tighten

tion), eliminate any leaks or replace the air

loose wires or hold-down clamps; replace dam-

compressor before operating the vehicle.

aged clamps.

21.3

Check the air pressure reserve.

Weekly Post-Trip Inspection

With the engine still off, make one full

brake application and observe the pres-

and Maintenance Procedures

sure drop on the primary air gauge. If

pressure drops more than 25 psi (172

1. Inspect the batteries and battery cables.

kPa), eliminate any leaks before operating

the vehicle.

12.9

Pre- and Post-Trip Inspections and Maintenance

WARNING

Battery posts, terminals, and related accessories

contain lead and lead compounds, chemicals

known to the State of California to cause cancer

and reproductive harm. To prevent possible per-

sonal injury, always wash your hands after han-

dling battery parts and related accessories.

1.1

Check the battery cables for chafing and

proper routing. Be sure the battery hold-

down is secure. If it is loose, tighten the

hold-down bolts; if it is damaged, replace

it. Replace the battery cable if damaged.

1.2

If the battery is equipped with a built-in

hydrometer, examine the hydrometer. If a

green dot shows in the sight glass, the

battery is sufficiently charged.

10/11/2001

f461916

If the sight glass is dark, the charge is low

and the battery must be recharged.

Steering Gear Mounting Bolt

Pitman Arm Pinch Bolt Nut

If the sight glass is clear, the battery has a

Drag Link Nut

low level of electrolyte and must be re-

placed.

Fig. 12.12, Steering Gear Fasteners

2. Inspect the outboard side of all wheel hubs and

Check the condition of the drive belts.

the hub oil seal area on the inboard side of each

Check the fan belt(s), alternator belt, and refrig-

wheel for signs of oil leakage.

erant compressor belt for signs of glazing, wear

If any oil is found on wheel and tire or brake

(frayed edges), damage (breaks or cracks), or oil

components, remove the vehicle from service

contamination. If a belt is glazed, worn, dam-

until the leak has been fixed.

aged, or oil soaked, replace it.

If needed, fill the hubs to the level indicated on

After resetting the air intake restriction indicator

the hub cap.

during the daily pretrip inspection, check the indi-

cator again with the engine off.

IMPORTANT: Before removing the fill plug, al-

ways clean the hub cap and plug.

5.1

Check an indicator with graduations to see

if air restriction exceeds 25 inH₂O.

3. Inspect the steering components.

Check a go/no-go indicator without gradu-

3.1

Inspect tie rods, steering arms, and the

ations to see if the colored bar shows

drag link for signs of looseness (i.e., shiny

through the clear window.

spots or rust tracks). See Fig. 12.12.

5.2

If air restriction exceeds the maximum al-

3.2

Check the steering gear mounting bolts

lowable value, operate the vehicle for one

and pitman arm nut, if equipped, for signs

more day, making sure not to run the en-

of looseness.

gine over rated rpm. Refer to the engine

3.3

Check the drag link nuts for missing cotter

operation manual for more information on

pins.

rated rpm for your engine.

3.4

Inspect the steering intermediate shaft and

end yokes for excessive looseness or

other damage.

12.10

Pre- and Post-Trip Inspections and Maintenance

5.3

If air restriction exceeds the maximum

value again, replace the air cleaner. For

instructions, refer to Group 09 of the Saf-

T-Liner C2 School Bus Maintenance

Manual.

Monthly Post-Trip Inspection

and Maintenance Procedures

WARNING

Battery posts, terminals, and related accessories

contain lead and lead compounds, chemicals

known to the State of California to cause cancer

and reproductive harm. To prevent possible per-

sonal injury, always wash your hands after han-

04/26/2012

f460513a

dling battery parts and related accessories.

A. Open caps and check fluid level.

B. Fill to this level.

1. Clean the batteries.

1.1

Remove any corrosion from the hold-down

Fig. 12.13, Check the Hydraulic Brake Fluid Level

(typical)

and the top of the battery.

3.2

Align a reference mark on the steering

NOTICE

wheel to a ruler, then slowly turn the

steering wheel in the opposite direction

Take care to keep the vent plugs tight so that the

until motion is again detected at the

neutralizing solution does not enter any of the

wheels. See Fig. 12.14.

battery cells and damage the battery.

1.2

Use a soda solution to neutralize the acid

present, then rinse off the soda solution

with clean water.

1.3

If the battery posts or cable terminals are

corroded, disconnect the terminals from

the posts. Clean them with a soda solution

and a wire brush. After cleaning, connect

the terminals to the battery posts, then

apply a thin coat of petroleum jelly to the

posts and terminals to help retard corro-

sion.

2. Check the fluid level in the hydraulic clutch reser-

voir, if equipped.

If necessary, add DOT 3 brake fluid. See

Fig. 12.13.

10/10/95

f461057

3. Check the steering wheel for excessive play.

A. Lash Area

3.1

Start the engine. With the front tires

Fig. 12.14, Measuring Lash at the Steering Wheel

straight ahead, turn the steering wheel

until motion is observed at the front

wheels.

12.11

Pre- and Post-Trip Inspections and Maintenance

3.3

Measure the lash (free play) at the rim of

the steering wheel. Excessive lash exists

if steering wheel movement exceeds 2-1/2

inches (64 mm) with a 20-inch (508-mm)

steering wheel, or 2-1/4 inches (57 mm)

with an 18-inch (457-mm) steering wheel.

3.4

If there is excessive lash, check the steer-

ing system for wear or incorrect adjust-

ment before operating the vehicle.

Check the brake lining wear on vehicles

equipped with air brakes.

Proper brake operation is dependent on periodic

maintenance and inspection of the brake linings.

4.1

Apply the parking brakes, and chock the

tires to prevent vehicle movement.

02/24/2010

f750039

4.2

If the axle assembly is not equipped with

Fig. 12.15, Body Mounting Bolts and Clip (number and

a dust shield or backing plate, measure

location vary)

the axle brake lining thickness. If any of

the brake linings are worn to less than

pressure washer to clean these areas, use the

3/16 inch (4.8 mm) at the thinnest point,

lowest possible pressure setting.

replace the linings on all brake assemblies

Clean the undercarriage of the bus.

on that axle.

Salt and de-icing material used on road surfaces

4.3

If the axle assembly is equipped with a

in winter months deteriorates the metal of the

dust shield or backing plate, remove the

vehicle. Use a high-pressure washer at the low-

inspection plugs to inspect the brake lining

est setting to clean the undercarriage of the bus.

thickness. If any of the brake linings are

If corrosion or separation of the undercoat to

worn to less than approximately 3/16 inch

body floor is visible, apply additional undercoat-

(4.8 mm) at the thinnest point, replace the

ing.

linings on all brake assemblies on that

axle.

4.4

Install the inspection plugs in the dust

shields or backing plates, if so equipped.

NOTE: The number and location of body mount-

ing bolts and clips vary, depending on the op-

tions and wheelbase of each vehicle.

5. Check that the body mounting bolts and clips are

securely fastened.

If needed, tighten the bolts 30 lbf·ft (41 N·m).

Figure 12.15 shows an example of body mount-

ing bolts and a clip.

NOTICE

When cleaning areas containing electrical com-

ponents and connections, take care to protect

these items from water intrusion. When using a

12.12

Cleaning and Care

Washing and Polishing

Care of Chrome Parts

To protect the new vehicle’s finish, follow these

To prevent rust, keep chrome parts clean and pro-

guidelines carefully:

tected at all times. This is especially important during

winter driving and in coastal areas where there is

• During the first 30 days, rinse the vehicle fre-

exposure to salt air.

quently with water. If the vehicle is dirty, use a

mild liquid soap. Do not use detergent.

When cleaning chrome parts, use clean water and a

soft cloth or sponge. A mild detergent may also be

• During the first 30 days, do not use anything

used.

abrasive on the vehicle. Brushes, chemicals,

and cleaners may scratch the finish.

Sponge gently, then rinse. If necessary, use a non-

abrasive chrome cleaner to remove stubborn rust or

• During the first 120 days, do not wax the

other material. Do not use steel wool.

vehicle.

To help protect the chrome after cleaning, apply a

To extend the life of the vehicle’s finish, follow these

coat of polishing wax to the surface. Never use wax

guidelines:

on parts that are exposed to high heat, such as ex-

• Avoid washing the vehicle in the hot sun. Al-

haust pipes.

ways use water. After the vehicle is completely

washed, dry it with a towel or chamois.

Dashboard and Instrument

• Do not dust painted surfaces with a dry cloth,

Panel Care

as this will scratch the paint.

• Do not remove ice or snow from a painted sur-

NOTICE

face with a scraper of any sort.

When cleaning the dashboard, instrument panel,

• To prevent damage to the finish, wax it regu-

or gauge lens covers, do not use Armor-All Pro-

larly. If the finish has become dull, remove oxi-

tectant®, STP Son-of-a-Gun®, window cleaner, or

dized paint using a cleaner specifically de-

other equivalent treatments. These cleaners con-

signed for this purpose before waxing. Remove

tain vinyl plasticizers which can cause stress

all road tar and tree sap before waxing.

crazing in the interior plastic panels and can re-

Freightliner recommends the use of a high

sult in cracking of the panels. Some cleaners can

quality brand of cleaner or cleaner-polish and

also have an adverse effect on the clear plastic

polishing wax be used.

of instrument panels and gauge lens covers, re-

• Do not let diesel fuel or antifreeze stand on a

sulting in a foggy or cloudy appearance. This

painted surface. If either should occur, rinse

type of damage is not covered by vehicle war-

the surface off with water.

ranty.

• To prevent corrosion, have any nicks or other

To clean the dashboard, instrument panel, and gauge

damage on the finish touched up as soon as

lens covers, use a cloth dampened with warm soapy

possible.

water. Make certain to wring the cloth out well before

cleaning, as excess water will damage the electrical

• Park the vehicle in a sheltered area whenever

components.

possible.

Vinyl Upholstery Cleaning

Care of Fiberglass Parts

To prevent soiling, frequent vacuuming or light brush-

Wash unpainted fiberglass air fairings and shields

ing to remove dust and dirt is recommended. Harsh

monthly with a mild detergent, such as dishwashing

cleaning agents can cause permanent damage to

liquid. Avoid strong alkaline cleansers.

vinyl upholstery. To preserve the upholstery and pre-

Apply a wax specifically designed for fiberglass.

vent damage, carefully review the following sections

for recommended cleaning procedures. Waxing or

refinishing improves soil resistance and cleanability

13.1

Cleaning and Care

for all vinyls. Any hard wax, such as that used on

tion to prevent the solution from seeping into the

automobiles, may be used.

seams or it will weaken the cotton thread.

Ordinary Dirt

Nail Polish and Nail Polish Remover

Wash the upholstery with warm water and mild soap,

Prolonged contact with these substances causes per-

such as saddle or oil soap. Apply soapy water to a

manent damage to vinyl. Careful blotting immediately

large area and allow to soak for a few minutes, then

after contact minimizes damage. Do not spread the

rub briskly with a cloth to remove the dirt. This can

liquid during removal.

be repeated several times as necessary.

Shoe Polish

If dirt is deeply imbedded, use a soft bristle brush

after applying the soap.

Most shoe polishes contain dyes which penetrate

If dirt is extremely difficult to remove, wall-washing

vinyl and stain it permanently. Shoe polish should be

preparations normally found around the home can be

wiped off as quickly as possible using naphtha or

used. Powdered cleaners, such as those used for

lighter fluid. If staining occurs, try the procedure used

sinks and tiles, are abrasive and must be used with

for sulfide stains.

caution as they can scratch the vinyl or give it a per-

manent dull appearance.

Ball Point Ink

Ball point ink can sometimes be removed if rubbed

Chewing Gum

immediately with a cloth dampened with water or

Harden the gum with an ice cube wrapped in a plas-

rubbing alcohol. If this does not work, try the proce-

tic bag, then scrape it off with a dull knife. Any re-

dure used for sulfide stains.

maining traces of gum can be removed with an all-

purpose light oil (peanut butter will also work) and

Miscellaneous

wiped off.

If stains do not respond to any of the treatments de-

scribed above, it is sometimes helpful to expose the

Tars, Asphalts, and Creosote

vinyl to direct sunlight for up to 30 hours. Mustard,

Tars, asphalts, and creosote stain vinyl after pro-

ball point ink, certain shoe polishes, and dyes often

longed contact. They should be wiped off immedi-

bleach out in direct sunlight, leaving the vinyl undam-

ately and the area carefully cleaned, using a cloth

aged.

dampened with naphtha.

Floor Cleaning

Paint and Shoe Heel Marks

Dirt and other abrasive material that accumulates on

Paint should be removed immediately. Do not use

the floor will shorten the life of the floor covering.

paint remover or liquid-type brush cleaner on vinyl.

Daily sweeping and cleaning should be performed to

An unprinted cloth, dampened with naphtha or tur-

maintain the floor covering. Do not use any floor

pentine may be used. Use care to prevent contact

sweeping cleaner or solvent, as they may cause the

with parts of the upholstery that are not vinyl.

floor covering to separate and lift from the floor.

Begin at the front of the vehicle and sweep toward

Sulfide Stains

the rear and side emergency door(s). This will en-

sure a check of the emergency door’s operation, as

Sulfide compounds, such as those found in eggs and

well as the removal of items that could keep the

some canned goods, can stain after prolonged con-

emergency door from sealing properly.

tact with vinyl. These stains can be removed by plac-

ing a clean, unprinted piece of cloth over the spotted

Oil and grease deteriorate the floor covering quickly

area and pouring a liberal amount of 6 percent hy-

and should be removed as soon as possible. Do not

drogen peroxide onto the cloth. Allow the saturated

use harsh detergents or excessive amounts of water

cloth to remain on the spot for 30 to 60 minutes. For

to remove these items. Instead, mop with a mild

stubborn spots, allow the hydrogen-peroxide satu-

soap solution and remove any excess water.

rated cloth to remain on the area overnight. Use cau-

13.2

In an Emergency

Hazard Warning Lights

The hazard warning light switch is part of the multi-

function turn signal switch. It is a red rocker switch

located on the top of the multifunction switch module.

See Fig. 14.1.

12/10/2003

f580375

1. Fire Extinguisher

2. First Aid Kit

3. Body Fluid Cleanup Kit

Fig. 14.2, Emergency Equipment

11/16/2001

f820386

Press down on the upper part of the rocker to activate

the flares and reflector along the side of the road to

the hazard warning lights.

alert other drivers that an emergency situation exists.

1. Washer Button

2. Wiper Control Dial

WARNING

3. Turn Signal Lever

4. Hazard Warning Light Switch (red)

Use extreme care when placing flares in emer-

5. Multifunction Switch Module

gency situations that involve exposure to flam-

Fig. 14.1, Multifunction Turn Signal Switch

mable substances such as fuel. An explosion or

fire could occur causing serious personal injury.

To activate the hazard warning lights, press down on

the upper part of the rocker switch (towards the

Emergency Starting With

dash). To cancel the hazard warning lights, press

down on the lower part of the rocker switch (towards

Jumper Cables

the steering wheel).

NOTE: Jumpstarting vehicles equipped with the

Eaton® Hybrid System is identical to non-hybrid

Fire Extinguisher

vehicles, which use the vehicle 12-volt battery

A fire extinguisher is located on the floor, to the right

system.

of the driver’s area at the front of the bus. See

When using jumper cables, follow the instructions

Fig. 14.2.

below.

Emergency Kit

WARNING

An optional emergency kit is located to the right of

Batteries release explosive gas. Do not smoke

the driver’s area at the front of the bus or in a com-

when working around batteries. Put out all flames

partment over the driver’s seat. The kit includes one

and remove all sources of sparks or intense heat

or more of the following: a first aid kit, a reflective

in the vicinity of the battery. Do not allow the ve-

vest, a triangular reflector, and a flare kit. See

hicles to touch each other. Do not lean over the

Fig. 14.2.

batteries when making connections, and keep all

If there is an emergency while driving, cautiously pull

other persons away from the batteries. Failure to

off the road. Turn on the hazard warning lights. Place

follow these precautions could lead to severe

14.1

In an Emergency

personal injury as a result of an explosion or

4. Connect the other end of the positive jumper

acid burns.

cable to the positive terminal on the booster bat-

tery providing the charge.

NOTICE

WARNING

Make sure that both starting systems are the

same voltage. Electronic devices on both ve-

Do the next step exactly as instructed and do not

hicles can be damaged when connected to a ve-

allow the clamps of one cable to touch the

hicle with a different operating voltage.

clamps of the other cable. Otherwise, a spark

could occur near a battery, possibly resulting in

1. Apply the parking brakes and turn off all lights

severe personal injury from explosion or acid

and other electrical devices.

burns.

IMPORTANT: Do not attempt to jump start a

5. Connect the negative (-) jumper cable to the

damaged battery.

negative terminal on the booster battery.

2. Open the battery door to access the batteries.

6. Connect the other end of the negative jumper

Pull both pull-pin spring latches and slide the

cable to the negative ground stud on the vehicle

battery tray out. See Fig. 14.3.

requiring the jump start.

7. Start the engine of the vehicle providing the jump

start and let the engine run for a few minutes to

charge the batteries of the other vehicle.

NOTICE

Do not crank the engine for more than 30 sec-

onds at a time during any of the following proce-

dures. Wait two minutes after each try to allow

the starter to cool. Failure to do so could cause

starter damage.

8. Attempt to start the engine of the vehicle with the

batteries receiving the charge.

9. When the engine starts, let it idle for a few min-

12/05/2003

f544365

utes.

1. Battery Access Door

3. Battery Tray

2. Pull-Pin Spring Latch

4. Battery

WARNING

Fig. 14.3, Battery Access

Do the next step exactly as instructed and do not

allow the clamps of one cable to touch the

NOTICE

clamps of the other cable. Otherwise, a spark

could occur near a battery, possibly resulting in

Always connect the batteries and jumper cables

severe personal injury from explosion or acid

correctly (positive-to-positive and negative-to-

burns.

negative). Connecting a charging device back-

wards (positive-to-negative) can severely damage

10. Disconnect the negative jumper cable from the

the vehicle electrical content and cause non-

negative cable stud on the jump started vehicle.

warrantable failures.

11. Disconnect the negative jumper cable from the

3. Connect the positive (+) jumper cable to the

booster battery.

positive terminal on the discharged battery. See

12. Disconnect the positive cable from the booster

Fig. 14.4.

battery.

14.2

In an Emergency

−

01/07/2011

f545725

Disconnect jumper cables in the REVERSE order that they were connected.

A. Discharged Battery

C. Positive Jumper Cable

E. Booster Battery

B. Negative Ground Stud

D. Negative Jumper Cable

1st Connection: Positive Jumper Cable to Discharged Battery

2nd Connection: Positive Jumper Cable to Booster Battery

3rd Connection: Negative Jumper Cable to Booster Battery

4th Connection: Negative Jumper Cable to Negative Ground Stud (discharged battery)

Fig. 14.4, Jumper Connections (three battery system shown for clarity)

13. Disconnect the other end of the positive jumper

Towing

cable from the jump started vehicle.

14. Pull both pull-pin spring latches and slide the

WARNING

battery tray back into position. Release the pull-

pin spring latches to lock the battery tray, then

Do not tow an unbraked vehicle if the combined

close the battery door.

weight of both vehicles is more than the sum of

14.3

In an Emergency

the gross axle weight ratings (GAWR) of the tow-

5. Attach the towing device. Due to the many vari-

ing vehicle. Otherwise brake capacity will be in-

ables that exist in towing, positioning the lifting

adequate, which could result in personal injury or

and towing device is the sole responsibility of the

death.

towing-vehicle operator.

IMPORTANT: When it is necessary to tow the

6. Lift the vehicle and secure the safety chains. If

vehicle, make sure the instructions below are

extra towing clearance is needed, remove the

closely followed to prevent damage to the ve-

front wheels.

hicle.

7. Connect the clearance lights, taillights, and sig-

nal lights. Connect any special towing lights re-

NOTICE

quired by local regulations.

When towing or pushing the vehicle, regardless

WARNING

of the distance or speed traveled, either discon-

nect the driveshaft at the rear axle and support it

Failure to chock the tires or connect the tow

as necessary, or remove the axle shafts. Failure

truck’s air brake system before releasing the

to do this when towing the vehicle with the rear

spring parking brakes could allow the disabled

wheels on the ground could result in damage to

vehicle to suddenly roll. This could cause prop-

the transmission and other parts.

erty damage or personal injury.

NOTE: Towing rules and regulations vary from

8. Chock the tires on the disabled vehicle and con-

federal, state, local, and transit authority. These

nect the towing vehicle’s air brake system to the

laws must be followed when towing the bus.

vehicle being towed. Then, release the spring

parking brake and remove the chocks.

Front Towing Hookup

Emergency Exits

NOTICE

Emergency Door

The vehicle should never be towed from the rear.

An emergency exit door is located at the rear of the

The gross axle weight rating (GAWR) of the front

bus. The emergency door has a locking capability in

axle may not be sufficient to support the in-

the open position to allow a clear exit from the bus.

creased load when towing from the rear. This

The release handle for the emergency exit door is

could damage the front axle.

protected to prevent accidental opening. Instructions

for opening the emergency exit door are clearly dis-

1. Disconnect the battery ground cables.

played on the door face. See Fig. 14.5.

2. Remove both drive axle shafts.

A warning buzzer in the bus activates when the re-

3. Cover the ends of the hubs with metal plates or

lease handle is not in the locked position.

plywood cut to fit the axle opening, and drilled to

IMPORTANT: The vehicle should not be driven if

fit the axle shaft studs. This prevents lubricant

from leaking out and will keep contaminants from

an emergency exit buzzer is sounding.

getting into and damaging the wheel bearings

and axle lubricant.

Using the Main Entry/Exit Door in an

Emergency

NOTICE

In an emergency, it may be necessary to use the red

switch above the main door to open the door. Push

Failure to protect the frame rails from the chains

down on the red switch to open the door, then push

could cause damage, leading to eventual frame

the door open. See Fig. 14.6 and Fig. 14.7.

failure.

4. Remove the bumper.

14.4

In an Emergency

NOTICE

TO RELEASE

OPENED

DOOR

FROM HELD POSTIION

− OPEN DOOR FULLY

− CLOSE DOOR

08/26/2008

f602145

Fig. 14.5, Emergency Door

Emergency Roof Escape Hatches

Running Out of Fuel

The bus may contain emergency roof escape

hatches located near the front and rear of the bus,

WARNING

according to Federal or State regulations. On buses

equipped with an emergency roof escape hatch, the

Do not mix gasoline or alcohol with diesel fuel.

opening instructions are clearly displayed on the

This mixture could cause an explosion. When fill-

hatch cover. See Fig. 14.8.

ing fuel tanks, do not smoke or use an open

flame near the fuel tanks. Combustion of diesel

Emergency Window Exits

fuel oil or fuel vapors could result, possibly caus-

ing personal injury or property damage.

The bus has windows designated as emergency

1. If possible, stop the vehicle on a level surface,

exits. To open the windows in emergency situations,

away from traffic.

follow the instructions that are clearly displayed on

the window frame.

2. Apply the parking brake.

NOTE: Some states require that the operating

IMPORTANT: Any time the vehicle runs out of

instructions be located on the window glass.

fuel, the fuel system should be primed. This will

14.5

In an Emergency

01/10/2007

f544925

1. Emergency Switch for Main Entry Door

3. Child Reminder Notice

2. Main Entry Door Emergency Release Operations Decal

Fig. 14.6, Emergency Switch for Main Entry Door

purge any trapped air in the system and allow

starter to cool. Failure to do so could cause

fuel to fill the fuel filter.

starter damage.

3. Prime the engine. See the engine manufacturer’s

5. After adding fuel to the fuel tank, start the en-

manual for instructions to prime the fuel system.

gine. Once the vehicle is running, let the engine

If further assistance is needed, call the Freight-

idle until it operates smoothly before driving the

liner Customer Assistance Center at 1-800-385-

vehicle.

4357 or 1-800-FTL-HELP.

Changing a Flat Tire

4. Add fuel to the fuel tank.

IMPORTANT: If a flat tire occurs while driving,

If the vehicle is equipped with a propane engine,

add at least 9 to 10 gallons (34 to 38 L) of liquid

gradually decrease vehicle speed. Holding the

propane.

steering wheel firmly, move to a safe place on

the side of the road.

NOTICE

1. Stop the vehicle on a level surface, away from

traffic.

Do not crank the engine for more than 30 sec-

onds at a time during the following procedure.

2. Apply the parking brake, place the transmission

Wait two minutes after each try to allow the

in neutral (N), and shut down the engine.

14.6

In an Emergency

EMERGENCYRELEASE

DISENGAGE

RELEASE

EMERGENCYRELEASE

DISENGAGE

RELEASE

PUSH FORWARD DOOR

TO RESET DOORS, DRIVER’S DOOR CONTROLS MUST BE IN

THE ’OPEN’ POSITION BEFORE RE−ENGAGING RELEASE

EMERGENCY

EXIT

DISENGAGE

RELEASE

PUSH

HERE

05/09/2007

f080145

Fig. 14.7, Disengaging the Main Entry Door in an Emergency

3. Turn on the hazard warning lights.

centered and within the bottom surface of the

bumper support as shown in Fig. 14.9. Do not

4. Block the wheel diagonally opposite the wheel

position the jack under the dropped frame rails

being changed.

in the center section of the bus.

5. Remove the spare wheel, jack, jack handle, and

lug wrench from storage.

6. Place the jack on a solid surface. Insert the jack

handle and pump the handle slightly. Do not

IMPORTANT: The jacking point for the front

raise the wheel off of the ground yet. Loosen the

wheels is on the front axle beam and other loca-

wheel lug nuts, but do not remove them.

tions shown in Fig. 14.9. The jacking point for

IMPORTANT: The dual rear wheels are attached

rear wheels is on the rear axle and at the loca-

using two-element lug nuts. The larger nut re-

tions on the rear suspension H-frame, shown in

tains the outer dual. The inner square stud re-

Fig. 14.9.

tains the inner dual. Remove and install these

Only use the front bumper locations if the bus is

nuts separately. The rear dual outer lug nut

equipped with a jackable bumper. When jacking

must be loosened to check and retighten the

the front bumper, the jacking point(s) must be

inner nut.

14.7

In an Emergency

snug. See Group 40 of the Saf-T-Liner C2

School Bus Workshop Manual for wheel tighten-

ing patterns and torque specifications. Lower the

vehicle until the wheel touches the ground.

Tighten the nuts.

10. Finish lowering the vehicle to the ground, then

remove the jack.

11. Remove the block, then stow the jack, jack

handle, and lug wrench.

12. After operating the vehicle for 50 to 100 miles

(80 to 161 km), retighten the wheel nuts to the

specified torque values.

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Fig. 14.8, Emergency Roof Escape Hatch

12/13/2010

f311093

1. Jack Locations—Front Axle

2. Jack Locations—Rear Axle

3. Jack Locations—Front Bumper

Fig. 14.9, Jack Placement

7. Raise the vehicle until the wheel is off of the

ground. Remove the lug nuts and the wheel.

8. Install the spare wheel and lug nuts. Make sure

that the beveled sides of the nuts face inward,

or, on hub-piloted wheels, make sure that the

hub-pilot pad is centered at the top.

IMPORTANT: When a tire is changed, the ve-

hicle should be taken to a mechanic as soon as

possible, to have the lug nuts tightened properly

with an impact air gun.

9. In a star pattern, tighten the nuts evenly until

14.8

Headlight Aiming

3. Mark the vertical distances found in step 2 on

Preliminary Checks

the screen or wall, directly in front of the head-

Before checking or adjusting the headlight aim, do

lights. These marks represent the desired loca-

the following:

tions of each headlight bulb center in the follow-

ing steps. See Fig. 15.2, Items 2 and 3.

• Check that the hood is closed and latched.

4. Turn on the low-beam headlights.

• Check the suspension for proper functioning of

the leveling mechanism. On buses with air sus-

5. Identify the center of each beam projection by

pensions, make sure that the height is properly

marking the area of brightest intensity on the

adjusted.

wall. The area of brightest intensity should fall on

or very near the marks made during step 3. See

• Remove any large amounts of mud or ice from

Fig. 15.3.

the underside of the fenders.

6. Use Table 15.1 to determine the maximum verti-

• Check the springs for sagging or broken

cal distance allowable between the marks made

leaves.

in step 3 and the marks made in step 5. If the

vertical distance between the marks made in

• Check for damage to the hood and hinge as-

steps 3 and 5 is greater than the maximum dis-

sembly. Repair as necessary.

tance given in Table 15.1, adjust the vertical po-

• Clean the headlight lenses. Use a soft cloth

sitioning of that headlight.

with mild, non-caustic soap or detergent, and

water.

Adjusting Headlight Aim

• With the vehicle unloaded, check that the tires

NOTE: Because of the various headlight assem-

are inflated to the recommended air pressure.

bly options offered, the location of adjustment

screws on the vehicle’s headlight assembly may

Checking Headlight Aim

vary from what is shown here.

1. Park the vehicle on a level surface, 25 ft (7.6 m)

1. Lift the flap over the rear end of the headlight

away from, and perpendicular to, a vertical

bucket to expose the two plastic adjusting knobs

screen or wall. Shut down the engine and set the

on each headlight. See Fig. 15.4.

parking brake. Chock the tires.

2. If necessary, adjust the horizontal positioning of

2. Each headlight has a height adjusting dot. See

the headlights so that each projection points di-

Fig. 15.1. Measure the distance from the ground

rectly forward.

to the height adjusting dot on each headlight.

Note those distances. See Fig. 15.2, Ref. A.

3. Turn the vertical adjustment knob to adjust the

headlight beam to meet the desired height. See

Table 15.1. Turn the knob clockwise to raise the

beam; turn the knob counterclockwise to lower it.

4. Adjust the other headlight.

11/06/2002

f544236

Measure beam height from the ground to the small dot

roughly in the center of the headlight lens.

Fig. 15.1, Headlight Beam Height Adjusting Dot

15.1

Hybrid Electric Vehicle

IMPORTANT: HSA being active does not mean

Hybrid Electric Vehicle (HEV)

that the brakes are being applied; only that the

Overview

system is prepared to engage the brakes when

needed.

A hybrid electric vehicle (HEV) has both a diesel en-

gine and an electric motor. Engine torque is aug-

While at a stop, the transmission will broadcast the

mented with electrical torque. The electric motor is

J1939 message indicating "ready" or "not ready". If

the transmission is broadcasting the "not ready" mes-

erative braking.

sage, the ABS will activate HSA. When active, HSA

monitors vehicle speed and brake pressure (force

The batteries cannot move the vehicle for long dis-

applied to the brake pedal). If vehicle speed is 0 and

tances at highway speeds. In the event of a diesel

there is a decrease in brake pressure, HSA will en-

engine failure, drive the vehicle to a safe location as

gage the brakes for up to 3 seconds while it waits for

quickly as possible.

the "ready" message. If the message is not received

Eaton Corporation developed and supplies the hybrid

within 3 seconds, HSA will continue to hold the ve-

electric system for Freightliner Trucks. The primary

hicle for up to 60 seconds. HSA will continue to en-

system components are the hybrid drive unit (HDU),

gage the brake until it receives the message from the

which includes the electric generator/motor and auto-

transmission or the driver reapplies pressure to the

mated transmission, power electronics carrier (PEC),

brake pedal.

and the motor inverter/controller.

If the transmission does not broadcast the "ready"

Freightliner Trucks designed the stand-alone liquid

message within 60 seconds of HSA engaging the

cooling system required to support the operation of

brakes, the ABS system will release the brakes and

Eaton’s HEV system. Its primary system components

the vehicle will roll freely if the driver does not apply

are the electric water pump, reservoir/expansion

pressure to the brake pedal.

tank, radiator, electric radiator fan, and coolant

plumbing.

High-Voltage Safety Features

The HEV has high-voltage safety cables and a ser-

Regenerative Braking

vice switch on the PEC. Areas of the vehicle that

Regenerative braking reduces vehicle speed by con-

contain hazardous voltage are marked with a warn-

verting some of the vehicle’s kinetic energy into elec-

ing label as shown in Fig. 16.1.

tric energy to charge the hybrid system’s batteries.

When the accelerator pedal is at idle while coasting,

or the service brake is depressed to slow the vehicle,

the hybrid system charges the batteries.

WARNING

The regeneration will feel as if the brake is being

HAZARDOUS VOLTAGE

lightly applied when you remove your foot from the

accelerator pedal. The full power of the service brake

INSIDE

is always available to the driver, and regenerative

MAINTENANCE ACCESS ONLY

braking is automatically shut off during an antilock

Failure to follow this warning may

result in property damage,

brake system (ABS) event.

personal injury, or death.

24−01680−000

The Eaton Hybrid Control Unit will automatically shut

10/20/2009

f080164

off regenerative braking when the batteries are fully

charged.

Fig. 16.1, Hazardous Voltage Warning Label

Hill Start Aid

High-voltage safety cables are covered in orange

insulation and labeled near each connector end.

Hill Start Aid (HSA) is a system used on the HEV

Each high-voltage component is tagged with a warn-

Saf-T-Liner C2 School Bus to prevent the vehicle

ing or danger label. See Fig. 16.2.

from rolling backward when it is stopped on a grade,

in gear, and the driver is not applying the service

brake.

16.1

Hybrid Electric Vehicle

cutting equipment, avoid high-voltage cables and the

Power Electronics Carrier (PEC). See Fig. 16.3 for

WARNING

the location of the high-voltage cables and PEC.

HAZARDOUS VOLTAGE

DO NOT CUT INTO ORANGE

HIGH VOLTAGE CABLES

Failure to follow this warning may

result in property damage,

personal injury, or death.

24−01677−000

10/20/2009

f080163

Fig. 16.2, High Voltage Cables Warning Label

IMPORTANT: The service switch on the PEC

should only be used for an emergency shut-

down, or when the service manual or trouble-

shooting guide calls for work on the high-voltage

system. The service manual and troubleshooting

guide for the hybrid electric system are available

04/17/2009

f545509

from www.roadranger.com.

Fig. 16.3, High Voltage Cables and Power Electronics

The red service switch is located next to the high-

Carrier (PEC) Location

voltage cable connections at one end of the PEC.

Pushing in the red service switch will shut down the

DANGER

engine. The hybrid system will be disabled, and the

high-voltage batteries in the PEC, though still live,

Unprotected contact with any live high-voltage

are isolated in the PEC.

components can cause serious injury or death.

NOTE: The PEC may be mounted in an area

Avoid direct pressure wash on high-voltage PEC

with limited access.

connections and the air intake and exhaust on the

For emergency shutdown information, see "In Case

PEC.

of an Emergency" in this chapter.

Engine Starting and Shutdown

Cooling System

The Cranking System

The HEV requires a liquid cooling system for the

HDU, inverter, and DC/DC converter. The HEV cool-

The primary engine starter is the electric motor in the

ing system is separate from the engine cooling sys-

HDU. The back-up cranking system is the standard

tem.

12-volt starter on the engine. If the hybrid system is

offline or the hybrid batteries are insufficiently

For coolant, use a 50/50 mixture of water and

charged, the vehicle will automatically use the 12-volt

extended-life antifreeze—the same coolant specified

cranking system to start the engine.

for the vehicle.

Starting

Safety Precautions

1. Set the parking brake.

The HEV has high-voltage components, including

2. Turn the ignition switch to the ON position.

340-volt Direct Current (DC) batteries and a 500-volt

Alternating Current (AC) motor.

Wait for the gauges on the instrument panel to

complete two sweeps (one from left to right, and

Never touch or cut high-voltage cables or connec-

tors. If it is necessary to remove occupants using

16.2

Hybrid Electric Vehicle

one from right to left) and return to their normal

Eaton Automated

ranges.

Transmission

3. Make sure that the transmission shift control is in

the Neutral (N) or Park (P) position.

The Hybrid Saf-T-Liner C2 School Bus is equipped

with an Eaton automated transmission. A T-handle

shift control is used by the driver to select the trans-

WARNING

mission ranges. See Fig. 16.4.

Never start the engine unless the parking brake

is applied. Accidental movement of the vehicle

could result in property damage, personal injury,

or death.

NOTE: The vehicle will crank after a brief delay.

4. Turn the ignition switch to the START position.

After the engine starts, release the key.

NOTICE

Do not crank the engine for more than 30 sec-

onds at a time. Wait two minutes after each try to

allow the starter to cool. Failure to do so could

cause starter damage.

5. Apply the service brake, then release the parking

brake.

04/15/2009

f270160a

6. With the service brake applied, press the desired

mode on the shift control to put the vehicle in

Fig. 16.4, T-Handle Shift Control (hybrid vehicle)

gear, then slowly release the service brake.

NOTE: The vehicle may be powered by the

P (Park)

electric motor or the diesel engine, depending

Use park when turning the engine on or off, to check

on battery charge and the demand for driveline

vehicle accessories, or to operate the engine in idle

torque. If the electric motor alone is powering

for longer than 5 minutes. This position places the

the driveline, the diesel engine will stay at idle.

transmission in neutral and engages the park pawl of

the transmission.

Engine Shutdown

NOTE: This does not apply the parking brake.

IMPORTANT: The transmission must be in neu-

The park pawl effectively grounds the transmis-

tral for proper shutdown.

sion output shaft, thereby preventing rotation of

1. With the vehicle stopped, place the transmission

the driveline. Provided the vehicle is stationary,

in Neutral (N).

selecting P (park) on the shift selector places

2. Set the parking brake.

the transmission in Neutral and engages the

park pawl.

3. Shut down the engine by turning the ignition

switch to the OFF position.

R (Reverse)

NOTE: Intermittent noises such as clicking and

The reverse position selects the reverse gear once

transmission shifting may be audible from the

the vehicle speed is less than 2 mph (3 km). When

transmission while it completes a self-test and

the selector is in reverse, the reverse warning signal

shutdown.

will sound. Always bring the vehicle to a complete

16.3

Hybrid Electric Vehicle

stop before shifting from a forward range to reverse,

Hybrid Electric Vehicle (HEV)

or from reverse to a forward range.

System Fault Lamps

Do not idle in reverse for more than 5 minutes. Se-

lect P (park), or N (neutral) when time at idle ex-

There are two lamps on the dashboard that indicate

ceeds 5 minutes.

a hybrid system fault is active—the red STOP HY-

BRID lamp and the amber CHECK HYBRID lamp.

N (Neutral)

See Fig. 16.5. When the red STOP HYBRID lamp is

illuminated, do not drive the vehicle; have it towed to

The neutral position places the transmission in neu-

a Thomas Built Bus dealer or an authorized service

tral. This position is used when starting the engine

center for repairs. When the amber CHECK HYBRID

and for stationary operation.

lamp is illuminated, the vehicle can still be driven,

When neutral is selected, the vehicle service brakes,

though it may operate without the assistance of the

parking brake, or emergency brake must be applied.

hybrid electrical system.

Selecting neutral does not apply vehicle brakes un-

less an auxiliary system to apply the parking brake is

installed.

Do not let the vehicle coast in neutral. If the vehicle

CHECK

is allowed to coast in neutral, the engine brake will

HYBRID

not work and you could lose control of the vehicle.

D (Drive)

STOP

HYBRID

The drive position selects the default start gear and

automatically upshifts and downshifts. In the drive

position, the transmission will initially go into first

range when drive is selected. As vehicle speed in-

07/09/2008

f611013

creases, the transmission will upshift automatically

Fig. 16.5, Hybrid System Fault Lamps

through each available range up to fourth range or

fifth range. As the vehicle slows, the transmission will

A gear display, located on the dash above the fault

downshift automatically.

lamps, will show the current gear selected, and any

When going downhill, downshift to a lower transmis-

fault codes for the transmission. F will flash for a

sion range to increase engine braking and to help

fault code, and the hybrid system fault lamps will illu-

maintain control. During downhill operation, the trans-

minate. If the gear display flashes CA, the driver is

mission may upshift to the next higher range, if the

being notified about clutch abuse.

engine is exceeding its governed speed in the lower

range.

Disabling the Hybrid Electric

H (Hold)

Vehicle (HEV) System

The hold position on the T-handle shifter holds the

The following information describes the three meth-

transmission in the current gear.

ods to disable the HEV system.

(Low Gear)

Option 1 (preferred method)

Use first range when pulling through mud or deep

Turn off the ignition.

snow, when maneuvering in tight spaces, or when

• The engine, dash lights, and HEV system will

driving up or down very steep grades. First range

shut down.

provides the vehicle with its maximum driving torque

and maximum engine braking effect.

• The HEV batteries are still active, but are iso-

lated in the Power Electronics Carrier (PEC).

16.4

Hybrid Electric Vehicle

Option 2

Disconnect the low-voltage (12 volt) vehicle batteries.

See Fig. 16.6.

• The engine and HEV system will shut down.

• The HEV batteries are still active, but are iso-

lated in the PEC.

Option 3

Push in the service switch on the PEC and shut

down the engine.

IMPORTANT: The red service switch on the

PEC should only be used for an emergency

shutdown or when the service manual or

04/22/2009

f545519

troubleshooting guide directs the hybrid-trained

Fig. 16.7, Service Switch

technician to perform work on the high-voltage

system.

down" procedure found in TRSM1000 located

on www.roadranger.com.

• Push in the service switch on the PEC and

shut down the engine. See Fig. 16.7.

In Case of an Emergency

• The hybrid system will be disabled.

Emergency Shutdown

• The HEV batteries are still "live" but are iso-

lated in the PEC.

IMPORTANT: After disabling the vehicle, power

is maintained in the high-voltage electrical sys-

tem for up to 5 minutes.

There are three options for performing an emergency

shutdown. The preferred method is to turn off the

ignition key. The second option is to disconnect the

low-voltage (12-volt) vehicle batteries. The final

method is to push in the service switch on the Power

Electronics Carrier (PEC). In any case, the engine,

dash lights, and hybrid electrical system will shut

down. The high-voltage batteries in the PEC will re-

main "live" but isolated in the PEC.

In Case of an Accident or Fire

If the HEV becomes involved in an accident or fire,

12/05/2003

f544365

be aware of the following:

1. Battery Access Door

3. Battery Tray

• Use CO2 or dry chemical extinguishers.

2. Pull-Pin Spring Latch

4. Battery

Lithium ion batteries are contained in the

Fig. 16.6, Battery Access

Power Electronics Carrier (PEC).

• Do not cut into high-voltage cables. The high-

IMPORTANT: These procedures should only be

voltage wiring is covered in orange insulation

used for an emergency. If service is required on

or convoluted tubing and marked with warning

the vehicle, refer to the "Hybrid Services Shut-

labels at the connectors.

• Do not cut into or open the PEC.

16.5

Hybrid Electric Vehicle

• Do not cut into or open the inverter.

If it is necessary to remove occupants using cutting

equipment, avoid high-voltage cables and the PEC.

See Fig. 16.3 for the location of the high-voltage

cables and PEC.

Jumpstarting

Jumpstarting vehicles equipped with the Eaton® Hy-

brid System is identical to non-hybrid vehicles, which

use the vehicle 12-volt battery system. See Chap-

ter 14 for jumpstarting instructions.

Towing

NOTICE

When towing or pushing the vehicle, regardless

of the distance or speed traveled, either discon-

nect the driveshaft at the rear axle and support it

as necessary, or remove the axle shafts. Failure

to do this when towing the vehicle with the rear

wheels on the ground could result in damage to

the transmission and other parts.

For instructions, see "Towing" in Chapter 14.

16.6

Propane Fuel System

with a minimum of 90% propane and a maximum of

General Information

5% propylene. This grade of propane is 100 plus oc-

tane and provides proper performance and emissions

CAUTION

control, which the fuel system is designed to deliver.

The engine is designed to operate properly on a

The propane fuel system requires special tools to

wide variety of liquid propane gas (LPG) blends

make repairs. Service and repair of the propane

which can fall in the category of HD5, and is not af-

fuel system should only be performed by trained

fected by "heavy ends" or other waxy hydrocarbons

propane service technicians. To prevent personal

that have traditionally affected other systems.

injury or damage to the fuel system, do not at-

tempt repairs yourself.

NOTICE

DANGER

LPG should be free of contaminants including,

but not limited to, rust, dirt, sand, water, salt, and

Never cut or weld on the propane storage tank.

brine. These contaminants can cause engine

Severe bodily injury or fire could result.

damage that is not covered by the engine war-

Propane is highly flammable. Keep sparks and

ranty.

open flames away from propane. Do not smoke

when refueling the vehicle. Failure to observe

WARNING

these safety precautions could cause serious

bodily injury or death.

The propane fuel system operates at pressures

The information provided in this chapter is specific to

up to 312 psi (2151 kPa). A sudden release of

the propane engine, however, other chapters in this

propane can cause serious injuries if it contacts

manual pertain to the propane operated vehicle.

the skin or eyes. Always wear approved protec-

These include, but are not limited to, the controls and

tive gloves and eye protection when handling

pretrip inspection and daily maintenance chapters.

propane.

IMPORTANT: For assistance with propane en-

LPG has no color. A distinctive odorant, similar to

gine related questions, contact Powertrain Inte-

sulfur or rotten eggs, is added to LPG to alert any-

one nearby in the event of a leak.

gration at 1-877-336-6308.

NOTE: Oil consumption is normal during opera-

Body Heater Loop Valve

tion of the propane engine. The rate of con-

The body heater loop valve circulates hot coolant to

sumption is highly dependent on vehicle loading

the body heaters, thereby providing heat inside the

and duty cycles. New engines may experience

vehicle.

higher oil consumption during the engine

break-in period. For further information, refer to

NOTICE

the engine manufacturer’s manual or contact

Powertrain Integration.

The body heater loop valve must be closed be-

fore operating the vehicle in temperatures of

NOTICE

100°F (38°C) or higher. Failure to do so could re-

sult in the loss of engine coolant, and cause en-

If the ignition switch is in the RUN position for

gine damage over time. See Fig. 17.1.

more than 15 seconds and the fuel tank is empty,

the fuel pump must be unplugged. Failure to fol-

Ignition Switch and Key

low this procedure will result in damage to the

fuel pump. Refer to the propane engine manual

The ignition switch has four positions: ACCESSORY,

for instructions on how to unplug the fuel pump.

OFF, RUN, and START. See Fig. 17.2.

HD5 grade propane is recommended for propane

In the OFF position, the key slot is vertical; the key

engines. HD5 is a heavy duty engine grade propane

can be inserted and removed only in this position.

17.1

Propane Fuel System

pressure and low oil pressure operate until minimum

pressures are built up.

IMPORTANT: The propane engine is equipped

with an amber wait to start indicator. The indica-

tor light illuminates when the ignition is in the

RUN position prior to engine start-up. Do not

crank the engine until the wait to start indicator

light goes out. See the "Ametek Panel" informa-

tion in this chapter for the location of the wait to

start indicator.

Turn the key fully clockwise to the START position to

start the engine. When the engine starts, release the

key.

12/09/2013

f200840

Engine Operation

To close the valve, it must be rotated 90 degrees so

that it is perpendicular to the coolant lines.

General Information

1. Body Heater Loop Valve

NOTE: Before starting the engine, read the

Fig. 17.1, Body Heater Loop Valve

"Ametek Panel" information in this chapter and

Chapter 5 for detailed information on how to

read the instruments and operate the controls.

Before operating the vehicle, perform the pretrip in-

spection and daily maintenance checks in Chap-

ter 11 and Chapter 12 of this manual.

NOTICE

If a vehicle does not start on the first attempt,

make sure that the engine has completely

stopped rotating before reapplying the starter

switch. Failure to do so can cause the pinion to

08/27/2013

f610509a

release and re-engage, which could cause ring

gear and starter pinion damage.

Fig. 17.2, Ignition Switch Positions

Moving a vehicle with the starter and/or using the

The following can be operated in the OFF position

starter to bump the engine for maintenance pro-

(regardless of whether the key is inserted): low beam

cedures is strictly prohibited. Use of these meth-

headlights, taillights, brake lights, road lights, clear-

ods to bump the engine over or move the vehicle

ance lights, turn signals, hazard warning lights, horn,

can cause the pinion to release and re-engage,

CB radio, clock, and electric oil pan heater.

which could cause ring gear and starter pinion

damage.

In the ACCESSORY position, the key is turned coun-

terclockwise. The radio (if so equipped), mirror heat,

Engine Starting

air dryer, backup lights, and all of the components

that are operable in the OFF position are operable in

1. Set the parking brake.

the ACCESSORY position.

2. Turn the ignition switch to the RUN position.

All electrical systems are operable in the RUN posi-

The amber wait to start indicator light illuminates

tion. The warning lights and the buzzer for low air

when the ignition is in the RUN position prior to

17.2

Propane Fuel System

engine start-up. Do not crank the engine until the

1. With the vehicle stopped, place the transmission

wait to start indicator light goes out.

in Neutral (N), or if so equipped, the Park (P)

position.

3. Make sure that the transmission shift control is in

Neutral (N), or if so equipped, the Park (P) posi-

2. Set the parking brake.

tion.

3. Idle the engine for two to three minutes before

shutting it down. This allows the lubricating oil

WARNING

and the coolant to carry heat away from the

combustion chambers, bearings, shafts, etc.

Never start the engine unless the parking brake

is applied. Accidental movement of the vehicle

NOTE: Long periods of idling are not needed or

could result in property damage, personal injury,

recommended.

or death.

4. Shut down the engine by turning the ignition

IMPORTANT: Do not depress the throttle pedal

switch to the OFF position.

while starting the engine.

Propane Refueling

4. Turn the ignition switch to the START position.

After the engine starts, release the key.

CleanFuel USA recommends that the Liquid Propane

Injection® (LPI) vehicle be refilled with fuel at sta-

NOTICE

tions that are specifically designed for vehicle refuel-

ing. For assistance locating LPG fuel stations, con-

Do not crank the engine for more than 30 sec-

tact CleanFuel USA at www.cleanfuelusa.com or at

onds at a time. Wait two minutes after each try to

1-512-864-0300.

allow the starter to cool. Failure to do so could

The propane fuel system utilizes a closed system,

cause starter damage.

with fuel supply and return lines. This requires more

5. Bring the engine up to operating speed gradually

advanced refueling equipment due to variances in

as it warms up and develops stable oil pressure.

pressure. When refueling the vehicle at a station not

specifically designed for dispensing propane (also

IMPORTANT: When the engine is started, it

referred to as autogas), the refueling process may be

takes a short time to build up a lubricating oil

very slow or the tank may not fill at all. The vehicle

film between the shafts and bearings, and be-

propane tank is subjected to heat from the pavement

tween the pistons and cylinder walls. The oil

and chassis components, which cause a normal in-

pressure gauge indicates any drop in lubricating

crease in tank pressure. The station pump may not

oil pressure within 15 seconds of engine startup.

be able to produce pressure high enough to over-

come that of the tank on the vehicle. It is recom-

Engine Shutdown

mended that the filling dispenser have a minimum of

90 psi (621 kPa) pump differential boost pressure

Shut down the engine immediately if:

over the storage tank pressure; most modern sta-

tions are designed to 130 psi (896 kPa) differential

• the oil pressure gauge needle swings back and

pressure. It is recommended to refuel the vehicle at

forth or falls sharply;

a modern station to prevent any customer inconve-

• engine power and rpm fall, even though the

nience.

accelerator pedal remains steady;

LPI fuel tanks are equipped with both an 80% fixed

• the exhaust pipe gives off heavy smoke;

liquid level gauge, and an automatic overfill protec-

tion device (OPD). The LPI system is designed to be

• the coolant and/or oil temperature climb abnor-

filled reliably and safely using only the OPD. There-

mally;

fore, it is not recommended to use the 80% fixed liq-

• abnormal sounds suddenly occur in the engine.

uid level gauge unless required by the filling station

attendant, or for annual OPD verification. See the

17.3

Propane Fuel System

CleanFuel USA Owners Manual Supplement for in-

this could result in serious injury. Replace the

structions on how to perform the annual OPD verifi-

O-ring before connecting the propane fill nozzle.

cation test.

6. Connect the propane fill nozzle to the tank fill

valve.

CAUTION

7. Rotate the propane fill valve nozzle clockwise

Liquid propane can cause serious burns should

until is is firmly attached to the tank fill valve.

it contact the skin or eyes. When handling pro-

8. Close the fill nozzle vent valve if so equipped.

pane, always wear approved protective gloves

and eye protection to prevent contact.

9. Open the 80% bleeder valve only if required.

CleanFuel USA does not recommend using the

Propane is extremely flammable, and can ignite if

bleeder valve. Use of the valve in a low emission

an ignition source is present, causing burns and

fuel station is prohibited.

other serious injuries. Keep sparks and flames

away from propane. Do not smoke near propane

10. Open the valve on the refueling nozzle.

or when refueling the vehicle.

11. Turn the propane dispenser on to begin refuel-

Propane is stored in the fuel tank under high

ing.

pressure. Never fill a leaking or damaged tank, as

12. When the OPD stops the flow of fuel into the

this could result in serious injury. Have the ve-

tank, close the filling valve.

hicle fuel tank(s) and fuel system inspected for

leaks by a trained technician annually.

If use of the 80% bleeder valve is required, stop

filling when liquid from the bleeder appears in the

Propane is a liquid under pressure and is stored in a

form of a white cloudy vapor.

pressure vessel unlike a gasoline or diesel tank. A

propane tank must never be filled to more than 80%

13. Turn the propane dispenser off.

of its actual capacity, to allow room for expansion.

80% is considered "full" for all propane tanks. When

CAUTION

the tank is filled to the correct 80% level, the fuel

gauge should read full.

Never overfill the propane fuel tank. Overfilling

the fuel tank can cause a dangerous condition,

The following steps describe a typical refueling pro-

resulting in serious injury and damage to the ve-

cedure. See Fig. 17.3 for an example of the dual

hicle.

propane tank system.

After refueling, if a strong smell of propane per-

1. Park the vehicle on level ground to ensure that

sists or if a hissing sound is heard, notify the

the tank is properly filled.

fuel station operator. Do not start the vehicle.

2. Turn the vehicle ignition to OFF and set the park-

14. Disconnect the filling nozzle from the tank fill

ing brake. Chock the tires if required.

valve.

3. Ensure that there are no open flames or ignition

14.1

If necessary, first open the vent valve on

sources in the area.

the nozzle, if so equipped, and release the

4. Turn the fuel tank cap counterclockwise and re-

pressure from the valve for safety.

move it.

14.2

Rotate the filling nozzle connector coun-

5. Inspect the fill valve O-ring, making certain the

terclockwise and remove it. Then return it

O-ring is seated in the groove and is not dam-

to the dispenser.

aged or missing.

15. Install the fuel cap.

CAUTION

16. Check for leaks on the fill valve and connecting

piping, and around the 80% bleeder valve.

Never connect the propane fill nozzle to the tank

17. Ensure that all of the fuel tank valves are in the

fill valve if the O-ring is damaged or missing, as

fully-closed position.

17.4

Propane Fuel System

09/18/2013

f470605

1. Propane Tank

4. Return Valve

7. Fuel Level Gauge

2. Bleeder Valve

5. Access Cover and Collar

8. Propane Tank

3. Fill Valve

6. Service Valve

9. Pressure Relief Valves

Fig. 17.3, Dual Propane Tank System

• Hour Meter

Ametek Instrument Panel

• Boost Pressure

The following information describes the Ametek in-

strument panel, used with liquid propane gas (LPG)

• Engine Oil Pressure

engines. The instrument panel is shown in Fig. 17.4.

• Coolant Temperature

NOTE: The instrument panel is shown with a

• Fuel Level

standard U.S. speedometer, which shows miles

per hour (mph) more prominently than kilome-

• Percent Engine Load

ters per hour (km/h).

• Engine RPM

During normal operation, the LCD displays the odom-

Message Display Center

eter value and chassis battery voltage on the top

The message display is a graphical, backlit, liquid

line, and driver selected parameters, such as the trip

crystal display (LCD) that relays information to the

odometer and fuel rate, on the second and third

vehicle operator. The messages displayed include:

lines.

• Odometer

Priority Messages

• Trip Odometer 1/Trip Odometer 2

Priority messages (including warning messages) are

• Chassis Battery Voltage

displayed in the LCD due to various inputs or data

messages. Unless noted otherwise, the priority mes-

• Instantaneous Fuel Rate

sage will take over the whole screen, allowing mul-

• Average Fuel Rate

tiple messages to be displayed in five second inter-

vals.

• Gear Attained Status

• Transmission Temperature

17.5

Propane Fuel System

12/05/2012

f611202

1. Tachometer

5. Primary Air Pressure Gauge

8. Dash Driver Display Screen

2. Dash Message Center

6. Secondary Air Pressure Gauge

9. Toggle Button, Down

3. Speedometer

7. Coolant Temperature Gauge

10. Toggle Button, Right

4. Fuel Level Gauge

Fig. 17.4, Gauge Layout (typical, U.S.), LPG Engines

Self-Test

Menu System

When the ignition is turned on, a required self-test

The menu system is shown on the driver display

automatically begins. Gauge needles will reset to

screen once the self-test is finished. The menu sys-

zero during the self-test, and then immediately move

tem responds to input from the driver and remains

to the position dictated by the data received. During

active as long as the ignition is on. In order for the

this time, the warning lights, alarm (buzzer), and

driver to operate the menu system, the ignition must

driver display screen will also perform a self-test.

be ON, and the park brake must be set (ON). The

main features of the menu system are described

NOTE: The driver can activate or deactivate the

below.

start-up self-test by accessing the setup menu.

17.6

Propane Fuel System

• Setup—this is used to set various parameters,

• maintenance intervals

which are saved when the ignition is turned off.

• transmission oil life remaining

Setup has select display units, startup screen,

LCD contrast, and reset parameters.

• transmission oil filter life monitor

• Maintenance—shows various maintenance in-

Maintenance Intervals

tervals such as engine oil, air filter, etc.

The maintenance intervals menu allows the driver to

• Diagnostics—this is used for setting and read-

set the change intervals for engine oil and engine air

ing inputs and outputs and checking the

filter. If the intervals are set to zero, the maintenance

gauges. It also shows the hardware and soft-

warnings must be disabled.

ware version of the instrument panel, and has

menus to retrieve active error codes from the

Transmission Oil Life Remaining

engine, transmission, and ABS controllers.

If transmission prognostics are enabled, this menu

NOTE: No lines can be highlighted in the menu

indicates how much useful oil life remains.

system screen. To get to the sections that can

be highlighted, press the right arrow toggle but-

Transmission Oil Filter Life Monitor

ton and hold it for two seconds. The display

If transmission prognostics are enabled, the trans-

screen will change and the options shown can

mission oil filter life monitor tells the driver if the

then be highlighted. Once a selection has been

transmission oil filter is clogged and in need of repair.

chosen and changes are made, press the right

A message will appear on the display screen as

arrow toggle button to go back to the main mes-

TRANS OIL FILTER FUNCTIONAL or TRANS OIL

FILTER CLOGGED.

sage display screen.

Diagnostic Menu

Setup Menu

Select Display Units

The diagnostic menu contains the following items:

The set units screen allows the driver to choose be-

• engine faults

tween English or metric units of measurement for the

• transmission faults

displayed values. To navigate to the set units screen,

see Fig. 17.5, screens H, I, and J.

• ABS faults

• check outputs

Startup Screen

The startup screen selection allows the driver to turn

• odometer diagnostics

the startup screen on or off.

• check gauges

LCD Contrast

• check indicators (warning lamps)

Select contrast from the menu to set the LCD con-

• check LCD

trast. Use the down toggle button to set the contrast

• check binary inputs

to the desired level. To navigate to the contrast

screen, see Fig. 17.5, screen M.

• check analog inputs

Reset Parameters

• check datalink

The reset parameters screen is included with ve-

• hardware/software version

hicles that have the Allison transmission prognostics

All of the items in the diagnostic menu can be ac-

feature.

cessed by using the toggle buttons and selecting the

auxiliary screens. Then navigate to the diagnostic

Maintenance Menu

sub-menu. Some of the more frequently used diag-

The maintenance menu has the following three sub

nostic menus are described further below.

menus:

17.7

Propane Fuel System

SETUP

Right Press

Down Hold

Current Units =

English

Down Press

Current Units =

English

Metric

Current Units =

Right Press

Metric

Select Display

Right Press

Units highlighted

Down Hold

Right Press

Down Hold

Startup Screen =

Enabled

Right Press

Down Press

Startup Screen

Startup Screen =

highlighted

Enabled

Disabled

Startup Screen =

Disabled

Right Press

Down Hold

Or (Right & Exit

Down Hold

highlighted)

Down Press

Highlight next

line of list.

Down Press

At middle,

At Min Contrast /

wrap to top

Set Contrast to Max

Right Press

Display Contrast

highlighted

Down Hold

Down Press

Not At Min Contrast /

Decrease Contrast

Right Press

Reset Parameters

highlighted

Down Hold

Right Hold

Reset Parameters

Right Press

Down Hold

AUXILIARY

SCREENS

09/23/2009

f040792

Fig. 17.5, Setup Menu Screens

17.8

Propane Fuel System

Engine Faults

fined in the system. The toggle buttons allow the

driver to select each analog input. This information is

This screen displays engine fault codes that are re-

continuously updated to assist in troubleshooting. To

ceived from the engine electronic control unit (ECU).

navigate to the check analog input screen, see

To navigate to the engine fault screen, see Fig. 17.6,

Fig. 17.8, screen AK.

screen AA.

Check Datalink

Transmission Faults

The check datalink screen allows the driver to view

This screen displays transmission fault codes that

all devices that communicate on the J1939, J1587,

are received from the transmission ECU. To navigate

and GMLAN datalinks. To navigate to the check da-

to the transmission fault screen, see Fig. 17.6,

talink screen, see Fig. 17.8, screen AL.

screen AB.

Menu Navigation

ABS Diagnostics

This screen displays Antilock Brake System (ABS)

The menu navigation screens are provided to illus-

fault codes that are received from the ABS ECU. To

trate the menu system. The paths to specific screens

navigate to the ABS diagnostic screen, see Fig. 17.6,

are shown, along with instructions for using the

screen AC.

toggle buttons to move from one screen to another.

See Fig. 17.5, Fig. 17.6, Fig. 17.7, Fig. 17.8,

Check Gauges

Fig. 17.9, Fig. 17.10, Fig. 17.11, Fig. 17.12,

Fig. 17.13, Fig. 17.14, Fig. 17.15, Fig. 17.16, and

The check gauges screen allows the driver to set

Fig. 17.17.

each gauge as a percentage of scale (either 0, 50, or

100%), as shown in the LCD. To navigate to the

IMPORTANT: Follow the steps below to change

check gauges screen, see Fig. 17.7, AG screens.

the three items (also known as favorites) shown

in the message display center. The message

Warning Lamp

display center is referred to as screen C in

The warning lamp screen allows the driver to test

Fig. 17.11.

each warning lamp (not the vehicle load) on and then

NOTE: The driver can check the pressure of the

off, displaying the lamp name and status in the LCD.

To navigate to the warning lamp screen, see

propane in the fuel rail (pressure of the fuel in

Fig. 17.7, screen AH.

both the tank and pump booster), and make this

one of the three items shown in the message

Check LCD

display center. Select the item with the fuel

pump and psi reading, then follow the directions

Selecting the check LCD screen displays the Freight-

liner Custom Chassis Corporation (FCCC) logo in

below to make it one of the favorites.

normal and reverse video three times and then re-

1. With the vehicle in park, turn the ignition to RUN,

turns to the menu. To navigate to the check LCD

and allow the self test to complete.

screen, see Fig. 17.7, screen AI.

2. Press the down toggle button to select an item to

Check Binary Inputs

change. The selected item will now be high-

lighted.

The check binary inputs screen displays the pin num-

ber and status of each binary input. The toggle but-

3. Press the right toggle button once to enter the

tons allow the driver to select each binary input. This

favorites display menu, shown in Fig. 17.11, as

information is continuously updated to assist in

screen D.

troubleshooting. To navigate to the check binary in-

4. Use the down toggle button to scroll through the

puts screen, see Fig. 17.7, screen AJ.

available items.

Check Analog Inputs

5. Highlight the new item, then press the right

The check analog inputs screen displays the pin

toggle button. The selected item will now appear

number and actual value of each analog input de-

in the message display center.

17.9

Propane Fuel System

Diagnostics

Screens AA,AB,AC Format For J1587

Down Press

Note 5:

Display Next Fault

Screen Z scrolls to display the

following items:

ENGINE FAULTS

TRANSMISSION FAULTS

Right Press

ABS FAULTS

Engine Faults

CHECK OUTPUTS

Highlighted

Down Hold

CHECK DATA INPUTS

ODOMETER DIAGNOSTICS

CHECK GAUGES

CHECK WARNING LAMPS

CHECK LCD

Down Press

CHECK BINARY INPUTS

Display Next Fault

CHECK ANALOG INPUTS

CHECK DATA LINK

VERSION INFORMATION

Right Press

EXIT

Trans Faults

The text DIAGNOSTIC MENU

Highlighted

Down Hold

remains fixed on the first line.

Down Press

Display Next Fault

Right Press

ABS Faults

Highlighted

Down Hold

Down Press

(Right & Exit

Change to

highlighted)

Next Output

Down Press

Highlight next

Right Press

line of list.

Check Outputs

At bottom,

Highlighted

Down Hold

wrap to top

Right Hold

Toggle Output

State Between

Off and On

Screen AE For J1587

Right Press

Odometer Diag

Right || Hold Down

Highlighted

09/23/2009

f040795

Fig. 17.6, Diagnostic Menu Screens, Screen 1

The instrument cluster has an emergency buzzer that

Warning and Indicator Lights

sounds when mission-critical conditions occur.

There are 19 warning and indicator lights (telltales)

A description of the standard warning and indicator

installed in the dash message center. See

lights are listed below.

Fig. 17.18. There are four rows of lights. Lights in-

stalled in the top row are optional and their positions

may vary. The lights in the bottom three rows are

installed in fixed positions on all vehicles. Most are

standard, but a few are optional.

17.10

Propane Fuel System

Other Text for Screen AG

Down Press

Change to

Next Gauge

Right Press

Check Gauges

Right || Hold Down

Highlighted

Right Hold

Step Gauge to

Next Position

Down Press

Change to

Next Telltale

Right Press

Warning Lamps

Right || Hold Down

Highlighted

Right Hold

Toggle State

Between

Off and On

Right Press

Right ||

Check LCD

9 Seconds Elapsed

Highlighted

|| Hold Down

Every 1.5 Seconds /

Invert Video of

Displayed Image

Down Press

Change to

Next Input

Right Press

Check Binary Inputs

Right || Hold Down

Highlighted

09/23/2009

f040796

Fig. 17.7, Diagnostic Menu Screens, Screen 2

• Transmission Prognostics Warning—if the

Maintenance Warning Light

transmission has prognostics enabled.

When the amber maintenance warning light illumi-

nates, the message display center will alert the driver

Left-Turn Signal Arrow

as follows:

The green left-turn signal arrow flashes on and off

• Oil Change Required—alerts the driver that the

whenever the outside left-turn signal lights are flash-

engine has reached the recommended oil

ing.

change interval.

Both turn signal arrows flash when the hazard warn-

• Air Filter Reminder—the air filter requires

ing flasher is turned on.

checking or replacement.

17.11

Propane Fuel System

Down Press

Change to

Next Input

Right Press

Screen AK

Check Analog Inputs

Input Name

Right || Hold Down

Pin pp of 26

Highlighted

xx.x Units

Down Press

Scroll Screen

Down 1 Line

Screen AL

Right Press

ECUs on Data Bus

Check Data Link

J1939 SA xx

Right || Hold Down

Highlighted

J1939 SA yy

Screen AM

Right Press

SOFTWARE VER: x.yy

Version Information

Right || Hold Down

CONFIG: ccccccc

Highlighted

HARDWARE VER: z

AUXILIARY

SCREENS

02/06/2012

f040797

Fig. 17.8, Diagnostic Menu Screens, Screen 3

bodily injury, property damage, or severe damage

Check Engine Indicator

to the engine.

The amber check engine indicator light illuminates

The red stop engine warning light illuminates to indi-

when certain faults are detected. If a critical engine

cate that the protection system available for the en-

condition exists (for example, low oil pressure or high

gine has been activated. The engine ECU will derate

coolant temperature), the check engine light will illu-

the engine, allowing it to run, but at lower rpm and

minate to alert the driver to correct the condition as

slower vehicle speed. The vehicle may be driven to a

soon as possible. If the condition gets worse, the

safe location.

stop engine light will illuminate.

NOTE: If the check engine light illuminates dur-

NOTICE

ing vehicle operation, take the vehicle directly to

an authorized Freightliner service facility.

Because operating the engine when the red stop

engine light is illuminated can lead to severe en-

Stop Engine Warning

gine damage, the driver must move the vehicle to

a safe location as quickly as possible and shut

down the engine.

WARNING

If the engine is shut down while the vehicle is in ser-

When the red STOP engine lamp illuminates, the

vice, a single restart attempt may be performed. De-

driver must immediately move the vehicle to a

pending on the nature of the fault condition, a cool-

safe location at the side of the road to prevent

down period may be required before restarting. If,

causing a hazardous situation that could cause

upon restarting, the fault condition still exists the

17.12

Propane Fuel System

Ignition On or

Headlamps On or

Marker Lamps On or

Park Brake Off

ACTIVE

Ignition Off &

( Headlamps On or

IGNITION

Marker Lamps On or

OFF

Park Brake Off )

Ignition On

Ignition

Off

IGNITION ON

NORMAL MODE

SELF TEST

Self Test

Enabled

DISPLAY

AUXILIARY

DOWNLOAD

MESSAGES

SCREENS

MODE

Right Hold

Park Brake On

No Warnings Active or

Active Warning

All Warnings

Messages

USB Drive Present &

Acknowledged

Park Brake On &

Vehicle Speed = 0 &

Not in Self Test

WARNING

MESSAGES

Ignition Off &

Headlamps Off &

Marker Lamps Off &

Park Brake On

09/23/2009

f040788

Fig. 17.9, Ignition On, Normal Mode

lamp will come on and the engine should be shut

IMPORTANT: Do not attempt to restart the en-

down. At this point, the vehicle is unsafe to drive and

gine while the vehicle is moving. Bring the ve-

should be transported to an authorized Freightliner

hicle to a safe stop and restart the engine with

service facility.

the vehicle stopped.

17.13

Propane Fuel System

SELF TEST

The Self Test screens display the FCCC

logo in normal video (Screen A) and in

reverse video (Screen B)

Startup Screen Enabled

Screen A

XXXXXXXXXXXXXXXXXXXXXX

Screen Displayed

for 1.5 Seconds

Startup Screen Disabled

Screen B

XXXXXXXXXXXXXXXXXXXXXX

Screen Displayed

for 1.5 Seconds

DISPLAY

MESSAGES

02/06/2012

f040789

Fig. 17.10, Self Test

Malfunction Indicator Lamp (MIL)

Headlight High-Beam Indicator

Indicates an engine emissions-related fault. See the

The blue high-beam indicator light (sideways beam

engine operation manual for details.

icon) illuminates when the headlight high beams are

on.

Low Air Pressure Warning

Wait to Start Indicator

The red low air pressure warning light and emer-

gency buzzer activate when the engine is turned on

The amber wait to start indicator light illuminates with

if air pressure in the primary or secondary air reser-

the ignition switch in the ON position prior to engine

voir is below 65 to 75 psi (448 to 517 kPa), and re-

start-up. Do not crank the engine until the wait to

main on until air pressure rises above that level in

start indicator light goes out.

both reservoirs.

Hydraulic Brake System Warning

The warning light and buzzer also activate during

operation whenever air pressure in the primary or

The red brake system warning illuminates if there is

secondary air reservoir falls below 65 to 75 psi (448

a hydraulic brake system failure, or if the vehicle is

to 517 kPa).

powered and the engine is not running.

17.14

Propane Fuel System

DISPLAY MESSAGES

Right Hold

Reset Highlighted Item

Down Hold

(if resettable)

Make No Changes

Screen C

Screen D

Selected Line 1 Data

Right Press

Favorites Display Menu

Selected Line 2 Data

Highlight First Item in List

Average Fuel Economy

Selected Line 3 Data

Gear Attained Status

Right Press

Down Press

Put Data For Highlighted Item

Move to, and Highlight,

Highlight CurrentLine

In Display Line CurrentLine

Next Item in List

HighlightTimer = 5 sec.

Right Hold

New Warning

Park Brake On

Message Active

HighlightTimer = 0

WARNING

AUXILIARY

MESSAGES

SCREENS

11/23/2011

f040790

Fig. 17.11, Display Messages

ABS Indicator

Check Transmission Indicator

The amber antilock brake system (ABS) indicator

NOTE: The LPG check transmission indicator

light illuminates when there is a malfunction in the

has a different icon (exclamation point), and illu-

vehicle ABS.

minates when the transmission fluid temperature

goes above a preset level.

NOTE: For more information about this light and

the ABS system, see Chapter 10.

The amber check transmission indicator illuminates

when the temperature of the transmission fluid goes

Traction Control Indicator

above the preset level set by the transmission manu-

facturer.

The amber traction control indicator illuminates when

the wheels lose traction.

For more information, see the transmission manufac-

turer’s manual provided with the vehicle.

Shift Inhibit Indicator

Stop Transmission Indicator

The amber shift inhibit indicator light illuminates

whenever all conditions for safe transmission shifting

The red warning light illuminates when the transmis-

have not been met.

sion control unit senses a malfunction.

17.15

Propane Fuel System

AUXILIARY SCREENS

Right Press

Setup

SETUP

highlighted

SETUP.

Right Press

Maintenance

MAINTENANCE

highlighted

Screen G

SETUP

MAINTENANCE

DIAGNOSTICS

Down Press

Right Press

Highlight next

Diagnostics

DIAGNOSTICS

line of list.

highlighted

At middle,

wrap to top

Down Hold

Right Press

Trip Data

TRIP DATA

highlighted

DISPLAY

MESSAGES

02/06/2012

f040791

Fig. 17.12, Auxiliary Screens

Right-Turn Signal Arrow

Fasten Seat Belts Warning

The green right-turn signal arrow flashes on and off

The red fasten seat belts warning light (seat belt

whenever the outside right-turn signal lights are

icon) illuminates for 15 seconds after the ignition

flashing.

switch is turned on.

Both turn signal arrows flash when the hazard warn-

Brake System Warning/Parking Brake

ing flasher is turned on.

On Indicator

The red brake system warning/parking brake on indi-

cator light (BRAKE legend) activates whenever the

parking brake is engaged.

17.16

Propane Fuel System

MAINTENANCE

Maint

Right Press

Down Hold

Down Press

(Right & Exit

Highlight next

highlighted)

line of list.

At middle,

Oil Change Baseline +

Right Hold

wrap to top

Oil Change Distance >=

Oil Change

Odometer

Baseline =

Odometer

Right Press

Engine Oil

Oil Change Distance =

else

Highlighted

Current Displayed

Down Hold

Value

Down Press

Right Hold

Display Next

Oil Change

Value of Oil

Distance = 0

Baseline =

Change Distance

Odometer

Right Press

Down Hold

Air Change Baseline +

Right Hold

Air Change Distance >=

Air Change

Odometer

Baseline =

Odometer

Right Press

Air Change Distance =

Engine Air Filter

else

Current Displayed

Highlighted

Down Hold

Value

Down Press

Right Hold

Display Next

Air Change

Value of Air

Distance = 0

Baseline =

Change Distance

Odometer

09/23/2009

f040793

Fig. 17.13, Maintenance Menu Screens, Screen 1

If the vehicle is moving at a speed of 2 mph (3 km/h)

Cruise Control Indicator

or more, the emergency buzzer will sound until the

parking brake is released.

A green indicator illuminates when the cruise control

is activated.

NOTE: The BRAKE legend is required in the

U.S. In Canada, the icon is required.

17.17

Propane Fuel System

Right Press

Transmission

Oil Life

Down Hold

Highlighted

Right Hold

Send SPN 1584 = 37

Right Press

Down Hold

Right Press

Transmission

Maint

Oil Filter

Down Hold

Highlighted

Right Hold

Send SPN 1584 = 39

Right Press

Down Hold

AUXILIARY

SCREENS

02/06/2012

f040794

Fig. 17.14, Maintenance Menu Screens, Screen 2

Emergency Buzzer

Speedometer and Tachometer

The emergency buzzer sounds during the ignition

Speedometer

sequence and whenever one of the following condi-

tions exists:

Three kinds of speedometer faces are available. The

U.S. version of the speedometer registers speed in

• The engine oil pressure falls below the preset

both miles per hour (mph) and kilometers per hour

level which is 6 psi (41 kPa) at 700 rpm, or 18

(km/h), with mph in larger numbers. See Fig. 17.19.

psi (124 kPa) at 4400 rpm.

The NAFTA version (not shown) of the speedometer

• The air pressure falls below the preset level,

face reverses this arrangement, with km/h in larger

which is 65 psi (448 kPa).

numbers. The metric-only version (not shown) shows

km/h exclusively.

• The parking brake is set with the vehicle mov-

ing at a speed greater than 2 mph (3 km/h).

Tachometer

• The coolant temperature rises above 253°F

(123°C) and the check engine and stop engine

The tachometer indicates engine speed in revolutions

lights illuminate. When the coolant temperature

per minute (rpm) and serves as a guide for shifting

falls below 244° (118°C) the emergency buzzer

the transmission and keeping the engine in the ap-

and stop engine light will turn off.

propriate rpm range. See Fig. 17.19.

NOTE: The check engine light will remain on

until the vehicle is inspected at an authorized

Freightliner service facility.

17.18

Propane Fuel System

Trip Data

Down Press

Highlight next

line of list.

At bottom,

wrap to top

Right Press

Correct Passcode /

Reset All

Reset Trip

Highlighted

Data

(Right & Exit

highlighted)

Down Press

Wrong Passcode /

Note 6:

Screen AO scrolls to display

the following items:

Trip Time

Right Press

Idle Time

Max RPM

Avg RPM

Max Speed

Avg Speed

Avg Fuel Economy

Reset All

Exit

AUXILIARY

SCREENS

09/23/2009

f040798

Fig. 17.15, Trip Data

Standard Instruments

Primary and Secondary Air Pressure

Gauges

Fuel Level Gauge

The fuel level gauge indicates the level of fuel in the

WARNING

fuel tanks. See Fig. 17.20. A low-level warning light

illuminates when the diesel fuel level registers 1/8th

If air pressure falls below minimum pressure, the

of capacity.

braking ability of the vehicle will be limited. Slow

the vehicle down and bring it to a gradual stop.

Do not attempt to move the vehicle until air pres-

sure has risen above the minimum level. Moving

a vehicle without adequate braking power could

17.19

Propane Fuel System

WARNING MESSAGES

Msg Displayed for 5 Sec. /

Display Next Entry in

Display 1^st Message

Warning Message List

in Warning

Message List

Screen AN

WARNING

Any Button Press

Warning Message

No Warning

Messages in List /

DISPLAY

MESSAGES

02/06/2012

f040799

Fig. 17.16, Warning Messages

cause an accident resulting in personal injury or

the vehicle to a safe stop and investigate the

death.

cause to prevent further damage. Do not operate

the engine until the cause has been determined

Air pressure gauges register the pressure in the pri-

and corrected.

mary and secondary air systems. Normal pressure

with the engine running is 100 to 120 psi (690 to 827

During normal engine operation, the coolant tem-

kPa) in both systems. See Fig. 17.21.

perature gauge should read 200 to 205°F (93 to

96°C). See Fig. 17.22. If the temperature remains

Air pressure gauges are required on all vehicles with

below 160°F (71°C) or exceeds 235°F (113°C), in-

air brakes. A low-air-pressure warning light and

spect the cooling system to determine the cause.

buzzer, connected to both the primary and secondary

See the vehicle workshop manual for troubleshooting

systems, activate when air pressure in either system

and repair procedures.

drops below a minimum pressure of 65 to 75 psi

(448 to 517 kPa).

The coolant temperature gauge is very important.

See Fig. 17.22. If the coolant temperature rises

When the engine is started, the warning light and

above 253°F (123°C), the check engine and stop

buzzer remain on until air pressure in both systems

engine lights will illuminate, and the buzzer will

exceeds minimum pressure.

sound. At this point, the engine will derate and idle

speed will increase, to speed up the cooling fan and

Coolant Temperature Gauge

water pump to cool the engine.

NOTICE

Grade Brake

A sudden increase in coolant temperature may

IMPORTANT: The grade brake is an optional

indicate engine or cooling system failure. Bring

auxiliary brake system that works through the

17.20

Propane Fuel System

IGNITION OFF

Park Brake Off

Park Brake On

Ignition On

Headlamps Off &

Marker Lamps Off &

Park Brake On

IGNITION

02/06/2012

f040800

Fig. 17.17, Ignition Off (shown when ignition is keyed OFF)

transmission. It should not be confused with ex-

haust brake or engine brake. Furthermore, the

grade brake should not be used in place of the

service brakes to stop the vehicle.

Chassis equipped with a propane engine may have

an optional grade brake. The grade brake is de-

signed to downshift the transmission—when going

downhill for example—without overspeeding the en-

gine. Refer to the Allison Operator’s Manual for

proper operation of the grade brake. See Fig. 17.23

for an example of the grade brake switch. An amber

light activates at the top of the switch when the

grade brake is activated.

17.21

Propane Fuel System

10/30/2012

f611201

1. Maintenance Warning Light

8. Headlight High-Beam Indicator

14. Check Transmission Indicator

2. Left-Turn Signal Arrow

9. Wait to Start Warning

15. Stop Transmission Indicator

3. Check Engine Indicator

10. Hydraulic Brake System Warning

16. Right-Turn Signal Arrow

4. Stop Engine Warning

11. ABS Indicator

17. Fasten Seat Belt Warning

5. Malfunction Indicator Lamp (MIL)

12. Traction Control Indicator

18. Parking Brake On Indicator

6. Low Air Pressure Warning

13. Shift Inhibit Indicator

19. Cruise Control Indicator

7. Engine Brake Light (not used)

Fig. 17.18, LPG Engine Warning and Indicator Lights

MPH

RPM

X 100

100

120

140

09/18/2013

f611217

1. Tachometer

2. Speedometer

Fig. 17.19, Speedometer and Tachometer (U.S. version)

17.22

Specifications

Torque Charts

Torque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads^†

Regular Hex

Flanged

Thread

Grade 5

Grade 5 or

Grade 8 or

Grade 5

Grade B

Grade 8 or

Grade G

Diameter—

Bolt

B Nut

8.2 Bolt

C Nut

Bolt

Nut

8.2 Bolt

Nut

Pitch

Torque: lbf·ft (N·m)

f230002

f230003

f230004

f230005

f230006

f230007

f230008

f230009

1/4-20

(9)

(11)

(8)

(14)

1/4-28

(11)

(12)

(9)

(16)

5/16-18

(20)

(22)

(18)

(28)

5/16-24

(22)

(23)

(19)

(31)

3/8-16

(35)

(38)

(31)

(50)

3/8-24

(41)

(43)

(34)

(57)

7/16-14

(57)

(61)

(47)

(81)

7/16-20

(64)

(68)

(54)

(89)

1/2-13

(87)

(92)

(75)

(123)

1/2-20

(98)

(104)

(88)

102

(138)

9/16-12

(125)

(133)

(108)

130

(176)

9/16-18

103

(140)

110

(149)

(122)

146

(198)

5/8-11

128

(173)

136

(184)

110

(149)

180

(244)

5/8-18

145

(197)

154

(209)

130

(176)

204

(277)

3/4-10

226

(306)

241

(327)

200

(271)

320

(434)

3/4-16

253

(343)

269

(365)

220

(298)

357

(484)

7/8-9

365

(495)

388

(526)

320

(434)

515

(698)

7/8-14

402

(545)

427

(579)

350

(475)

568

(770)

1-8

—

582

(789)

—

1-12

—

637

(863)

—

1-14

—

652

(884)

—

* FCCC recommends that all plated and unplated fasteners be coated with oil before installation.

†

Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed, Geomet 321XL

coated, or waxed).

Table 18.1, Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads

18.1

Specifications

Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads^†

Regular Hex

Flanged

Thread

Grade 5 or B

Grade 8 or 8.2

Grade 8 or C

Grade 8 or 8.2

Diameter—

Grade 5 Bolt

Grade G Nut

Nut

Bolt

Nut

Bolt

Pitch

Torque: lbf·ft (N·m)

f230002

f230003

f230004

f230005

f230008

f230009

1/4-20

(11)

(14)

—

1/4-28

(12)

(16)

—

5/16-18

(20)

(30)

5/16-24

(23)

(34)

—

3/8-16

(38)

(54)

3/8-24

(42)

(61)

—

7/16-14

(61)

(88)

7/16-20

(68)

(95)

—

1/2-13

(95)

(129)

1/2-20

(102)

110

(149)

—

9/16-12

100

(136)

140

(190)

140

(190)

9/16-18

110

(149)

155

(210)

—

5/8-11

135

(183)

190

(258)

190

(258)

5/8-18

155

(210)

215

(292)

—

3/4-10

240

(325)

340

(461)

340

(461)

3/4-16

270

(366)

380

(515)

—

7/8-9

385

(522)

540

(732)

—

7/8-14

425

(576)

600

(813)

—

1-8

580

(786)

820

(1112)

—

1-12

635

(861)

900

(1220)

—

1-14

650

(881)

915

(1241)

—

* Threads may have residual oil, but will be dry to the touch.

†

Male and female threads (bolt and nut) must both be unlubricated and unplated. If either is plated or lubricated, use Table 18.3. FCCC recommends that

all plated and unplated fasteners be coated with oil before installation.

Table 18.2, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads

18.2

Specifications

Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads^†

Thread

Class 8.8 Bolt

Class 8 Nut

Class

10.9 Bolt

Class 10 Nut

Diameter—

Pitch

Torque: lbf·ft (N·m)

8.8

10.9

f230010

f230011

f230012

f230013

(7)

(9)

(16)

(23)

M8 x 1

(18)

(24)

M10

(33)

(46)

M10 x 1.25

(37)

(52)

M12

(57)

(81)

M12 x 1.5

(58)

(84)

M14

(89)

(129)

M14 x 1.5

(98)

103

(140)

M16

103

(140)

148

(201)

M16 x 1.5

110

(149)

157

(213)

M18

147

(199)

203

(275)

M18 x 1.5

165

(224)

229

(310)

M20

208

(282)

288

(390)

M20 x 1.5

213

(313)

320

(434)

M22

283

(384)

392

(531)

M22 x 1.5

315

(427)

431

(584)

M24

360

(488)

498

(675)

M24 x 2

392

(531)

542

(735)

M27

527

(715)

729

(988)

M27 x 2

569

(771)

788

(1068)

M30

715

(969)

990

(1342)

M30 x 2

792

(1074)

1096

(1486)

* FCCC recommends that all plated and unplated fasteners be coated with oil before installation.

†

Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated,

cadmium-plated, or waxed, Geomet 321XL coated, or waxed).

Table 18.3, Torque Values for Metric Thread Fasteners With Lubricated or Plated

Threads

18.3

Specifications

Conversion Charts

Metric/U.S. Customary Conversion

When You Know U.S.

Multiply

When You

Multiply

To Get Metric

To Get U.S. Customary

Customary

Know Metric

Length

inches (in)

25.4

millimeters (mm)

0.03937

inches (in)

2.54

centimeters (cm)

0.3937

inches (in)

feet (ft)

0.3048

meters (m)

3.281

feet (ft)

yards (yd)

0.9144

meters (m)

1.094

yards (yd)

miles (mi)

1.609

kilometers (km)

0.6215

miles (mi)

Area

square inches (in²)

645.16

square millimeters (mm²)

0.00155

square inches (in²)

6.452

square centimeters (cm²)

0.155

square inches (in²)

square feet (ft²)

0.0929

square meters (m²)

10.764

square feet (ft²)

Volume

cubic inches (in³)

16387.0

cubic millimeter (mm³)

0.000061

cubic inches (in³)

16.387

cubic centimeters (cm³)

0.06102

cubic inches (in³)

0.01639

liters (L)

61.024

cubic inches (in³)

fluid ounces (fl oz)

29.54

milliliters (mL)

0.03381

fluid ounces (fl oz)

pints (pt)

0.47318

liters (L)

2.1134

pints (pt)

quarts (qt)

0.94635

liters (L)

1.0567

quarts (qt)

gallons (gal)

3.7854

liters (L)

0.2642

gallons (gal)

cubic feet (ft³)

28.317

liters (L)

0.03531

cubic feet (ft³)

0.02832

cubic meters (m³)

35.315

cubic feet (ft³)

Weight/Force

ounces (av) (oz)

28.35

grams (g)

0.03527

ounces (av) (oz)

pounds (av) (lb)

0.454

kilograms (kg)

2.205

pounds (av) (lb)

U.S. tons (t)

907.18

kilograms (kg)

0.001102

U.S. tons (t)

0.90718

metric tons (t)

1.1023

U.S. tons (t)

Torque/Work Force

inch-pounds (lbf·in)

11.298

Newton-centimeters (N·cm)

0.08851

inch-pounds (lbf·in)

foot-pounds (lbf·ft)

1.3558

Newton-meters (N·m)

0.7376

foot-pounds (lbf·ft)

Pressure/Vacuum

inches of mercury (inHg)

3.37685

kilo Pascals (kPa)

0.29613

inches of mercury (inHg)

pounds per square inch (psi)

6.895

kilo Pascals (kPa)

0.14503

pounds per square inch (psi)

Table

18.4, Metric/U.S. Customary Conversion

Temperature Conversion

Then

When You Multiply

Then

When You Know

Subtract

To Get

Divide By

Know

Add

degrees Fahrenheit (°F)

1.8

degrees Celsius (°C)

1.8

degrees Fahrenheit (°F)

Table 18.5, Temperature Conversion

18.4

Specifications

Fluid and Lubricant

Specifications

See Table 18.6 for fluid and lubricant specifications.

Fluid and Lubricant Specifications

Component

Recommended Fluid or Lubricant

Front Axle Spindle Pins, Tie Rods, Drag Link,

Multipurpose Grease Lithium 12- Hydroxy Stearate NLGI No.

2; for

Intermediate Steering Shaft, Front Brake and

temperatures below 0°F (-18°C), use MIL-G-10924B

Pedal Shafts, Slip Spline and Universal Joints

Hydraulic Brake Master Cylinder

Heavy-Duty DOT 3 Brake Fluid

Brake and Pedal Pivots

Starplex 2 (lithium soap-based grease)

Engine

See Manufacturer’s Recommendations

Transmission

Mobil Delvac Synthetic ATF

Fuel

Ultralow-Sulfur Diesel Fuel

HD5 Grade Propane

Disc Brake Caliper Rails

FCCC No. 4JD623 Brake Caliper Slide Grease

Rear Axle Differential

See Manufacturer’s Recommendations

Hydraulic System Reservoir

ATF must meet Dexron® III or TES-389 specifications

Engine Coolant

50% Water/50% Ethylene Glycol Antifreeze

Chevron Delo Antifreeze No. 275110 (propane engines only)

Table 18.6, Fluid and Lubricant Specifications

Fuse Information

Main PDM Fuse Identification

CAV

Description

Fuse

See Table 18.7 for descriptions of a typical set of

F17

Chassis Module

30A

fuses. Fuse identification varies with options.

F18

Bulkhead Module

30A

F19

Chassis Module

30A

Main PDM Fuse Identification

F20

Bulkhead Module

30A

CAV

Description

Fuse

F21

Expansion Module 2

30A

VCU (spare)

10A (—)

F22

Bulkhead Module

30A

Blower Motor

30A

F23

Expansion Module 2

30A

Engine ECU

20A

F24

Hydraulic Pump and RLY (spare)

25A (—)

RR Wall HTR RLY LO/HI

30A

F25

Adjustable Pedals

10A

Ignition Switch

10A

F26

Chassis Module

30A

Hydromax RLY (spare)

30A (—)

F27

Heater Booster Pump

20A

Stepwell HTR RLY LO/HI

30A

F28

Bulkhead Module

30A

ICU3-M2

10A

F29

Crossing Arm RLY

10A

Transmission ECU

10A

F10

Expansion Module 1

30A

Table 18.7, Main PDM Fuse Identification

F11

Expansion Module 1

30A

F12

Radio/Diagnostic

20A

F13

Expansion Module 1

30A

F14

Expansion Module 2

30A

F15

Bulkhead Module

30A

F16

ABS ECU

15A

18.5

Index

Subject

Page

Subject

Page

Parking Brake Control Valve

5.11

Bus Amenities

3.8

Adjusting Headlight Aim

15.1

Storage

3.8

Aftertreatment System (ATS)

Regen Switch

5.5

Aftertreatment System, EPA10

and Newer Engines

8.1

Canadian Motor Vehicle Safety

ATS Warning Lamps

8.2

Standard Labels

1.2

DPF Maintenance

8.3

Care of Chrome Parts

13.1

Parked Regen

8.2

Care of Fiberglass Parts

13.1

Principles of Operation

8.1

Changing a Flat Tire

14.6

Air Brake Operation

10.1

Checking Headlight Aim

15.1

Caging the Parking Brakes

10.2

Conversion Charts

18.4

Operating the Brakes

10.2

Parking Brake Interlock,

Optional

10.1

Allison On-Highway

Daily Pretrip Inspection and

Transmissions

9.1

Maintenance Checklist

11.2

Operating Instructions, 2000

Daily Pretrip Inspection and

Series Transmissions

9.2

Maintenance Procedures

12.1

Operating Instructions, 3000

Dashboard and Instrument

Series

9.3

Panel Care

13.1

Range Inhibit Indicator, 2000

Diesel Exhaust Fluid and Tank,

Series

9.2

EPA10 and Newer Engines

8.3

Safety Precautions

9.1

DEF Tank

8.4

Ametek Instrument Panel

17.5

DEF Warnings and Engine

Menu Navigation

17.9

Limits

8.4

Menu System

17.6

Diesel Exhaust Fluid

8.3

Message Display Center

17.5

Fuel/DEF Gauge

8.4

Priority Messages

17.5

Disabling the Hybrid Electric

Self-Test

17.6

Vehicle (HEV) System

16.4

Assist Rails and Access Steps

2.1

Option 1 (preferred method)

16.4

Folding Steps

2.1

Option 2

16.5

Automatic Tire Chain Control

5.5

Option 3

16.5

Braking and Stopping

5.6

Drive Axles, Detroit^™ and

Meritor^™

9.6

Engaging/Disengaging the

Tire Chains

5.5

Drive Axles With Differential

Lock

9.6

Use of the Tire Chains While

They Are Engaged

5.6

Driver Switch Panel Controls

5.4

Driving Precautions

9.1

Dual Air Brake System

10.1

Emergency Braking System

10.1

Battery Access

2.2

Parking Brakes

10.1

Battery Compartment

2.2

Primary Air Brake System

10.1

Battery Disconnect Switch,

Secondary Air Brake System

10.1

Optional

2.2

Bosch Hydraulic Pin Slide

Brakes

10.3

General Information

10.3

Eaton Automated Transmission

16.3

Operation

10.3

(Low Gear)

16.4

Braking Controls

5.11

D (Drive)

16.4

Meritor^™ WABCO® Antilock

H (Hold)

16.4

Braking System (ABS)

5.11

N (Neutral)

16.4

I-1

Index

Subject

Page

Subject

Page

P (Park)

16.3

R (Reverse)

16.3

Federal Motor Vehicle Safety

Electrical System General

Standard Labels

1.1

Information

6.1

Fire Extinguisher

14.1

Emergency Door

2.4

Floor Cleaning

13.2

Rear Emergency Door

2.4

Fluid and Lubricant

Using the Main Entry/Exit

Specifications

18.5

Door in an Emergency

2.5

Front Door Opening and

Emergency Exits

14.4

Closing

2.2

Emergency Door

14.4

Buses with Exterior Door

Emergency Roof Escape

Control

2.2

Hatches

14.5

Buses without Exterior Door

Emergency Window Exits

14.5

Control

2.2

Using the Main Entry/Exit

Fuse Information

18.5

Door in an Emergency

14.4

Emergency Kit

14.1

Emergency Roof Escape Hatch

2.4

Emergency Starting With

General Information

17.1

Jumper Cables

14.1

Body Heater Loop Valve

17.1

Emergency Window Exits

2.5

Grade Brake

17.20

Vehicles Built Since January

9, 2008

2.5

Emissions Labels

1.2

Aftertreatment System

Hazard Warning Lights

14.1

Indicators Label

1.3

Heater/Air Conditioner/Defrost

EPA Noise Emission Control

Control Panel

5.11

Label

1.2

Air Conditioning

5.15

Vehicle Emission Control

Information Label

1.3

Air Selection Switch

5.12

Engine Operation

17.2

Booster Pump

5.15

Engine Shutdown

17.3

Climate Control Panel

5.12

Engine Starting

17.2

Defrosting

5.15

General Information

17.2

Fan Switch

5.12

High Idle Options

7.3

Fresh Air Mode

5.14

Engine Shutdown

7.4

Passenger Heater Switch

5.12

Engine Starting and Shutdown

16.2

Recirculation Mode

5.14

Engine Shutdown

16.3

Temperature Control Switch

5.14

Starting

16.2

Hood Opening and Closing

2.3

The Cranking System

16.2

Closing the Hood

2.4

Engine Starting

7.1

Tilting the Hood

2.3

General Information

7.1

Horn Control

5.7

Starting After Extended

Hybrid Electric Vehicle (HEV)

Shutdown or Oil Change

7.1

Overview

16.1

Entering and Exiting the Bus

2.1

Cooling System

16.2

Entering the Bus

2.1

High-Voltage Safety

Features

16.1

Exiting the Bus

2.1

Hill Start Aid

16.1

Stepwell Light

2.1

Regenerative Braking

16.1

Exhaust Brake

10.5

Hybrid Electric Vehicle (HEV)

Driving Downhill

10.6

System Fault Lamps

16.4

General Information

10.5

Operating Characteristics

10.6

Shutting Down the Engine

10.7

Starting the Engine

10.6

I-2

Index

Subject

Page

Subject

Page

Ignition Switch and Key

5.1

Optional Instruments

4.10

In Case of an Emergency

16.5

Air Intake Restriction Gauge

4.10

Emergency Shutdown

16.5

Ammeter

4.11

In Case of an Accident or

Axle Oil Temperature Gauge,

Fire

16.5

Rear

4.11

Instrumentation Control Unit

4.1

Digital Clock

4.11

Dash Message Center

4.1

Engine Oil Temperature

Ignition Sequence

4.2

Gauge

4.12

Mode/Reset Switch

4.4

Pyrometer

4.12

Odometer

4.4

Transmission Fluid

Temperature Gauge

4.13

Turbocharger Boost

Pressure Gauge

4.13

Jumpstarting

16.6

Power Distribution Modules

6.1

Powertrain Controls

5.8

Lighting Controls

5.1

Axle Switches

5.9

Footwell Light

5.2

Cruise Control Switch

5.8

Headlight/Parking Light

Switch

5.1

Exhaust Brake Switch

5.9

Interior Dome Lights

5.2

Fast Idle System

5.9

Panel Light Increase/

Transmission Controls

5.9

Decrease Switch

5.2

Preliminary Checks

15.1

Pretrip and Post-Trip Inspection

General Information

11.1

Propane Refueling

17.3

Meritor Cam-Master® Q Plus

Brakes

10.3

Cam-Master Q Plus

Operation

10.3

Replacement Light Bulbs

18.6

Meritor WABCO® Pneumatic

Running Out of Fuel

14.5

Antilock Braking System

(ABS)

10.3

Automatic Slack Adjusters

10.5

Automatic Traction Control

10.4

Safety Precautions

16.2

Pneumatic ABS Operation

10.4

Seat Belts and Tether Belts

3.6

Mirrors

3.1

General Information

3.6

Mirror Heat Switch, Optional

3.1

Seat Belt Inspection

3.7

Power Mirrors, Optional

3.1

Seat Belt Operation

3.7

Monthly Post-Trip Inspection

Seats

3.2

and Maintenance Checklist

11.3

Bench Seats

3.3

Monthly Post-Trip Inspection

Bostrom Seat

3.4

and Maintenance Procedures

12.11

General Information

3.2

Multifunction Turn Signal Switch

5.2

National 2000 Series Seat

3.4

Hazard Warning Lights

5.4

Sears Seat

3.5

Headlight High Beams

5.3

Track-Mounted Seats

3.3

Turn Signal Lever

5.2

Speedometer and Tachometer

4.8

Windshield Wiper/Washer

Controls

5.3

Speedometer

4.8

Tachometer

4.8

Standard Instruments

4.8

I-3

Index

Subject

Page

Subject

Page

Coolant Temperature Gauge

4.8

High Exhaust System

Engine Oil Pressure Gauge

4.8

Temperature (HEST) Lamp

4.6

Fuel Level Gauge

17.19

Hydraulic Brake System

Warning

17.14

Fuel/Diesel Exhaust Fluid

(DEF) Gauge

4.9

Left-Turn Signal Arrow

4.6

Primary and Secondary Air

Low Air Pressure Warning

4.7

Pressure Gauges

4.9

Low Battery Voltage Warning

4.6

Voltmeter

4.10

Low Oil Pressure Warning

4.6

Steering Controls

5.7

Maintenance Warning Light

17.11

Malfunction Indicator Lamp

(MIL)

4.5

Optional Indicator Lights

4.7

Tire and Rim Information

1.2

Right-Turn Signal Arrow

4.7

Torque Charts

18.1

Shift Inhibit Indicator

17.15

Towing

16.6

Stop Engine Warning

4.5

Front Towing Hookup

14.4

Stop Transmission Indicator

17.15

Traction Control Indicator

17.15

Transmission Overheat

Indicator

4.5

Vehicle Certification Plate and

Wait to Start Indicator

17.14

Data Plate

1.1

Water In Fuel Indicator

4.6

Vehicle Loading

1.2

Washing and Polishing

13.1

Vinyl Upholstery Cleaning

13.1

Weekly Post-Trip Inspection

Ball Point Ink

13.2

and Maintenance Checklist

11.3

Chewing Gum

13.2

Weekly Post-Trip Inspection

Miscellaneous

13.2

and Maintenance Procedures

12.9

Nail Polish and Nail Polish

Windows

3.1

Remover

13.2

Driver’s Window

3.1

Ordinary Dirt

13.2

Passenger Windows

3.1

Paint and Shoe Heel Marks

13.2

Windshield Washer Reservoir

3.9

Shoe Polish

13.2

Sulfide Stains

13.2

Tars, Asphalts, and Creosote

13.2

Warning and Indicator Lights

4.4

ABS Indicator

4.5

Brake System Warning/

Parking Brake On Indicator

4.6

Check Engine Indicator

4.4

Check Transmission

Indicator

17.15

Cruise Control Indicator

4.7

Diesel Particulate Filter

(DPF) Lamp

4.6

Emergency Buzzer

4.7

Fasten Seat Belts Warning

4.6

Headlight High-Beam

Indicator

4.7

High Coolant Temperature

Warning

4.6

I-4

Saf-T-Liner C2 School Bus. Driver’s Manual (2012) - page 2