Service Manual Introduction - Central States Bus Sales, Inc.
Contents
1. 005 11 A3 Introduction A3FE and A3RE Maintenance Keys o 8 47 L A Croat 9 42 00 5 02 4 6 9 49 1 2 6 AEN ite ale uem eal JN xl 1 5 2011 Figure 1 A3FE Maintenance Key p 0039 9 9 060 0 6 9 9000 66 nerd oT a 00 0 Figure 2 A3RE Maintenance Key 005 122. Weekly or as needed depending on application 8 8 8 8 8 Example 1 3 000 means every month or every 3 000 miles 8 8 8 ois SOS gU N N General Instructions Air Brake Operation See Section 030 Brakes Clean amp Replace Air Comp Filters e Bendix filter 243009 BB 1339993 Clean Governor e Disassemble all valves and lubricate at 100 000 miles Inspect Bendix Air Dryer e See Bendix Service Data sheet S D 08 04 Inspect amp Clean Cyclo gard Air See Cyclo gard Air Dryer Form 313 Dryer Clean Anchorlok Air Dryer Tank e See Anchorlok Air Dryer Service Instructions Service in spring and fall and Flush Drain Valve Inspect Heated Reservoir Drain See Stark Expello Valve Form S 103 Maintenance free no adjustment or Valve cleaning necessary Drain Air Tanks Daily cold weather Drain Condensation Weekly warm weather Check Pop Off Valves Disassemble all valves and lubricate at 100 000 miles Check Single amp Double Check e Disassemble all valves and lubricate at 100 000 miles Valves Clean amp LubeTreadle Valve e Disassemble all valves and lubricate at 100 000 miles Clean Relay Valves Disassemble all valves and lubricate at 100 000 miles Clean Spring Brake Valves Disassemble all valves and lubricate at 100 000 miles Clean Parking Brake Valve Disassemble all valves and lubricate at 100 000 miles Clean Quick Release Valves Disassemble all valves and lubricate at 100 000 miles Inspect Brake
3. Chambers e Clean Pressure Protection Valves Disassemble all valves and lubricate at 100 000 miles See Rockwell Field Maintenance Manual No 4 Eaton EB 31 Service Manual or See Eaton EB 32 Service Manual Lube Parking Brake Linkage e 4 Fittings See key No 8 page 005 12 Use NLGI Grade No 2 Grease Adjust Parking Brake e See A3 Operator s Manual Lubricate Brake Camshaft e 4 Fittings Use NLGI Grade No 2 Grease See key No 9 page 005 12 Lube Brake Slack Adjusters e 4 Fittings Use NLGI Grade No 1 Grease Special Stopmaster Grease See key No 10 page 005 12 Hydraulic Brake Operation Check Brake Fluid Level of Master Replenish if necessary Fluid BB 0607671 Vendor 218 or Wagner FL Cylinder Reservoir 10341 Check the Hydro Max Exterior amp e Replenish if necessary Fluid BB 0607671 Vendor 218 or Wagner FL Connecting Lines for Leaks 10341 Check for Loose or Disconnected e Electrical Connections and Damaged Wiring Check Brake Linkage e Do Not Lubricate Check Brake Calipers for Fluid e No adjustment R equired Leaks Lubricate Brake Calipers e Lubricate each time caliper is removed for pad change or repair NOTE Refer to the 1999 All American Operator s Manual for most maintenance procedures 005 8 Chassis Component Maintenance Chart A3 Introduction Operation Inspect Cable Service
4. Intervals Months Miles Whichever Occurs First Service Intervals to be performed on a continuing basis Example 1 3 000 means every month or every 3 000 miles General Instructions Check cable for proper connection cracking abrasion or deterioration No lubrication required Clean amp Lube Treadle Valve See Williams Control Service Bulletin S 051 Clean amp Lube Slave Cylinder See Williams Control Service Bulletin S B388UIC3D Inspect Exhaust Piping and J oints Check Battery Water Level Use distilled water to fill Check Battery P osts e Clean more often if corrosion appears Use heavy grease to help prevent corrosion Inspect Alternator e See Delco Remy Service Bulletin1G 266 Inspect Quick Starting Aid e Check system for proper operation Check wiring and tubing for proper connection and deterioration Replace parts as necessary Inspect Engine Block Heaters Check wiring and hoses for proper connection cracking abrasion and deterioration Replace parts as necessary Inspect piping and joints for leakage corrosion etc Replace clamps if joint is leaking Clamps are not reusable Reseal with exhaust sealant and install new clamp Check Fluid Level Daily See Allison Operators Manual Use Dexron or Dexron II fluid See key No 11 page 005 12
5. alone then listen and feeling for irregularity Replace damaged wheels or fans to prevent vibratory damage Check Heater Panels amp Housing e Fasteners which connect and retain structural amp access panels should be checked and tightened as necessary Tighten Heater Hose Clamps 1st 1 000 Miles and Heater hose clamps are located atthe underseat heater coil behind the Annually Thereafter access door in the heater hose covering immediately forward of the left front wheelhousing amp under the floor near right front and driver s heaters Inspect Mounting Bolts Adjust Mirrors As Required Loosen adjusting nuts make adjustment then retighten nuts Inspect Mounting Fasteners ighten fasteners if required Inspect Cushion Attachments Weekly Tighten with Phillips head screwdriver if required Inspect Upholstery e Inspect for cuts tears wear and soiled areas Lubricate Driver s Seat e Apply lubricant to all working part joints Use Aerosol Lithium base grease Inspect S eat Belts Weekly Inspect for torn or frayed areas Inspect Seat Belt Buckles Weekly Inspect for adjustability and proper operation Lubricate Seat Belt Buckles As Required Lubricate buckles to insure ease of operation Use Graphite type lubricant Clean Seat Belt Webbing As Required Clean using warm water and detergent solution NOTE Refer to the 1999 All American Operator s Manual for most maintenance procedures
6. Change Fluid See Allison Operators Manual Use Dexron or Dexron Il fluid See key No 11 page 005 12 Change External Filter 1st 5 000 Miles then at Normal F ilter located on RH side of engine block Filter AC 25011122 or PF 897 Oil Change Intervals Change Internal Filter e Remove transmission fluid pan Use vendor kit 23019201 Check Vent e Inspect Shift Cable e No lubrication required Adjust S hift Cable Required Inspect Driveshaft e See Section 050 Drivelines Lubricate Universal J oint e Use NLGI Grade No 1 or 2 Grease See key No 12 page 005 12 Lubricate Slip J oint e Use NLGI Grade No 1 or 2 Grease See key No 13 page 005 12 Torque Capscrews amp Bolts If Damaged or Removed for Service Straighten Balance Angles and If Damaged or Removed for P hasing Service NOTE Refer to the 1999 All American Operator s Manual for most maintenance procedures 005 9 A3 Introduction Body Component Maintenance Chart Operation Adjust Door Control Rod Service Intervals Months Miles Whichever Occurs First Service Intervals to be performed on a continuing basis Example 1 3 000 means every month or every 3 000 miles General Instructions Adjust Door D Rod As iL B ust door rod for m em Adjust door control rod for proper open amp closed position Adjust Roller Bracket Adjust roller bracket f
7. Ibs Check Transverse Leaf Bolts e Torque to 290 310 ft Ibs Check Shock Mtg Bolts e Torque to 200 240 ft Ibs Check Air Spring Fasteners e 1 Torque to 30 35 ft Ibs 34 Torque to 30 35 ft Ibs Check Shocks e Inspect for leaks Check Height of Suspension e Shock length eye eye 18 50 25 NOTE Refer to the 1999 All American Operator s Manual for most maintenance procedures 005 6 Axle Maintenance Chart A3 Introduction Operation Check Lubricant Service Intervals Months Miles Whichever Occurs First 1 3 000 35 000 324 000 Service Intervals to be performed on a continuing basis Example 1 3 000 means every month or every 3 000 miles General Instructions See Section 020 Rear Axle Keep oil to level of filler plug Drain amp refill at first 1 000 to 3 000 miles and then at recommended intervals Check level Change Lubricant testing plug on rear of axle bowl See key No 2 page 005 12 Inspect Vent See key No 3 page 005 12 Check Hydraulic Reservoir Fluid Level Lubricate King Pin e 4 Fittings Use NLGI Grade No 2 Grease See key No 4 page 005 12 Lubricate Tie Rod e 2 Fittings Use NLGI Grade No 2 Grease See key No 5 page 005 12 Inspect Alignment and Caster 39 1 positive Camber 09 7 162 RH amp LH Toe In 0 to 1 16 Component Wear If Tire Wear Indicates Spring and Neway Air suspensions Axle
8. Table of Contents CAS introduction Service Manual Introduction Table of Contents BLUE BIRD Master Table of Contents eere 1 List of Maintenance Charts eese 3 Table of Contents ccce eee ee eere eere 3 Suspension 6 List of Maintenance Charts ccccccccccccccccccccccece 3 Axle 7 MIL REN 4 Brake Maintenance 8 Warnings and Cautions scsccscessessessesseeceees 4 Chassis Component Maintenance 9 so sva au 4 Body Component Maintenance 10 General Dimensions 4 Fluid Capacities eee eere eee e eere nere 5 Jacking Instructions eee esee eene eene 5 Maintenance Charts ecce esee esee e eese eee 6 Maintenance K6y vo noon aaa re en aeu 12 005 3 A3 Introduction Safety Summary The purpose of this safety summary is to ensure the safety and health of service personnel and the protection of equipment All users of this publication shall read understand and apply this safety summary when performing maintenance and operating procedures Before using this manual to perform any service procedures the applicable war
9. espond to the Blue Bird Parts Catalog group numbers that may already be familiar to you For example group 030 in the Parts Catalogs and section 030 in this Service Manual both apply to brakes A list of the sections is located on page 005 1 of this manual General Dimensions Exterior 96 inches Exterior height 118 to 121 inches Exterior height w AC add 16 inches Interior width 90 34 inches Headroom 74 to 77 inches Fluid Capacities Engine Crankcase Oil w filter w o filter Cummins ISB 18 quarts 16 quarts Cummins ISC 24 quarts 20 quarts Cat 3126 seen 30 quarts 27 quarts Engine Coolant Cummins ISB w auto transmission 24 6 quarts Cummins ISB w manual transmission 23 6 quarts Cummins ISC eese 38 quarts Cat 3126 iiid e 4 quarts NOTE Engine coolant capacity is dependent upon a number of factors such as hose lengths and heater options See Section 040 Cooling System for aid in determining total system capacity Transmission Fluid Cummins ISB w auto transmission 20 quarts Cummins ISB w manual transmission 6 5 quarts Cummins ISC 19 quarts 20 quarts Rear Axle Fluid Capacities Spicer J 190 S Single Speed 31 5 pints Spicer J 210 S S
10. ingle Speed 31 5 pints Spicer J 230 SB Single Speed 31 5 pints Spicer M 190 T Two Speed 35 pints Jacking Instructions WARNING PROPER JACKING PROCEDURES MUST BE FOLLOWED TO ENSURE THE SAFETY OF THE OPERATOR ALWAYS CHECK THAT THE APPROPRIATE JACKS OR JACK STANDS ARE SECURELY IN PLACE AND THAT THE PARKING BRAKE HAS BEEN SET BEFORE POSITIONING YOURSELF UNDER A BUS Park the vehicle on flat level concrete or comparable surface capable of supporting the jacking device A3 Introduction 2 Apply the parking brake 3 Place chocks at the front and rear of tires opposite wheel or wheels to be lifted 4 Use jacks and jack stands or blocks of sufficient capacity to support the vehicle Following the jack manufacturer s recommended procedure place jack securely under the axle at spring or suspension beam 5 Jack the vehicle to required height for servicing WARNING FAILURE TO ENSURE THAT ANY LOCKING DEVICE ON THE JACK IS IN PLACE AND OPERATING AND THAT THE VEHICLE IS SOLIDLY SUPPORTED COULD RESULT IN SERIOUS INJURY OR EVEN DEATH 6 Support the vehicle under the main frame rails with jack stands or blocks before working under or around the bus 7 After servicing is complete reverse the above procedure A JACK HANDLE LUG NUT JACK LUG WRENCH AXLE Figure 1 Jacking Procedure 005 5 A3 Introduction Suspension Ma
11. intenance Chart Service Intervals Months Miles Whichever Occurs First Service Intervals to be performed on a continuing basis 8 8 8 8 Example 1 3 000 means every month or every 3 000 miles Operation d 9 g General Instructions Check Front U bolt Torque e orque to 300 310 ft 105 Check Rear U bolt Torque e Torque to 325 ft Ibs Check S pring Pin Lock Bolt e Bolt hardened flatwasher and locknut must be in position Lubricate S pring P in e 6 Fittings Lubricate at first 1 000 miles and then at regular intervals Front Suspension Use NLGI grade No 2 Grease See key No 1 page 005 12 Inspect Suspension e Inspect all spring components for damage or misalignment Inspect Shocks e Inspect for leaks Check Hanger Bracket Fastener e Torque to 80 5 ft lbs Non Huck Fasteners Only TUE Check U bolt Torque orque to 400 450 ft Ibs Check Torque Arm Bolts Torque to 150 205 ft Ibs Check Shock Mtg Bolts Torque to 50 70 ft 105 Upper 260 320 ft lbs Lower Check Air Spring Fasteners 2 Torque to 30 35 ft 105 34 Torque to 30 35 ft Ibs Inspect Shocks Inspect for leaks Check Ride Height Shock length eye eye 24 75 25 FE 21 75 25 RE Check Front Axle to e orque to 260 280 ft Ibs Suspension Fasteners C heck Front Pivot Bolts e Torque to 450 480 ft
12. nings and cautions must be read Warnings and cautions are located throughout this manual accompanying the appropriate service procedures WARNINGS Cautions and Notes All users of this publication shall read and understand all WARNINGS and Cautions WARNING WARNINGS REFER TO A PROCEDURE OR PRACTICE THAT IF NOT CORRECTLY OBSERVED COULD RESULT IN INJURY OR DEATH Caution Cautions refer to a procedure or practice that if not correctly observed could result in damage to or destruction of equipment NOTE Notes refer to a practice to help do the work or indicate a special area of information 005 4 About this Manual The purpose of this manual is to help you get the best value from your All American Bus This manual can help you decide what work must be done and provides for routine maintenance as well as common service procedures This manual has diagnostic and repair procedures to use when trouble occurs We have tried to make this service manual as comprehensive as possible However in some cases only the high volume options have been included Additional information will be continually developed and made available in future revisions Please contact the Blue Bird Customer Service department in the event that you need service information that is not found in this manual The manual is divided into sections Each section corresponds to a functional category of parts or assemblies These section numbers corr
13. or easier door operation Adjust Control Rod Bracket Adjust bracketto prevent pivot pin binding Lubricate Hinge Pin Lubricate Hinge Lubricate each hinge lug Use LPS No 1 lubricant Lubricate hinge pin Use LPS No 1 lubricant Lubrication Adjust Air Pressure amp Switch No lubrication required Adiustment AsR i uired B ust air for Es and of am Lubrication Lubricate breakaway hinge at four 4 pivot points Use Tri Flow Dupont lubricant Inspect Outer Fasteners Check outer fasteners for tightness Lubricate Entrance Door pu Internal Fasteners Check inner fasteners for uc Lubricate bushing amp shaft in center at base of lock handle Use Apply lubricant Lubricate Entrance Door Key Lock S pray lubricant into key lock Use Apply lubricant Lubricate Sliding Bolt Lubricate sliding bolt mechanism Use LPS No 1 lubricant Lubricate Lock Mechanisms amp Adjust Door No lubrication and adjustment Wash AS m S pray lubricant into lock mechanism Use Silicon spray Lubricate Roof Hatch Spray silicon lubricant into lock mechanism Work lock handle back amp forth to insure smooth operation Use Silicon spray Lubricate Door Hinge Spray lubricant into hinge lugs Use LPS No 1 Lubricate Rear Emerg Door Inspect All Mounting Fasteners Grease with door closed
14. settings are the same for both radial and bias ply tires Check level sight glass Use Dexron Il Change Reservoir Filter More frequent filter changes may be necessary in a dusty environment BB filter 2108199 Lubricate Drag Rod 2 Fittings Use NLGI Grade No 2 Grease See key No 6 page 005 12 Inspect Power Steering Pump e Check for leakage around the shaft or housing If leak is evident fluid oozing out it should be corrected immediately Inspect Steering Gear e Check for leakage around the shaft or housing If leak is evident fluid oozing out it should be corrected immediately See key No 7 page 005 12 Index Pitman Arm See Section 120 Steering Lubricate Steering Column Lubricate the slide Access to slide is obtained by removing rubber boot Use NLGI Grade No 2 Grease Lubricate Steering Gear Check Tires Weekly See Section 120 Steering Grease fitting located on rear of gear Use hand grease gun only Use NLGI Grade No 2 Grease See key No 7 page 005 12 NOTE Refer to the 1999 All American Operator s Manual for most maintenance procedures 005 7 A3 Introduction Brake Maintenance Chart Service Intervals Months Miles Whichever Occurs First Service Intervals to be performed on a continuing basis Brake Inspection and Adjustment
15. use low temp grease per ASTM D4950 GC LB Positive Hold pi Grade 2 60 ss to 350 sm Fahrenheit One zx 7 ud Inspect all emergency equipment mounting bracket fasteners to insure tightness NOTE Refer to the 1999 All American Operator s Manual for most maintenance procedures 005 10 A3 Introduction Body Component Maintenance Chart continued Service Intervals Months Miles Whichever Occurs First Service Intervals to be performed on a continuing basis Example 1 3 000 means every month or every 3 000 miles 1 3 000 IE 32A 000 Operation 1 General Instructions Lubricate Hinges Lubricate all hinge lugs Use lightweight lubricating oil Lubricate Roller Gears Lubricate roller gears where required Use lightweight grease such as White Lube Check amp Adjust Curtain Replace Bulb Lubricate Latch Spray lubricant into window latch mechanism Use Silicon spray Lubricate Window Slides lubricant into frame of window Use Silicon Check Heater Hoses Check hoses for kinks cracks or other visible signs of damage Clean Heater Coil amp RH Front Keep air flow passage free of dust amp dirt by cleaning w compressed air or Heater Air Filter vacuum amp a Soft bristle brush Straighten damaged fins with a fin comb Check Motor Wheels amp Fans e Check wheels and fans for obstructions or damage by running each fan
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