COOling SyStem - Central States Bus Sales, Inc.
Contents
1. 9 FMG 2900 2900 PSI Cummins ISC d PSI 2610 PSI Cummins ISB amp Caterpillar S P1 He El LT lt gt Es 4 0 GPM cimi P2 E 2170 PSI STG ST STR Control Valve Reverse Side Flow Flow Hydraulic Filter Flow Flow gt Drain Line 4 Flow Flow Radiator Charge Air Cooler Hydraulic Oil Cooler X ASA Hydraulic Pump 4 Flow Drain Line 4 Flow 4 Flow Flow 693 Steering Gear Hydraulic Fan Drive A3RE 0 BLUE BIRD2. radiator is not equipped with the pivot option drain the coolant 7 1 Position a clean receptacle under the petcock drain at the bottom of the radiator Remove the filler pressure cap Open the petcock drain Tip After draining at the petcock stops it is often helpful to also loos en the lower radiator hose clamp and insert a screwdriver between the hose and the radiator This allows additional coolant to drain from the dip in the lower hose Radiator drain petcock 7 2 Disconnect the radiator hoses Loosen the deaeration vent hose clamp at the top of the radiator and push the vent hose end off the radiator Loosen the upper and lower radiator hose clamps and push the hoses back enough to ensure they are unstuck and will slip off when the radiator is removed 8 Remove the harness clamp bolts which secure the harness along the driver s side of the radiator 11 Ifthe bus is equipped with the pivot radiator feature release the clasp at the lower left of the fan shroud This lets the shroud expand slightly to provide needed clearance with the fan when the radiator hinges Disconnect radiator hoses after draining Not necessary on buses equipped with pivot radiator feature Remove the harness clamps from the radiator and push the harness out of the way Viewed from under the radiator On buses with pivoting radiators a clasp on the right side of the fan shroud allows it to expand to provide clearance from the fan
3. Overview Coolant is circulated through the closed presurized system by the engine s wa ter pump whenever the engine is running When the engine is cold coolant flow through the radiator is blocked by a conventional thermostat mounted at the engine coolant outlet The closed thermostat causes the coolant to be directed through a bypass integral to the engine block when the engine is cold As the engine warms heat is transferred to the coolant and the thermostat grad ually opens the radiator circuit while increasingly obstructing the bypass Coolant from the engine s coolant outlet increasingly enters the radiator at the top passes through the radiator s coils and leaves the radiator at the bottom on its way back to the engine coolant inlet When the engine has reached full normal operating tem peratature the thermostat is fully open the bypass path is closed and all coolant circulates through the radiator During normal running engine cooling is regulated by controling the effective ness of the radiator This is accomplished by powering and de powering the fan which draws ambient air over the coils of the radiator On Forward Engine All Ameri cans the fan is mounted to an electromagnetic fan clutch assembly mounted to the front of the engine and driven by the fan belt The engagement and disengagement of the fan clutch is controlled by the engine ECM The electrically controlled fan clutch of the All American Forward Engine is describe
4. Cat C7 Only Viewed from the left side of the engine 000201 Shutters Hydraulic A3FE optiona 0 BLUE BIRD Lubricate upper and lower pivot points and track Shutter solenoid mounted to lower left side of engine closeout panel ISB only Cummins ISB Install on left side of air intake manifold elbow Cummins ISC amp Cat Install inport on left CAC tube a Mount bracket to threaded boss just above oil pan flange Thermostat gt Housing Turbo Side Of Valve Cover s O7 EVA S 4 A gt 54 Hf LA 0 EM lt Cummins ISB Cat C7 Cummins ISC a To Accessory Port at Wet Tank Sh utters Air A3FE Optional 0002015 0 BLUE BIRD E et lt L 4 L d 5 vi Radiator On both All American Forward Engine and All American Rear Engine buses the ra diator is pre assembled to a similarly constructed Charge Alr Cooler however other than being assembled and mounted as a combined cooling pack the two units serve two separate circuits and do not directly interact While the radiator serves to remove heat from the circulating engine coolant the Charge Air Cooler removes heat from the engine intake air Both
5. e BLUE BIRD ALL AMERICAN SERVICE MANUAL Hydraulic Fan Drive All American Rear Engine The cooling system on an All American Rear Engine is similar to that of an All Ameri can Forward Engine in respect to coolant flow between the engine and the radiator Heat created by the engine will transfer to the coolant as the coolant flows through the engine and then to the radiator A fan is used to create air flow across the outer surface of the radiator fins allowing the heat in the coolant to transfer into the mov ing air This cycle of engine coolant absorbing heat from the engine and discharging heat at the radiator is very similar for both products The major difference between the two products is how the fan creating the air flow across the radiator is driven The fan on an All American Rear Engine is driven by a hydraulic motor rather than by a belt The hydraulic system that drives and controls the engine cooling fan shares some of its components with the steering system creating an integrated hydraulic fan drive steering system Oil for the hydraulic system is supplied by a vented reservoir located in the upper right area of the engine compartment Two supply lines connected to the bottom of NT the reservoir provides an adequate supply of clean oil to the pump The pump hous ing incorporates a two stage gear type pump configuration of equal displacement Each stage of the pump has its own supply port and delivery port The stage of
6. Operate the engine until the thermostat opens Then stop the engine and let it cool for 15 30 minutes Check the entire cooling and heat ing system for leaks Recheck coolant levels and top off with the same premixed coolant as is installed Obtain a coolant sample from the radiator drain petcock and test the glycol level with a refractometer to ensure the glycol level is 5096 minimum If the glycol level is less than 5096 drain the appropriate amount of coolant and add concentrate per the engine manufactur er s instructions for increasing glycol percentage to correct level Pressure test the cooling system for leaks If no leaks are found the bus may be returned to normal service 687 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Fan Clutch All American Forward Engine During normal running engine temperature is regulated by controlling the cooling effectiveness of the radiator This is accomplished by powering and de powering the fan which draws ambient air over the coils of the radiator On All American Forward Engine buses the fan is mounted to an electromag netic clutch mechanism The outer housing drum of the fan clutch is a pully driven by the fan belt and rotates whenever the engine is running The fan blade assembly is mounted to the inner rotor of the fan clutch An electromagnetic mechanism within the fan clutch assembly engages disengages the inner rotor with the outer drum and also serves to cushion the ini
7. blades when the radiator is pvioted 0 BLUE BIRD 12 The radiator assembly is mounted on four rubber cushioned mounts two on each side If the bus is equipped with the pivot feature remove only the fasteners on the driver side and only loosen the fasteners on the curbside These will serve as hinges when loosened Pull outward on the driver side of the radiator to hinge it outward Ensure that the Driver side CAC tube does not snag Hinge the radiator far enough to insert the hold open rod mount ed above the radiator into the hole in the top of the radiator 13 Ifthe bus is not equipped with the radiator pivot feature completely remove all four mounting bolts eight washers and four nuts With an assistant lift the radiator forward and away from the bus As the radiator is pulled out support the CAC pipes with one hand with the other hand under the bottom Loosen all four radiator mount bolts On pivoting radiators remove only the driver side two On non pivoting radiators remove all four of the radiator Reassembly Having the radiator removed or hinged provides access to engine front components After the service procedures are complete reinstall the radiator bumper rock guard CAC tubes and grille in reverse order of the removal proceure outline If the coolant has been drained into a clean recepticle and if it is still within its service life it may be reinstalled After refilling bleed the heater syste
8. cleaned of con taminates The filter mount is fitted with two shut off valves Closing both valves closes the inlet and outlet lines to allow removal and replacement of the filter element without excessive coolant spillage The amount of coolant lost is that contained in the volume of the filter element All American buses built during or after August 2006 have one of three specific 672 coolants installed at the factory see Factory Installed Coolants in this chapter The same Wix replacement filter element cartridge is used for all three of the factory in stalled coolants Blue Bird Part Number 0064641 Wix Part Number 24070 Do not use coolant filter elements which dispense Supplemental Coolant Additives SCAs to the system Coolant Filter Element Replacement The coolant filter should be replaced every 6 months or 6 000 miles whichever oc curs first 1 Fully close both shut off valves at the filter mount 2 Remove the filter element by turning it counter clockwise 3 Fill a new filter element of the proper type for the coolant in use withi pre mixed coolant of the same type already in the engine Install the new and filled filter element 4 Open both shut off valves 0 BLUE BIRD 5 0116955 SUPPLY LINE RIGHT HAND FRONT DROP RAIL RER 1 I UE 22 WS Coolant Filter A3FE Optional 673 lE B FLYWHEEL HOUSING 674 RADIATOR MOUNT
9. the control valve through the steering return port STR 0 Oil flow entering the control valve through the fan circuit supply port P1 from the secondary stage of the pump will combined internal of the manifold with the excess oil from the steering circuit The combined oil flows through the fan port FM on the control valve to the inlet port of the fan motor Unlike the steering circuit the fan circuit does not have a flow regulator valve The oil flow available for the fan circuit is subject only to pump speed The higher the RPMs of the pump the more oil flow the fan circuit will receive It is important to understand that fan speed is directly proportional to the rate of oil flowing through the fan motor Therefore one of the two controlling factors of fan speed is how fast the pump is running which is directly related to engine speed The fan circuit incorporates two control valves which working together provides two functions that govern the fan circuit The cartridge style pressure differential poppet control valve and the cartridge style pilot operated solenoid valve work to gether to monitor fan circuit pressure and engine cooling requirements If excessive pressure occurs in the fan circuit the valve will open the fan circuit to the reservoir return port T lowering the pressure to a normal operating range The second func tion the valves provides is a means of controlling fan speed according to the cooling requirements of the
10. to proceed 0 BLUE BIRD When excessively high operating temperature is observed first check for proper fluid level at the sight glass of the deaeration tank If the fluid level is low and cannot be maintained without constant refill inspect for leaks at pipe and hose connections Also look for damaged hoses due to heat or chaffing from incorrect routing Remem ber that the heater system is a potential area for leaks The heating system can be isolated by closing the gate valves at the engine s heater outlet and the transmission cooler s inlet In the case of overheating the next step is to verify the proper operation of the thermostats Refer to the appropriate engine manufacturer s service publication for instructions on the removal and testing of the thermostats CAN The engine coolant and transmission fluid may be very hot possibly above the boiling point at atmospheric pressure Allow the system to cool completely before working on it Engine coolant use and disposal is gov erned by environmental regulations Read carefully and abide by the warnings and guidelines on the coolant label O gt 653 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Driver Side Heater Remote Heater Valve CLLLLLLLLLLLLO 4 QUITTER R 6 23333133 Passenger Compartment Heaters Auxiliary Pump Optional pump helps circulate engine coolant through heaters May be inst
11. Blue Bird advises strictly abiding by the following policy for all coolant maintenance for the life of the vehicle Never Mix Coolant Types Routine coolant addition top off must match the installed coolant type and brand Do not mix coolants of different colors types or brands in the same engine Strictly Follow The Engine Manufacturer s Specifications Each engine manufacturer publishes its own specific requirements for testing and maintaining coolant in their respective engines Blue Bird recommends strictly abid ing by the engine manufacturer s testing and maintenance schedules and draining flushing refilling procedures to maintain compliance with the engine warranty re quirements Blue Bird recommends that you maintain accurate vehicle specific ser vice records of all coolant system maintenance procedures performed For Caterpillar or Cummins engines equipped with John Deere Cool Gard cool ant follow the engine manufacturer s maintenance schedules for standard life cool ant not for extended life coolant For Caterpillar engines using Caterpillar ELC extended life coolant perform test ing at a qualified coolant laboratory per the Caterpillar Operation and Maintenance Manual Label sample as Extended Life coolant Coolant test kits are locally avaliable The red dye commonly used in extended life coolants may cause erroneous readings of test strips Always follow engine manufacturers recommendations for coolant and coolant man
12. ESSOR OUTLET ON RADIATOR TO LOWER PORT et d ON RADIATOR Cooling System A3FE Cummins ISB 07 Hi Torq NOTE INSTALL TEFLON TAPE ON ALL THREADS ON PARTS THAT ARE INSTALLED IN THE SURGE TANK USE PIPE SEALANT ON ALL OTHER PIPE THREADS SURGE TANK MOUNTING BRACKET IS A SUBPART TO THE FRONT STRUCTURE lt gt CUT LINE SCRAP DETAIL A USE FASTENERS SUPPLIED WITH FAN CLUTCH TORQUE TO 20 25 FT LBS ANCA 8 3 4 PORT ON WATER INLE NOTE COOLANT RECOVERY TANK MOUNTS IN FRONT OF RIGHT HAND OUTRIGGER ALSO ITEM 12 IS NOT VISIBLE TO ENGINE WATER INLET RO Qo 2 2 ZR TRANSMISSION e e COOLER ASSY o X 659 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL HOOD LEDGE TO PREVENT HOSE ITEM 104 FROM RUBBING ON THE STRUCTURE TO LOWER PORT ON RADIATOR pd SWINGOUT RADIATOR TO AIR INTAKE ELBOW ON LEFT SIDE OF ENGINE TO ENGINE WATER OUTLET TO TURBO COMPRESSOR OUTLET Cooling System A3FE Cummins ISB 07 Lo Torq BLUE BIRD NOTE INSTALL TEFLON TAPE ON ALL THREADS ON PARTS THAT ARE INSTALLED IN THE SURGE TANK USE PIPE SEALANT ON ALL OTHER PIPE THREADS CUT LINE SURGE TANK MOUNTING BRAC
13. ING BRACE RETURN FROM FILTER OUTLET TO ENGINE WATER PUMP INLET SUPPLY FROM ENGINE REAR TO FILTER TOP INLET LH SUBFRAME Coolant Filter A3RE Optional BLUE BIRD 213178 01 Radiator Shutters Your bus may be equipped with Radiator Shutters a popular option on both Forward Engine and Rear Engine All American buses operated in colder climates Shutters restrict ambient air passing through the radiator and over the engine and thereby shorten warm up time for the engine and passenger compartment heaters The Kysor Radiator Shutters unit is a window blind like assembly of adjustable leuvers mounted on the fan side of the radiator The shutters are spring loaded in a normally open position On buses equipped with air brakes the shutter mecha nism is closed at certain temperatures by an air cylinder and on buses with hydraulic brakes by an hydraulic actuator Unlike the radiator fan shutters are not controlled by the engine ECU but by their own independent circuit Two temperature sensors one mounted in the en gine coolant circuit and the other in the intake tract of the Charge Air Cooler sys tem are wired in the Radiator Shutters control circuit Both sensors are normally closed When ignition is on current passes through both sensors and energizing the Shutter control solenoid to close the shutters As the engine warms one or both of the two sensors create an open in the circuit de energizing the
14. KET IS A SUBPART TO THE FRONT STRUCTURE SCRAP DETAIL USE FASTENERS SUPPLIED WITH FAN CLUTCH TORQUE TO 20 25 FT LBS 6 661 b gt TO 3 4 PORT ON WATER INLET o 6 A TO ENGINE R INLET NOTE COOLANT RECOVERY TANK MOUNTS IN FRONT OF RIGHT HAND OUTRIGGER ALSO ITEM 12 NOT VISIBLE 34876 010 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL 662 0 BLUE BIRD ITEM NO TORQUE VALUE 33 AND 44 80 90 FT LBS 37 29 33 FT LBS 49 8 9 FT LBS 14 amp 15 60 IN LBS PLACE STRAIGHT SEAL PRIOR TO MOUNTING PLACE RUBBER SEAL ON VERTICAL SECTION OF SHROUD ONLY PRIOR TO PLACEMENT ON RADIATOR APPLY RUBBER SEAL TO ALL CLOSEOUT BAFFLE EDGES PRIOR TO PLACING ON BODY UTILIZE GIVEN HARDWARE IN ASSY 0112437 4 CAPSCREWS 1 2 13 X 1 50 4 NUT HEX HD 1 2 13 LOCKING 8 WASHERS FLAT 531X2 250X11GA YDICH RMOSTAT HOUSING SHOULD HAVE A CONTINUOUS DOWNWARD SLOPE TO THEIR CONNECTION TO RADIATOR THERMOSTAT HOUSING ON ENGINE UNUSED HOLES OMMITED FOR CLARITY Cooling System A3RE With Cat C7 07 TO MTG BRACKET STABILIZER 33 33 2 HUCK BOLT SUPPLIED WITH SUBFRAME ATTACHING 663 TO ENGINE INTAKE TO LOWER RADIATOR CO
15. NNECTION NOTE FOR RETARDER OPTION ONLY TO WATER PUMP INLET TO THERMOSTAT HOUSING A 012096 BLUE BIRD PLACE STRAIGHT SEAL PRIOR TO MOUNTING 664 PLACE RUBBER SEAL ON VERTICAL SECTION OF SHROUD ONLY PRIORTO PLACEMENT ON RADIATOR APPLY RUBBER SEALTO ALL CLOSEOUT BAFFLE EDGES PRIOR TO PLACING ON BODY FOR COOLANT OVERFLOW HOSE UTILIZE GIVEN HARDWARE IN ASSY 0112437 4 CAPSCREWS 1 2 13 X 1 50 4 NUT HEX HD 1 2 13 LOCKING 8 WASHERS FLAT 531X2 250X11GA YDICI 5 HOUSING ON ENGINE gt SHOULD HAVE CONTINUOUS DOWNWARD SLOPE TO THEIR CONNECTION RADIATOR 39 a y 2 PX TO TURBO 18 ISC ONLY Cp 2 lt TO ALTERNATOR 75715 24 ISB ys BRACKET ISCENGINEONLY ITEM NO TORQUE VALUE 33 AND 44 80 90 FT LBS 37 29 33 FT LBS 49 8 9FT LBS 58158 22 25 FT LBS 58 ISC 53 58 FT LBS UNUSED HOLES OMMITED FOR CLARITY HEATER PLUMBIN 6 6 5 ISC AND ISB RETARDER OPTION ISC ONLY NOTE J ISB HUMP HOSE ONLY 4 CONNECTION TO UPPER INTAKE TO THERMOSTAT BYPASS HOSE LOCATED ON ENGINE TO RADIATOR OUTLET TO RADIATOR INLET PLUG W OUT 9 iu ENGINE WATER OUTLE
16. T NOTE CONNECTION TO WATER OUTLET ISB07 ONLY ISC INSTALL ONLY WATER PUMP INLET ISB ONLY N N NOTE MOUNTS TO THE TOP OF THE ALTERNATOR BRACKET ON ISB ONLY NOTE MOUNTS TO FRONT FACE OF THE CYLINDER HEAD ON ISC ONLY 0111 0 BLUE BIRD T E Ve 667 To Upper Radiator Tube Elbow To Radiator Side Tank At Elbow Item 41 E m lt e n 5 19 ALL AMERICAN SERVICE MANUAL About Coolant As emission and performance regulations become more stringent the normal op eration temerature range for turbocharged diesel engines increases One of the con sequences is that careful maintenance of the cooling system becomes increasingly critical in prolonging the life of the engine At higher temperatures relatively minor imbalances or impurities in the coolant can dramatially increase the potential for corrosion Establish a disciplined and consistent regimine for monitoring and testing the coolant in your Blue Bird school buses Keep accurate records use only coolants recommended by the engine manufacturer Change coolant within its specifi
17. alled at various locations depending upon heater configuration as Right Front Heater COOL OOOO TI IIT IIIT IIT 4 e BLUE BIRD Coolant Filter Optional filter unit mounted in Fan Clutch Motor an alternate parallel path for is controlled by coolant to flow Shut off valves the engine ECM On A3FE electromagnetic Fan Clutch cycles on and off provided to isolate the filter for element change iE Y ATE Le 4 lt KEKEKKEKEKKEKE Kp lt a x 444444441 4 44 EA vi vi STII lt 97772 24324222 UEEEER PrP PPO DPD 4427 8244440 9 SS 1444444444 Transmission Cooler Aa coil through which transmission fluid circulates is bathed in engine coolant to carry away heat Also serves as the return point of coolant circulating through heaters Heater Cut Off Valves On A3RE hydraulic motor varies in s
18. at the highest point of the cooling system flow circuits Tubes lead to the deaeration tank from the tops of the radiator the engine and the transmission cooler This provides a path for air bubbles in the circuits to rise to the deaeration tank When pressure inside the sys tem rises sufficiently to overcome the spring of the filler neck s pressure cap air that has collected in the top of the deaeration tank escapes reducing the system pressure to normal A sight glass is provided on the deaeration tank to inspect coolant level Rear Engine Cat C7 shown heater supply cutoff valve Coolant level should be maintained at just above the sight glass the glass is full nte cinema On Forward Engine All American s the radiator must be removed to gain access to certain service components on the front of the engine To facilitate this an option popularly installed on Forward Engine buses is a swing out radiator which provides limited access without requiring draining of the coolant The three main symptoms of trouble in the cooling system are overheating overcooling and loss of coolant A cooling system should first be diagnosed by a thorough visual inspection Debris accumulation in the radiator fins or bent fins re Rear Engine heater return cutoff valve Accessible from under the bus forward of the radiator stricting airflow can cause overheating If visual inspection reveals no cause tools and test equipment will be needed
19. cation lifetime and never mix different types of coolant Periodic testing and maintenance of the coolant should be performed in accor dance to the engine manufacturer s specifications Testing and maintenance proce cures differ between standard life and extended life coolants Locally available test strips may be used to test standard life coolants However such test strips are not appropriate for long life coolants therefore long life or extended life coolants must be sample tested at qualified cooant laboratories Because specification recommen 668 dation and terminologies differ among engine manufacturers Blue Bird advises st ictly adhering to the coolant maintenance specifications of the engine manufacturer Carefully following the engine manufacturer s recommendations is the surest way to maintain compliance with engine warranties Beginning in January of 2007 Blue Bird implemented a program to simplify the coolant types installed at the factory Standard Equipment Coolant John Deere Cool Gard 50 50 premix green in color is installed as standard equip ment across all the above listed bus products powered by Caterpillar Cummins or John Deere engines This coolant meets John Deere s specifications and requirements for extended life coolant It is to be considered standard life coolant when installed in Caterpillar or Cummins engines Optional Extended Life Coolant Two optional coolants are offered as extended life coolants
20. colored coolant inspect the cap neck and deaeration tank for accumulation of foreign material or staining If stained clean the components If the stain cannot be re moved replace the components If the coolant is not discolored and there is no accumulation on theses components do not replace these components 1 9 Reconnect all hoses that were disconnected while replacing compo nents Check all hose connections and clamps 1 10 If the thermostat has been removed in an earlier step reinstall ther mostats following engine manufacturer s procedures 2 Clean the Cooling System Follow the engine manufacturer s instructions for chemically cleaning the entire cooling system On Caterpillar engines If sludge or oil is evident use Caterpillar s 30 Day 685 cleaner For scale or deposits use Caterpillar Quick Flush type cleaner On Cummins engines If sludge or oil is evident Use Fleetguard Restore For scale or heavy metal deposits use Fleetguard Restore Plus 2 1 Afterthe engine has been stopped and the cooling system has cooled drain the cleaner from the entire system following the steps describe in the initial drain including blowing the system with 15 PSI max of shop air 2 2 Close all drains and reconnect all hoses that have been removed 23 Fill the system with fresh water and run for minimum of 30 minutes on high idle with heater pumps on and all heater valves open 24 After the 30 minute minimum run
21. d in the electrical chapter On Rear Engine All Americans the fan is driven by a remotely mounted hydraulic motor Unlike the single speed on off cycling of the fan on Forward Engine All Amer ican s the speed of the fan on Rear Engine units is variable and runs faster or slower as controlled by temperature sensors The hydraulic fan motor of the All American Rear Engine is described in the Hydraulic System chapter On buses operated in colder climates the radiator may be fitted with optional Radiator Shutters a vane like assembly which serves to block air from passing over the radiator coils This prevents over cooling and aids warm up of the coolant so that interior heaters become effective sooner The Radiator Shutters may be either hy draulically controlled powered by engine oil pressure or pneumatically controlled powered by air pressure from the supply tank of units with air brakes or air suspen sion The cooling system components are plumbed using either standard black rubber hoses or optional hoses which are blue in color and typically have longer life The bus may be fitted with an optional Perry Coolant Filter which is attached to the engine water jacket at two loctions creating an alternate side path for coolant to flow The filter traps contaminates as coolant circulates through the replaceable filter Engine coolant also circulates through a separate transmission cooler Unike the coolant filter this poriton of the coolan
22. d skin irritant Protective gear should be worn when working with coolant Allow the system to cool before draining and flushing Engine coolant is a threat to the environment Use suitable containers for disposal All applicable federal state and local laws must be observed when disposing of engine coolant 1 3 Placea drain pan under the radiator drain and open the drain petcock Drain and discard the coolant from the cooling system following all applicable federal state and local laws governing disposal of engine coolant Be sure that all the heater valves are open in order to com pletely drain the engine heaters coolers hose etc 1 4 After system has drained disconnect both the pressure and return heater hoses Using a shop air hose set at a maximum of 15 PSI blow air into the heater hoses to blow the remaining coolant from the heat er system 1 5 Open the lowest coolant drain port or plug from the engine to drain any remaining coolant from the engine 1 6 Close all drains reconnect heater hoses and reinstall all plugs that have been opened or removed 1 2 If the system has a coolant filter close the valves to the filter and re move the filter element 1 8 On All American Forward Engine Only If the system has any mate rial collected on the cap neck or deaeration tank remove and replace 0 BLUE BIRD the radiator cap 1325430 brass neck 0033762 and plastic deaera tion tank 0032865 If the system has dis
23. ed water are not available Whenever tap water alone has been added the bus should be taken to a service facility and the entire cooling system should be completely drained flushed and refilled with premix coolant 0 BLUE BIRD FACTORY INSTALLED COOLANTS John Deere Cool Gard Green in color Standard equipment coolant in all A3FE A3RE BBCV BCCV Qualifies as extended life coolant in John Deere engines Considered standard life coolant in Caterpillar and Cummins engines Concentrate version may be mixed with the pre mix version to lower freezing point 50 50 Premix BLUE BIRD NUMBER JOHN DEERE NUMBER 1 Gallon Container 0109179 TY25081 2 1 2 Gallon Container TY16036 55 Gallon Drum TY16037 330 Gallon Tote TY24504 Concentrate 1 Gallon Container TY16034 Caterpillar ELC 671 Red in color Optional coolant in A3FE A3RE BBCV BCCV with Caterpillar engines Qualifies as extended life coolant in Caterpillar engines Blue Bird installs 50 50 premix which is available in one gallon and larger listed containers The 50 50 premix may be mixed with the concentrate version per Caterpillar instructions to achieve 60 40 ratio Concentrate version may be mixed with the pre mix version to lower freezing point 50 50 Premix BLUE BIRD NUMBER CATERPILLAR NUMBER 1 Gallon Container 101 2844 Case of six 1 Gallon Containers 0113986 55 Gallon Drum 101 2845 275 Gallon Tote 222 1534 Concentrate 1 Gallon Container 0113987 119 9150 Fleet
24. emixed coolant Blue Bird recommends always topping off coolant with the same pre mixed coolant as is installed rather than topping off with water If water is used for top off use only deionized water Never add tap water to the cooling system unless absolutely necessary in roadside emer gency situations Never mix coolants of different color type or brand Keep accurate records of all coolant changes and maintenance 686 5 Bleed Air From the Cooling and Heater System 51 Fully open the pressure side heater hose cut off valve Fully close the return side heater cut off valve located near the transmission cool er 5 2 the Driver s area open all heater temperature controls to their full on position and turn on all heater pumps The number of heater controls and the presence of heater pumps depends upon optional equipment purchased on the bus 5 3 With the engine stopped and a cool engine remove the radiator cap 5 4 On American buses locate the 4 bleeder tube which is located near the deaeration tank The bleeder tube originates from a low point ofthe cooling system where the return heater hose returns coolant to the transmission cooler and runs to a location near the deaeration tank On All American Forward Engine buses Open the front grille panel The bleeder tube is tucked horizontally along the top of the radiator Pull out the bleeder hose and insert its free end into the open filler neck of the deaeratio
25. engine When the engine ECM senses the engine coolant tem perature or the charge air temperature is reaching a set point and cooling is needed a pulse width modulation PWM signal will be sent to the fan control solenoid valve The nature of the PWM signal drives the solenoid valve to vary the flow of oil to the fan motor thus varying the fan speed according to engine cooling requirements The returning oil from the fan motor will flow through the hydraulic oil cooler located below the radiator and back to the control valve through the fan motor return port FMR Oil flow returning form the steering circuit and the fan oil cooler circuit will merge together in the manifold and flow out of the return port T through a 10 micron nominal hydraulic oil filter and back to the reservoir 691 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Port FMG Test Port Fan Circuit Port DR Port ST Steering Port Drain Port Port STG Test Port Steering Circuit Control Valve PortT Port STR Return Port Steering Return Port Port P2 Steering Circuit Supply Control Valve Reverse Side Fan Circuit Control Valve Port P1 Fan Circuit Supply Port FM F n Mator Port Steering Circuit Flow Control Valve Port FMR Steering Circuit Pressure Control Valve Fan Motor Return Port Fan Circuit Pressure Control Valve FM DR FMR
26. for the above listed bus models when not powered by John Deere engines Extended Life Coolant for Caterpillar Engines Caterpillar ELC 50 50 premix red in color is installed in the above listed bus products equipped with Caterpillar engines when purchased with an option for extended life coolant Extended Life Coolant for Cummins Engines Fleetguard ES Optimax 60 40 premix red in color is installed in the above listed bus products equipped with Cummins engines when purchased with an option for extended life coolant 0 BLUE BIRD gt Coolant Filter On all of the above listed bus models equipped with an optional coolant filter the same Wix replacement filter element cartridge is used Biro Part 0064641 Wix Part 24070 The coolant filter should be replaced every 6 months or 6 000 miles whichever oc curs first Coolant Decals On all of the above listed bus models Blue Bird installs a decal stating The type of coolant installed at the factory The coolant manufacturer s part number for one gallon quantity suitable for regular top off and refill coolant manufacturer s part number for one gallon quantity of the con centrate version of the installed coolant suitable for formulating stronger gly col mixture ratio Blue Bird also installs a second decal containing radiator warnings Both decals are mounted near the coolant fill neck Coolant Maintenance
27. guard ES Optimax Red in color Optional coolant in A3FE A3RE BBCV BCCV with Cummins engines Qualifies as extended life coolant in Cummins engines Blue Bird installs 60 40 premix which is not available in one gallon containers but is available in larger containers listed The 50 50 premix may be mixed with the concentrate version per Fleetguard instructions to achieve 60 40 ratio Concentrate version may be mixed with the pre mix version to lower freezing point 50 50 Premix BLUE BIRD NUMBER FLEETGUARD NUMBER 1 Gallon Container 0109178 2785 2785 60 40 55 Gallon Drum CC2770 2770X 275 Gallon Tote CC2790 2790X Concentrate 1 Gallon Container 0109552 CC2780 2780X 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Coolant Filter Optional Your Blue Bird bus may be equipped with an optional Perry Coolant Filter a separate filter assembly with a replaceable spin on filter element On All American Forward Engine buses the filter is mounted to the left side of the engine block On All Ameri can Rear Engine the filter is mounted to the radiator brace mounting bracket at the left side of the engine compartment The entire volume of coolant does not pass through the filter on each cycle Rather the filter assembly is connected to two coolant ports on the engine block effectively providing an alternate path for coolant to flow As coolant circulates through the system that volume which passes through the filter is
28. ibility at the right side of the radiator fan shroud flange is fitted with a release clasp to provide clearance from the fan blades when the radiator is pivoted A set of slotted bumper brackets which allow the bumper to pivot downward without complete removal 679 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Radiator Removal All American Forward Engine The following radiator removal procedure is illustrated with a bus which has the swing out radiator option Differences between this and the standard installation are noted in the procedure text To remove the radiator 1 Completely secure the bus against accidental movement Remove the igni tion key Chock all wheels Disconnect the positive battery terminals or turn off the master power switch if so equipped 2 Pivot or remove the front bumper 2 1 Remove the stepwell rock guard plate bolted between the bottom right flange of the bumper and the forward edge of the stepwell 5 bolts washers nuts 2 2 Look inside the bumber openings at the mounting brackets just above the tow hooks If the top bracket bolt is mounted in a curved slot of 680 the brackets the bumper is a pivoting bumper On each side loosen the bolt in the curved slot Then loosen the bottom bolts If the brack ets are not slotted remove the four bolts completely and remove the bumper Tip If the bus is equipped with a pivoting bumper it serves as an effective parts tray f
29. m to remove trapped air and ensure that the coolant level is topped off to the proper level Pivoted radiator provides engine front access without draining coolant Obtain assistance in lifting out non pivoting radiator 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Cooling System Drain Flush amp Refill The following is a general procedure for complete coolant change drain flush re fill Blue Bird recommends that an authorized Caterpillar Cummins and John Deere dealer distributor perform this flush and fill in their respective engines If there are differences between the information in this procedure and the engine manufacturer s Operator s or Maintenance Manuals follow the engine manufacturer s instruction 1 Drain the cooling system 1 1 Park bus on a level surface apply parking brake turn off engine re move ignition key and chock wheels 1 2 Allow the engine to cool Then remove the radiator cap Locate and open both heater hose cut off valves Open all heater control valves fully Removal of the thermostat may assist in draining flushing rins ing and refilling process Follow engine manufacturers recommenda tions on thermostat removal and installation 684 ULM Coolant released under pressure can cause serious burns Re move filler cap only when cool enough to touch with bare hands Slowly loosen cap to first stop to vent pressure before fully removing Engine coolant is toxic and is an eye an
30. n servicing the cooling system or when it is desireable to prevent heaters from warming up during summer months The heater supply tubing from the engine leads to the Driver s remote heater valve an electrically controlled valve which enables the Driver to control the ef fectiveness of all heaters by regulating the amount of engine coolant circulating 6 5 2 through the heater circuit Forward Engine heater supply cutoff valve Accessible from interior engine compartment hood Depending upon the heaters configuration the heater circuit may be equipped with an optional auxilliary water pump to help force circulate coolant through the heaters The auxilliary pump on Forward Engine All Americans resides in a dedicated housing mounted to the floor along the heater piping On Rear Engine All Americans the auxilliary water pump is mounted forward of the radiator and is accessible from under the rear overhang The inlet side of the auxilliary pump receives coolant from the high pressure side of the engine water jacket The outlet side leads to the series Forward Engine heater return cutoff valve Accessible from of heaters and then returns via the transmission cooler as described above Thus the under the bus forward of the entrance stepwell transmission cooler receives coolant that has cooled by transferring its heat to the heaters and or by passage through the radiator The cooling filler neck is connected to a deaeration tank located
31. n tank Then open the in line bleed valve fully During bleeding overflow coolant will be returned directly to the de aeration tank On All American Rear Engine buses The bleeder tube is located under neath the deaeration tank and its end is already connected to the to the tank Open the in line bleed valve fully During bleeding overflow coolant will be returned directly to the deaeration tank 0 BLUE BIRD 5 5 5 6 2 7 5 8 5 9 5 10 5 11 5 12 gt Start engine and operate at 1800 to 2000 rpm Watching the coolant temperature gauge ensure the engine reaches 180 190 degrees the temperature at which the engine s thermostat normally fully opens Operate the engine with the bleeder valve open until all air has been purged from the system During this time monitor the level of cool ant in the deaeration tank sight glass As air trapped in the system escapes the coolant level will occasionally rise and drop Top off the coolant level with pre mixed coolant whenever it drops below the full level mark Air has been fully purged from the system when the coolant level no longer fluctuates and the stream of coolant from the bleeder hose is constant This may take 15 30 minutes After the air has been purged and solid stream is present allow the engine to return to idle to cool down gradually Close the bleeder valve and store the bleeder line in its original position Install the radiator cap
32. or fasteners throughout the procedure 3 Remove the front grille panel 3 1 Open the hinged grille panel Spread one closed end of the S hook at the upper end of the support cable to unlatch it from the bracket Then close the panel 3 22 Remove the four phillips screws two on each side between the slots Pivoting bumper of the lower portion below the hinge of the front grille panel 3 3 Open the hinged panel Carefully lift the grille assembly upward and away from the bus Grille removed 0 BLUE BIRD 4 Remove the cross bar which spans the radiator opening near the bottom of the radiator Four bolts washers lockwashers and nuts 5 Inside the bus remove the engine cover and housing 5 1 Open the hinged cover Remove the bolt lockwasher and nut which secures the bottom end of the support cable 5 2 Unlatch the five clasp latches which secure the cover housing 5 3 Being careful to separate the rubber gasket from the opening sur rounding without damaging it lift out and remove the whole engine cover assembly 6 Loosen CAC tubes Loosen the rearmost clamp of the red flex tube which connects the left CAC pipe to the engine intake elbow Similarly loosen the rearmost clamp of the right side CAC pipe Push forward on the flex tubes to make sure they are unstuck and can slip off when the radiator is removed Loosen CAC clamps 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL 7
33. peed 4 N222222222122212212211227 Shutters open and close according to temperature measured at both the water jacket and the intake air 655 e BLUE BIRD 656 lE ETF ALL HOOD LEDGE TO PREVENT HOSE ITEM 104 FROM RUBBING ON THE STRUCTURE TO AIR INTAKE ELBOW ON LEFT SIDE OF ENGINE MERICAN SWINGOUT RADIATOR SERVICE MANUAL TO UPPER PORT ON RADIATOR TO LOWER PORT ON RADIATOR p d S SN Y y NS TO ENGINE WATER OUTLET TO TURBO COMPRESSOR OUTI FT Cooling System A3FE With Cat C7 07 NOTE INSTALL TEFLON TAPE ON ALL THREADS ON PARTS THAT ARE INSTALLED IN THE SURGE TANK USE PIPE SEALANT ON ALL OTHER PIPE THREADS SURGE TANK MOUNTING BRACKET IS A SUBPART TO THE FRONT STRUCTURE CUT LINE Z io RS Vi TO ENGINE WATER INLET NOTE COOLANT RECOVERY TANK MOUNTS IN FRONT OF RIGHT HAND OUTRIGGER BOLTS TO LOWER INSIDE OF RH DROP RAIL COOLER ASSY 0115 657 BLUE BIRD CAEN ACF ALL MERICAN service manuat 658 lE 5 INSTALL ITEM 121 TO THE UNDERSIDE OF THE FROM RUBBING ON THE STRUCTURE s 6 HOOD LEDGE TO PREVENT HOSE ITEM 104 d m TO UPPER PORT URE SWINGOUT RADIATOR TO AIR INTAKE ELBOW ON LEFT SIDE OF ENGINE TO TURBO COMPR
34. perform their functions by passing ambient air drawn by the radiator fan across tubing coils which contain coolant in the radiator or filtered intake air in the Charge Air Cooler The thin corregated fins of each unit conduct heat from the internal coils and thereby disperses it across a broad surface area allowing it to be carried away by the flow of air See the Intake chapter for a more complete functional description of the Charge Air Cooler system In the descriptions below references to the radiator assembly re fer to the combined cooling pack since the radiator and CAC are handled as a unit If the bus is equipped with optional radiator shutters the shutters unit is also attached to the radiator and all three components are removed and installed together Swing Out Radiator On Forward Engine All Americans servicing components at the front of the engine and behind the radiator assembly such as pulleys water pump fan belt fan clutch air conditioner compressors or radiator shutters may require removal of the radiator A popular option on Forward Engine units therefore is a special set of parts which allow the radiator to be pivoted slightly without disconnecting coolant hoses and draining coolant The actual mounting of the radiator unit itself is very similar between the stan dard installation and that of the swing out radiator option The components which differ are Longer coolant hoses to allow the necessary flex
35. shutter control sole noid and allowing the leuver vanes to open the shutters Air powered shutter solenoids receive actuation air from a line leading directly to the supply wet air tank When the solenoid opens the air which was closing the shutters is expelled through the solenoid s exhaust port Hydraulically powered shutter solenoids receive engine oil from a line leading from an oil supply port on the left side of the engine When the solenoid opens the oil which was closing the shutters is returned to the engine sump through the sole drain line Shutters should be inspected regularly and kept free of obstructing debris The pivot points of the leuvers and their linkages should be lubricated periodically with a light spray lubricant such as WD40 or a graphite spray 675 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Lubricate upper and lower pivot points and track Shutter solenoid mounted to lower left side of Engine closeout panel ISB only Cummins ISB Install on Left side of air intake manifold elbow 676 Cat C7 Install in port On left Intake Elbow To oil supply port onleft side of engine Si Ze Turbo Side SA Of Valve Cover 22 D SA Sl 8 A KADA O VES Mounts to threaded boss just above oil pan flange c Cummins ISB
36. stop the engine and allow it to cool Then drain the water from the entire system following the steps describe in the initial drain including blowing the system with 15 PSI max of shop air 2 5 With the hoses disconnected and the drain valves open run fresh water through the heater system radiator transmission cooler and engine until the water is clear 2 6 Repeat steps 2 2 thru 2 5 as many times as required to ensure that the system is clean and the chemicals are completely removed After having used cooling system cleaners be sure the systems are flushed 3 5 times to remove all cleaner from the system If cleaner is not completely removed ammonia salts will be left from the cleaner and severe copper corrosion can occur 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL 3 If the bus is equipped with an optional coolant filter check the filter head clean filter head and lines as required to remove all of the old coolant and any residue Install a new coolant filter element 4 Refill the cooling system with coolant recommended by the engine manu facturer Read the About Coolant section of this chapter thoroughly for infor mation about the coolants installed at the Blue Bird factory and for Blue Bird recommendations Blue Bird recommends using only pre mixed coolant or mixing of premixed coolant with concentrate of the same type and brand as opposed to mixing concentate with water to raise the glycol ratio above that of the pr
37. t s flowpath is not a parallel alternate path of the cooant flow Once the engine has reached normal operating temperature and the thermostat has fully opened all the coolant passes through the transmission cooler in series with the radiator The inlet side of the transmission cooler receives coolant that has already passed through the radiator Inside the transmission cooler the water circulates around a coil through which transmission fluid circulates At 651 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL normal operating temperatures the engine coolant is signifciantly cooler than the the transmission fluid and thereby serves to cool the transmission fluid In extremely cold climates during engine warm up the warming engine coolant helps bring the transmission fluid up to sufficient temperature for the transmission to operate Heated engine coolant also provides the heat for the bus s interior heating units The heater plumbing circuit is a parallel circuit which begins at the high pressure side of the engine water jacket cycles through the various heater elements and re turns by way of an inlet to the transmission cooler There it rejoins the coolant bath circulating through the transmission cooler and thereby finds its way back to the engine inlet A cut off valve is provided at engine heater outlet pipe and at the trans mission cooler s heater circuit inlet This allows the heating circuit to be blocked at both ends whe
38. the pump furthest from the mounting flange is the primary stage and provides oil flow to the steering circuit The secondary stage closest to the pump mounting flange supplies oil for the fan circuit The pump is gear driven by the engine power train and creates equal oil flow from each stage of the pump when the engine is running Oil from both stages of the pump will flow through separate hydraulic hoses that connect to steering circuit supply port and the fan circuit supply port on the control valve The control valve is an integrated design consisting of an aluminum manifold with an integral fan control solenoid valve two pressure control valves and a steering circuit flow control valve Internal of the manifold the flow control valve receives its supply of oil from the primary stage of the pump through the steering circuit sup ply port P2 The valve regulates the flow of oil available to the steering circuit to 4 gallons per minute GPM Having satisfied the steering circuit flow requirements the remaining oil flow from the primary stage of the pump will combine with the oil flow from the secondary stage of the pump internal of the manifold as it enters the fan circuit supply port P1 A cartridge style pressure control valve monitors steering cir cuit pressure and will open the steering circuit to the reservoir return port T when excessive pressures occurs in the steering system The returning oil form the steering gear will flow back to
39. tial shock of engagement The engagement and disengagement of the fan clutch is controlled by the en gine ECU The ECU electronically monitors a signal it receives from a temperature sensor mounted near the engine coolant outlet When the temperature signal reach es a pre defined value the ECU provides 12V current to engergize the fan clutch The clutch engages and the fan blades are driven at engine speed drawing more air through the radiator 688 When the fan clutch is de energized the collapsing magnetic field momentarily induces a current with reversed polarity in the stator The electrical connector of the fan clutch contains a diode which provides the induced current a low resistance path to ground to protect other circuits from being affected 0 Reinstallation Reinstall in reverse order of the removal procedure observing these requirements 1 If the fan clutch assembly has been removed from the mounting bracket be sure to align the anti rotation boss on the mounting side of the fan clutch with the hole on the bracket 2 Use these torque values when reassembling Journal Shaft to mounting bracket 100 ft Ibs 135 Nm Fan mounting bolts to clutch hub 25 28 ft Ibs 34 38 Nm Mounting bracket bolts to engine 18 22 ft Ibs 24 30 Nm 18 22 ft Ibs 24 30 Nm _ 25 28 ft lbs 34 38 Nm 100 ft Ibs 135 Nm Be sure the anti rotation boss aligns with the hole in the mounting bracket
40. ufacturer recommendations and specifications for testing e BLUE BIRD ALL AMERICAN SERVICE MANUAL For Cummins engines using Fleetguard ES Optimax extended life coolant send coolant samples to Fleetguard for Monitor testing as specified in the Cummins Operator s Manual Label sample as Extended Life coolant For Caterpillar Cummins or John Deere engines using John Deere Cool Gard coolant send coolant samples to a John Deere lab for Cool Scan testing or test man ually using a John Deere Three Way test strip supplied in John Deere 3 Way Heavy Duty Coolant Test Kit TY6175 Always Mix Concentrate With Premix Coolant Not Water If concentrated coolant is added in order to raise the glycol ratio use only the con centrate version of the same premix coolant type and brand as installed Do not mix the concentrate with water Instead mix the concentrate with the premix version of the same coolant Only Add Tap Water In Emergency Situations A regularly scheduled bus inspection and maintenance program should be followed 670 to prevent coolant losses due to damaged or worn hoses loose clamps etc If coolant is lost while the bus is in use and roadside emergency measures called for replenish the coolant with the same premix type and brand if possible If the proper coolant is not available and water must be used use only de ionized water if possible Ordinary tap water should only be used if proper coolant or de ion iz
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