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SPECS & MAINTENANCE - Central States Bus Sales, Inc.

1. Non Designated Metric Class 10 9 TORQUE FT LBS SIZE Min Max M4 2 0 2 9 M5 42 6 M6 7 10 M8 17 25 M10 33 58 M12 58 83 M14 93 133 M16 137 196 M20 235 336 M24 465 664 0 BLUE BIRD SPECS amp MAINTENANCE Service Precautions This section proscribes safe working practices which must be followed in order to minimize the risk of personal injury and or damage to the vehicle Additional Warn ings and Cautions appear throughout this manual Also follow all warnings and cautions printed in the various manuals from com ponent manufacturers included in this manual as chapter Appendixes Whenever Working Under the Bus Never move under a bus supported only by a hydraulic jack Use only proper jack stands or lifts Always check lifting equipment thoroughly to verify proper working condition before each use Ensure that the lifting equipment is rated for lifting the weight of the bus Ensure that the surface under all jacks stands or lifts is hard level and secure enough to support the weight of the bus concentrated on the footprint of the jack Chock all wheels to prevent rolling in either direction Disconnect battery cables to ensure the vehicle cannot be started About Modifications School buses are built in conformance to several levels of stringent governmental regulations Any user performed modification of the bus may potentially result in a non confor
2. Clamps Steering Lubricate Axle Steering Linkage Drag Link NLGI 2 EP multipurpose grease rated GC LB or equivalent Lubricate Axle Steering Linkage King Pins NLGI 2 EP multipurpose grease rated GC LB or equivalent Lubricate Axle Steering Linkage Tie Rod NLGI 2 EP multipurpose grease rated GC LB or Ends equivalent Lubricate Intermediate Steering Shaft Slip Lubricate splines with multipurpose grease Joint Every 3 Months or 24 000 Miles Brakes Inspect Air Brakes Air Dryer See Bendix appendix for specific model in Air Brakes Chapter Inspect Hydraulic Brakes Booster amp Master Inspect for signs of leakage or physical damage Cylinder e BLUE BIRD e BLUE BIRD Warning Devices amp Signs Lubricate Destination Sign Hinges Every 6 Months or 6000 Miles Lubricate Destination Sign Roller Gears Lightweight grease such as White Lube Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Shock Absorbers Inspect for signs of leakage wear or damage Tighten upper shock mounts to 50 70 ft Ib Tighten lower shock mounts to 150 180 ft Ib Inspect Comfort Air Suspension Whole Assmebly Visually inspect for damage Brakes Replace Air Brakes Air Compressor Filter Clean Air Brakes Check Valves Clean amp Lubricate Air Brakes Treadle Valve See Bendix Treadle Valve Appendix in Air Brakes Chapter Clean Air Compressor Governor Inspe
3. Inspect Comfort Air Suspension Whole Assmebly Visually inspect for damage Brakes Replace Air Brakes Air Compressor Filter Clean Air Brakes Check Valves Clean amp Lubricate Air Brakes Treadle Valve See Bendix Treadle Valve Appendix in Air Brakes Chapter Clean Air Compressor Governor Inspect Hydraulic Brakes Calipers Inspect for signs of leakage or physical damage Adjust Hydraulic Brakes Park Brake Lever Adjust engagement pressure at the lever to achieve 120 125lbs at break over center Cooling System Replace Coolant Filter Electrical Inspect Battery Battery Posts Clean and apply anti corrosion agent Exhaust System Inspect Exhaust Pipe Joints Inspect for loose clamps leaks damage Fuel System Replace Fuel Filter Filter Element Clean Fuel Filter Inlet Screen Steering Lubricate Steering Gear Pitman Arm Pivot Clean Replace if damaged NLGI 2 EP multipurpose grease rated GC LB or equivalent Use hand operated grease gun SPECS amp MAINTENANCE Every 6 Months or 10 000 Miles Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Tighten to 20 30 ft Ib Air Spring Anchor Bolts Inspect amp Tighten Comfort Air Suspension Torque to 30 35 ft Ib Air Spring Fasteners Inspect amp Tighten Comfort Air Suspension Tighten to 60 85 in Ib Leveling Valve Mount Bolt Inspect amp Tighten Comfort Air Suspension Tight
4. Lubricate Jack Knife Door Hinge Pins LPS 1 Adjust Jack Knife Door Roller Bracket Adjust for proper open closed position Adjust Jack Knife Door Switch See Body Construction Doors Jack Knife Door Adjust Outward Opening Door Control Rod Adjust Outward Opening Door Control Rod Bracket Adjust for full and secure closure without binding Adjust amp Lubricate Outward Opening Door Linkage Adjust linkage for firm closure and to ensure rear panel closes first Lubricate Outward Opening Door Pivots Lubricate pivot pins with LPS 1 Adjust Outward Opening Door Roller Bracket Adjust for full and secure closure without binding Lubricate Power Jack Knife Door Air LPS 1 Pressure amp Switch Lubricate Power Jack Knife Door Hinge LPS 1 Lubricate Wheelchair Lift Lube Points See model specific literature provided with lift 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL e BLUE BIRD Emergency Exits Lubricate All Emergency Exits Hinges LPS 1 Lubricate Rear Emergency Door Hold Open Apply ASTM D4950 GC LB Grade 2 Lubricate Roof Hatch Hatch Seal and Latch Silicone lubricant to prevent sticking of rubber seal Spray silicon lubricant into latch mechanism Floor Inspect Floor Drains Check drawin hole in each body section under window for debris obstruction Seats Lubricate Driver s Seat Lubricate per manufactuers recommendation In
5. Optional Hendrickson Comfort Air Trailing arm design with 2 heavy duty rolling lobe air springs Quick align feature for axle dog track adjustment Sachs 1 375 diameter bore shock absorbers with bonded eye bushings Tires Goodyear or Michelin 11R 22 5 H ply tubeless XZE Highway Tread Tow Hooks Two front and rear tow hooks are frame mounted Transmission Allison PTS 2200 2500 and 3000 Series transmission 5 Forward speeds 1 reverse 33 000 Ibs GVW Synthetic transmission fluid is standard Wheels Aluminum and Hub Piloted steel 10 stud disc wheels single front dual rear 22 5 x 8 25 rims e BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Forward Engine General Specification Body Access Panels Interior Hinged access door on engine hood for access for routine daily engine in spection amp service Exterior All access panels include keyed locked latches Electrical Terminal 27 x 16 hinged door located exterior below driver s windows for access to body electrical junction terminals and circuit breakers Door has re tainer to hold in open position Front Grill Hinges downward for service access to fill and sight glass Right Front 19 x 15 Y hinged door provides access to heater air intake screen air restriction indicator and wiper motor Left Front 19 x 15 1 hinged door permits access to windshield washer reservoir power steering reservoir and wiper motor Compartments Batte
6. temperatures when the system detects an out of range condition Oil pressure and coolant level sensors mounted on the engine provide input to the engine protection system Minimum pressure cap rating is 15 psi at sea level Thermostats open at 180 F and fully open 200 F Fan is fully on at 210 F engine coolant temperature SPECS amp MAINTENANCE Fuel Water Seperator supplied with engine John Deere 8 1 CNG All American Rear Engine buses equipped for Compressed Natural Gas are powered by a 250 horsepower John Deere 8 1 engine This engine is spark ignited with electronically controlled gaseous emission management system lean burn closed loop adaptive learn technology and electronically controlled wa stegate turbo charger Supplied with a turbo aspirated 13SCFM air compressor This engine is 2004 EPA CARB Certified at 1 5 Grams NOx NMHC and 0 0l g bhp hr PM Catalytic muffler is standard All American Rear Engine Caterpillar C7 Configurations Engine Horsepower RPM Torque RPM Transmission Caterpillar C7 7 2L Turbo Diesel 207 2300 190 520 standard 195 2500 Governed ae Caterpillar C7 7 2L Turbo Diesel 210 2300 R 210 520 202 2500 Governed 520 ft Ib 1440 Allison PTS 2500 Caterpillar C7 7 2L Turbo Diesel 230 2200 230 540 21482500 Governed APER Caterpillar C7 7 2L Turbo Diesel 23002200 Allison PTS 3000 230 660 22162500 Governed 660 ft Ib 1440 S
7. 0 76 A Hypoid Gear Oil GL 5 S A E 85W 140 410 F 12 2 C 0 76 B Hypoid Gear Oil GL 5 S A E 80W 140 15 F 26 1 C 0 76 D Hypoid Gear Oil GL 5 S A E 80W 90 15 F 26 1 C 0 76 E Hypoid Gear Oil GL 5 S A E 75W 90 40 F 40 C 0 76 J Hypoid Gear Oil GL 5 S A E 75W 40 F 40 C 35 F 1 6 C 0 76 L Hypoid Gear Oil GL 5 S A E 75W 140 40 F 40 C No upper limit on these temperatures However axle sump temperature must never exceed 250 F 121 C 0 BLUE BIRD 0 ALL AMERICAN SERVICE MANUAL General Maintenance Schedules The following charts list maintenance procedures which should be performed with regularity For convenience some of these tables are also duplicated in their respec tive areas throughout the manual About Service Intervals The charts show recommended minimum service intervals More frequent service intervals should be considered if the vehicle is operated in extreme conditions such as high humidity and or dusty environments Time intervals are shown in terms of months or mileage The correct interval is whichever is the first to occur Some components should be regularly inspected but do not lend themselves to universal intervals because their normal service life is highly dependent upon local conditions For these components any estimated interval would result in overser vicing in some locales and underservicing in others Such intervals are left
8. 37 41 ft Ib Inspect amp Tighten Body Tie Downs Rear Inspect rubber discs for cracking or damage Inspect spring Isolator Mounts amp fastener for damage Tighten bracket to 70 80 ft Ib Tighten Isolator to 54 58 ft Ib First 1000 Miles Then Every 6 Months or 6000 Miles Axle amp Suspension Front Lubricate Parabolic Spring Suspension NLGI 2 Grease Spring Pins Axle amp Suspension Rear Inspect Comfort Air Suspension Ride Shock length eye to eye 22 68 25 Height First 1000 Miles Then Every 6 Months or 10 000 Miles Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Tighten 7 8 U Bolts to 400 450 ft Ib Tighten 3 4 U Bolts U Bolts to 260 320 ft Ib e BLUE BIRD First 1000 Miles Then Every 12 Months or 12 000 Miles Heaters amp Defrosters O O 24 Inspect Front Heater Hoses amp Clamps Inspect for evidence of leaks or deterioration replace with proper parts Axle amp Suspension Front Inspect amp Tighten Parasteer Suspension Torque to 260 320 ft Ib Axle To Suspension Fasteners First 5000 Miles Then Every 12 Months or 24 000 Miles Transmission o Replace Transmission Sump Filter First 5000 Miles Then Every 24 Months or 24 000 Miles Transmission Replace Transmission Main Fluid Filter First 11 000 Miles Then Every 3 Months or 5000 Miles or 250 Engine Ho
9. 40 22 F 30 C 122 F 50 C SAE 10W 30 0 F 18 C 104 F 40 C SAE 10W 40 0 F 18 C 122 F 50 C SAE 15W 40 15 F 9 5 C 122 F 50 C SAE 10W 30 is the preferred viscosity for the C7 engine when ambient temperature is above 0 F 18 C and below 104 F 40 C Viscosity Grade Minimum Outside Temperature Maximum Outside Temperature SAE OW 40 40 F 40 C 104 F 40 C SAE 5W 30 22 F 30 C 86 F 30 C SAE 10W 40 4 F 20 C 104 F 40 C SAE 15W 40 5 F 15 C 122 F 50 C SAE 30W 32 F 0 C 104 F 40 C SAE 15W 40 is the preferred viscosity for the John Deere 8 1 BLUE BIRD ALL AMERICAN SERVICE MANUAL 0 BLUE BIRD Fluids amp Filters Rear Engine Fluids amp Filters Rear Engine Fluid Type Capacity Filter Comments Engine Caterpillar C7 See your Caterpillar Operation amp Maintenance Manual Engine Oil Caterpillar DEO 22 Quarts 21 liters for more details See Engine Oil Viscosity chart below for viscosity temperature range pur 7 V Gallons BB 0064641 Caterpillar equipped buses may have optional extended life Engine Coolant 50 50 premix exdudin ilie ater system Wix 24070 coolant installed Never mix different coolant colors types stand d only 9 y or brands See Engine Cooling System chapter for details Engine Cummins ISC i 24 Quarts High Quality
10. Air Pressure See Body Construction Doors Jack Knife Door Adjust Jack Knife Door Control Rod Adjust for proper open closed position Adjust Jack Knife Door Control Rod Bracket Adjust to prevent pivot pin binding Lubricate Jack Knife Door Hinge Pins LPS 1 Adjust Jack Knife Door Roller Bracket Adjust for proper open closed position Adjust Jack Knife Door Switch See Body Construction Doors Jack Knife Door Adjust Outward Opening Door Control Rod Adjust Outward Opening Door Control Rod Bracket Adjust for full and secure closure without binding Adjust amp Lubricate Outward Opening Door Linkage Adjust linkage for firm closure and to ensure rear panel closes first Lubricate Outward Opening Door Pivots Lubricate pivot pins with LPS 1 Adjust Outward Opening Door Roller Bracket Adjust for full and secure closure without binding Lubricate Power Jack Knife Door Air LPS 1 Pressure amp Switch Lubricate Power Jack Knife Door Hinge LPS 1 Lubricate Wheelchair Lift Lube Points See model specific literature provided with lift 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL 0 BLUE BIRD Emergency Exits Lubricate All Emergency Exits Hinges LPS 1 Lubricate Rear Emergency Door Hinges Lubricate at hinge grease fittings Lubricate Rear Emergency Door Hold Open Apply ASTM D4950 GC LB Grade 2 Lubricate Roof Hatch Hatch
11. Outside side panels are constructed of 16 gauge smooth steel includes window line seat line floor line and skirt line rubrails Side panels extend from below the side windows to a distance of 19 3 4 below the floor Rear corner panels are constructed of 20 gauge steel Front cowl panels are constructed of 16 gauge steel Engine Compartment Door Constructed of 190 aluminum Roof Front roof cap is formed from 18 gauge steel Rear roof cap is formed from 20 gauge steel Roof sheets are of 20 gauge steel and span the entire width of the bus window header to window header Roof sheets include an embossed rain visor over side windows Floor Panels are constructed of 14 gauge steel and are reinforced with full width U channel cross members All riveted floor joints are reinforced with full width 3 16 x 1 1 2 x 2 structural steel angles Panels Interior A removable 18 gauge steel front upper inner panel is provided to allow access to the front roof cap area Wire molding over window provides easy access to body wir ing harness Textured aluminized fully hemmed steel inside side panels are provided extending from the window sill down to the floor gusset seat ledge for the entire length of the body on both left and right sides Perforated acoustic headlining pan els spanning the entire width of the bus window header to window header are constructed of 22 gauge steel and are double hemmed to provide additional joint strength Ra
12. SAE 15W 40 mus Engine Oil heavy duty engine oil such as Ee roc See your Cummins ISC Owner s Manual for more details Valvoline Premium Blue without filter change John Deere j z Cummins equipped buses may have optional extended life Engine Coolant an Ro ie aene cat coolant installed Never mix different coolant colors types stand ie only 9 y or brands See Engine Cooling System chapter for details Fleetguard Fuel Filter BFF5488 Fleetguard Water Separator Filter FS1003 Engine John Deere 8 Used during first 2500 miles during break in period See Engine Break In Oil John Deere Engine Bresicin oll John Deere JourJohn Deere Operators Manual for more details 24 Quarts 23 liters Full Flow with new oil filter JD Option Use oils conforming to API Servcie Classification G 4 with Engine Oil ps ie 2 1201 0 5 to 1 0 sulfated ash content Do not use ashless ntural gas eng gas engine oils Wines John Deere Cool Gard is extended life coolant when Engine Coolant Cool Gard BB 0064641 installed in John Deere engines Never mix different coolant 9 50 50 premix Wix 24070 colors types or brands See Engine Cooling System chapter P for details CNG Fuel TOR QU eh jid n See your John Deere Operator Manual for more details SPECS amp MAINTENANCE Fluids amp Filters Rear Engine Fluid Type Capacity Filter Comments Transmission Transmi
13. System Test Entire Cooling System Pressure Test Cooling system Engine Test Engine Starting Aid Block Heater Steering Inspect Hydraulic Pump Body amp Seals Inspect for leaks Inspect Steering Gear Body amp Seals Inspect for leaks Every 12 Months or 24 000 Miles Brakes Clean Air Brakes Pop Off Valves Steering Replace Hydraulic Reservoir Filter Element Replace element and fluid Replace more frequently in severe operating conditions Dextron III Transmission Replace Transmission Fluid Use Dextron III fluid Inspect Transmission Shift Cable Inspect Transmission Vent Clear vent hose of debris or obstruction Every 12 Months or 50 000 Miles Axle amp Suspension Rear Replace Rear Axle Petroleum Based Lubricant Hypoid Gear Oil Viscosity depends upon operating climate See Viscosity Temperature chart Every 12 Months or 100 000 Miles Axle amp Suspension Rear Replace Rear Axle Synthetic Lubricant Viscosity depends upon operating climate See Viscosity Temperature chart e BLUE BIRD Every 18 Months or 20 000 Miles Cooling System Lubricate Shutters Pivots Use Anti Seize spray lubricant Every 24 Months or 24 000 Miles Brakes Clean Air Brakes Parking Brake Valve See Bendix Appendixes in Air Brakes Chapter Clean Air Brakes Quick Release Valves See Bendix Appendixes in Air Brakes Chapter Clean Air Brakes Relay Valves See Bendix A
14. caps front and rear BLBS lettering and Bus numbers e BLUE BIRD 0 ALL AMERICAN SERVICE MANUAL Lights Back Up Two 5 clear right and left rear Clearance Two amber front and two red rear single with shields Switch operates clearance cluster and side marker lights Cluster Three amber front and three red rear with shields Daytime Running Head lamps tail license plate parking clearance amp marker lights activated when engine is running Directionals 7 Front and rear two plain amber front two amber rear Sealed shock mounted side directionals mounted at front belt line area Dome 15 Candlepower Two rows equally spaced at center over aisle Two switches front and rear Separate switch to control the last two dome lights of the dual row Driver s dome light activated with separate switch Headlights Four rectangular Halogen single sealed beam Parking 4 Amber right and left front Side Marker Amber right and left intermediate side marker lights Stepwell 14 Candlepower Wired to operate with ID lights with entrance door open Stop and Tail Two combination lights 4 right and left rear license panel in combina tion with 7 stop and tail lights with clear red lens Warning System Weldon 8 light sequential system with dual hoods Mirrors Exterior All exterior mirrors will be heated Heat is controlled by an on off switch Crossview A Rosco Mini Hawkeye crossview mirror system is
15. high 52 5 x 37 7 42 nominal Michelin 11R 22 5 H ply tubeless XZE Highway Tread RE Dimensions amp Payload Weight standard equipment BODY CURB TOTAL OVERALL TURN WHEELBASE MODEL CAPACITY PAYLOAD WEIGHT WEIGHT LENGTH RADIUS 189 AARE3204 66 8070 20 700 28 770 395 76 29 9 217 AARE3408 72 8790 20 900 29 690 423 76 34 2 245 AARE3700 78 9510 21 700 31210 451 76 38 4 273 AARE3904 84 10 230 22 500 32 730 479 76 42 6 Pupil weight amp 120 Ib each Driver 150 Ib Approximate curb amp total weights are based on standard equipment units Optional equipment may significantly increase these estimated weights e BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Fastener Grades The following information defines chassis fastener grades to be used for the instal lation of various items on the Blue Bird chassis The fastener grades shown are mini mums and the information applies to Blue Bird installed fasteners only It does not apply to vendor supplied or installed fasteners except where noted Chassis fasten ers not specified below must be grade 2 at a minimum The grade of the hexnut used must be equal to the grade of the bolt to which it is assembled General Torque Procedure Grade 8 and Grade 5 fasteners must be tightened to the recommended torque values listed in the Designated Fastener table When the washer is on the threaded hex nut side
16. hold the bolt head and tighten the hex nut while reading the torque Observe the torque to ensure it is in the specified range It is usual practice to always torque the nut and not the bolt wherever possible When there are washers on both sides of the bolt capscrew or it is assembled into a threaded hole torque the bolt head to the specified value Do not lubricate the components when applying torque SIZE SPECS amp MAINTENANCE SAE arabe 8 FT LBs 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 13 1 2 20 9 1612 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 7 8 9 7 8 14 1 8 Designated Metric Class 10 9 TORQUE FT LBS Min Max 2 6 2 9 5 6 9 10 22 25 53 58 75 83 133 176 302 336 598 0 BLUE BIRD SAE arabe 2 FT LBs SAE arabe 5 rr Lss SAE crape 8 FT LBs SIZE Min Max Min Max 1 4 20 2 4 6 1 4 28 gt 7 5 16 18 8 13 5 16 24 9 14 3 8 16 15 23 3 8 24 17 26 7 6 14 24 37 7 6 20 27 4 1 2 13 37 57 1 2 20 41 64 9 16 12 53 82 9 16 18 59 91 5 8 11 73 112 5 8 18 83 128 3 4 10 129 200 3 4 16 144 223 7 8 9 125 322 7 8 14 138 355 1 8 188 1 12 205 529 1 14 210 541
17. including warning buzzer Warning Devices amp Signs Test Stop Arms amp Crossing Arms Windows Inspect All Mirrors Clean adjust mirrors Inspect All Windows Clean Windshield door glass driver s window rear vision windows rear door windows Brakes Inspect Air Brakes Air Lines amp Fittings Inspect for leaks or physical damage Drain Air Brakes Air Tanks Drain daily in cold weather weekly in warm weather Inspect Air Brakes Brake Chambers See Air Brakes Chapter for inspection criteria Inspect Air Brakes Brake Shoes Wear depends upon application environment See Meritor Cam Brakes Appendix in Air Brakes Chapter for guidelines SPECS amp MAINTENANCE Cooling System Inspect Coolant Level Top off with premixed coolant of same type as installed Never mix coolants of different colors types or brands See engine Operator s Manual for details Inspect Entire Cooling System Visually inspect for any signs of leakage Electrical Inspect All Lights Check all running stop marker hazard and warning lights for proper operation Engine Inspect Oil Level See Engine operators manual for oil specifications Fuel System Inspect Fuel Cap Inspect Water Separator Petcock Drain Check for water contamination Intake System Inspect Intake Tract Duct amp Elbow Visually inspect for proper fit and sealing cuts abarsions signs of
18. mounted to wire molding located in the upper left above driver s window 6 fan mounted to windshield header center of body Floor Aisle 34s thick ribbed gray rubber in aisles and at entrance aisle area Aluminum Aisle trim over joint in floor covering full length of body Underseats 1 thick smooth gray rubber Galvanized steel cove molding at wall Wheelhousing Molded black smooth rubber with galvanized steel trim Underfloor 5 amp AB marine grade plywood attached with screws Headroom Full 74 over floor covering and 3 plywood floor measured at center aisle Heater defroster Goodyear Hi Miler heater hose with constant torque clamps at all joints Includes all heater hoses and hose clamps within the body heater system Electrically controlled water regulating valve Front Heater Defroster 90 000 BTU with washable air filter Driver selects air flow up to 100 for defrosting windshield driver s window and entrance door as conditions require Auxiliary 12 000 BTU two speed heater under driver seat left side Dual ball type heater cut off valves isolate system from engine and radiator when necessary Insulation The roof sides front and rear including corners amp bows are insulated with 1 2 thick material providing an R value of 5 75 Driver s left hand close out panel is insulated inside and outside Lettering 3M Diamond Grade SCHOOL BUS 8 black vinyl letters on yellow reflective tape on roof
19. replenished clean and not expired Inspect First Aid Kit Mounting Bracket Ensure that mounting bracket is secure and operates correctly Emergency Exits Inspect All Emergency Exits Test all emergency exits for proper operation including warning buzzer Warning Devices amp Signs Test Stop Arms amp Crossing Arms Windows Inspect All Mirrors Clean adjust mirrors Inspect All Windows Clean Windshield door glass driver s window rear vision windows rear door windows Brakes Inspect Air Brakes Air Lines amp Fittings Inspect for leaks or physical damage Drain Air Brakes Air Tanks Drain daily in cold weather weekly in warm weather Inspect Air Brakes Brake Chambers See Air Brakes Chapter for inspection criteria Inspect Air Brakes Brake Shoes Wear depends upon application environment See Meritor Cam Brakes Appendix in Air Brakes Chapter for guidelines SPECS amp MAINTENANCE Cooling System Inspect Coolant Level Top off with premixed coolant of same type as installed Never mix coolants of different colors types or brands See engine Operator s Manual for details Inspect Entire Cooling System Visually inspect for any signs of leakage Electrical Inspect All Lights Check all running stop marker hazard and warning lights for proper operation Engine Inspect Oil Level See Engine operators manual for oil specificat
20. spin on type mounted on engine and supplied by engine manufacturer Fuel pump Mounted on engine Horn Electrical dual with non glare horn button emblem Backing Safety Horn Activated whenever the bus is shifted into reverse Sounds between 87 and 112 db automatically adjusting itself depending on the ambient noise level in the proximity of the alarm Instruments Gauges Individual gauges for each function are positioned to minimize driver dis traction back lit with lighted pointers Gauges have automatic self test at power up needles sweep while the display indicates TEST Slide dash dimmer Speedometer with English major and metric minor display Seven digit Odometer Re settable Trip Odometer Engine Tachometer Seven digit Engine Hourmeter Engine Oil Pressure SPECS amp MAINTENANCE gauge Coolant Temperature gauge Fuel Level gauge Voltmeter digital Clock Front Air Pressure gauge Rear Air Pressure gauge Ammeter LED Tell Tale Warning Indicators Positioned at center of dash for excellent vis ibility Right and left directional green High Beam indicator blue Service Brake Applied red Stop Engine red Check Transmission red ABS Active amber Service Engine Soon amber Low Coolant Level amber Dash Mounted Switches New generation rocker type identified with backlighted laser etched international symbols control dual headlights and parking lights In cremental high engine idle with low idle return Crui
21. tapered end of the tool has SPRING entered the hole in the piston inside the CHAMBER chamber Insert the tool until it bottoms BRAKE RELEASE RELEASE 6 3 Rotate the release stud tool a quarter turn STUD clockwise and pull outward to engage the toggle end with the piston While holding the bolt in its engaged position install the washer and nut onto the end of the tool NUT Turn the nut down against the flat washer until finger tight RELEASE i STUD TOOL 6 4 Using a 3 4 hand wrench do not use an CARRYING POCKET impact type wrench turn the release nut NN clockwise until the internal spring is fully caged NUT TANGS 0 BLUE BIRD SPECS amp MAINTENANCE 6 5 Repeat the procedure for the spring brake chamber on the oppo site side of the bus The spring brakes are now released having their springs compressed by the release bolts 7 With the axle shafts removed and air spring brakes caged the bus is pre CEN The tow hooks are pared for towing The All American may be equipped with optional tow designed for horizontal pulling hooks located just inside the access openings of the front and or rear bum only not for lifting Never attempt per Appendix 1 of the Front Axle amp Suspension chapter contains additional to lift the bus by the tow hooks information about towing proced
22. to hold it open at approx 95 Slide bolt security latch prevents door from being opened from the outside when engaged Bolt is connected to an interlock assembly which prevents engine starting when door is locked If the lock is activated after the engine is running an audible alarm is sounded in the driver s area Outward Opening Entrance Door Manual Operation Two panels open outward and close to seal against outside edge of lower step Includes laminated green tinted glass Ball bearing suspended for ease of operation and wear resistance A Manual locking mechanism is built into the forward outward opening door assembly This will disconnect the door from the manual control rod and allow the door to be SPECS amp MAINTENANCE opened from the outside of the bus The latch located in the front door panel and accessible from outside the bus is lockable with the LL25 key 4 wide black fire block upholstery header pad over the door opening inside the bus Stainless steel assist rail at the rear of the stepwell Manual over center control with an automatic latching device built into the handle for holding the door closed Driver manually disengages the latch as the door is opened Pivot bearings are oil impregnated bronze Electrical Power Socket Accessory With Cap Provides 12 volt power socket for connecting electrical accessories such as cellular phones CB radios etc Only one per vehicle Fans Driver s Auxilliary Fans 6 fan
23. to the judgement of the local technican and the service interval indicated is As Required It is important to understand that this designation should not be taken as an optional inspection Every item in the following tables should be considered mandatory and an As Required interval should be viewed as emphasizing the importance of the lo cal service operation first determining and then strictly adhering to an appropriate interval Regardless of the interval determined appropriate the operation must not be overlooked Vendor Supplied Maintenance Guidelines The technician should bear in mind that many of the components which are installed on a bus are neither manufactured nor serviced by the bus manufacturer Service and Maintenance information more detailed than that presented in this manual may be available from the component manufacturer or may be included in the chapter appendixes Wherever practical and available component specific material from our vendors has been included on the CD which accompanies this manual and refer ences to those documents are given in the maintenance charts Please be aware that these supplemental documents are provided as a courtesy and are reproduced in their entirity Therefore they may also include information on other component models offered by the vendor but not specifically applicable to the Blue Bird bus When referring to the appendixes documents always check the model of the component and be cer
24. valve transmission selector dimmer switch self canceling directional signal switch hazard signal switch headlamp switch and instrument panel with rheostat con trolled lighting Key type starter switch Engine compartment Remote engine start switch starter button compartment light switch oil pressure gauge e BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Cooling system Valeo Engine Cooling System Charge air and cross flow radiator in tandem located on left side at rear of vehicle A 26 diameter Nylon cooling fan with nine blades is hydraulically driven and thermostatically modulated by sensors in both coolant jacket and engine charge air intake Black rubber coolant hose with constant torque clamps Long life 55 45 coolant mix provides anti freeze protection to 40 f Transmission Cooling Transmission fluid cooled by 2100 btu min heat exchanger external to radiator Drive line Spicer SPL 70 SPL 100 or SPL 140 with protective guard around shaft 1610 series 273 wb Engine Blue Bird All American Rear Engine buses are equipped with a Caterpillar C7 stan dard a Cummins ISC or a John Deere 8 1 Compressed Natural Gas engine PNUD Blue Bird diesel fuel systems are not compatible with biodiesel Engine manufacturer s warranty regarding performance emissions and dura bility can be affected by using biodiesel Caterpillar C7 Electronically controlled with electronic throttle Turbo charged
25. 2 access panel between the davenport seats is provided for engine service The panel is removable from inside the body Glove box An 11 x 6 1 2 glove box above windshield on right side with door and latch Doors Outward Opening Entrance Door Air powered operation Two panels open out ward and close to seal against outside edge of lower step Includes laminated green tinted glass Keyed security lock mechanism includes a deadbolt from the door panel to the header above the door Ball bearing suspended for ease of operation and wear resistance Doors are activated by a means of an air cylinder with an electrically con trolled valve assembly located over the door and a rocker type switch accessible to a seated driver Includes an emergency release valve in door header cover An air pressure protection valve is also included There is a 4 wide header pad covered with solid black fire block upholstery over the door opening inside the bus and a stainless steel assist rail at the rear of the stepwell Emergency Door Left side emergency door required all are optional Electrical Accessory Power Socket With Cap Provides 12 volt power socket for connecting electrical accessories such as cellular phones CB radios etc One per vehicle Fans 6 fan mounted to wire molding located in the upper left above driver s window 6 fan mounted to windshield header center of body e BLUE BIRD 0 ALL AMERICAN SERVICE MANUAL Floor A
26. 2 wide strip on each side of unit at approxi mately floor level Front and rear roof cap with Black 8 SCHOOL BUS lettering Canada 1 wide strip of yellow reflective vinyl on each side of the bus above the passenger windows Vertical 1 strips of yellow reflective vinyl at both the rear bow and front corner post both sides of the bus Rubrails Four double ribbed 16 gauge steel applied rubrails are installed along both sides of the body The rubrails are installed as follows One below side windows one at seat passenger level one near the floor level one at the bottom of the skirt The window rail extends from the front bow on the right side or the front cowl post on the left side to the rear corner radius The seat rail extends from the front bow both right and left around the rear corner radius The floor rail extends from the front bow both right and left to the rear corner radius The skirt rail extends from the front bow on the right side or the front cowl post on the left side to the rear bumper interrupted by wheelhousing cut out Bumper rubrail installed below rear emergency door im mediately above the rear bumper Safety Equipment Triangular Warning Device floor mounted Seat belt cutter included as standard equipment when lift door is ordered Seats Driver s Bostrom Routemaster black vinyl with gray fabric insert high back pedestal type with seven inch fore and aft travel and five inch vertical adjustment Seat be
27. 4 wraparound at corners and double A frame bracing Controls Electronic operated throttle hydraulic brake pedal hand applied parking brake with warning light transmission selector dimmer switch instrument panel rheostat con trolled lighting and key type starter switch Cooling System Engine Charge air and down flow radiator mounted in tandem at vehicle front 25 dia nylon cooling fan with nine blades equipped with a fully on or fully off elec tromagnetic fan clutch driven by polyvee fan belt with spring loaded tensioner Fan controlled by engine ECM Black rubber coolant hose with constant torque clamps Transmission Transmission fluid cooled by 2100 BTU minute heat exchanger exter nal to radiator Long life 55 45 Coolant mix provides anti freeze protection to 40 F Drive Line Spicer SPL 70 or SPL 100 with protective guard around shaft SPECS amp MAINTENANCE Engine Forward Engine All Americans are built with Caterpillar C7 or Cummins ISB engines Caterpillar C7 series turbo diesel in one of several horsepower torque configurations shown in the table below Includes electric fan clutch and 500W 120V AC internal engine block heater serves as a heater start aid Includes a power cord All American Forward Engine Caterpillar C7 Configurations Engine Horsepower RPM Torque RPM Transmission Brakes Caterpillar C7 7 2L Turbo Diesel 207 2300 190 520 standard 195 2500 Gov
28. LGI Grade 1 or 2 multipurpose grease Lubricate Driveshafts U Joint Bolts NLGI Grade 1 or 2 multipurpose grease Inspect amp Tighten Driveshafts U Joint Bolts Tighten to 45 50 ft Ib Electrical Inspect Alternator Connections Inspect for loose wires damaged terminals damaged insulators Inspect Battery Ground Strap Check for solid connection tight fasteners and absense of corrosion Fuel System Inspect Fuel Lines Inspect for leaks or signs of abrasion Lubricate Fuel Stop Solenoid Inspect Fuel Tank Vent Inspect for obstruction Intake System Inspect Air Cleaner Filter Element Inspect for proper seating secure lid Replace if soiled wet or damaged Inspect Intake Tract All Fasteners Inspect for signs of contaminate infiltration loose clamps wear spots holes in piping Inspect Intake Tract Charged Air Tubing Inspect for signs of contaminate infiltration loose clamps wear spots holes in piping Inspect amp Tighten Intake Tract Hose Clamps Tighten to 10 in Ib Inspect amp Tighten Intake Tract Spring Loaded Clamps Tighten to near full spring compression Inspect Intake Tract Support Bracket Visual inspection Repair damaged parts immediately SPECS amp MAINTENANCE Inspect amp Tighten Intake Tract T Bolt Tighten to 50 in Ib Clamps Inspect amp Tighten Intake Tract Worm Gear Tighten to 38 42 in Ib
29. Miles Then Every 6 Months or 6000 Miles Cooling System 24 Inspect Charge Air Cooler Inspect for clogging debris e BLUE BIRD SPECS amp MAINTENANCE E BIRD As Specified by Engine Manufacturer Cooling System Replace Coolant See your Engine Ooperator s Manual Use only premixed coolant s approved by the engine manufacturer Never c mix different types or brands of coolant Engine Replace Oil amp Filter See Engine operators manual for oil and filter specifications and maintenance interval Adjust Valves See Engine manufacturer s Service Manual for interval As Specified by Transmission Manufacturer Transmission Adjust Transmission Shift Cable See Transmission Chapter e BLUE BIRD e BLUE BIRD Every Day Doors Test Wheelchair Lift Follow the manufacturers recommendations Emergency Equipment Inspect Fire Extinguisher Charge Ensure that Extinguisher Charge is not expired Inspect Fire Extinguisher Mounting Bracket Ensure that Extinguisher bracket is secure and operates correctly Inspect First Aid Kit Contents Ensure that kit supplies are fully replenished clean and not expired Inspect First Aid Kit Mounting Bracket Ensure that mounting bracket is secure and operates correctly Emergency Exits Inspect All Emergency Exits Test all emergency exits for proper operation
30. RALL REAR LENGTH OVERHANG WHEELBASE 141 AAFE2803 54 6630 17 023 346 97 117 62 169 AAFE3007 60 7350 17 156 374 97 117 62 190 AAFE3306 66 8070 17 876 409 97 131 62 190 AAFE3408 72 8790 18 930 423 97 145 62 211 AAFE3503 72 8790 19 108 430 97 131 62 211 AAFE3700 78 9510 19 419 451 97 152 62 232 AAFE3904 84 10230 20 156 479 97 159 62 232 AAFE3904 90 10950 20 156 479 97 159 62 Pupil weight 120 Ib each Driver 150 Ib Approximate curb amp total weights are based on standard equipment units Optional equipment may significantly increase these es timated weights 0 BLUE BIRD SPECS amp MAINTENANCE Dimensions Rear Engine The dimensions shown exclude exterior mirrors marker and signal lights bumpers fender skirts washers wipers and frames and rub rail and are taken under static conditions at design height Overall maximum height varies from 115 to 118 de pending upon choice of tires suspension system and body model Add 3 for roof vents and 3 for 77 headroom Rear bumper adds 1 25 to overall body length Front bumper adds 2 to overall body length Width Interior Width Height Height with Air Conditioning Front Overhang Rear Overhang Skirt Length Interior Headroom Front Door Rear Emergency Door Wheel Cut Tire Size 96 90 34 118 121 134 137 85 51 121 25 19 34 747 77 27 wide 78
31. SPECS amp MAINTENANCE gt Forward Engine General Specification Chassis Specifications are for standard equipment unless otherwise stated Alternator 200 Amp Bosch 12 Volt High Output standard 185 270 or 320 amp Leece Neville 12 Volt High Output optional on FE with Cat C7 engines All American FE Alternator Output Idle 200 amp Bosch standard ENGINE Hor 80c Caterpillar C7 159 amps 136 amps 185 amp Leece Neville optional ENGINE Hor 93c Caterpillar C7 161 amps 139 amps 270 amp Leece Neville optional ENGINE HOT 93c Caterpillar C7 200 amps 175 amps 320 amp Leece Neville optional mone peso hortozo Caterpillar C7 225 amps 178 amps Axle Front The front axle model is Hendrickson Steertek with a Gross Axle Weight Rating of 13 200 Ibs capacity Synthetic oil bearing lubrication and windowed hubcaps Axle Rear Meritor single reduction speed with synthetic bearing lubrication Standard model is RS21 145 21 000 Ib GAWR 5 29 1 reduction ratio All American FE may be equipped with optional models depending upon GVWR and reduction ratio suspension and or brakes options Meritor Model GAWR Details RS19 144 19 000 Ibs RS21 145 21 000 Ibs Standard RC23 160 23 000 Ibs RS23 160 23 000 Ibs e BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Batteries Two 8D 12V 225 AMP 2800 CCA combined 4 0 gauge battery cables are included Battery cables p
32. Seal and Latch Silicone lubricant to prevent sticking of rubber seal Spray silicon lubricant into latch mechanism Floor Inspect Floor Drains Check drawin hole in each body section under window for debris obstruction Seats Lubricate Driver s Seat Lubricate per manufactuers recommendation Inspect amp Tighten Passenger Seats Mountings Use standard torque for bolt size tread type and grade Warning Devices amp Signs Lubricate Stop Arm Electric 4 Point Pivot Lubricate four hinge pivot ponts with Try Flow lubricant Inspect amp Tighten Stop Arm Electric Fasteners Check interior and exterior fasteners for loosening Windows Lubricate Passenger Windows Latches amp Slides Use silicone lubricant Electrical Inspect Battery Electrolyte Level Replenish with distilled water SPECS amp MAINTENANCE e BLUE BIRD Every Month or 6000 Miles Warning Devices amp Signs Adjust Stop Arm Air Air Pressure Adjust for full deployment and retraction Every Month or 10 000 Miles Axle amp Suspension Rear Inspect Rear Axle Lubricant Level If low refil to bottom of filler opening Use same lubricant type as already installed Every Month or 300 000 Miles Brakes Inspect Hydraulic Brakes Fluid DOT 3 brake fluid Every 3 Months or 3000 Miles Cooling System Inspect Radiator Fins Clean debris from fins Inspect Water Pump Belt Inspect condit
33. Tighten to near full spring compression Inspect Intake Tract Support Bracket Visual inspection Repair damaged parts immediately SPECS amp MAINTENANCE Inspect amp Tighten Intake Tract T Bolt Tighten to 50 in Ib Clamps Inspect amp Tighten Intake Tract Worm Gear Tighten to 38 42 in Ib Clamps Steering Lubricate Axle Steering Linkage Drag Link NLGI 2 EP multipurpose grease rated GC LB or equivalent Lubricate Axle Steering Linkage King Pins NLGI 2 EP multipurpose grease rated GC LB or equivalent Lubricate Axle Steering Linkage Tie Rod NLGI 2 EP multipurpose grease rated GC LB or Ends equivalent Lubricate Intermediate Steering Shaft Slip Lubricate splines with multipurpose grease Joint Every 3 Months or 24 000 Miles Brakes Inspect Air Brakes Air Dryer See Bendix appendix for specific model in Air Brakes Chapter Inspect Hydraulic Brakes Booster amp Master Inspect for signs of leakage or physical damage Cylinder e BLUE BIRD e BLUE BIRD Warning Devices amp Signs Lubricate Destination Sign Hinges Every 6 Months or 6000 Miles Lubricate Destination Sign Roller Gears Lightweight grease such as White Lube Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Shock Absorbers Inspect for signs of leakage wear or damage Tighten upper shock mounts to 50 70 ft Ib Tighten lower shock mounts to 150 180 ft Ib
34. WR Details RS19 144 19 000 Ibs RS21 145 21 000 Ibs RC23 160 23 000 Ibs RS23 160 23 000 lbs Standard Batteries Two 8d 12v 225 amp 2600 cca combined 3 0 gauge battery cables are included Braking System Emergency Parking 30 sq in spring brake system with treadle valve modulation Instrument panel mounted valve provided for parking Service Brakes Dual full air with Meritor S cam 16 5 x 6 front and 16 5 x 7 rear Non asbestos Q Plus extended service linings Dust shields are optional Wider 8 62 or 10 brake linings are installed on some All American Rear Engine buses according to optional equipment and dependent upon GVWR 24 sq in front and 30 sq in rear service brake chambers Air Tanks One single and one dual compartment tank 2000 cu in each and one 1650 cu in tank Total capacity of 5650 cu in Air Compressor Bendix 13 2 cfm capacity 81250 rpm compressor gear driven Uses filtered and turbo charged clean engine air Automatic Slack Adjusters Meritor Antilock ABS Air brakes include electronic control unit remote mounted to facili tate service Bumpers Bumpers are die formed 12 high with 90 flanges top and bottom Front One piece 1 4 thick steel plate with step holes for cleaning windshield Rear One piece 3 16 thick steel plate with 14 wraparound at corners and double a frame bracing Controls Driver Controls Electronic throttle high idle switch air brake pedal parking brake
35. af ter cooled in line six cylinder engine Air intake is equipped with an intake manifold grid heater An engine protection system on the Cat C 7 de rates available power and maximum vehicle speed based on coolant temperature above 226F A diagnos tic code is logged at such time The Cat C 7 low oil pressure alarm is set to 6psi for Blue Bird monitoring Coolant alarm activation temperature maximum allowed tem perature of 220F per Cat 215F on Blue Bird monitoring Thermostats begin opening at 190F full open at 208F Battery capacity 1800CCA min in temperatures below OF Cummins ISC 05 Cummins ISC 05 engines are certified for EPA and CARB at 2 8 grams of NOx Nitrogen Oxides and NMHC Non Methane hydrocarbons for 2005 EPA standards This engine includes a diesel oxidation catalyt DOC The Cummins ISC 05 engine includes a high pressure common rail fuel system is electronically controlled and is turbo charged Includes a 18 7 CFM single cylinder air compressor and SAE 2 Flywheel housing Corrosion resistor water coolant filter is standard The ISC 05 engine protection system monitors key engine parameters and logs diagnostic faults when an abnormal operating condition occurs The engine de rates available power and maximum vehicle speed when certain fluid parameters pass a limit threshold or a maximum coolant temperature of 225 F The ECM keeps an elec tronic data log of time of occurrence elapsed times extreme pressures and extreme
36. bers Inspect for leakage or damage Torque upper and lower mount bolts to 50 70 ft Ib Inspect amp Tighten Parasteer Suspension Transverse Rod Bolts Torque to 138 159 ft Ib Axle amp Suspension Rear Inspect Comfort Air Suspension Ride Height Shock length eye to eye 24 68 25 Inspect Comfort Air Suspension Ride Height Shock length eye to eye 21 75 25 SPECS amp MAINTENANCE e BLUE BIRD Inspect amp Tighten Comfort Air Suspension Shock Absorbers Inspect for leakage or damage Torque upper mount bolts to 50 70 ft Ib Torque lower mount bolts to 160 180 ft Ib Inspect amp Tighten Comfort Air Suspension Torque Arm Bolts Torque to 150 205 ft Ib Inspect amp Tighten Comfort Air Suspension U Bolts Torque 7 8 bolts to 400 450 ft Ib Torque 3 4 bolts to 260 320 ft Ib Cooling System Test Entire Cooling System Pressure Test Cooling system Engine Test Engine Starting Aid Block Heater Steering Inspect Hydraulic Pump Body amp Seals Inspect for leaks Inspect Steering Gear Body amp Seals Inspect for leaks Every 12 Months or 24 000 Miles Brakes Clean Air Brakes Pop Off Valves Steering Replace Hydraulic Reservoir Filter Element Replace element and fluid Replace more frequently in severe operating conditions Dextron III Transmission Replace Transmission Fluid Use Dextron III fluid Inspect Transm
37. ccess doors The skirt rail extends from the front bow on the right side or the front cowl post on the left side to the rear side access doors interrupted by wheelhousing cutouts Safety Equipment Triangular warning device floor mounted Seats Driver s Bostrom Routemaster Black vinyl with gray fabric insert High back pedestal type with seven inch fore and aft travel and five inch vertical adjustment Seat belt is three point floor mounted anti cinch emergency locking retractor Adjustable pil lar loop provides approximately 7 1 2 vertical adjustment at the shoulder belt top mount Driver s armrest to left of driver on rear portion of switch panel Passenger All passenger seats are optional and are upholstered in fire block vinyl solid gray Stepwell Straight 3 step 24 3 4 depth stainless steel Step treads with white abrasive stripe inserted and bonded into a recessed area 3 white rubber abrasive wear plate is lo cated at the floor level step of the entrance door e BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Stop Arm A Specialty solid state electric operated high intensity reflective octagonal stop arm red with a white border and 6 high lettering STOP or ARRETT on both sides In cludes red led cluster lights over and under the word stop visible from both sides Sun visor Transparent dark green tint 6 5 x 30 smooth edge plastic Located in front of driver Adjustable vertically o
38. ct Hydraulic Brakes Calipers Inspect for signs of leakage or physical damage Cooling System Replace Coolant Filter Electrical Inspect Battery Battery Posts Clean and apply anti corrosion agent Exhaust System Inspect Exhaust Pipe Joints Inspect for loose clamps leaks damage Fuel System Replace Fuel Filter Filter Element Clean Fuel Filter Inlet Screen Steering Lubricate Steering Gear Pitman Arm Pivot Clean Replace if damaged NLGI 2 EP multipurpose grease rated GC LB or equivalent Use hand operated grease gun SPECS amp MAINTENANCE Every 6 Months or 10 000 Miles Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Tighten to 20 30 ft Ib Air Spring Anchor Bolts Inspect amp Tighten Comfort Air Suspension Torque to 30 35 ft Ib Air Spring Fasteners Inspect amp Tighten Comfort Air Suspension Tighten to 60 85 in Ib Leveling Valve Mount Bolt Inspect amp Tighten Comfort Air Suspension Tighten to 100 150 in Ib Lever Linkage Locknut Inspect amp Tighten Comfort Air Suspension Tighten to 260 320 ft Ib Lower Shock Mount Inspect amp Tighten Comfort Air Suspension Tighten to 525 575 ft Ib Quick Align Bolts Brakes Lubricate Air Brakes Cam Shaft Housing NLGI 2 EP multipurpose grease rated GC LB or equivalent Use hand operated grease gun Lubricate Air Brakes Haldex Slack See Haldex lubricant specs in Air Brakes chap
39. d blades Electric windshield washer with hard plas tic one gallon capacity reservoir located behind Ih front access panel washer outlets installed on wiper arms Wiring Color and number coded in molding on top of side windows for access to harness without removing windows Body wiring protected by automatic resetting circuit breakers located in easy access exterior wire terminal junction under driver win dow SPECS amp MAINTENANCE 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Dimensions Forward Engine The dimensions shown exclude exterior mirrors marker and signal lights bumpers fender skirts washers wipers and frames and rub rail and are taken under static conditions at design height Overall maximum height varies from 114 to 118 de pending upon choice of tires suspension system and body model Add 3 for roof vents and 3 for 77 headroom Rear bumper adds 1 25 to overall body length Front bumper adds 2 to overall body length Width Interior Width Height Height with Air Conditioning Front Overhang Skirt Length Interior Headroom Front Door Rear Emergency Door Wheel Cut Tire Size 96 90 34 118 121 134 137 88 35 19 34 74 77 27 wide 78 high 52 5 x 37 7 42 nominal Michelin 11R 22 5 H ply tubeless XZE Highway Tread FE Dimensions amp Payload Weight standard equipment BODY CURB MODEL CAPACITY PAYLOAD WEIGHT OVE
40. d rear tow hooks are frame mounted Transmission Allison 2500 PTS series transmission is standard 5 forward speeds with 1 reverse 33 000 GVW Synthetic transmission fluid is standard Requires optional Allison 3000 PTS on 273 wheelbase See Engine for more details SPECS amp MAINTENANCE Rear Engine General Specification Body Access panels Exterior All access panels include keyed locked latches Front Access Panels A 19 x 15 1 2 hinged door at right front providing access to wiper motor and heater fresh air intake screen A 19 x 15 1 2 hinged door at left front providing access to windshield washer reservoir and wiper motor Electric Panel A 27 x 16 hinged keyed lock door on exterior below driver s window providing access to the electrical junctions circuit breakers and terminals for body wiring Compartments Battery Enclosed compartment 23 63 x 24 00 with rolling tray Includes two retain ing pins with cable to secure the tray in a closed position Hinged door with recessed locking paddle handle latch Located behind rear axle right side holds 2 8 d bat teries or 3 delphi freedom batteries Engine Compartment Top hinged aluminum perforated door with gas lift assist cylinders 80 wide x 34 high installed at rear providing access to engine for service Additional hinged forward doors on right and left sides 26 x 33 for access to radia tor and air cleaner Davenport Engine Access A 18 x 2
41. dio AM FM PA CD console mounted with 8 deluxe speaker system Wiring for two way radio system Two way radio is not included SPECS amp MAINTENANCE Reflectors Standard reflectors include Two 3 amber mounted on side of body near front Two 3 red mounted on side of body near rear e Two 3 red mounted on rear of body Two 3 amber right and left intermediate side reflectors on vehicles 30 and longer Reflective tape 3M Diamond Grade One inch minimum width strip surrounds each emergency exit 1 3 4 wide rear structure and 2 wide strip on each side of unit at ap proximately floor level Front and rear roof cap with black 8 school bus lettering Canada 1 wide strip of yellow reflective vinyl on each side of the bus above the Passenger windows Also provides vertical 1 strips of yellow reflective vinyl at both the rear bow and front corner post both sides of the bus Rubrails Four double ribbed 16 gauge steel applied rubrails are installed along both sides of the body The rub rails are installed as follows one below side windows one at seat passenger level one near the floor level one at the bottom of the skirt The window rail extends from the front bow on the right side or the front cowl post on the left side to the rear corner radius The seat rail extends from the front bow both right and left tothe rear corner radius The floor rail extends from the front bow both right and left to the rear side a
42. dirt contamination Inspect Intake Tract Restriction Indicator Replace filter element if indicator is red Steering Inspect Power Steering Fluid Level Replinish to full mark Dextron III Tires amp Wheels Inspect All Tires amp Wheels Check air pressure Visually inspect tires tread wear lug nuts including spare Transmission Inspect Transmission Fluid Level Check production order for proper type of fluid to be added 0 BLUE BIRD Every Week Seats Inspect amp Tighten Passenger Seats Cusion Screws Inspect for loose cushions clips Inspect Passenger Seats Seat Belts Lubricate buckles clean webbing as required Replace any damaged webbing straps Inspect Passenger Seats Upholstery Inspect for cuts tears wear and soiled areas Brakes Inspect Hydraulic Brakes Pads Replace if worn to within 1 8 lining remaining 0 BLUE BIRD SPECS amp MAINTENANCE Every Month or 3000 Miles Doors Clean amp Lubricate All Doors Rubber Seals Lubricate with Silicon Spray or protectant Lubricate All Doors Vandal Locks Spray Apply lubricant into key locks Use LPS 1 for sliding bolt locks Adjust Jack Knife Door Air Pressure See Body Construction Doors Jack Knife Door Adjust Jack Knife Door Control Rod Adjust for proper open closed position Adjust Jack Knife Door Control Rod Bracket Adjust to prevent pivot pin binding
43. el in combination with 7 stop amp tail lights with clear red lens on engine compartment door Warning Lights Weldon 8 light sequential system with dual hoods Mirrors Exterior All exterior mirrors are heated Heat is controlled by an on off switch Crossview A Rosco Mini Hawkeye crossview mirror system is provided to allow a seated driver to view pedestrians while the bus is stopped The crossview mirror system is comprised of a 10 8 x 12 5 elliptical mirror with tinted upper portion to reduce glare supported by a center mounting post with ball stud mounted on both Ih and rh sides of the bus The mirror mounting posts are attached to the front cowls and feature a breakaway pivot to reduce damage in the event of accidental contact The crossview mirror system allows for viewing all areas along the front and sides of the bus which are not visible by direct view Rearview The Rosco Avia rearview mirror system is designed to provide a view of the roadway to the rear as well as a view of the ground along both sides of the bus The rearview mirror system is comprised of 9 x 17 oval heads each containing 74 sq in flat and 38 sq in convex mirror on both left and right sides The right rearview mirrors are located to be visible through the wiped area of the windshield The left rearview mirrors are located so as to be visible through the driver s window The rear view mirrors on both right and left sides feature a spring breakaway pivot a
44. en to 100 150 in Ib Lever Linkage Locknut Inspect amp Tighten Comfort Air Suspension Tighten to 260 320 ft Ib Lower Shock Mount Inspect amp Tighten Comfort Air Suspension Tighten to 525 575 ft Ib Quick Align Bolts Brakes Lubricate Air Brakes Cam Shaft Housing NLGI 2 EP multipurpose grease rated GC LB or equivalent Use hand operated grease gun Lubricate Air Brakes Haldex Slack See Haldex lubricant specs in Air Brakes chapter Adjusters Lubricate Air Brakes Meritor Slack See Meritor lubricant specs in Air Brakes chapter Adjusters Steering Lubricate Steering Column Vision manual says to lubricate steering column Where With what Check model applicability e BLUE BIRD Every 12 Months Intake System Test Intake Tract Restriction Indicator Every 12 Months or 12 000 Miles e BLUE BIRD Test indicator with vaccuum gauge and pump Heaters amp Defrosters Tighten Front Heater Fasteners All fasteners holding such heaters in place in unit For details on fasteners check installation prints Clean Front Heater FIlter amp Core Clean dust from cores Replace filter elements Bleed Heater System Bleed air from heater circulation system This procedure is done to keep system operating correctly Clean Underseat Heaters Filter Elements Clean dust from cores Axle amp Suspension Front Inspect Parabolic Spring Suspension Entire Assembly Visual
45. erned 320 ft Ib 91440 Hydraulic Brakes Caterpillar C7 7 2L Turbo Diesel 210 2300 210 520 20202500 Governed 520 ft Ib 01440 Allison PTS 2500 i Caterpillar C7 7 2L Turbo Diesel 230 2200 540 ft lb 1440 Brakes 230 540 214 2500 Governed Caterpillar C7 7 2L Turbo Diesel 230 2200 230 660 22162500 Governed GGO M IDG 140 Caterpillar C7 7 2L Turbo Diesel 250 2200 Allison PTS 3000 Air 250 660 24002500 Governed 660 Ib 01440 5 speed Brakes Caterpillar C7 7 2L Turbo Diesel 275 2200 275 800 26402400 Governed GSO ID Q140 Exhaust Stainless steel muffler 4 O D 16 gauge aluminized steel tailpipe exits through bum per road side Tailpipe is 0 to 1 2 beyond bumper Wide band exhaust clamps used at all joints Floor Driver Area Raised 2 above floor has 62 plywood with 19 ribbed rubber floor cover Frame Main Frame Dual C channels 9 63 high with 3 flanges made of 25 thick 50 000 PSI steel Section Modulus 10 1 in cu Sub Frame Dual C channels 9 high with 2 3 8 flanges made of 25 thick 50 000 PSI steel Section Modulus 8 4 in cu Fasteners All permanent fixtures on frame are attached with hi tensile strength Huck Spin fasteners with swaged lock nuts Fuel System 100 gallon capacity available only with 211 232 wheelbase or 60 gallon capacity available only with 141 169 190 wheelbase Aluminized steel safety tank mounted between frame rails Includes a sender ins
46. es Then Every 6 Months or 6000 Miles Axle amp Suspension Front Lubricate Parabolic Spring Suspension NLGI 2 Grease Spring Pins Axle amp Suspension Rear Inspect Comfort Air Suspension Ride Shock length eye to eye 22 68 25 Height First 1000 Miles Then Every 6 Months or 10 000 Miles Axle amp Suspension Rear Inspect amp Tighten Comfort Air Suspension Tighten 7 8 U Bolts to 400 450 ft Ib Tighten 3 4 U Bolts U Bolts to 260 320 ft Ib e BLUE BIRD First 1000 Miles Then Every 12 Months or 12 000 Miles Heaters amp Defrosters O O 24 Inspect Front Heater Hoses amp Clamps Inspect for evidence of leaks or deterioration replace with proper parts Axle amp Suspension Front Inspect amp Tighten Parasteer Suspension Torque to 260 320 ft Ib Axle To Suspension Fasteners First 5000 Miles Then Every 12 Months or 24 000 Miles Transmission o Replace Transmission Sump Filter First 5000 Miles Then Every 24 Months or 24 000 Miles Transmission Replace Transmission Main Fluid Filter First 11 000 Miles Then Every 3 Months or 5000 Miles or 250 Engine Hours Engine Inspect All Belts Inspect condition and tension of belt First 11 000 Miles Then Every 6 Months or 250 Engine Hours Bra Brakes 00 0000000000000 00 Replace Air Brakes Air Compressor Filter First 11 000
47. ion and tension of belt e BLUE BIRD e BLUE BIRD Brakes Lubricate Air Brakes S Cam Every 3 Months or 5000 Miles See Meritor Cam Brakes Appendix in Air Brakes Chapter for guidelines Lubricate Hydraulic Brakes Calipers Lube per meritor specs Driveline Lubricate Driveshafts Slip Joint NLGI Grade 1 or 2 multipurpose grease Lubricate Driveshafts U Joint Bolts NLGI Grade 1 or 2 multipurpose grease Inspect amp Tighten Driveshafts U Joint Bolts Tighten to 45 50 ft Ib Electrical Inspect Alternator Connections Inspect for loose wires damaged terminals damaged insulators Inspect Battery Ground Strap Check for solid connection tight fasteners and absense of corrosion Fuel System Inspect Fuel Lines Inspect for leaks or signs of abrasion Lubricate Fuel Stop Solenoid Inspect Fuel Tank Vent Inspect for obstruction Intake System Inspect Air Cleaner Filter Element Inspect for proper seating secure lid Replace if soiled wet or damaged Inspect Intake Tract All Fasteners Inspect for signs of contaminate infiltration loose clamps wear spots holes in piping Inspect Intake Tract Charged Air Tubing Inspect for signs of contaminate infiltration loose clamps wear spots holes in piping Inspect amp Tighten Intake Tract Hose Clamps Tighten to 10 in Ib Inspect amp Tighten Intake Tract Spring Loaded Clamps
48. ions Fuel System Inspect Fuel Cap Inspect Water Separator Petcock Drain Check for water contamination Intake System Inspect Intake Tract Duct amp Elbow Visually inspect for proper fit and sealing cuts abarsions signs of dirt contamination Inspect Intake Tract Restriction Indicator Replace filter element if indicator is red Steering Inspect Power Steering Fluid Level Replinish to full mark Dextron III Tires amp Wheels Inspect All Tires amp Wheels Check air pressure Visually inspect tires tread wear lug nuts including spare Transmission Inspect Transmission Fluid Level Check production order for proper type of fluid to be added 0 BLUE BIRD Every Week Seats Inspect amp Tighten Passenger Seats Cusion Screws Inspect for loose cushions clips Inspect Passenger Seats Seat Belts Lubricate buckles clean webbing as required Replace any damaged webbing straps Inspect Passenger Seats Upholstery Inspect for cuts tears wear and soiled areas Brakes Inspect Hydraulic Brakes Pads Replace if worn to within 1 8 lining remaining 0 SPECS amp MAINTENANCE Every Month or 3000 Miles Doors Clean amp Lubricate All Doors Rubber Seals Lubricate with Silicon Spray or protectant Lubricate All Doors Vandal Locks Spray Apply lubricant into key locks Use LPS 1 for sliding bolt locks Adjust Jack Knife Door
49. isle 3 16 thick ribbed gray rubber in aisles and at entrance aisle area Aluminum aisle trim over joint in floor covering full length of body Under seats 1 8 inch thick smooth gray rubber Cove molding at wall is galvanized steel Wheelhousing Front and rear molded black smooth rubber Galvanized steel wheel house trim Subfloor 5 8 AB marine grade plywood attached with screws Headroom Full 74 over 5 8 marine grade plywood and floor covering measured at center aisle Heater Defroster Dual ball type heater cut off valves isolate system from engine and radiator when necessary Auxiliary pump with heavy duty motor seals and housing Mounted in the engine compartment Goodyear hi miler heater hose with constant torque clamps at all joints including all heater hoses and hose clamps within the body heater system Electrically controlled water regulating valve Front Heater Defroster 90 000 BTU with washable air filter Driver selects air flow up to 10096 for defrosting windshield driver s window and entrance door as conditions require Auxiliary 12 000 btu two speed heater under driver seat left side Insulation Roof sides front and rear including corners amp bows are insulated with 1 1 2 thick material providing an R value of 5 75 Drivers left hand close out panel is insulated inside and outside Lettering 3M Diamond Grade SCHOOL BUS 8 black vinyl letters on yellow reflective tape on roof caps fron
50. ission Shift Cable Inspect Transmission Vent Clear vent hose of debris or obstruction Every 12 Months or 50 000 Miles Axle amp Suspension Rear Replace Rear Axle Petroleum Based Lubricant Hypoid Gear Oil Viscosity depends upon operating climate See Viscosity Temperature chart e BLUE BIRD Every 12 Months or 100 000 Miles Axle amp Suspension Rear Replace Rear Axle Synthetic Lubricant Viscosity depends upon operating climate See Viscosity Temperature chart Every 18 Months or 20 000 Miles Cooling System Lubricate Shutters Pivots Use Never Seize spray lubricant e BLUE BIRD
51. ized steel tailpipe exits through bumper on curb side Tailpipe is 0 to 1 2 beyond bumper Wide band exhaust clamps are used at all joints Floor driver area 2 high raised driver platform has 62 plywood with 19 ribbed rubber floor cover Frame Main frame Dual C channels 9 63 high with 3 flanges made of 25 thick 50 000 psi steel section modulus 10 1 in cu Insert Liner across rear suspension is dual C channels 9 1 6 web with 2 3 4 flanges made of 25 thick 50 000 psi steel Insert section modulus 9 5 in cu Total section modulus 19 6 in cu Sub frame dual C channels 50 000 psi steel Sub frame rails are turned with flanges outward and lowered 6 below main frame to best accommodate engine and related components Section modulus 7 80 in cu Sub frame rails are 65 long and overlap main rail and insert 24 where joining is reinforced with dual 3 x 3 1 4 thick angle Fasteners All permanent fixtures on frame are attached with hi tensile strength huck spin fasteners with swaged lock nuts Fuel system Tank 100 gallon capacity aluminized steel safety tank mounted between frame rails Includes a sender inspection plate and right hand fill opening with spring load ed locking door Filter Primary fuel filter water separator is Racor 490r30 rated at 90 gph 30 micron with see thru bowl and self venting drain 200 watt heater Filter head includes in tegral check valve on inlet side Secondary fuel filter is
52. l on All American Rear Engine with Cummins ISC or Cat C7 engines All American RE Alternator Output Idle 200 amp Bosch standard ENGINE Cummins ISB Cummins ISC Caterpillar C7 ENGINE Cummins ISB Cummins ISC Caterpillar C7 John Deere 8 1 ENGINE Cummins ISB Cummins ISC Caterpillar C7 ENGINE Cummins ISB Cummins ISC Caterpillar C7 Axle Front cwe asd nor Boe Bang Bam 185 amp Leece Neville optional fF cwe asd nor lose DITS Hans DET 270 amp Leece Neville optional cwe asd werissd Tang ramp Vans 320 amp Leece Neville optional cwe asd nor lose ramp ramp Hendrickson Steertek or Meritor Easy Steer Synthetic lubed bearings Hubcaps with window seal included 13 200 Ibs capacity Other models may be installed depend ing upon GVWR suspension and or brakes options Meritor Model FF944 FF966 FF967 FG941 0 BLUE BIRD GAWR 13 200 Ibs 12 000 Ibs 13 200 Ibs 14 600 Ibs Details 5 0 drop Easy Steer Design 3 5 drop Double Drop Beam 12 000 Ib Standard 3 5 drop Double Drop Beam 13 200 Ib 3 5 drop Easy Steer Design SPECS amp MAINTENANCE Axle Rear Meritor single reduction speed with synthetic lubed bearings Standard model is RS23 160 23 000 Ibs capacity 5 38 to 1 ratio All American RE may be equipped with optional models depending upon GVWR and reduction ratio suspension and or brakes options Meritor Model GA
53. lt is three point floor mounted anti cinch emergency locking retractor Adjustable pil lar loop provides approximately 7 vertical adjustment at the shoulder belt top mount Driver s armrest to left of driver on rear portion of switch panel Passenger Seat Upholstery All Passenger seats are optional and will be upholstered in Fire Block vinyl solid gray Stepwell Three step 24 34 depth stainless steel Step treads with white abrasive stripe in serted and bonded into a recessed area 3 white abrasive wear plate is located at the floor level step of the entrance door Includes a stainless steel assist rail at the rear of stepwell SPECS amp MAINTENANCE Stop Arm An electric operated High Intensity Reflective octagonal stop arm red with a white border and 6 high lettering STOP or ARRETT on both sides Includes red LED clus ter lights over and under the word STOP visible from both sides Sun Visor Transparent dark green tint 6 5 x 30 smooth edge plastic Located in front of driver Adjustable vertically on two arms pivoted at ends of visor and at anchor points on windshield header Switch Panel Mounted left and right of driver with rocker type self illuminated switches for electri cal equipment Brightness of illumination is controlled by a separate dimmer switch located in the left switch panel Ventilation Air Intake Heater intake on right front below windshield level is electrically con trolled Man
54. ly inspect for damage or misalignmnent Inspect amp Tighten Parabolic Spring Suspension Hangar Bracket Bolts Tighten to 75 85 ft Ib Inspect Parabolic Spring Suspension Shock Absorbers Visually inspect for leakage or damage Inspect amp Tighten Parasteer Suspension Air Spring Fasteners Torque to 20 30 ft Ib Inspect amp Tighten Parasteer Suspension Front Pivot Bolts Torque to 450 480 ft Ib Inspect amp Tighten Parasteer Suspension Ride Height Shock Length eye to eye 18 5 25 Inspect amp Tighten Parasteer Suspension Shock Absorbers Inspect for leakage or damage Torque upper and lower mount bolts to 50 70 ft Ib Inspect amp Tighten Parasteer Suspension Transverse Rod Bolts Torque to 138 159 ft Ib Axle amp Suspension Rear Inspect Comfort Air Suspension Ride Height Shock length eye to eye 24 68 25 Inspect Comfort Air Suspension Ride Height Shock length eye to eye 21 75 25 SPECS amp MAINTENANCE e BLUE BIRD Inspect amp Tighten Comfort Air Suspension Shock Absorbers Inspect for leakage or damage Torque upper mount bolts to 50 70 ft Ib Torque lower mount bolts to 160 180 ft Ib Inspect amp Tighten Comfort Air Suspension Torque Arm Bolts Torque to 150 205 ft Ib Inspect amp Tighten Comfort Air Suspension U Bolts Torque 7 8 bolts to 400 450 ft Ib Torque 3 4 bolts to 260 320 ft Ib Cooling
55. mance For this reason it is Blue Bird s policy that end users should not perform any equipment modifications to the bus Contact your Athorized Blue Bird Dealer for advice and consultation before adding any electrical accessories or non standard mechanical equipment Whenever Working Around Moving Parts Use extreme caution to avoid accidental entaglement Do not wear loose clothing Remove all jewelry including watches and rings Securely cover long hair Wear eye hearing and respiratory protection Whenever Working Inside the Engine Compartment Disconnect batteries to prevent accidental engine starting Exercise extreme cau tion around hot components and wear sufficiently protective clothing Whenever possible allow components to cool completely before working Be mindful of any system which operates under pressure and ensure that pressure is released before working on that system When closed system components such as those associated with the fuel system cooling system or charge air system have been removed always take appropriate measures to prevent contamination of the system by dust dirt or debris Replacing Fasteners Do not re use fasteners in high torque locations Replace with new fasteners of ap propriate hardness grade e BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Performing Structural Repairs Welding Modern school buses are equipped with sensitive electronic equipment such as the
56. multiplex system and the ECUs of engine transmission and ABS brakes Such components can be permanently damaged by current fluctuations In addition to the welding precautions you would normally take to isolate components which may be damaged by heat the repair technician must also bear in mind the potential for expensive damage to electronic systems It is highly recommended that the mul tiplex Main Bus Controller and other such electronic control units be disconnected before performing any welding anywhere on the body or chassis Whenever Rendering Roadside Assistance Take measures to ensure the safety of passengers first Move passengers away from the disabled bus to a safe location in an organized fashion Use the roadside emer gency markers to clearly warn traffic of the hazard Call for help and alternate pas senger pick up immediately If at all possible avoid performing service procedures roadside and instead have the bus towed to a proper and safe service facility Hazardous Materials Vehicle fluids including engine coolant transmission fluid engine oil and power steering fluid are hazardous to the environment and to the individual performing maintenance and repair on the vehicle The handling storage and disposal of these fluids are subject to government regulation Read and strictly follow the warnings and instructions on the labels of all fluids and compounds The anti freeze in engine coolant is Ethylene Glycol This is a
57. n Softek Spring Suspension Standard 3 x 52 semi elliptic progres sive variable rate 14 leaf slipper springs 11 500 lbs Capacity each at the ground Maintenance free rubber bushed radius leaf permits axle adjustment for dog track ing Oil slinger installed in wheel end to channel lube away from brake lining in the event of failed oil seal Monroe direct acting 1 75 diameter bore double action pis ton type with long life bonded bushings Hendrickson Comfort Air Suspension Optional Trailing arm suspension with 2 heavy duty rolling lobe air springs mounted rearward of axle and steel springs for ward of axle Quick align axle dog tracking adjustment Transverse track rod controls lateral motion Vertical motion controlled by two 132 bore Sachs shock absorbers Single height control valve maintains suspension height at all loads Ridewell Model 227 Air Suspension Optional 4 bag parallelogram design Long life maintenance free torque arm bushings Urethane thrust washers Lateral motion controlled by transverse track rod Vertical motion controlled by adjustable heavy duty Koni shock absorbers Two leveling valves permitting leveling side to side and front to rear Axle dog tracking adjustable via eccentric torque arm bolts Tires Goodyear or Michelin 11r 22 5 h ply steel belted radial tires xze highway tread Alu minum or hub piloted steel 10 stud disc wheels single front dual rear 22 5 x 8 25 rims Tow hooks Two front an
58. n two arms pivoted at ends of visor and at anchor points on windshield header Switch Panel Mounted left of driver with rocker type self illuminated switches for electrical equip ment Brightness of illumination is controlled by a separate dimmer switch located in the left switch panel Ventilation Air Intake Heater intake on right front below windshield level is electrically con trolled Manual driver s fresh air vent on left by driver s feet Static non closing vent in front roof Windows Driver s Double sliding aluminum sash with security fastener for locking both sash es laminated green tinted glass Rear Emergency Large 22 1 2 x 55 Push out tempered dark tinted window assist ed by self contained air spring that holds in open position Lettering EMERGENCY EXIT and or SORTIE DE SECOURS Two inch black double faced decals on inside above glass Includes a plug lock cylinder to prevent movement of locked handle Side 9 split sash tempered tinted glass in aluminum frame provides nine inch clear opening when lowered Windshield The windshield consists of four separate pieces of flat shaded safety plate glass To facilitate cleaning of the windshield from the outside there are non glare black grip handles above the windshield glass on each side of the vehicle with assist steps in bumper Windshield Wipers Electric intermittent single switch parallelogram type bottom mounted with re mote control non glare arms an
59. nd are adjustable without tools Interior Rearview 6 x 30 with 3 16 clear safety glass laminated to steel backing plate Mirror has 1 3 4 radius rounded corners Perimeter of mirror is padded for safety The interior rearview mirror is installed above the seated driver on the front upper inner panel and is designed to provide a clear view of the interior of the ve hicle and of the roadway to the rear Mudguards amp Flaps Front Metal guard forward of front axle left side Mudflaps to full length installed behind front wheels Fenders black rubber Rear 23 x 30 mudflaps both sides without logo and extended Fenders black rub ber e BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Paint Exterior National school bus yellow with black trim and black bumpers OEM heat cured polyurethane Interior Astro white hot sprayed on baked enamel except on aluminized inner side panels Seat frames black heaters and trim black switch consoles and dash gray Rust Proofing Body parts thoroughly rust proofed after fabrication and before as sembly Undercoat Underside of body floor skirt and wheelhousing thoroughly undercoat ed prior to body mount to ensure best coverage and maximum corrosion resistance Undercoat material offers optimum corrosion protection Roof cap A minimum area of 3 band of black background is painted around front and rear warning lights Panels Exterior Body 19 3 4 skirt
60. nd of the brass drift with the hammer will dislodge the tapered dowels e Vd eB Do not use a chisel or wedge to loosen the axle shaft and tapered dowels Doing so can damage the axle shaft gasket seal or axle hub r Brass Drift 4 Mark the axle shaft so that it can easily be identified for reinstallation on the side of the axle from which it is removed Carefully remove the axle shaft tak ing measures to catch the axle lubricant which may spill Install a cover plate over the open end of the hub to prevent dirt contamination and lubricant spillage during towing 5 Repeat the above procedure to remove the other axle shaft 6 If the bus is equipped with air brakes and if full working air pressure is not present in the system the spring brakes must be mechanically caged before the vehicle can be towed Proceed as follows VITAMIN Caging the spring brakes disables the parking brake Ensure that the bus is completely secured against rolling by wheel chocks before caging the spring brakes 6 1 On each of the rear combination brake chambers a special release stud tool is carried in a storage socket cast into the body of the cham ber Remove the nut and washer from the end of the release stud tool and remove the tool from its socket 6 2 Remove the rubber dust cap from the access hole in the upper end of the spring brake chamber Insert the toggle end of the release stud tool into the access hole Be sure that the
61. nsmission Fluid Transynd 7 4 Quarts 7 liters BB 0033381 transmission cavities after draining Rear Axle Axle Oil R 19 144 33 3 pints 15 2 liters Axle Oil RS21 145 Hypoid Gear Oil 33 3 pints 15 2 liters See Rear Axle Viscosity Chart for appropriate viscosity Axle Oil RS23 160 39 5 pints 18 7 liters Front Axle Chevron Dura Lith Grease Front Axle Grease EP NLGI 2 2 1 pounds Chevron RPM Synthetic Trans Front Axle Oil mission Fluid SAE 50 4 pints 1 9 liters Brake System DOT 3 and DOT 5 must not be mixed If brake system becomes contaminated with DOT 5 the system must be flushed and major components may require Brake Fluid DOT 3 BB 0067254 replacement On units with hydraulic brakes and brake interlock Brake Interlock DOT 5 BB 1940881 feature Hydraulic System Hydraulic Steering Dexron III 2 quarts approximate Pneumatic System AD 9 Air Dryer Element BB 0020138 On units with air brakes AD IP Air Dryer Element BB 0066221 On units with air brakes Fuel System Fuel Filter Water Separator BB 1967009 Other Windshield Washer Fluid 1 05 gallons SPECS amp MAINTENANCE Engine Oil Viscosity Temperature Caterpillar C7 Viscosity Grade Minimum Outside Temperature Maximum Outside Temperature SAE OW 20 40 F 40 C 50 F 10 C SAE OW 30 40 F 40 C 86 F 30 C SAE OW 40 40 F 40 C 104 F 40 C SAE 5W 30 22 F 30 C 86 F 30 C SAE 5W
62. nstructed of 20 gauge steel and span the entire width of the bus window header to window header Roof sheets include an embossed rain visor over side windows Floor 14 gauge steel reinforced with full width U channel cross members All riv eted floor joints are reinforced with full width 34e x 1 V x 2 structural steel angles Panels Interior A removable 18 gauge steel front upper panel provides access to the front roof cap area Wire molding over window provides easy access to body wiring harness Tex tured aluminized fully hemmed steel inside side panels extend from the window sill down to the floor gusset seat ledge for the entire length of the body on both left and right sides Perforated acoustic headlining panels spanning the entire width of the bus window header to window header are constructed of 22 gauge steel and are double hemmed to provide additional joint strength Radio AM FM PA CD console mounted with 8 deluxe speaker system Wiring for two way radio system Two way radio is not included 0 BLUE BIRD 0 ALL AMERICAN SERVICE MANUAL Reflectors Standard reflectors include Two 3 amber mounted on side of body near front e Two 3 red mounted on side of body near rear e Two 3 red mounted on rear of body e Two 3 amber right and left intermediate side reflectors Reflective Tape 3M Diamond Grade 1 minimum width strip surrounds each emer gency exit 1 34 wide rear structure and
63. ositive and negative are loomed complete from terminal end to ter minal end Enclosed in large locking heavy duty battery compartment Braking System Service Brakes Hydraulic Both front and rear systems have 15 diameter x 1 438 thick rotor Meritor Quadraulic hydraulic brakes at all wheels 70MM dual system 4 pistons per caliper Self adjusting design Meritor ABS Dustshields are included Emergency Parking Units with Hydraulic Brakes Standard park brake installed on All American Forward Engine buses with hydraulic brakes is an internal expand ing transmission mounted 9 diameter x 3 wide cable actuated assembly oper ated by a control lever at the driver s left Service Brakes Air Meritor air actuated drum brakes are optional on most All Ameri can Forward Engine units and are required by certain engine options and or GVWRs See Engine for more info All American Forward Engine units equipped with air brakes have 6 Meritor Q Plus linings on front and either 7 or 8 62 lining on rear depending upon GVRW Emergency Parking Units with Air Brakes All American Forward Engine buses equipped with air brakes employ dual chamber air brakes in the rear which incorpo rate a spring brake in the outer chamber Bumpers Front and rear bumpers are die formed 12 high with 90 flanges top and bottom Front One piece 1 4 thick steel plate with step holes for cleaning windshield Rear One piece 3 16 thick steel plate with 1
64. pection plate and right hand fill opening with spring loaded locking door Primary fuel filter water separator is a Racor 30 mi cron filter with see thru bowl and self venting drain Filter head includes integral check valve on inlet side 200 watt heater Secondary spin on fuel filter mounted on engine Fuel pump mounted on engine e BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Horn Electrical dual with non glare horn button emblem Backing Safety Horn Activated whenever the bus is shifted into reverse Sounds between 87 and 112 db automatically adjusting itself depending on the ambient noise level in the proximity of the alarm Instruments Gauges Speedometer with English major and metric minor seven digit Odometer resettable Trip Odometer Tachometer seven digit engine Hourmeter Oil Pressure Voltmeter Fuel Level Coolant Temperature Front Brake Pressure Rear Brake Pres sure digital Clock Panel Dimmer slide Ammeter Gauges have automatic self test at power up Needles sweep while display indicates TEST LED Telltale Warnings Indicators Right and left directional green high beam in dicator blue Service Brake Applied red Park Brake Applied red ABS Active am ber Stop Engine red Service Engine Soon amber Check Transmission Red Low Coolant Level Amber Dash Mounted Switches Headlights with Parking Light position incremental High Idle with Low Idle Return Cruise Cont
65. peed or Allison PTS 3000 Caterpillar C7 7 2L Turbo Diesel 250 2200 5 speed 250 660 240 2500 Governed 660 ftIb 1440 with retarder Allison PTS 3000 Caterpillar C7 7 2L Turbo Diesel 275 2200 za aterpillar C7 7 2L Turbo Diese or 275 800 264 2400 Governed 660 ftID 1440 icon PTS 3000 5 speed with retarder or Allison PTS 3000 6 speed Caterpillar C7 7 2L Turbo Diesel 300 2200 _ oF 300 860 240 2500 Governed 860 ft ib 01440 Er spee with retarder Brakes Air Brakes All American Rear Engine Cummins ISC Configurations Engine Cummins ISC 5 8 3 L Turbo Diesel Horsepower RPM 260 2200 Torque RPM Transmission 660 ft Ib 1300 800 ft Ib 1300 Allison PTS 3000 Engine John Deere 8 1 L Turbo CNG 250 800 260 660 250 2500 governed Cummins ISC 5 Turbo Diesel 285002000 285 800 275602200 governed Cummins ISC 5 Turbo Diesel 260002000 300 860 285602500 governed 860 ft Ib 1300 All American Rear Engine John Deere 8 1 CNG Horsepower RPM 250 2200 250 2500 governed Torque RPM Transmission 800 ft Ib 1350 Allison PTS 3000 Brakes Air Brakes Brakes Air Brakes BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Exhaust 4 O D 2 ply stainless steel bellow flex style piping from engine turbo charger to muf fler Heavy duty stainless steel muffler 4 O D 16 gauge alumin
66. ppendixes in Air Brakes Chapter Clean Air Brakes Spring Brake Valve See Bendix Appendixes in Air Brakes Chapter e BLUE BIRD SPECS amp MAINTENANCE e s BLUE BIRD Maintenance Task Schedule A3RE Ensure that the Safety information warnings and instructions are read and under stood before operation or maintenance procedures are performed Use whichever interval listed time mileage engine hours occurs first Engines operated in severe operating conditions may require more frequent maintenance See engine manufac turer s specifications for more information First Month Then Every 3 Months or 3000 Miles Cooling System Inspect amp Tighten Hose Clamps Tighten radiator hose clamps to 90 in Ib Tighten heater hose clamps to 45 in Ib First 100 Miles Then Every 10 000 Miles Tires amp Wheels Inspect amp Tighten Lug Nuts Torque to 450 500 ft Ib with calibrated torque wrench Do not over tighten Do not lubricate nuts or studs Operating conditions may require more frequent checks First 1000 Miles Then Every 3 Months or 6000 Miles Frame Inspect amp Tighten Body Tie Downs Body Inspect for missing damaged rubber pads Tighten clamps Tie Down Clamps to 37 41 ft Ib Inspect amp Tighten Body Tie Downs Rear Inspect rubber discs for cracking or damage Inspect spring Isolator Mounts amp fastener for damage Tighten bracket to 70 80 ft Ib Tighten Isolator to 54 58 ft Ib First 1000 Mil
67. provided to allow a seated driver to view pedestrians while the bus is stopped The crossview mirror system is comprised of a 10 8 x 12 5 elliptical mirror with tinted upper portion to re duce glare The mirror mounting posts are attached to the front cowls and feature a breakaway pivot to reduce damage in the event of accidental contact The crossview mirror system allows for viewing all areas along the front and sides of the bus which are not visible by direct view Rearview The Rosco Avia rearview mirror system is designed to provide a view of the roadway to the rear as well as a view of the ground along both sides of the bus The Rearview mirror system is comprised of a 9 x 17 oval heads each containing 74 sq in flat and a 38 sq in convex The right rearview mirrors are located so as to be visible through the wiped area of the windshield The left rearview mirrors are lo cated so as to be visible through the driver s window Rearview mirrors on both right and left sides feature spring breakaway pivots and are adjustable without tools Mirrors Interior Rearview 6 x 30 with 34e clear safety glass laminated to steel backing plate Mirror has 1 34 radius rounded corners Perimeter of mirror is edged with 6 diameter rub ber padding The interior rearview mirror is installed above the seated driver on the front upper inner panel and is designed to provide a clear view of the interior of the vehicle and of the roadwa
68. rol includes two dash switches Cruise Control On Off Cruise Set Resume Steering Full power Ross TAS 65 integral unit with 20 4 to 1 ratio with gear driven hydraulic pump Tilt telescoping steering column with 18 diameter two spoke padded steer ing wheel Suspension Front Front Spring Suspension Standard Hendrickson SofTek 4 x 56 single stage three leaf parabolic leaves with up turned eyes 1 25 diameter pins in graphite im pregnated steel backed bronze bushings with urethane seals at each end 7 300 Ibs capacity each at ground One inch spacer block between the front spring and the axle Direct acting 1 75 diameter bore double action piston type Monroe shock ab sorbers with long life bonded bushings Front Air Suspension Optional Hendrickson AirTek 14 600 Ib rated Integrated front air suspension and steer axle that work together to form an integrated torsion system delivering superb ride stability and handling characteristics with reduced weight and maintenance Suspension Rear Rear Spring Suspension Standard Hendrickson Softek 3 x 52 semi elliptic pro gressive variable rate 13 leaf slipper springs Capacity rating varies depending upon wheelbase Maintenance free rubber bushed radius leaf permits axle adjustment for dog tracking Monroe direct acting 1 75 diameter bore double action piston type shock absorbers with long life bonded bushings SPECS amp MAINTENANCE Rear Air Suspension
69. ry Enclosed compartment 23 63 x 24 00 with rolling tray Includes two retain ing pins with cable to secure the tray in a closed position Hinged door with recessed locking Paddle Handle latch Located on left side behind front wheel well Emergency Provides key locking compartment for storing certain emergency equip ment located in upper front Key lock is equipped with switch and wired to buzzer to indicate that compartment is locked when ignition is turned on Glove Box 11 x 6 door above windshield on right side with door and latch Doors Rear Center Emergency Door 37 7 wide x 52 5 high opening Latching mecha nism includes a single point bar lock with inside handle and guard and an outside 6 chrome plated recessed handle Door includes upper and lower tempered green tinted safety glass Doors are identified as EMERGENCY DOOR 2 black letters above the door on the outside of the bus Includes Emergency door arrows inside and out side 6 long x 34 wide black arrow on the emergency door near the handles to indi cate direction of turn for opening On the outside arrow points up and approximate ly 45 inboard of door inside the arrow points up Arrows are in addition to standard OPERATING INSTRUCTIONS decal A DOT warning buzzer activated by movement of the door latching mechanism is included A 5 black fire block upholstery header pad is included A telescopic prop support attached to the top inside of the emergency door
70. se control includes two dash switches On Off and Set Resume Steering Steering Gear Full power Ross tas 65 integral unit with 20 4 to 1 ratio with gear driven hydraulic pump Column Tilt telescoping steering column with 18 diameter two spoke padded steering wheel Suspension Front Hendrickson SofTek Spring Suspension Standard 4 x 56 single stage heavy duty 3 leaf springs with up turned eyes 1 25 diameter pins in graphite impregnated steel backed bronze bushings with urethane seals at each end 7 300 Ibs Capacity each at ground Monroe direct acting 1 75 diameter bore double action piston type shock absorbers with long life bonded bushings Hendrickson AirTek Suspension Optional 14 600 Ib rated Integrated front air sus pension and steer axle that work together to form an integrated torsion system de livering superb ride stability and handling characteristics with reduced weight and maintenance Ridewell Model 227 Air Suspension Optional Parallelogram design with four air cushions carrying 10096 of axle load Long life maintenance free bushings and urethane thrust washers Lateral motion controlled by transverse track rod Vertical motion controlled by two adjustable heavy duty Koni shock absorbers Ride height maintained at all loads by a single leveling valve Caster adjustable via eccentric torque arm bolts e BLUE BIRD 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Suspension Rear Hendrickso
71. skin eye and respiratory irritant and is toxic to humans and animals Certain other materials such as plastics rubber compounds solvents and paints are also considered environmental hazards Always exercise caution to protect your health and the environment when working with or disposing of any chemically ac tive material or compound including cleaning materials Protective Gear Always wear proper eye protection and other required personal protective equip ment to help prevent personal injury when performing vehicle maintenance repair or service These include but are not limited to Skin protection Long sleeves appropriate gloves an appropriate apron etc Eye protection Safety glasses a facemask serviceable eye wash equipment etc e Respiratory protection A filter mask appropriate for the material being used properly ventilated work area emergency breathing aids etc e Hearing protection Earplugs earmuffs etc SPECS amp MAINTENANCE Jacking and Towing Jack Points VL Proper jacking procedures and basic safety mea sures must be observed to ensure the safety of personnel while working under the bus Always check the serviceability of any lift ing equipment prior to use Ensure that the lifting device is of suf ficient strength to handle the bus and that the surface provides the necessary firmness to support the weight of the bus concen trated on the footprint of the jack Never move under a b
72. spect amp Tighten Passenger Seats Mountings Use standard torque for bolt size tread type and grade Warning Devices amp Signs Lubricate Stop Arm Electric 4 Point Pivot Lubricate four hinge pivot ponts with Try Flow lubricant Inspect amp Tighten Stop Arm Electric Fasteners Check interior and exterior fasteners for loosening Windows Lubricate Passenger Windows Latches amp Slides Use silicone lubricant Electrical Inspect Battery Electrolyte Level Replenish with distilled water Warning Devices amp Signs Adjust Stop Arm Air Air Pressure Every Month or 6000 Miles Adjust for full deployment and retraction Every Month or 10 000 Miles Axle amp Suspension Rear Inspect Rear Axle Lubricant Level If low refil to bottom of filler opening Use same lubricant type as already installed Every Month or 300 000 Miles Brakes Inspect Hydraulic Brakes Fluid DOT 3 brake fluid SPECS amp MAINTENANCE Every 3 Months or 3000 Miles Cooling System Inspect Radiator Fins Clean debris from fins Inspect Water Pump Belt Inspect condition and tension of belt e BLUE BIRD e BLUE BIRD Brakes Lubricate Air Brakes S Cam Every 3 Months or 5000 Miles See Meritor Cam Brakes Appendix in Air Brakes Chapter for guidelines Lubricate Hydraulic Brakes Calipers Lube per meritor specs Driveline Lubricate Driveshafts Slip Joint N
73. ssion refill capacity is substantially less than the initial fill because some fluid remains in the transmission Transmission Fluid Transynd 7 4 Quarts 7 liters BB 0033381 cavities after draining Rear Axle Axle Oil RS19 144 33 3 pints 15 2 liters Axle Oil RS21 145 Hypoid Gear Oil 33 3 pints 15 2 liters See Rear Axle Viscosity Chart for appropriate viscosity Axle Oil RS23 160 39 5 pints 18 7 liters Front Axle Chevron Dura Lith Grease Front Axle Grease EP NLGI 2 2 1 pounds Front Axle Oil FF944 FF966 Chevron RPM Synthetic Trans FF967 mission Fluid SAE 50 4 pints 1 9 liters Front Axle Oil Chevron RPM Synthetic Trans FG941 mission Fluid SAE 50 Brake System DOT 3 and DOT 5 must not be mixed If brake system becomes contaminated with DOT 5 the system must be Brake Fluid DOT 3 BB 0067254 flushed and major components may require replacement Brake Interlock DOT 5 BB 1940881 On units with hydraulic brakes and brake interlock feature Hydraulci System Hydraulic Steering Dexron III 2 quarts approximate Pneumatic System AD 9 Air Dryer Element BB 0020138 On units with air brakes AD IP Air Dryer Element BB 0066221 On units with air brakes Fuel System Fuel Filter Water Separator BB 1967009 Other Windshield Washer Fluid 1 05 gallons Rear Axle Viscosity Temperature Chart Meritor Lubricant Specification Description Cross Reference Minimum Outside Temperature Maximum Outside Temperature
74. t and rear Blbs lettering and bus s License panels Two license plate embosses right and left rear on engine compartment door Nylon nuts with slot head screws installed at emboss left side Lights Back Up Two 5 clear right and left rear on engine compartment door Clearance Two amber front and two red rear single with shields Tail light switch operates clearance cluster and side marker lights Cluster Three amber front and three red rear with shields Daytime Running Headlamps tail license plate parking clearance amp marker lights activated when engine is running Directional 7 front and rear two plain amber front two amber rear Sealed shock mounted side directional mounted at front belt line area SPECS amp MAINTENANCE Dome Two rows equally spaced at center over aisle Two switches front and rear Driver s Dome Light Activated with separate switch plus a separate switch to con trol last two dome lights 15 candlepower Engine Compartment Two red lights activated with the hazard lights visible when door is open Headlights Four rectangular halogen single sealed beam with alarm indication when ignition is off and head lamps are on Parking 4 amber right and left front Side Marker Amber right and left intermediate side marker lights Stepwell Wired to operate with ID lights with entrance door open 14 candlepow er Stop Tail Two combination lights 4 right and left rear license pan
75. tain that you are using the applicable portions of the appendix documents Also some of the manufacturer supplied component manuals contain rebuild procedures As a general rule Blue Bird does not recommend rebuilding of compo nents especially in safety critical systems such as air or hydraulic control valves Blue Bird strongly recommends component replacement over rebuild SPECS amp MAINTENANCE e gt BLUE BIRD Maintenance Task Schedule A3FE Ensure that the Safety Information warnings and instructions are read and under stood before operation or maintenance procedures are performed Use whichever interval listed time mileage engine hours occurs first Engines operated in severe operating conditions may require more frequent maintenance See engine manufac turer s specifications for more information First Month Then Every 3 Months or 3000 Miles Cooling System Inspect amp Tighten Hose Clamps Tighten radiator hose clamps to 90 in Ib Tighten heater hose clamps to 45 in Ib First 100 Miles Then Every 10 000 Miles Tires amp Wheels Inspect amp Tighten Lug Nuts Torque to 450 500 ft Ib with calibrated torque wrench Do not over tighten Do not lubricate nuts or studs Operating conditions may require more frequent checks First 1000 Miles Then Every 3 Months or 6000 Miles Frame Inspect amp Tighten Body Tie Downs Body Inspect for missing damaged rubber pads Tighten clamps Tie Down Clamps to
76. ter Adjusters Lubricate Air Brakes Meritor Slack See Meritor lubricant specs in Air Brakes chapter Adjusters e BLUE BIRD Every 12 Months Intake System EN Test Intake Tract Restriction Indicator Every 12 Months or 12 000 Miles e BLUE BIRD Test indicator with vaccuum gauge and pump Heaters amp Defrosters Tighten Front Heater Fasteners All fasteners holding such heaters in place in unit For details on fasteners check installation prints Clean Front Heater FIlter amp Core Clean dust from cores Replace filter elements Bleed Heater System Bleed air from heater circulation system This procedure is done to keep system operating correctly Clean Underseat Heaters Filter Elements Clean dust from cores Axle amp Suspension Front Inspect Parabolic Spring Suspension Entire Assembly Visually inspect for damage or misalignmnent Inspect amp Tighten Parabolic Spring Suspension Hangar Bracket Bolts Tighten to 75 85 ft Ib Inspect Parabolic Spring Suspension Shock Absorbers Visually inspect for leakage or damage Inspect amp Tighten Parasteer Suspension Air Spring Fasteners Torque to 20 30 ft Ib Inspect amp Tighten Parasteer Suspension Front Pivot Bolts Torque to 450 480 ft Ib Inspect amp Tighten Parasteer Suspension Ride Height Shock Length eye to eye 18 5 25 Inspect amp Tighten Parasteer Suspension Shock Absor
77. ual driver s fresh air vent on left by driver s feet Static Vent Static non closing type in front roof Windows Driver s Double sliding aluminum sash with security fastener for locking both sash es laminated green tinted glass Side 9 Split Sash tempered tinted glass in aluminum frame 9 clear opening when lowered Rear Vision Tinted tempered Windshield The windshield consists of four separate pieces of flat shaded safety plate glass To facilitate cleaning of the windshield from the outside there are non glare black grip handles above the windshield on each side of the vehicle with steps in the bumper Windshield Wipers Electric intermittent single switch parallelogram type bottom mounted with re mote control non glare arms and blades Electric windshield washer with hard plas tic 6 quart capacity reservoir located behind right front access door washer outlets mounted on wiper arms Wiring Color and number coded in molding above windows for access to harness without removing windows Body wiring protected by automatic resetting circuit breakers located in easy access exterior wire terminal junction under driver s window e BLUE BIRD ALL AMERICAN SERVICE MANUAL Rear Engine General Specification Chassis Specifications are for standard equipment unless otherwise stated Alternator 200 Amp Bosch 12 Volt High Output standard 185 270 or 320 amp Leece Neville 12 Volt High Output optiona
78. ure Front Tow Hooks One on each side Rear Tow Hooks Rear Tow Hooks 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL 0 BLUE BIRD Fluids amp Filters Forward Engine Fluids amp Filters Forward Engine Fluid Type Capacity Filter Comments Engine Caterpillar C7 See your Caterpillar Operation amp Maintenance Manual for more details See Engine Oil Viscosity chart below Engine Oil Caterpillar DEO 22 Quarts 21 liters for viscosity temperature range John Deere Caterpillar equipped buses may have optional Cool Gard extended life coolant installed Never mix different 50 50 premix 7 1 2 Gallons BB 0064641 coolant colors types or brands See Engine Cooling Engine Coolant standard only excluding heater system Wix 24070 System chapter for details Engine Cummins ISB High Quality SAE 15W 40 ee j heavy duty engine oil such as 19 Qui its See your Cummins ISC Owner s Manual for more details Engine Oi Valvoline Premium Blue without filter change John Deere Cummins equipped buses may have optional extended Cool Gard life coolant installed Never mix different coolant colors 50 50 premix 7 1 2 Gallons BB 0064641 types or brands See Engine Cooling System chapter Engine Coolant standard only excluding heater system Wix 24070 for details Transmission Transmission refill capacity is substantially less than the initial fill because some fluid remains in the Tra
79. urs Engine Inspect All Belts Inspect condition and tension of belt First 11 000 Miles Then Every 6 Months or 250 Engine Hours Bra Brakes 00 0000000000000 00 Replace Air Brakes Air Compressor Filter First 11 000 Miles Then Every 6 Months or 6000 Miles Cooling System 24 Inspect Charge Air Cooler Inspect for clogging debris e BLUE BIRD SPECS amp MAINTENANCE E BIRD As Specified by Engine Manufacturer Cooling System Replace Coolant See your Engine Ooperator s Manual Use only premixed coolant s approved by the engine manufacturer Never 6 mix different types or brands of coolant Engine Replace Oil amp Filter See Engine operators manual for oil and filter specifications and maintenance interval Adjust Valves See Engine manufacturer s Service Manual for interval As Specified by Transmission Manufacturer Transmission Adjust Transmission Shift Cable See Transmission Chapter e BLUE BIRD e BLUE BIRD Every Day Doors Test Wheelchair Lift Follow the manufacturers recommendations Emergency Equipment Inspect Fire Extinguisher Charge Ensure that Extinguisher Charge is not expired Inspect Fire Extinguisher Mounting Bracket Ensure that Extinguisher bracket is secure and operates correctly Inspect First Aid Kit Contents Ensure that kit supplies are fully
80. us sup ported only by a hydraulic jack 1 Parkthe bus on a flat level surface of sufficient firmness to sup port the jack 2 Chockthe wheels in both directions 3 Useonly jacks and jack stands of sufficient capacity to support the bus Following the jack manufacturer s recommendations place the jack securely under the axle at the spring or suspen sion beam nearest the tire wheel to be repaired 4 Jackthe bus only to the height necessary to service 5 Support the bus with blocks or jack stands under the frame rails Towing If the bus is towed with the rear wheels on the road the driveshaft must be prevent ed from turning in order to avoid possible damage to the automatic transmission This is accomplished by removing the rear axle shafts and covering their openings with caps to prevent rear axle lubricant spillage Also on All American s equipped with air brakes if full normal air pressure is not present in the air system the spring brakes must be mechanically caged to prevent their engagement 1 Apply the parking brake and chock the wheels while preparing the vehicle for towing 2 Remove the stud nuts and washers from the center hub 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL 3 To loosen the tapered dowels which surround each stud use a 1 5 diameter brass drift and 5 6 Ib hammer Hold the brass drift against the center of the axle shaft flange inside the round driving lugs Firmly striking the e
81. y to the rear SPECS amp MAINTENANCE Mud Flaps Front Metal guard forward of front axle left side Mudflaps to full length installed behind front wheels Black rubber fenders Rear 23 x 30 mudflaps both sides without logo and with extensions included Black rubber fenders Paint Exterior National school bus yellow with black trim and black bumpers OEM heat cured polyurethane Interior Astro White hot sprayed on baked enamel except aluminized inner side panels Seat frames heaters and trim are Black switch consoles and dash medium gray Rust Proofing Body parts thoroughly rust proofed after fabrication and before as sembly Undercoat Underside of body floor skirt and wheelhousings thoroughly undercoat ed prior to body mount to insure best coverage and maximum corrosion resistance Undercoat material offers optimum corrosion protection Roof Cap A Minimum area of 3 band of black background is painted around warn ing lights front and rear Panels Exterior Body 19 34 Skirt panels Outside side panels are constructed of 16 gauge smooth steel Side panels extend from below the side windows to a distance of 19 34 below the floor Rear corner panels are constructed of 20 gauge steel and include a license plate emboss both right and left Front cowl panels are16 gauge steel Roof The front roof cap is formed from 18 gauge steel The rear roof cap is formed from 20 gauge steel Roof sheets are co

SPECS & MAINTENANCE - Central States Bus Sales, Inc.

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SPECS &amp; MAINTENANCE - Central States Bus Sales, Inc.

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SPECS & MAINTENANCE - Central States Bus Sales, Inc.