specs & maintenance - Central States Bus Sales, Inc.
Contents
1. BRAKE hole Be sure that the tapered end of the tool RELEASE RELEASE fue o STUD has entered the hole in the piston inside the n chamber Insert the tool until it bottoms 6 3 Rotate the release stud tool a quarter turn clockwise and pull outward to engage the NUT toggle end with the piston While holding the bolt in its engaged position install the RELEASE washer and nut onto the end of the tool STUD TOOL CARRYING Turn the nut down against the flat washer POCKET until finger tight aa NUT TANGS 0 BLUE BIRD SF LD Ee ia SERVICE MANUAL 23 gt FE 6 4 Using a 3 4 hand wrench do not use an impact type wrench turn the release nut clockwise until the internal spring is fully caged 1014 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 9 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 p only not for lifting Never attempt per Appendix 1 of the Front Axle amp Suspension chapter contains additi2. Engine Horsepower RPM Torque RPM Transmission Cummins ISB 07 200 2300 F 200 520 standard 2600 Governed 520 ft Ib 1600 Allison PTS 2500 Cummins ISB 07 22002300 Hr ma 520 61600 Allison PTS 2500 Cummins ISB 07 24002300 Allison PTS 2500 w ae 620 ft lb 1600 SEM or 2600 Governed Allison PTS 3000 Cummins ISB 07 260 2400 Allison PTS 2500 w Me 620 ft Ib 1600 SEM or 2600 Governed Allison PTS 3000 Cummins ISB 07 28002300 Allison PTS 2500 w 280 660 2600 Governed E a Exhaust Stainless steel muffler 4 O D 16 gauge aluminized steel tailpipe exits ahead of rear axle road side except on 141 and 169 wheelbases Wide band exhaust clamps used at all joints 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 60 gallon capacity standard 100 gallon capacity available only with 190 211 232 wheelbase Aluminized steel safety tank mounted between frame rails Includes a sender inspection plate and right hand fill opening with spring loaded locking door Primary fuel filter is a Racor 490 with primer pump Filter provides a 10 micron 90 G
3. Inspect Entire Cooling System Visually inspect for any signs of leakage BLUE BIRD SERVICE MANUAL D3FE 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 abrasions signs of dirt contamination Inspect Intake Tract Restriction Indicator Replace primary filter element when gauge on Filter Minder goes into the red area regardless of time or mileage If filter has secondary or safety filter replace at minimum every 2nd primary filter replacement Steering Inspect Power Steering Fluid Level Replinish to full mark Dexron 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 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
4. 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 BLUE BIRD 0 BLUE BIRD SERVICE MANUAL Reflectors Standard reflectors include e Two 3 Diamond grade adhesive backed amber mounted on side of body near front e Two 3 Diamond grade adhesive backed red mounted on side of body near rear e Two 3 Diamond grade adhesive backed red mounted on rear of body e Two 3 Diamond grade adhesive backed 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 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 seat rail and floor rail extends from the fro
5. Drift brass drift with the hammer will dislodge the tapered dowels TID 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 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 CAN 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 SPRING the spring brake chamber Insert the toggle CHAMBER end of the release stud tool into the access
6. Valves Steering Replace Hydraulic Reservoir Filter Element Replace element and fluid Replace more frequently in severe operating conditions Dexron III Transmission Replace Transmission Fluid Use TransSynd 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 Lubricant Replace Rear Axle Petroleum Based Hypoid Gear Oil Viscosity depends upon operating climate See Viscosity Temperature chart Every 12 Months or 90 000 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 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 Appendixes in Air Brakes Chapter Clean Air Brakes Spring Brake Valve See Bendix Appendixes in Air Brakes Chapter Intake System Replace Air Cleaner Filter Element BLUE BIRD
7. and 3000 Series transmission 5 Forward speeds 1 reverse 33 000 Ibs GVW Synthetic transmission fluid is standard Wheels Hub Piloted steel 10 stud disc wheels single front dual rear 22 5 x 8 25 rims BLUE BIRD SERVICE MANUAL 0 BLUE BIRD 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 are standard non locking Keyed locked latches optional Electrical Terminals 27 5 x 21 75 hinged door located exterior below driver s win dows for access to body electrical junction terminals and circuit breakers Door has retainer to hold in open position Chassis PDU 27 5 x 15 hinged door located exte rior below body electrical junction terminals and circuit breakers Front Grill Lifts upward for service access Right Front and Left Front Hinged doors provide access to heater air intake screen air restriction indicator wiper motors windshield washer reservoir power steering reservoir and hydraulic master cylinder reservoir Compartments Battery Enclosed compartment 23 5 x 15 5 with rolling tray Includes two retaining 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 i
8. steel cove molding at wall Wheelhousing Molded black smooth rubber with galvanized steel trim Underfloor 6 AB marine grade plywood attached with screws Headroom Full 78 over floor covering and 54 plywood floor measured at center aisle Heater defroster Black rubber heater hoses with constant torque clamps at all joints Includes all heat er hoses and hose clamps within the body heater system 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 Optional 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 neces sary 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 caps front and rear BLBS lettering and Bus numbers BLUE BIRD SERVICE MANUAL 5 EF JI L l Lights Back Up Two 4 clear right and left rear Clearance Two LED amber front and two LED red rear single Switch operates clear ance cluster and side marker lights Cluster Three amber front and three red rear Daytime Running Head lam
9. 909 84 10230 20 427 30 657 479 93 153 45 31 1 35 6 232 D3FE4004 84 10230 20 916 31 146 486 93 160 45 31 1 35 6 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 estimated weights BLUE BIRD SPECS 8 MAINTENANCE 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 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 torq
10. E 0 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 Fluid be flushed and major components may require Brake Fluid DOT3 BB 0067254 replacement Fluid On units with hydraulic brakes and brake interlock Brake Interlock DOT5 BB 1940881 feature Hydraulic System Hydraulic Steering Dexron lll 3 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 0 BLUE BIRD 00 SERVICE MANUAL Fy Rear Axle Viscosity Temperature Chart Meritor Lubricant Specification Description Cross Reference Minimum Outside Temperature Maximum Outside Temperature 0 76 A Hypoid Gear Oil GL 5 S A E 85W 140 10 F 12 2 C MI 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 6 No upper limit on these temperatures However axle sump temperature must never exceed 250 F 121 C BLUE BIRD SPECS 8 MAINTENANCE General Mainte
11. PH heated with water in fuel sensor for Cummins ISB 07 BLUE BIRD BLUE BIRD SERVICE MANUAL Horn Electrical dual with non glare horn button emblem Backing Safety Horn Optional Activated whenever the bus is shifted into reverse Sounds between 87 and 112 db automatically adjusting itself depending on the am bient noise level in the proximity of the alarm Instruments Gauges Speedometer with English major and metric minor seven digit Odometer resettable Trip Odometer Tachometer Oil Pressure Voltmeter Fuel Level Coolant Temperature Front Brake Pressure Rear Brake Pressure 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 Steering Full power Ross THP 60 integral unit with 18 2 to 1 ratio with gear driven hydraulic pump Tilt telescoping steering column with 18 diameter four spoke padded steer ing wheel Suspension Front Front Spring Suspension Standard Hendrickson SofTek 13 200 Ib rated 4 x 60 two leaf parabolic taper springs maintenance free rubber bushings each end at shackle bracket 1 38 diameter bore double actio
12. SPECS MAINTENANCE 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 All American FE Alternator Output Idle 200 amp Bosch standard ENGINE HoT 806 Cummins ISB 158 amps 135 amps 185 amp Leece Neville optional ENGINE HoT 93c Cummins ISB 158 amps 135 amps 270 amp Leece Neville optional ENGINE HoT 93c Cummins ISB 180 amps 160 amps 320 amp Leece Neville optional meme peso hortozo Cummins ISB 225 amps 170 amps Axle Front The front axle model is Hendrickson Steertek with a Gross Axle Weight Rating of 13 200 Ibs capacity Petroleum oil bearing lubrication and windowed hubcaps Hendrickson Model GAWR Details SteerTek 13 200 lbs 4 25 Drop Standard SteerTek 13 200 Ibs 5 36 Drop SteerTek 14 600 Ibs 4 25 Drop SteerTek 14 600 Ibs 5 36 Drop 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 brake 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 BLUE BIRD BLUE BIRD SERVICE MANUAL Ba
13. Upholstery Inspect for cuts tears wear and soiled areas Brakes Inspect Hydraulic Brakes Pads Replace if worn to within 1 8 lining remaining BLUE BIRD Every 60 000 Miles Fuel System Replace Fuel Filter SPECS 8 MAINTENANCE Every Month or 3000 Miles Doors Clean 6 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 Outward Opening Door Control Rod Adjust Outward Opening Door Control Rod Bracket Adjust for full and secure closure without binding Adjust 6 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 Wheelchair Lift Lube Points See model specific literature provided with lift 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 debri
14. age to HVC Arm Torque to 10 12 ft Ib Inspect amp Torque AirTek Suspension Rear Shackle Bracket to Shackle Plate Torque to 290 310 ft Ib Inspect amp Torque AirTek Suspension Rear Shackle Bracket to Spring Eye Torque to 290 310 ft Ib Inspect amp Torque AirTek Suspension Shackle Bracket Lock Nuts Torque to 114 126 ft Ib Inspect amp Torque AirTek Suspension Shocks Eye Bolts Torque to 125 135 ft Ib Inspect amp Torque SofTek Spring Suspension Axle Clamp Group Nuts Torque to 285 305 ft Ib Inspect amp Torque SofTek Spring Suspension Front Frame Hanger to Front Leaf Spring Eye Torque to 290 310 ft Ib Inspect amp Torque SofTek Spring Suspension Rear Shackle Bracket to Shackle Plate Torque to 290 310 ft Ib Inspect amp Torque SofTek Spring Suspension Rear Shackle Bracket to Spring Eye Torque to 290 310 ft Ib Inspect amp Torque SofTek Spring Suspension Shackle Bracket Lock Nuts Torque to 114 126 ft Ib Inspect amp Torque SofTek Spring Suspension Shocks Eye Bolts SPECS amp MAINTENANCE Torque to 125 135 ft Ib Axle amp Suspension Rear Inspect amp Torque Comfort Air Suspension Air Spring to Cross Channel Torque to 20 30 ft Ib Inspect amp Torque Comfort Air Suspension Cross Channel to Main Support Member Torque to 260 320 ft Ib Inspect amp Torque Comfort Air Suspension HCV Linkage to Height Control Val
15. 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 Panels Exterior Body Outside side panels are constructed of 20 gauge smooth steel Side panels ex tend from below the side windows to a distance of 19 34 below the floor Rear corner panels are constructed of 20 gauge steel Front cowl panels are 20 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 constructed 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 zinc coated steel 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 Headlining panels spanning the entire width of the bus window header
16. ble 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 Manual 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 clear tempered glass Side 12 Split Sash tempered clear glass in aluminum frame 12 clear opening when lowered Rear Vision Clear laminated glass bonded into structure Windshield Two piece curved tinted laminated safety glass bonded into the structure Windshield Wipers Electric intermittent single switch pantograph type bottom mounted with remote control non glare arms and blades Electric windshield washer with hard plastic 4 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 BLUE BIRD Dimensio
17. ch 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 3 16 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 Electronic operated throttle hydraulic brake pedal foot 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 Cool Guard coolant mix provides anti freeze protection to 34 F SPECS 8 MAINTENANCE Drive Line Spicer SPL 70 or SPL 100 with protective guard around shaft Engine Forward Engine All Americans are built with ISB 07 engines Includes electric fan clutch Optional 500W 120V AC internal engine block heater serves as a heater start aid Includes a power cord All American Forward Engine Cummins ISB 07 Configurations
18. d 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 e Skin protection Long sleeves appropriate gloves an appropriate apron etc Eye protection Safety glasses a facemask serviceable eye wash equipment etc Respiratory protection A filter mask appropriate for the material being used properly ventilated work area emergency breathing aids etc Hearing protection Earplugs earmuffs etc BLUE BIRD 00 I E ERNE MANUAL wh Jacking and Towing 10 12 Jack Points pa Front Jack Point 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 bus sup ported only by a hydraulic jack 1 Park the bus on a flat level surface of sufficient firmness to sup port the jack Rear Jack Point 2 Chock the wheels in both directions The parking brake functionality relies on the rear wheels remaining in contact with the surface the bus is parked on o TAS If one o
19. ewelry 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 0 BLUE BIRD SPECS 8 MAINTENANCE Performing Structural Repairs Welding Modern school buses are equipped with sensitive electronic equipment such as the 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 s
20. hould 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 certain 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 BLUE BIRD D3 FE SERVICE MANUAL BLUE BIRD Maintenance Task Schedule Ensure that the Safety Information warnings and instructions are read and under stood before operation or maintena
21. lchair 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 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 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
22. ll areas along the front and sides of the bus which are not visible by direct view Rearview The Mirror Lite Viewmaster non detent rearview mirror system is de signed to provide a view of the roadway to the rear as well as a view of the ground along both sides The Rearview mirror system is comprised of a hand adjustable 7 75 10 Flat mirror lens tray hand adjustable 7 75 x 7 75 Pie shaped convex mirrors and mirror glass lefthand grab handle type arm for viewing mirror throgh driver s window and righthand non breakaway overhead type arm for viewing mirrors through windshield Mirrors Interior Rearview 6 x 30 with 3 6 clear safety glass laminated to steel backing plate Mirror has 1 34 radius rounded corners Perimeter of mirror is edged with 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 roadway to the rear 0 BLUE BIRD SPECS 8 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 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
23. m fins Inspect Water Pump Belt Inspect condition and tension of belt BLUE BIRD SPECS 8 MAINTENANCE Every 3 Months or 5000 Miles Brakes Lubricate Air Brakes S Cam See Meritor Cam Brakes Appendix in Air Brakes Chapter for guidelines Lubricate Hydraulic Brakes Calipers Lube per meritor specs Cooling System 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 5 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 Duct and All Fasteners Inspect for signs of contaminate infiltration loose clamps wear spots holes in piping Inspect Intake Tract Support Bracket Visual inspection Repair damaged parts immediately Inspect amp Tighten Intake Tract T Bolt Clamps Tighten to 7 ft Ib Inspect amp Tighten Intake Tract Worm Gear Clam
24. n Sachs shock absorbers Anti splay clip to maintain spring stack alignment Anti noise urethane wear pads be tween spring leaves at ends softens ride Front Air Suspension Optional Hendrickson AirTek 14 600 Ib rated Vertical load carried by air spring lateral load carried by single 4 x 60 steel spring which includes front safety wrap leaf for school bus applications Maintenance free rubber bushings each end at shackle bracket 1 38 diameter bore double action Sachs shock absorb ers with long life bonded rubber bushings Leveling valves to maintain ride height at all load conditions Suspension Rear Rear Spring Suspension Standard Drive axle spring suspension system with 3 x 52 flat two stage variable rate 13 leaf slipper springs Capacity rating varies de pending upon wheelbase Maintenance free rubber bushed radius leaf permits axle adjustment for dog tracking 1 38 diameter bore double action Sachs shock absorb ers with long life bonded rubber bushings Rear Air Suspension Optional Hendrickson Comfort Air 23 000 Ib rated trailing arm design with 2 heavy duty rolling lobe air springs Sachs 1 38 diameter bore shock absorbers with long life bonded rubber bushings Single height control level ing valve to maintain ride height at all load conditions SPECS 8 MAINTENANCE Tires Goodyear 10R 22 5 LRG G149 RSA Tow Hooks Two front and rear tow hooks are frame mounted Transmission Allison PTS 2500
25. n 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 42 wide x 58 25 high opening Latching mechanism includes a single point bar lock with inside handle and guard and an outside 6 black 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 outside 6 long x 34 wide black arrow on the emergency door near the handles to indicate direction of turn for opening On the outside arrow points up and approximately 45 inboard of door inside the arrow points up Arrows are in addition to standard OPERATING INSTRUC TIONS 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 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 Ent
26. nance 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 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 s
27. nce 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 12 000 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 for missing damaged rubber pads Tighten clamps Tie Down Bolts to 37 41 ft Ib Inspect Front Rubber Isolators Replace any worn isolators Tighten bolts to 52 56 ft Ibs 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 0 25 Height SPECS 8 MAINTENANCE First 1000 Miles Then Every 12 M
28. ns SERVICE MANUAL 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 125 de pending upon choice of tires suspension system and body model Add 3 for roof vents Rear bumper adds 1 25 to overall body length Front bumper adds 2 to over all 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 Dimensions amp Payload Weight standard equipment 96 90 34 123 126 Add 16 94 48 19 78 32 wide 81 high 43 3 4 wide 62 high 50 nominal Goodyear 10R 22 5 LRG G149 RSA RADIUS RADIUS BODY CURB OVERALL REAR CURB TO WALL TO WHEELBASE MODEL CAPACITY PAYLOAD WEIGHT WEIGHT LENGTH OVERHANG CURB WALL 141 D3FE2903 54 6630 17 907 24 537 353 93 118 45 22 26 1 169 D3FE3107 60 7350 18 420 25 770 381 93 118 45 23 7 28 3 190 D3FE3406 72 8790 18 813 27 603 416 93 132 45 26 5 31 190 D3FE3508 72 8790 19 142 27 932 430 93 146 45 26 5 31 211 D3FE3603 72 8790 19 440 28 230 437 93 132 45 29 5 34 1 211 D3FE3800 78 9510 20 052 29 562 458 93 153 45 29 5 341 232 D3FE3
29. nt bow to the rear corner radius Safety Equipment Triangular Warning Device floor mounted Seat belt cutter included as standard equipment when lift door is ordered Seats Driver s National Driver s Seat This seat has 4 height adjustment by fingertip con trols 7 fore and aft seat slides recline angle infinitely adjustable mechanical lumbar adjustment Seat covering is gray colored fire block vinyl with pebble top grain A 3 point single bar lock seatbelt with adjustable pillar loops provides approximately 7 1 2 of vertical adjustment at the shoulder belt top mount Single emergency locking retractor includes male locking bar tongue on the left retracting side 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 Black ribbed step treads non abrasive with white nosing 3 white ribbed rubber 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 8 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 incan descent 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 Adjusta
30. onal to lift the bus by the tow hooks information about towing procedure Front Tow Hooks Front Tow Hooks Rear Tow Hooks Rear Tow Hooks 0 BLUE BIRD SPECS amp MAINTENANCE GE _ 7 Fluids amp Filters Fluids amp Filters Forward Engine 1015 Fluid Type Capacity Filter Comments Engine Cummins ISB 21 4 Quarts High Quality SAE 15W 40 including filter See your Cummins ISB Owner 5 Manual for more heavy duty engine oil such 5 19 Quarts details Engine Oi Valvoline Premium Blue without filter change Cummins Fleetguard Cummins equipped buses may have optional extended ES Compleat life coolant installed Never mix different coolant colors 50 50 premix 6 8 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 Transmission Fluid Transynd 7 4 Quarts 7 liters BB 0033381 transmission 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 Chevron RPM Synthetic Trans Front Axle Oil mission Fluid SA
31. onths or 12 000 Miles Heaters 6 Defrosters Inspect Front Heater Hoses amp Clamps Inspect for evidence of leaks or deterioration replace with proper parts First 5000 Miles Then Every 12 Months or 24 000 Miles Transmission 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 Brakes Replace Air Brakes Air Compressor Filter First 11 000 Miles Then Every 6 Months or 5000 Miles Cooling System Inspect Charge Air Cooler Inspect for clogging debris BLUE BIRD D3 FE SERVICE MANUAL As Specified by Engine Manufacturer Cooling System 1020 Replace Coolant See your Engine Ooperator s Manual Use only premixed coolant s approved by the engine manufacturer Never 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 BLUE BIRD SPECS 8 MAINTENANCE Every Day Doors Test Whee
32. orque to 115 135 ft Ib BLUE BIRD SERVICE MANUAL D3FE Every 12 Months Intake System 1030 Test Intake Tract Restriction Indicator Every 12 Months or 12 000 Miles 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 amp Adjust AirTek Suspension Ride Height Shock Length eye to eye 17 25 0 25 Axle amp Suspension Rear Inspect amp Torque Spring Suspension Shock Absorbers Inspect for signs of leakage wear or damage torque locknuts to 75 100 ft Ib Inspect amp Torque Spring Suspension U Bolts Torque u bolt nuts to 280 310 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 SPECS 8 MAINTENANCE Every 12 Months or 24 000 Miles Brakes Clean Air Brakes Pop Off
33. ps Tighten to 38 42 in Ib BLUE BIRD 3 FE SERVICE MANUAL Steering Lubricate Axle Steering Linkage Drag Link NLGI 2 EP multipurpose grease rated GC LB or 1026 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 NLGI 2 EP multipurpose grease rated GC LB or equivalent 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 Every 6 Months or 5000 Miles Warning Devices amp Signs Lubricate Destination Sign Hinges Lubricate Destination Sign Roller Gears Lightweight grease such as White Lube BLUE BIRD SPECS 8 MAINTENANCE Every 6 Months or 6000 Miles Axle 6 Suspension Front Lubricate AirTek Suspension Grease Fittings Use NLGI 2 EP or equivalent Lube with suspension loaded Brakes Replace Air Brakes Air Compressor Filter Clean Air Brakes Check Valves Clean 6 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 ph
34. ps 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 in wire molding Separate switch to control the last two dome lights of the dual row Driver s dome light activated with separate switch Headlights 7 Round halogen with replaceable bulb Alarm recognition when head lights are on and igntion is off Side Marker 2 LED 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 8 light sequential system with optional dual hoods Mirrors Exterior All exterior mirrors will be heated Heat is controlled by an on off switch Crossview A Mirror Lite High Definition crossview mirror system offers a revolu tionary new mirror lens design for increased pedestrian safety and driver visual con fidence The crossview mirror system is comprised of a 10 8 x 12 5 elliptical mirror 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 sys tem allows for viewing a
35. r both wheels are lifted off the surface the park brake will ee _ 9 gt not function and the bus may move resulting in potential bodily harm or death 3 Use only 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 Jack the 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 0 BLUE BIRD SPECS 8 MAINTENANCE 2 Removethe stud nuts and washers from the center hub 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 end of the Bass
36. rance 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 8 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 mounted to wire molding located in the upper left above driver s window 6 fan mounted to windshield header center of body Floor Aisle 346 thick ribbed gray rubber in aisles and at entrance aisle area Aluminum Aisle trim over joint in floor covering full length of body Underseats 12 thick smooth gray rubber Galvanized
37. s 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 BLUE BIRD D3 FE SERVICE MANUAL Warning Devices amp Signs Lubricate Stop Arm Electric 4 Point Pivot Lubricate four hinge pivot ponts with Try Flow lubricant 1024 Inspect amp Tighten Stop Arm Electric Check interior and exterior fasteners for loosening Fasteners Windows Lubricate Passenger Windows Latches amp Use silicone lubricant Slides Brakes Inspect Hydraulic Brakes Fluid DOT 3 brake fluid Adjust Hydraulic Brakes Park Brake Lever Adjust engagement pressure at the foot pedal to achieve 130 150 Ibs on the fourth click on the parking brake lever detent Inspect Hydraulic Brakes Interlock Fluid DOT 5 brake fluid Electrical Inspect Battery Electrolyte Level Replenish with distilled water Every Month or 5000 Miles Warning Devices amp Signs Adjust Stop Arm Air Air Pressure Adjust for full deployment and retraction Every Month or 12 000 Miles Axle amp Suspension Rear Inspect Rear Axle Lubricant Level If low refill to bottom of filler opening Use same lubricant type as already installed Every 3 Months or 3000 Miles Emergency Exits Lubricate Rear Emergency Door Hinges LPS 1 Cooling System Inspect Radiator Fins Clean debris fro
38. tteries Three 12V 3375 CCA combined 4 0 gauge battery cables are included Battery ca bles positive and negative are loomed complete from terminal end to terminal 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 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 foot 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 Air Tanks One dual compartment tank with 1 250 cu in for the wet tank and 1 250 cu in for the primary tank One secondary tank with 1 760 cu in Two tanks with a total of 4 260 cu in Emergency Parking Units with Air Brakes All American Forward Engine buses equipped with air brakes employ dual chamber air brakes in the rear whi
39. uch 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 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 an
40. ue BLUE BIRD SERVICE MANUAL SAE GRADE 8 FT LBs SIZE 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 1 6 20 1 2 13 1 2 20 2612 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 1 8 9 14 18 Designated Metric Class 10 9 TORQUE FT LBS Min Max 26 29 5 6 9 10 22 25 53 58 75 83 133 176 302 336 598 BLUE BIRD SPECS 8 MAINTENANCE Non Designated Fasteners Torque Chart Plated Fasteners U S Standards SAE arabe 2 FT LBS SAE arabe 5 FT LBS SAE GRADE 8 FT LBs SIZE Min Max Min Max 1 4 20 2 4 6 1 4 28 5 7 5 16 18 8 13 5 16 24 9 14 3 8 16 15 23 3 8 24 17 26 7 16 14 24 37 60 27 41 3 37 57 1 2 20 4 64 0612 53 82 9 16 18 59 91 5 8 11 73 5 8 18 83 128 3 4 10 129 200 3 4 16 144 223 1 8 9 125 322 14 138 355 138 188 1 12 205 529 1 14 210 541 Non Designated Metric Class 10 9 TORQUE FT LBS SIZE Min Max M4 2 0 2 9 M5 4 2 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 BLUE BIRD SERVICE MANUAL 00 FP ZL Service Precautions This section proscribes safe working practices which must be followed in order to 10 1 0 minimi
41. ve Arm Torque to 80 90 in Ib Inspect amp Torque Comfort Air Suspension Height Control Valve to Frame Bracket Torque to 40 50in Ib Inspect amp Torque Comfort Air Suspension Linkage Rod Assembly Locknut Torque to 80 90 in Ib Inspect amp Torque Comfort Air Suspension Quick Align Bolts Torque to 525 575 ft Ib Inspect amp Torque 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 Torque Comfort Air Suspension Suspension Hanger Torque to 175 ft Ib Inspect amp Torque Comfort Air Suspension Transverse Torsion Rod to Axle Bracket Torque to 90 122 ft Ib Inspect amp Torque Comfort Air Suspension Transverse Torsion Rod to Frame Torque to 90 122 ft Ib Inspect amp Torque Comfort Air Suspension U Bolts Torque 7 8 U Bolts to 400 450 ft Ib Torque 3 4 U Bolts to 285 305 ft Ib Inspect Comfort Air Suspension Whole Assmebly Visually inspect for damage Driveline Inspect amp Torque SPL 100 amp 70 Driveshafts U J oint Bolts Inspect for wear and damage every time vehicle is serviced Torque to 45 50 ft Ib Lubricate SPL 140 Driveshafts U J oint Bolts Grease meeting NLGI Grade 2 grease specifications Inspect amp Torque SPL140 amp 170 Driveshafts U J oint Bolts Inspect for wear and damage every time vehicle is serviced T
42. ysical damage Cooling System Replace Coolant Filter Electrical Inspect Battery Battery Posts Clean and apply anti corrosion agent Exhaust System Inspect Exhaust Pipe J oints Inspect for loose clamps leaks damage Fuel System Replace Fuel Filter Filter Element Clean Fuel Filter Inlet Screen Clean Replace if damaged Steering Lubricate Steering Gear Pitman Arm Pivot NLGI 2 EP multipurpose grease rated GC LB or equivalent Use hand operated grease gun Every 6 Months or 12 000 Miles 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 Adjusters See Haldex lubricant specs in Air Brakes chapter Lubricate Air Brakes Meritor Slack Adjusters See Meritor lubricant specs in Air Brakes chapter BLUE BIRD SERVICE MANUAL D3FE Every 6 Months or 25 000 Miles BLUE BIRD Axle amp Suspension Front Inspect amp Torque AirTek Suspension Air Spring to Air Spring Bracket Torque to 20 30 ft Ib Inspect amp Torque AirTek Suspension Air Spring to Top Pad Torque to 20 30 ft Ib Inspect amp Torque AirTek Suspension Clamp Group Hardware Torque to 285 305 ft Ib Inspect amp Torque AirTek Suspension Front Frame Hanger to Front Leaf Spring Eye Torque to 290 310 ft Ib Inspect amp Torque AirTek Suspension HVC Link
43. ze 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 conformance 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 j
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