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North Carolina School Bus Inspection Manual

1. 30 Engine Controls 31 Gauges Indicators Dash Lights amp Horn 31 Engine Warning Lights and Buzzer 32 Interior Wiring Cab Hoses and Fire Wall Seals 32 General Condition Bus Interior 33 Windshield Wipers amp Washers 34 Heaters Defrosters amp External Driver Fan 34 T Mirror Adjustments amp Condition 35 A Driver s Seat and Belt 35 Passenger Seats 36 B Emergency Door Windows Hatches 37 L Windshield Side amp Rear Windows 37 E Wheelchair Lift Door and Securement System 38 Outside Bus O All Exterior Lights amp Backup Alarm 38 F Clearance Lights Reflectors amp Strobe Light 40 Eight Light Warning System Stop Arm amp Crossing Arm 40 General Condition Bus Exterior 41 Road Test Road Test
2. 42 C O N T E N T S BRAKE TESTING PROCEDURE Inspection criteria for all sections are based upon Federal Motor Carrier Safety Regulations These regulations will be noted at the beginning of each section 393 52 Brake performance A brake performance test shall be performed by an inspector technician on all school buses when PM services are conducted not on monthly inspections a Upon application of its service brakes a motor vehicle or combination of motor vehicles must under any condition of loading in which it is found on a public highway be capable of 1 Developing a brake force at least equal to the percentage of its gross weight specified in the table in paragraph of this section 2 Decelerating to a stop from 20 miles per hour at not less than the rate specified in the table in paragraph c of this section and 3 Stopping from 20 miles per hour in a distance measured from the point at which movement of the service brake pedal or control begins that is not greater than the distance specified in the table in paragraph d of this section b Upon application of its emergency brake system and with no other brake system applied a motor vehicle or combination of motor vehicles must under any condition of loading in which it is found on a public highway be capable of stopping from 20 miles per hour in a distance measured from the point at which movement of the emergency brake control begins that
3. c The distances in column 4 and the decelerations in column 3 are not directly related Brake system application and braking distance in feet column 4 is a definite measure of the overall effectiveness of the braking system being the distance traveled between the point at which the driver starts to move the braking controls and the point at which the vehicle comes to rest It includes distance traveled while the brakes are being applied and distance traveled while the brakes are retarding the vehicle d The distance traveled during the period of brake system application and brake force buildup varies with vehicle type being negligible for many passenger cars and greatest for combinations of commercial vehicles This fact accounts for the variation from 20 to 40 feet in the values in column 4 for the various classes of vehicles e The terms GVWR and GVW refer to manufacturers gross vehicle weight rating and the actual gross vehicle weight respectively Tapley Brake Meter Test for North Carolina School Bus Inspectors REGARDLESS OF THE TYPE OF BRAKING SYSTEM USED ON THE BUS IT MUST BE ABLE TO PRODUCE A BRAKING EFFICIENCY OF AT LEAST 60 PERCENT UNLOADED The purpose of requiring 60 percent braking efficiency is to be able to test the bus without the pupil load Sixty 60 percent braking efficiency is the equivalent of the 43 5 percent braking efficiency required by law with a full load 5 AIR BRAKE CHAMBER STRO
4. Inspect for condition and securement of all chassis and body braces Make repairs if there is any cracked brace underneath the body or if any bumper brace is broken cracked or missing 5 Skirts Inspect body skirts for securement and condition Make repair if any body skirt brace has cracked or broken sheet metal or mounting points 6 Frame Rails Inspect condition of chassis frame rails crossmembers and all hardware attaching points The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if there is any crack in either frame rail or any crossmember if there is any loose or missing rivet or other fastener securing a crossmember to the frame UNDERNEATH BUS EXHAUST SYSTEM 1 Exhaust Leaks With engine running and at operating temperature inspect exhaust system for leaks condition and securement Make repairs if exhaust junction gasket or hardware is broken or missing or if there is any physical damage to exhaust system The vehicle should be taken out of service until repairs can be made if there is any leakage which is audible and can be felt around any portion of the exhaust system including manifold s pipe sections or any junction 2 Mounting Inspect mounting of the exhaust system Make repairs if any of the following conditions exist if there is any exhaust system hanger which is not securely mounted if any exhaust pipe or clamp is loose if any cla
5. Floor Inspect floor covering plywood subfloor if installed aisle and cove molding strips for condition adhesion and or fastening holes or cracks and ribbed rubber aisle Make repairs if any of the following conditions exist if the rubber floor covering is loose deteriorated or cracked if plywood is rotten or soft if cove molding is loose or fasteners are missing The vehicle should be removed from service until repairs can be made if the following exist if there are any unsealed holes or cracks through the underside of the bus if any aisle molding strip is not securely fastened to the floor or aisle or if cove molding presents a sharp edge or protrusion if there is any damage to the rubber floor covering which could cause a tripping hazard if Watch Your Step decal is missing or unreadable flat floor equipped buses only 2 Stepwell Check condition of stepwell and tread Make repairs if step tread is not secure or sealed at inside edge where it meets the next step if stepwell tread and leading edge at aisle is not flush and securely adhered if stepwell tread is worn more than four 4 inches in width The vehicle should be removed from service until repairs can be made if stepwell support structure is broken or stepwell is rusted through 3 Handrails s Check for the presence and secure mounting of entrance handrail s The vehicle should be removed from service until repairs can be made if the entrance handrail s
6. if a tension gauge is used If ruler method is used make repairs if any belt is less than 1 2 inch deflection too tight when firm pressure is applied The vehicle should be taken out of service until repairs can be made if any of the following conditions exist any belt tensioner does not pivot or move freely and apply spring pressure on belt any tension on any belt is too loose based on specifications of type tension gauge used tension of any belt using ruler method is too loose when firm pressure is applied greater than 34 inch deflection Condition Visually inspect belt s for glazing oil contamination dry rotting cuts and separation of plies Check belts for twisting and distortion Make repairs if any of the following conditions exist if any belt is glazed if any belt is oil saturated dry rotted cut or plies of belt s are separated if any belt is distorted or twisted Routing Visually inspect belt s for rubbing or contact with objects other than pulleys and for routing around correct pulleys Make repairs if any of the following conditions exist if any belt is making contact with objects other than pulley s if any belt is routed around incorrect pulley s Belt Alignment Visually inspect belts for proper alignment Make repairs if any belt s is not inline or if any belt s is misaligned and could result in failure ENGINE COMPARTMENT HOSES NOTE References to hoses includes all types of hoses loca
7. 2 pkg 1 inch adhesive compress 16 per pkg 2 pkg 40 inch triangular bandage with two safety pins 2 sets Plastic gloves 1 pair medium and 1 pair large Make repairs if partial contents are missing Remove the vehicle from service if entire contents or kit are missing 3 Body Fluid Cleanup Kit Check the container for condition Check the contents of the box for the following 1 2 oz Package of T I L S C powder sanitizes deodorizes encapsulates 1 odor reducing mask 1 pair latex gloves large 2 antiseptic wipes 2 paper crepe towels 1 scraper 1 plastic disposal bag w scoop and tie Make repairs if partial contents are missing Remove the vehicle from service if entire contents or kit are missing 4 Reflectors Check for emergency roadside reflectors These are required on all buses 2000 and newer Remove the bus from service if reflectors are missing Check quantity for three 3 reflectors INSIDE BUS NEUTRAL SAFETY SWITCH 1 Check to determine if automatic transmission bus has a functional neutral safety switch that will allow the starter to operate only in park or neutral The vehicle should be taken out of service until repairs can be made if the starter will engage in any gear other than park or neutral INSIDE BUS SHIFTER 1 Check that shifter operates easily that it correctly indicates the gear that the transmission is in and has a functional detent mechanism with
8. Key switch in ON position and Engine operating with service Light OFF Brakes applied 2 Check brake pedal reserve distance from floor upon one 1 firm brake application engine off hydraulic boost depleted If brake pedal reserve is less than one 1 inch from floor the vehicle should be removed from service until repaired a Check brake pedal fade continues to fall to floor after initial firm application with engine off If there is any brake pedal fade falling away after initial firm application the bus should be removed from service until repaired b Check all brake hardware and components inside the bus for secure mounting routing and condition including pushrod and clevis assembly brake pedal assembly and rubber cover pad if originally equipped Repair rubber cover if it is worn If rubber cover pad is missing or worn out the bus should be removed from service until repaired c Check the emergency brake control assembly If emergency brake control assembly is hard to operate or doesn t latch and release properly the vehicle should be removed from service until repaired d Parking Brake Operation With vehicle stopped engine running apply park brake When engine torque is applied by placing transmission selector in Drive and accelerating the engine to a fast idle approximately 1 200 rpm s the vehicle should not move forward If park brake doesn t hold or functions improperly the vehicle should b
9. a ball knob handle on end of shift lever Make repairs if any of the following conditions exist Shifter does not shift easily into all gears if indicator is misaligned or if there is a loose ball or knob handle The vehicle should be taken out of service until repairs can be made if shifter will not shift into all gear positions if the indicator indicates wrong gear if detent is non functional or if ball or knob handle is missing from end of shifter lever 30 INSIDE BUS ENGINE CONTROLS 1 2 3 Key Switch Make repairs if the key sticks in switch or if it is loose or not mounted in OEM location The vehicle should be taken out of service if the switch operates without a key or if the bus is equipped with a push button or other devices other than key type switch if the engine will not crank or start or if the switch sticks in any position if the switch doesn t function properly in start run off or accessory position or is intermittent in any position Accelerator Check and insure that accelerator pedal control design and mounting securement are OEM Inspect the pedal assembly and linkage for loose or missing hardware All engines must have two 2 throttle return springs Check for smooth operation of pedal assembly and linkage in the accelerating and coast position Inspect for unauthorized built up pedal i e wooden blocks installed on pedal Make repairs if pedal cover as originally equipped is worn
10. air and hydraulic brake lines for routing securement and condition Make repairs if any of the following conditions exist if brake line bracket s or securement system is loose or missing if any brake line is rubbing on other components or is abraded if any brake line is not of OEM material size or type The vehicle should be taken out of service if any brake line is crimped or damaged significantly and restricting air pressure or hydraulic fluid or if any brake line or connection is leaking air pressure or hydraulic fluid Chambers Inspect front brake chamber assembly ies for securement condition and proper size Make repairs if any front brake chamber or mounting fastener is damaged or loose The vehicle should be taken out of service until repairs can be made if any front brake chamber mounting bracket is cracked bent or broken or if either chamber is not of the original size or size of chambers is not matched left and right both sides should be the same size Slacks Inspect slack adjusters and S cam assemblies for wear condition operation and securement Make repairs if any of the following conditions exist if slack adjuster is mounted so that adjuster bolt is facing chamber if S cam shaft and or S cam bushing total wear up and down is greater that 040 if S cam in and out endplay is more than 060 if slack adjuster s are dirty and prevent technician from inspecting for cracks or prevents the lock sleeve from
11. and reproduce this document for their personnel Anyone else wishing to copy this manual are requested to contact the North Carolina Department of Public Instruction Transportation Services Section NC DPI Transportation Services DRAFT June 15 2000 Z O mH Z les e Table of Contents Brakes Brake Testing Procedure Brake Stroke Measurements amp Brake Adjustment Inside Bus Brake Component Checks Inside Bus Hydraulic Brake System Checks Steering Battery Inside Bus Steering Component Check Outside Bus Steering Component Check Outside Bus Battery Check Hn y gt Engine Compartment Fluid Levels ZIS Air Filter Assembly Power Steering Pump Air Compressor and Filter Water Pump Fan Alternator Fue
12. bumper is missing The vehicle should be taken out of service until repairs can be made if any leaf spring s is broken cracked or missing if any spring eye is worn or spread such that bushings are loose in spring eye If any coil spring s is broken or insecurely mounted or non OEM blocks or spacers are installed if there is any misalignment of spring leaves or other evidence that center pin is loose or broken if either front coil or leaf spring is worn so that the rubber frame bumper is damaged or worn due to frequent bottoming of front suspension if any alignment wedge is loose or damaged if on any air bag type spring assembly air bag is damaged or leaking 12 Wheel Seals Check for condition and leakage Make repairs if either front wheel seal is damaged or leaking 18 UNDERNEATH BUS FRONT BRAKES 1 2 3 4 5 6 7 Brake Hoses Inspect front brake flexible hoses for condition securement and routing Make repairs if any of the following conditions exist if any front brake flex hose supporting brackets are damaged or have loose fasteners if any front brake flex hose is rubbing or routed against other components The vehicle should be taken out of service until repairs can be made if any front brake flex hose or connection is leaking fluid or air pressure if any front brake flex hose is kinked collapsed bulging has damaged plies or cord or is damaged below outer covering Lines Inspect
13. cover pad is worn The vehicle should be removed from service if the clutch pedal cover pad is missing c Check clutch master and slave cylinders for hydraulic leaks and operation The vehicle should be removed from service if either the master or slave cylinders are leaking or inoperable 7 Clutch Adjustment if equipped a Check free play travel of the clutch pedal This is the first easy movement of the clutch pedal and should be no more than 1 2 inches and no less than 3 4 inch of travel Repairs should be made if no adjustment can be made 21 UNDERNEATH BUS FLUID LEAKS 1 2 3 4 Oil Inspect for engine oil leaks at all potential locations and determine severity Make repairs if any of the following conditions exist if engine oil leakage is causing deterioration of any rubber parts such as steering linkage boots hoses etc if engine oil is dripping at any location except on exhaust system The vehicle should be removed from service until repairs can be made if engine oil is dripping on any portion of exhaust system Coolant Inspect all potential locations for coolant leaks Make repairs if there is coolant seepage at radiator hoses heater core engine oil cooler thermostat housing head gaskets freeze plugs reservoir water pump or other potential locations The vehicle should be removed from service until repairs can be made if the coolant leakage is excessive and could result in imminent en
14. damaged or any protruding window hardware into the passenger compartment Sun Visor Check drivers sun visor for condition and operation Make repairs if sun visor is too tight and cannot be adjusted or if driver sun visor is cracked damaged clouded dirty or will not stay in position or has unauthorized stickers INSIDE BUS WHEELCHAIR LIFT DOOR AND SECUREMENT SYSTEM 1 2 3 Operate lift through complete cycle and inspect for proper operation condition safety features manual backup system fluid leaks mounting barrier operation warning light buzzer operation and overall mechanical condition Make repairs if any of the following conditions exist if dome light at inside lift area is inoperative if lift door or latch does not operate smoothly if there is any fluid seepage at the lift if white light if equipped at exterior lift area is inoperative if lift control cable or wiring is damaged or routed improperly if lift does not fold unfold lift and lower properly or jerks and binds if lift leaks fluid onto or below floor if there is excessive side play more than two 2 inches in the lift mechanism when the platform is partially or fully extended if the lift jacks up the vehicle if manual backup system does not function properly The vehicle should be removed from service until repairs can be made if elevator lift platform is not flush with floor in up position if any part of the lift mechanism or hard
15. damaged or missing Check the pitman arm for looseness or Pitman arm grease fitting if originally Any play is observed between pitman arm misalignment at sector shaft splines and equipped is loose or missing repair and sector shaft looseness at all joints Check looseness of pinch bolt and fasteners and condition of Pinch bolt at sector shaft is loose or missing pitman arm Pitman arm to sector shaft timing marks are misaligned 11 Inspection Procedures Repair or note If Out of Service if Drag Link Check the drag link ends shaft and fasteners for looseness and condition on vehicles with I beam suspension Any drag link end grease fitting as equipped is loose or missing or will not take grease repair Drag link end boot is damaged or missing repair Drag link needs lubrication repair Drag link dust boot as originally equipped is cut damaged or missing repair Drag link ball stud is loose in pitman arm or upper steering arm Any nut is loose or missing or cotter pin is missing Drag link shaft is damaged or bent Drag link end non adjustable type has more than 1 16 inch axial not rotational play Horizontal socket type adjustable drag link end has more than 1 16 inch axial or laterial play Steering Arm 1 Check upper steering arm Ackerman arm and left and right side lower steering arms for securement and condition 2 Check condition and securement of steering s
16. drum or if any drum is not mounted securely to hub or fasteners are loose 19 8 9 Rotors Inspect front brake rotor s for mounting and condition Make repairs if the following conditions exist if rotor mounting is not secure if friction surface is contaminated with oil grease or brake fluid if any rotor friction surface is significantly grooved or damaged Wheel Cylinders or Calipers Inspect wheel cylinder s or caliper s for leaks and mounting and condition Make repairs if any wheel cylinder or caliper is not securely mounted or has loose or missing fasteners if there is uneven brake lining or brake pad wear evidence of rotor or drum damage evidence of dragging or other evidence that any wheel cylinder or caliper may be sticking 10 Brake Adjustment a For air wedge brakes or hydraulic drum brakes adjust front brakes at every monthly inspection as follows Brakes must be adjusted until brake drum does not turn then back off brake adjustment until there is slight drag on drum surface 020 clearance between lining and drum The vehicle should be removed from service if there is any damage or condition that prevents proper adjustment of air wedge or hydraulic drum brakes b For S cam or air disc brakes at every monthly inspection brake chamber pushrod travel must be checked see Air Brake Chamber Stroke Measurements page 4 6 at all four wheel positions and brakes must be adjusted as necessary to achieve
17. for condition mounting securement and adjustment of linings drum linkage and all other related hardware Make repairs if any of the following conditions exist if lining is worn down to 2 32 inch from top of rivet head if lining is contaminated with grease or oil The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if lining is broken cracked or loose if drum is cracked or has excessive heat damage or scoring of friction surface if any actuating or mounting hardware or 23 fastener is damaged loose or missing if park brake is not adjusted per manufacturer s specifications UNDERNEATH BUS REAR SUSPENSION 1 2 3 4 5 6 7 8 Axle Housing Inspect axle housing for condition and leakage Make repairs if there is leakage at or around axle housing ends The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any portion of axle housing is cracked or bent if any portion of axle housing is leaking lubricant due to cracks porous metal or defective weld Vent Inspect condition of axle housing vent Make repairs if vent cap is clogged or if vent hose if originally equipped is cracked clogged or missing Differential Inspect differential assembly for condition lubricant level and leakage Make repairs if any of the following conditions exist if lubricant level is low if diff
18. from service until repairs can be made if bus is not equipped with the following lettering or it is not readable e School Bus 8 letters on front and rear e North Carolina Public Schools 6 letters on both sides e County or School Unit Name 3 letters below North Carolina Public Schools on both sides e Bus Number 6 letters on front sides and rear e Emergency Door 2 letters on all emergency doors 8 Emergency Door Operation Check emergency door for operation from exterior of bus Make repairs if emergency door latch mechanisms or hinges need lubrication Remove the vehicle from 41 service until repairs can be made if emergency door latch mechanism requires more than 40 pounds to release or if emergency door handle is mounted horizontally to allow hitching onto the bus 9 Engine Hood Check hood for operation condition and safety latch Make repairs if any of the following conditions exist if hood is misaligned or rubbing cowl if hood hinges are not lubricated or are damaged Repair if any bumper or securement device is damaged or missing The vehicle should be removed from service until repairs can be made if the hood cannot be opened as designed if the safety latch does not secure hood if hood prop rod or hold open feature does not function properly 10 Cleanliness Check exterior of bus for cleanliness Make repairs if the exterior of the bus is dirty T
19. if slack adjuster is mounted so that adjuster bolt is facing chamber if S cam shaft and or S cam bushing total wear up 25 5 6 7 8 9 and down is greater than 040 if S cam in and out endplay is more than 060 The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any portion of slack adjuster or S cam is missing broken cracked or badly worn if S cam snap ring is missing if slack adjuster has frozen or stripped worm gear or ratchet assembly Pushrods Inspect pushrod assembly ies for condition securement and alignment Make repairs if pushrod is rubbing against body of chamber or chamber is misaligned The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any portion of pushrod assembly locknut pushrod clevis and pin or cotter pin is loose missing or damaged if pushrod on left and right sides are not mounted in identical same slack adjuster location holes same effective slack adjuster length Linings Inspect brake lining through inspection cover or hole Make repairs if any of the following conditions exist if friction surface is contaminated with oil grease or brake fluid if lining is worn to within 1 8 inch of shoe table riveted type shoe if lining is worn to within 1 16 inch of shoe table bonded type lining The vehicle should be taken out of service if lining is br
20. is not greater than the distance specified in the table in paragraph d of this section c Conformity to the stopping distance requirements of paragraphs a and b of this section shall be determined under the following conditions 1 Any test must be made with the vehicle on a hard surface that is substantially level dry smooth and free of loose material 2 The vehicle must be in the center of a 12 foot wide lane when the test begins and must not deviate from that lane during the test d Vehicle brake performance table Service Brake Systems Emergency Brake Systems Type of Motor Vehicle Braking force as a Deceleration in Application and Application and Percentage of gross feet per second braking distance Braking distance Vehicle or combination per second in feet from in feet from weight initial speed of 20 initial speed of 20 2 m p h 4 m p h 5 A Passenger carrying vehicles 1 Vehicles with a seating capacity of 10 Persons or less including driver and built on a passenger car chassis 2 Vehicles with a seating capacity of more Than 10 persons including driver and Built on a passenger car chassis vehicles Built on a truck or bus chassis and having a manufacturer s GVWR of 10 000 pounds 3 All other passenger carrying vehicles B Property carrying vehicles 1 Single unit vehicles having a manufacturer s GVWR of 10 000 pounds or less 2 Single unit vehicles having a manufacturer s GVWR of
21. less than or equal to the maximum pushrod travel The vehicle should be removed from service if there is any damage or condition that prevents proper adjustment of S cam or air disc type brakes c Automatic slack adjusters ASA must be checked as follows Check the pushrod travel before any adjustment is made If needed manually adjust the ASA Make repairs if slack adjuster travel is beyond stated limit prior to adjustment The vehicle should be removed from service if any automatic slack adjuster arm or mechanism is damaged or loose If adjusted stroke pushrod travel of any automatic slack adjuster equipped brake exceeds maximum shown in charts on pages 4 6 UNDERNEATH BUS ENGINE TRANSMISSION MOUNTS STARTER MOUNTING 1 2 Engine Transmission Mounts Inspect engine and transmission mounts for condition and securement Repairs should be made if the following conditions exist Any mounting fasteners are loose missing or broken if any mount is cracked or has deteriorated rubber Starter Mounting Inspect starter for securement and condition Check for presence of heat shield if equipped Make repairs if any of the following conditions exist if heat shield is loose if any starter mounting bolts studs or nuts are loose damaged missing or broken if starter is loose or damaged if heat shield is missing if equipped 20 UNDERNEATH BUS TRANSMISSION CHECKS 1 Transmission Bolts Inspect transmission as
22. more than 10 000 pounds except truck tractors Combinations of a 2 Axle towing vehicle and trailer having a GVWR of 3 000 pounds or less All combinations of 2 or less vehicles in a driveaway or towaway operation 3 All other property carrying vehicles and Combinations of property carrying vehicles NOTE a There is a definite mathematical relationship between the figures in columns 2 and 3 To obtain the percentage of braking force take the deceleration number and divide by 32 2 feet per second For example 21 divided by 32 2 equals 65 2 percent Column 2 is included in the tabulation because certain brake testing devices utilize this factor b The decelerations specified in column 3 are an indication of the effectiveness of the basic brakes and as measured in practical brake testing are the maximum decelerations attained at some time during the stop These decelerations as measured in brake tests cannot be used to compute the values in column 4 because the deceleration is not sustained at the same rate over the entire period of the stop The deceleration increases from zero to a maximum during a period of brake system application and brake force buildup Also other factors may cause the deceleration to decrease after reaching a maximum The added distance which results because maximum deceleration is not sustained is included in the figures in column 4 but is not indicated by the usual brake testing devices for checking deceleration
23. on Air Brake Equipped Vehicles 1 2 3 4 5 6 Air Pressure Gauges On buses built after March 1975 check for the presence of two 2 gauges or single gauge with dual needles One 1 gauge or needle should indicate air pressure available to the front air brake system and the other should indicate air pressure available to the rear brake system Both gauges must be accurate to within 7 at 100 lbs X 7 71bs Note If bus is equipped with anti lock braking system refer to appropriate Manufacturer s Service Manual for inspection criteria Air Compressor Governor Check air brake system governor operation While building up system air pressure note pressure at which governor cuts out compressor quits compressing With engine still running pump brakes to lower air pressure until governor cuts in starts compressing again Note pressure If cutout pressure is below 120 p s i For buses equipped with air dryer system it needs to be repaired If the cutout pressure is too low below 100 p s i or too high above 130 p S i it should be repaired before operating Air Compressor Operation Air reservoir should be drained thoroughly before making this check Check time required for system air pressure to build up from 85 to 100 psi with engine at fast idle approximately 1 200 R P M Repairs should be made if time for system buildup 85 100 p s i exceeds 40 seconds Air compressor should also be checked f
24. or deteriorated to the point that failure could occur 4 Auxiliary Filter Inspect transmission external filter assembly if equipped for securement and condition Make repairs if any of the following conditions exist if external filter mounting is insecure or has loose or missing fasteners or if the filter canister is damaged The vehicle should be taken out of service until repairs can be made if the body of the transmission cooler including all hose connections is cracked or damaged 5 Cooler Inspect transmission cooler as equipped for securement and condition Make repairs if the mounting of separate transmission cooler if equipped is insecure or has loose or missing fasteners 6 Clutch Operation if equipped a Check pedal linkage and clutch and release bearing for wear slippage and abnormal noises in the engaged and released positions Make repairs if the following conditions exist if there are loose bolts or nuts if the release bearing is noisy if the clutch is out of adjustment The vehicle should be taken out of service until repairs can be made if and of the following conditions exist the clutch cannot be adjusted to specifications the release bearing is excessively noisy the clutch is slipping grabbing or has excessive chatter when engaging clutch if the linkage or return spring is binding or sticking if the transmission is hard to shift b Visually check clutch pedal pad for wear Make repairs if the pedal
25. or loose 15 ENGINE COMPARTMENT ALTERNATOR 1 Check securement and condition of alternator assembly Make repairs if alternator is noisy or if any portion of the alternator mounting bracketry or fastener is cracked loose or missing 2 Routing and Condition Check routing securement and condition of all wiring and any electrical cable in the engine compartment Make repairs if any of the following conditions exist if there is any loose damaged or corroded wiring connector or terminal end if any repair has been made using improper gauge wiring The vehicle should be taken out of service until repairs can be made if there is any unsecured or poorly routed wiring that could cause a potential short or fire due to abrasion or heat damage or if there is any burnt wiring or wiring other than ground wires missing insulation ENGINE COMPARTMENT FUEL SYSTEM AND LINES 1 Visually check the condition operation and securement of all fuel system components including fuel lines and routing in the engine compartment Make repairs if any of the following condition s exist there is evidence of dirt algae or water in the fuel water separator if equipped if there is any or unsecured or poorly routed or loose fuel line or hose that could cause potential fire due to abrasion or heat damage The vehicle should be removed from service if any fuel system connection is stripped loose cracked or leaking ENGINE COMPARTMENT R
26. the proper type if any warning light lens is damaged and white light is visible if any warning light lens has darkened faded is misaimed or is dirty affecting the color of the light or reducing the visibility to less than 500 feet in bright sunlight if warning lights do not function 2 Stop Arm Check stop arm for specifications operation fully extends to 90 degrees and condition Make repairs if any of the following conditions exist if wiring ground strap is loose or not properly routed and secured if hinge or bushing s is dry of lubrication if stop arm assembly or blade mounting is loose if stop arm extends more or less than 90 degrees if stop arm does not fully extend or retract or is slow if air operated stop arm diaphragm has an air leak if any stop arm paint or decal is significantly faded or discolored The vehicle should be removed from service until repairs can be made if any stop arm light does not flash or does not flash between 60 and 120 timer per minute or if stop arm does not operate as required 3 Crossing Control Arm Crossing arms required on all 1977 and newer buses Check front bumper mounted student crossing arm for operation condition and mounting Make repairs if crossing arm mount bolts are loose if hinge bushings need lubrication or are damaged if air leaks from air operated diaphragm The vehicle should be removed from service until repairs can be made if any of the following conditions exist
27. 184mm 2 5 64mm 8 3 32 206mm 2 5 64mm For 3 maximum stroke type 24 chambers NOTE A brake at the adjustment limit is not a violation TIE ROD STYLE PISTON BRAKE CHAMBER DATA OUTSIDE BRAKE ADJUSTMENT LIMIT DIAMETER 6 1 2 165MM 2 5 64mm NOTE A brake at the adjustment limit is not a violation 6 BOLT TYPE BRAKE CHAMBER DATA OUTSIDE DIAMETER 6 15 16 176mm 9 3 16 234mm 8 1 16 205mm 5 1 4 133mm 6 3 16 157mm 11 279mm 9 7 8 251mm BRAKE ADJUSTMENT LIMIT 1 3 8 35mm 1 3 4 45mm 1 3 4 45mm 1 1 4 32mm 1 3 8 35mm 2 1 4 57mm 2 51mm NOTE A brake at the adjustment limit is not a violation ROTOCHAMBER DATA OUTSIDE DIAMETER 4 9 32 109mm 4 13 16 122mm 5 13 32 138mm 5 15 16 151mm 6 13 32 163mm 7 1 16 180mm 7 58 194mm 8 7 8 226mm BRAKE ADJUSTMENT LIMIT 1 1 2 38mm 1 1 2 38mm 2 51mm 2 51mm 2 51mm 2 1 4 57mm 2 3 4 70mm 3 76mm NOTE A brake at the adjustment limit is not a violation DD 3 BRAKE CHAMBER DATA OUTSIDE DIAMETER BRAKE ADJUSTMENT LIMIT 8 1 8 206MM 2 1 4 57MM NOTE This chamber has 3 airlines and is found on motor coaches NOTE A brake at the adjustment limit is not a violation INSIDE BUS BRAKE COMPONENT CHECK Air Brakes All of the following items should be inspected
28. ADIATOR 1 Radiator Mounting Check radiator assembly and mounting for securement and condition Make repairs if any portion of the radiator or mounting system is cracked damaged or has loose or missing fasteners 2 Cap Check condition of radiator cap Warning always use proper procedures when removing radiator cap Make repairs if any of the following conditions exist the radiator cap is hard to open or close The radiator cap leaks down slowly at psi rating the radiator cap is of the wrong psi rating if there is visible damage to the pressure seat or vacuum relief seat of the cap The vehicle should be taken out of service if the radiator cap is missing 3 Reservoir Check coolant reservoir including any deaeration or overflow tank and sight glass if equipped for mounting and condition Make repairs if any portion of the coolant reservoir or mounting system is cracked or damaged is leaking or has loose or missing fasteners 4 Fan Shroud Check fan shroud for mounting and condition Make repairs if any portion of the fan shroud or shroud mounting is cracked damaged or has loose or missing fasteners or if fan shroud is missing 16 UNDERNEATH BUS FRONT SUSPENSION CHECKS 1 Wheel Bearings Inspect front wheel bearings and related components for condition and proper adjustment of bearings With front wheels raised wheels unloaded grasp tire and attempt to rock wheel to check for movement Spin tire
29. KE MEASUREMENTS amp BRAKE ADJUSTMENT Another way to determine if the brakes require adjustment is to measure the at rest and applied distance of the brake push rods The procedure is to bring reservoir pressure between 90 and 100 psi 620 690KPA turn the engine off release the park brake and take an at rest measurement from the end of the brake chamber to the center of the push rod clevis Re apply the brakes and check the measurement again at the same points Subtract the difference and this would be your applied stroke You then check the chart for the appropriate brake chamber and determine if the brake needs adjusting Refer to manufacturers service manual for correct brake adjustment procedure Commercial Vehicle Safety Alliance North American Uniform Out Of Service Criteria Reference Charts CLAMP TYPE BRAKE CHAMBER DATA OUTSIDE BRAKE ADJUSTMENT LIMIT DIAMETER 4 1 2 114mm 1 1 4 32mm 5 1 4 133mm 1 3 8 35mm 5 11 16 145mm 1 3 8 35mm 6 25 32 172mm 1 3 4 45mm 7 7 32 184mm 1 3 4 45mm 8 3 32 206mm 2 51mm 9 229mm 2 1 4 57mm 6 3 8 162mm 1 3 4 45mm NOTE A brake at the adjustment limit is not a violation LONG STROKE CLAMP TYPE BRAKE CHAMBER DATA OUTSIDE BRAKE ADJUSTMENT LIMIT DIAMETER 5 11 16 14 5cm 1 3 4 4 5cm 6 3 8 162mm 2 0 51mm 6 25 32 172mm 2 0 51mm 7 7 32 184mm 2 0 51mm 7 7 32
30. North Carolina School Bus Inspection Manual Regulations And Procedures ATTENTION This manual has been developed for those engaged in school bus inspection with the goal of inspection uniformity thereby increasing the likelihood that fewer buses will be operated in an unsafe condition The regulations described herein are accurate and complete excerpts of the Official Motor Vehicle Inspection Regulations dealing specifically with the procedures for school bus inspection North Carolina General Statute 115C 248 a states the following The superintendent of each local school administrative unit shall cause each school bus owned or operated by such local school administrative unit to be inspected at least once each 30 days during the school year for mechanical defects or other defects which may affect the safe operation of such bus This means that each school and activity bus being operated is required an inspection each 30 calendar days The State Vehicle Fleet Management System schedules buses for inspection and causes them to appear 7 days before they exceed the required 30 day interval This should give technicians ample time to conduct the inspection before they are in violation of N C G S 115C 248 a Any questions comments or inquiries regarding this inspection manual should be directed to the North Carolina Department of Public Instruction Transportation Services Section All North Carolina School systems may copy
31. accurate damaged or difficult to read if odometer doesn t work or is not working properly or if odometer is unreadable Make repairs if tachometer fails to function properly The vehicle should be removed from service until repairs can be made if oil or temperature gauges do not function or are unreadable if speedometer doesn t work or is confirmed to be inaccurate or if speedometer is unreadable or damaged if air pressure gauge is inaccurate unreadable or not working 31 2 Indicators and Dash Lights Check for the presence and operation of the following indicators A Low air pressure B High beam light C Left and right turn signal and 4 way hazard D All dash and control panel lights for illumination at gauges and switches Make repairs if the light bulb for the following gauges or control is inoperative oil pressure temperature fuel voltmeter ammeter or engine shutdown Make repairs if one or more lights for the control switches are inoperative or one or more panel lights is inoperative 3 Horn Check horn and horn button for proper operation Make repairs if horn fails to operate properly INSIDE BUS ENGINE WARNING LIGHTS AND BUZZER Check for presence and operation of the following warning lights and buzzer or bell A High coolant temperature dash warning light or buzzer or bell on diesel buses The vehicle should be removed from service until repairs can be made if high coolant temperature warning lig
32. amination is drained Make repairs if there is moisture in reservoir desiccant type air dryer equipped vehicles only Repair if excessive oil is found in air system The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if the safety valve leaks or does not release pressure if there is excessive sludge or oil contamination in the reservoir more than 8 fluid ounces if reservoir leaks due to corrosion or is cracked UNDERNEATH BUS DRIVELINE 1 Driveshafts Inspect driveshafts for condition Make repairs if any of the following conditions exist if any driveshaft balancing weight if originally equipped is missing if there is any foreign matter wrapped around driveshaft The vehicle should be taken out of service until repairs can be made if any driveshaft is bent or seriously dented or if there are cracks or other damage in the driveshaft which could cause structural failure 2 U Joints Prior to lubrication inspect U joints or constant velocity CV joints if equipped for condition phasing alignment of joints lubrication and presence of all hardware Make repairs if U joints or constant velocity joints are dry of lubrication or zerk grease fitting if equipped is missing clogged or inaccessible The vehicle should be taken out of service until repairs can be made if any of the following exist if there is any missing hardware or fasteners in any U joint or CV join
33. ce if there is any damage or condition that prevents proper adjustment of air wedge or hydraulic drum brakes b For S cam or air disc brakes at every monthly inspection brake chamber pushrod travel must be checked see Air Brake Chamber Stroke Measurements page 4 6 at all four wheel positions and brakes must be adjusted as necessary to achieve less than or equal to the maximum pushrod travel The vehicle should be removed from service if there is any damage or condition that prevents proper adjustment of S cam or air disc type brakes c Automatic slack adjusters ASA must be checked as follows Check the pushrod travel before any adjustment is made If needed manually adjust the ASA Make repairs if slack adjuster travel is beyond stated limit prior to adjustment The vehicle should be removed from service if any automatic slack adjuster arm or mechanism is damaged or loose or if adjusted stroke pushrod travel of any automatic slack adjuster equipped brake exceeds maximum shown in charts on pages 5 7 26 UNDERNEATH BUS BODY SECUREMENTS AND STRUCTURE 1 Body Holddowns Inspect for securement and condition of all body holddowns chassis cowl mounts and frame pads Body holddowns include any J bolt U bolt or clamp type holddown used to secure body to chassis frame Make repairs if any of the following conditions exist if any body holddown is loose or misaligned or there are any cracks or stripped fasteners at floor sill secure
34. d or is dirty significantly affecting the visibility or color of the light 2 Reflectors Check reflectors for condition and location Reflectors are required as follows a Buses over 30 in length two 2 red on rear one 1 intermediate amber on side b Buses under 30 in length is same except intermediate amber is not required Make repairs if any of the following conditions exist if any reflector is damaged or cracked if any required reflectors are missing if any red reflector is faded significantly affecting it s original color 3 Strobe Light Check roof mounted white flashing strobe light if equipped for operation location and condition Make repairs if the strobe light does not function Strobe lights required on all 1998 and newer buses OUTSIDE BUS EIGHT LIGHT SYSTEM STOP ARM amp CROSSING ARM 1 Eight Light Warning System Lights Check eight light warning system lights for operation and condition Make repairs if any of the following conditions exist if any amber or red pilot light fails to function if any light hood if equipped is damaged so that it obstructs visibility of the light The vehicle should be removed from service until repairs can be made if any of the following conditions exist if any amber or red light does not function or is dim if amber red lights both front and rear do not alternately flash side to side if any warning light is not red outer or amber inner or is not
35. d and not suspended With engine running have an assistant move the steering wheel back and forth repeatedly to load steering components Visually observe the following external steering and related suspension and frame components for looseness while the assistant works steering also see specific procedures under each component a Column shaft hardware and steering linkage boots b Column U joints or flexible coupling as equipped c Coupling at steering gearbox d Steering gearbox e Pitman Arm f Drag link g Steering knuckle or arms h Tie rod ends i Idler arm as equipped j Check the vehicle frame cross members and frame cross members and frame braces including associate rivets and fasteners for looseness and condition 2 Have assistant carefully operate steering to full left and right turn and check for power assist pop off and steering stops 3 As a follow up to the above steering check also perform a visual and hands on check of each of the listed components See the following chart for details of component inspection Inspection Procedures Repair or note If Out of Service if Steering Gear Box Mounting Check mounting condition and Steering gear box is loose ightness of steering gear box and check frame frame braces and associated There is any binding in steering gear box rivets or fasteners for looseness land condition Frame frame braces and associated rivets or fasteners are loose
36. e by the time the pressure drops to 50 psi Start the engine and build system air pressure Warning buzzer and light should deactivate by 70 psi If either light or buzzer is inoperative or buzzer fails to operate by 50 psi or continues to operate above 70 psi the vehicle should be repaired before operating Note If air brake gauge failed previous check for accuracy do not perform this check until gauge is repaired Hydraulic Brakes All of the following items should be checked on hydraulic brake equipped vehicles 1 Any visible leaks in the brake or hydraulic assist system If any leaks are found in the brake or hydraulic system the vehicle should be taken out of service until repaired Check the brake warning and backup systems using the appropriate manufacturer procedure below Brake Failure Warning System Check NAVISTAR CONDITION NORMAL OPERATION PARK BRAKE LIGHT Key switch in START position Light ON w park brake released Bulb check Key switch ON w park brake Light ON applied BRAKE PRESSURE LIGHT Key switch OFF Light OFF electric hydraulic Pump operates when service Brakes are applied Key switch in ON position Light ON and electric hydraulic Engine not operating pump Pump operation some vehicles and bulb check SEE NAVISTAR MANUAL Light ON and electric hydraulic Pump operates when service Brakes are applied Key switch in START position Light ON momentarily and Electric hydraulic pump operates
37. e if taillight circuit fails to function or if any tail light lens is not red or is not proper type meeting SAE specifications Backup Lights Check backup lights for proper operation and condition Make repairs if either backup light doesn t function or if any backup lens is cracked The vehicle should be removed from service if the bus is not equipped with functional white backup lights or if backup light s stay on all of the time or stay on in any gear position other than reverse Backup Alarm Check operation and condition if equipped of backup alarm Check operation by placing transmission selector in reverse gear engine running and listening for audible alarm sound Make repairs if backup alarm doesn t function properly Backup alarms required on all 1997 and newer buses Parking Lights Check parking lights if equipped for proper operation Make repairs if any of the parking lights if equipped are inoperable or if any park light lens is cracked or broken 39 OUTSIDE BUS CLEARANCE LIGHTS REFLECTORS amp STROBE LIGHT 1 Clearance and Marker Lights Check light s and lens for operation condition and location Make repairs if any of the following conditions exist if any clearance light fails to function If any clearance light lens is damaged or white light is visible if any rear clearance light lens is not red or any intermediate or front lens is not amber if any clearance light lens has darkened fade
38. e removed from service until repaired INSIDE BUS STEERING COMPONENT CHECK Check for play in the steering system at the steering wheel using the following procedures 1 Visual check from inside the bus with the engine running rotate the steering wheel lightly from side to side until the turning motion can be observed at the tires and note free play lash at the steering wheel outer diameter This procedure must be performed with the vehicle on the ground If steering wheel is cracked plastic in the contact area it must be repaired If free play lash exceeds the amounts specified in the chart below the vehicle should be taken out of service until repaired Federal Motor Carrier Safety Regulations 393 209 STEERING WHEEL PLAY LASH MEASUREMENTS Steering Wheel Size Free Play Lash Measurements Power Assist 16 or less 18 20 22 Note For power systems if steering wheel movement exceeds 45 degrees before steering axle tires move proceed as follows Rock steering wheel left to right between points of power steering valve resistance If that motion exceeds 30 degrees the vehicle should be placed out of service until repaired To check power assist operation run the engine at fast idle and turn steering wheel a full right and left turn and feel for binding jamming or belt slippage 2 Column check steering column inside the bus for up and down play parallel to shaft side to side play perpend
39. e same type e g lug or rib and size if any tire is below minimum load rating if radial and bias ply tires are intermixed on the same axle Alignment Inspect tires for evidence of proper alignment Make repairs if any tire is feather edged cupped or has uneven tread wear or if lateral runout of any tire rim assembly exceeds 4 inch The vehicle should be removed from service until repairs can be made if tires wheels are grossly misaligned affecting steering Wheel Hardware Inspect for presence type condition and securement of all wheel hardware Check for proper spacing or rear dual wheels and tires The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if there is improper matching of rims and lock rings if there is evidence of slippage of wheel assembly on cast spoke hub if stud holes are elongated If any wheel or stud is loose or there is rust or corrosion indicating possible looseness if any wheel stud or nut is broken or missing if an improper spacer has been installed between dual wheels Color and Condition Paint color on wheel assemblies of North Carolina School Buses shall remain black If color other than black is detected or if wheels are faded repairs should be made as soon as possible INSIDE BUS EMERGENCY EQUIPMENT 1 Fire Extinguisher Check for presence of fire extinguisher Check the gauge for the correct pressure Check for presence o
40. ead groove Measurement shall not be taken at a wear bar and all three 3 points shall be less than 4 32 inch before tire is rejected Measurement shall be taken at the most worn groove of the tire if measured tread depth of either front tire is 2 32 inch or less 1 32 inch for rear tires measured at the most worn single point of the tire except at wear bar If there is evidence that any recapped tire has been re grooved if any front tire is a recapped or re grooved type tire if there is evidence that any tire has been re grooved using a procedure not approved by the tire manufacturer or dealer 2 Pressure With tire cold check pressures on all tires and record on inspection form Make repairs if any of the following conditions exist if pressure in any tire is less than the maximum cold inflation pressure stated on the sidewall of the tire minus 20 if pressure in any tire is greater than 5 above maximum cold inflation pressure stated on sidewall of the tire Adjust pressure if there is more than a 20 difference in pressure tires on a particular axle 3 Damage Inspect for damage to wheels and tires Make repairs if any of the following conditions exist if there is foreign material in the tire tread which could cause damage or loss of air pressure if any valve cap or extension is missing if there are minor dents or bends in a rim The vehicle should be taken out of service until repairs can be made if any of the following conditio
41. erential gaskets or seals are leaking if any external differential hardware or fasteners are loose or missing The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if there is no lubricant in the differential if differential pinion yoke has endplay or side play exceeding manufacturer s specifications if pinion yoke end nut is loose or missing Springs Inspect rear springs for condition securement and alignment Make repairs if any of the following conditions exist if there are any loose missing broken or worn spring clips if any leaf spring or air suspension ride height is less than manufacturer s specifications if rubber frame bumper is missing The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any leaf spring is broken or missing if on any air bag type spring assembly air bag is damaged or leaking or airlines and valving are damaged or leaking if there is any misalignment of spring leaves or other evidence that centering pin is loose or broken if either rear leaf spring is worn to the point that suspension bottoming has damaged rubber frame bumper U Bolts Inspect spring U bolts for condition and securement Make repairs if any U bolt is misaligned or if there is rust underneath U bolt nuts indicating possibility of looseness The vehicle should be taken out of service until repairs can be made if any U b
42. f inspection sticker or tag and inspection date Check for secure mounting and accessibility Check for proper UL Underwriters Laboratory rating Check the nozzle for looseness or damaged parts Check for the presence of a safety pin and tamper proof seal Make repairs if any of the following conditions exist if bracket mount to panel is loose if inspection will expire before next scheduled inspection if pressure is above or below the green zone if fire extinguisher is not accessible to driver or not secured in mounting bracket or box The vehicle should be taken out of service until repairs can be made if the rating is less than 2 1 2 pound minimum and 10BC rating if there is no fire extinguisher on bus if tamper proof seal material cannot be broken NOTE Six 6 years from the manufacturing date all type ABC BC or Halon fire extinguishers require a six 6 year maintenance They are also required to have a hydro test twelve 12 years from the manufacturing date To determine the manufacturing date look for a stamped date on the bottom of the cylinder on the label or around the rim These are required to meet National Fire Protection Association NFPA requirements in pamphlet 10 and OSHA requirements 29 2 First Aid Kit Check the box and condition Check to insure that the box is labeled as First Aid Kit Check the contents of the box for the following 2 pkg 4 inch bandage compresses 2 pkg 2 inch bandage compresses
43. fluid or air pressure if any rear brake hose is kinked collapsed bulging has damaged plies or cord or is damaged below outer covering 2 Lines Inspect air and hydraulic brake lines for routing securement and condition Make repairs if any brake line s or securement system is loose or missing or if any brake line is rubbing on other components or is abraded The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any brake line is bent crimped or damaged significantly restricting air pressure or hydraulic fluid if any brake line or connection is leaking air pressure or hydraulic fluid if any brake line is not of OEM material size or type 3 Chambers Inspect rear brake chamber assembly ies for securement condition and proper size Make repairs if any rear brake chamber or mounting fastener is damaged or loose The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any rear brake chamber mounting bracket is cracked bent or broken if either chamber is not original size or size of chamber is not matched both sides to be same size 4 Slacks Inspect slack adjusters and S cam assemblies for wear condition operation and securement Make repairs if any of the following conditions exist if slack adjuster s are dirty and prevent technician from inspecting for cracks or prevents the lock sleeve from seating
44. gine failure Transmission Inspect for transmission fluid leaks at all potential locations and determine severity Make repairs if transmission fluid is causing deterioration of any rubber parts such as steering linkage boots hoses etc or if transmission fluid is seeping at any location except on exhaust system The vehicle should be removed from service until repairs can be made if transmission fluid is dripping on any portion of the exhaust system Power Steering Inspect the power steering for power steering fluid leaks at all potential locations and determine the severity Make repairs if power steering fluid is causing deterioration of any rubber parts such as steering linkage boots hoses etc or if power steering fluid is seeping The vehicle should be removed from service until repairs can be made if the power steering fluid is dripping UNDERNEATH BUS FUEL TANK 1 2 3 4 Leaks Inspect fuel tank assembly for leaks The vehicle should be taken out of service until repairs can be made if any of the following conditions exist there is any fuel leakage from the tank connections or cap if the fuel tank has any cracks if any connection s are loose at the tank Mounting Inspect fuel tank mounting system and barrier if equipped for securement and condition The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any portion of fuel tank mounti
45. h if sealed beam lens is foggy cracked or light is dim if high beam indicator doesn t light if upon visible inspection there is any obvious misaiming of headlights if dimmer switch sticks is hard to operate or doesn t function if headlight switch is damaged nor securely mounted or knob is mounted The vehicle should be 38 2 3 4 5 6 7 8 9 removed from service until repairs can be made if lights go out after being on a short time or operation is intermittent Turn Signals Check turn signals including bulbs and lenses for operation and condition Make repairs if any of the following conditions exist if any front rear or side mounted turn signal lens is cracked if any front top of fender rear or side mounted turn signal does not flash or is dim if turn signal indicator does not properly indicate right and left if turn signal switch does not function properly or will not maintain set position if turn signal switch does not cancel or return to neutral position if any front rear or side mounted turn signal lens is damaged and white light is visible if any turn signal lens has darkened faded or is dirty significantly affecting visibility or color of the light Hazard Lights Check hazard lights for operation and condition Make repairs if any of the following conditions exist If any lens is cracked or dirty if any four way hazard light fails to function if hazard switch does not func
46. he vehicle should be removed from service if the bus is dirty to the point that visibility through any window or light lens is significantly reduce ROAD TEST 1 Road Test Every bus is required to have a road test when monthly inspections are performed The following items should be checked during the road test a Travel angle The travel angle should be checked while the vehicle is being driven Observe centerline on highway and check for side evenness to centerline If travel angle is uneven the vehicle should be taken out of service until repairs are made b Steering Gear Operation Check steering gear for smooth operation lost motion and shimmy Refer to chart on page 18 for maximum free play in steering If free play exceeds maximum allowable amount the vehicle should be removed from service until repairs are made If excessive tire shimmy occurs the vehicle should be removed from service until repairs are made If roughness is detected in steering gear the vehicle should be removed from service until repairs are made c Engine Performance Check engine for acceleration smooth operation noise in engine or valve train and excessive smoke Make repairs if engine fails to operate efficiently Remove the vehicle from service until repairs can be made if excessive noise is detected or if engine fails to operate properly d Rear axle and driveline Check rear axle and driveline for vibration and noise Make repairs if noi
47. ht or buzzer or bell is inoperative either constant or momentary B Low oil pressure dash warning light and buzzer or bell on diesel bus The vehicle should be removed from service until repairs can be made if the low oil pressure warning light or buzzer or bell is inoperative either constant or momentary INSIDE BUS INTERIOR WIRING CAB HOSES AND FIRE WALL SEALS 1 Interior Wiring Inspect visible wiring for mounting condition chafing abrasion corrosion loose connectors or improper repairs Make repairs if any of the following conditions exist If wiring or connectors are unsecured corroded or improperly routed If any connection of any connector is not secure The vehicle should be taken out of service if any wire or connector is cut or severely chafed or if the conductor is exposed or routed against a sharp edge or if there is interference with the driver controls 2 Cab Hoses Inspect all hoses for leaks condition routing abrasion and presence of heater hose shielding Make repairs if any hose is weathered cracked abraded or improperly routed if hose is unshielded in the driver s compartment 3 Firewall Seals Inspect firewall for any cracks unsealed openings and sound insulation material Make repairs if sound deadening insulation package is unsecured or deteriorated or if there is any open hole or unsealed area in the firewall 32 INSIDE BUS GENERAL CONDITION BUS INTERIOR 1
48. icular to shaft and for proper mounting If side to side play in steering column exceeds 14 inch or up and down play exceeds one 1 inch the vehicle should be placed out of service until repaired If column assembly mounting including floor mounting plate or fasteners are loose the vehicle should be placed out of service until repaired Vehicle should also be placed out of service if any of the following conditions exist the tilt telescopic assembly if equipped will not stay in the locked position the steering column U joint inside the bus if equipped is loose damaged or noisy after lubrication the flexible coupling if equipped rag joint has loose or missing fasteners damaged flexible disc or elongated holes if any column u joint inch bolt other column fasteners or input shaft coupling is loose damaged or missing if steering gearbox is loose on frame or fasteners or lock tabs are loose or missing if any frame braces or crossmembers are loose or missing if any rivets or other fasteners at frame braces or crossmembers are loose or missing if any axle or suspension component is loose beyond specifications prescribed elsewhere in this manual The firewall rubber boot should also be checked for proper seal Make repairs if the boot is found damaged torn 10 OUTSIDE BUS STEERING COMPONENT CHECK Steering Gear Box and other external components will be checked using the following procedure 1 Vehicle should be on the groun
49. if the bus is not equipped with a student crossing arm assembly and arm if crossing arm does not extend 90 degrees from bumper If crossing arm does not deploy when stop arm is activated 40 OUTSIDE BUS GENERAL CONDITION BUS EXTERIOR 1 Mirror Mounts and Mirror Glass Check all exterior mirror mounting and bracketry and mirror glass for tightness and condition Make repairs if mounting or bracket bolts or mirror glass is loose or if mounting or bracket bolts are missing The vehicle should be removed from service if mirror brackets are bent broken or mounting is insecure and if mirror glass is discolored or if any required driver or passenger mirror is missing 2 Body Glass Check all body glass gaskets and frames for cracks discoloration and looseness Make repairs if any side glass is cracked loose or discolored orif any piece of glass is Plexiglas Remove the vehicle from service until repairs can be made if windshield glass is cracked and could be dislodged or is discolored and prevents driver from having clear visibility or if any glass is missing 3 Bumpers Check bumpers for mounting condition color and body seal rear bumper Make repairs if of bumper is not black or if bumper is equipped with any unauthorized stickers or decals only stickers approved by DPI Transportation Services are to be installed The vehicle should be removed from service until repairs can be made if bumper is significantly bent or ha
50. ing frame or attaching hardware is missing or damaged The vehicle should be removed from service if any bus is not equipped with a padded safety barrier in front of any passenger seat that does not have another seat in front of it if any fire blocking crash barrier fabric is repaired or replaced using unapproved procedures or non fire blocking material 36 INSIDE BUS EMERGENCY DOOR WINDOWS HATCHES 1 Operation Inspect for operation and condition of rear emergency door and side door door latch door hold open feature if equipped door seal emergency windows and emergency exits ventilator roof hatches Make repairs if any of the following conditions exist if rear door opens too far damaging lights if door handle latch or mounting hardware is loose if mounting of guard for inside rear door handle is loose if any emergency door latch does not operate smoothly and easily when closing or opening if door hold open feature if equipped does not function or secure door in the open position if inside door handle is not equipped with a guard if any emergency door does not open and close from the inside and outside easily if weather strip seal is damaged or does not seal properly if roof hatch seal is damaged or dislodged if roof hatch does not open easily to full emergency open position The vehicle should be removed from service until repairs can be made if any emergency door is equipped with any type of a hasp lock or a
51. is missing or not securely mounted if any handrail fails the NHTSA String and Nut Test 4 Paneling Check all interior sidewall rear ceiling and driver s area paneling for secure fastening projections or sharp edges and condition Make repairs if any of the following conditions exist if there is graffiti or unauthorized stickers seating charts and safety information are approved on interior panels if there are loose or missing attachment screws on any light bar panel or other maintenance access panel If any interior paneling is mildewed or paints where required is missing or damaged The vehicle should be removed from service until repairs can be made if there are any sharp edges rust through or projections from paneling that could cause injury to passengers or driver If there are any unauthorized items affixed to the interior paneling of the bus 5 Loose Objects Secured Check to insure that all objects within the bus are secure The vehicle should be removed from service if there are any aerosol cans other containers or liquids of flammable or volatile chemicals on the bus or if any aerosol can is not labeled 6 Dog House Engine Cover Inspect dog house engine cover for seals soundproofing weather stripping prop rod and latch operation Make repairs if soundproofing is not present or is deteriorated or if latch is hard to operate or does not secure dog house engine cover properly The vehicle should be removed f
52. ist if zerk grease fitting is missing or damaged or ball joint will not take lubrication if any ball joint has more than 3 32 inch axial play The vehicle should be taken out of service until repairs can be made if the following conditions exist any ball joint is loose or missing or cotter pin is missing if ball joint to A frame mounting is cracked or loose or has been welded U Bolts Inspect spring U bolts for condition and securement Make repairs if any of the following conditions exist if any U bolt s is misaligned if there is rust underneath U bolt nuts indicating the possibility of looseness The vehicle should be taken out of service until repairs can be made if any U bolt seating plate shock mount bracket or nut is loose or missing cracked or stripped 10 Shocks Inspect shocks for condition and securement Repair if any of the following conditions exist if there is wetness around shock body due to leaking shock fluid if any shock mounting or fastener is loose missing cracked or broken if any shock is broken if any shock fails to function 11 Springs Inspect front springs for condition securement and alignment Make repairs if any of the following conditions exist if there are any loose missing broken or worn spring clips if any coil or leaf spring has flattened and ride height is less than manufacturer s specifications if either front spring saddle if equipped is worn out or missing if rubber
53. ked pitted clouded or deteriorated to the extent that vision is obscured All mirror systems must meet criteria of and be in compliance with FMVSS111 Crossview Mirror System Check crossview mirrors for vision condition and mounting Correct adjustment will provide the driver with indirect vision of an area at ground level from the front bumper forward and the entire width of the bus to a point where the driver can see by direct vision It will also provide the driver with indirect vision of the area at ground level around the left and right front corners of the bus to include the tires and service entrance on all types of buses to a point it overlaps with the rear vision mirror system Make repairs if mirrors are not in correct adjustment or if mounting brackets or mirror assembly is loose The vehicle should be removed from service if any mirror is missing or if any mirror is cracked pitted clouded or deteriorated to the extent that vision is obscured All mirror systems must meet criteria of and be in compliance with FMVSS111 INSIDE BUS DRIVER S SEAT AND BELT 1 Check driver s seat and belt for condition mounting and operation Make repairs if any of the following conditions exist if seat adjustment binds or is difficult to operate if seat adjustment is loose or adjustment hardware is missing if seat upholstery or foam is deteriorated or damaged if seat bottom is loose in frame or mispositioned if seat belt retractor co
54. ked at any spring mounting location Pins and Bushings Inspect pins and bushings as follows Inspect front spring pins and bushings for wear and lubrication Check for wear with front axle loaded Insert a pry bar between spring eye and fixed point at frame and pull down Measure total free play in pins and bushings Make repairs if any of the following condition s exist if any spring pin assembly will not accept lubrication or zerk grease fitting is damaged or missing if total free play up and down of pins and bushings exceed 4 inch if inner sleeve or rubber bushing type assembly ies is worn through or rubber bushing is excessively worn rubber is compacted or deteriorated resulting in free play between the rubber and spring eye or the inner sleeve A Frames and Bushings Inspect A frames and bushings for condition and securement Make repairs if any of the following condition s exist if rubber bushing s is split badly deteriorated or badly extruded from suspension joints if any A frame assembly is bent missing broken or any fasteners or U bolt s are loose or missing The vehicle should be taken out of service if the mounting of bushing assembly ies is not secure if any rubber bushing s is missing or if any A frame bushing or pivot arm has more than 050 free play at pivot point Ball Joints Inspect ball joint s for condition securement and lubrication Make repairs if any of the following conditions ex
55. l System and Lines Radiator C O N T E N T S Underneath Bus Front Suspension Checks Front Brakes Engine Transmission Mounts Starter Mounting Transmission Checks Fluid Leaks Fuel Tank Brake Equipment Driveline Rear Suspension Rear Brake Body Securements and Structure Exhaust System Wheel and Tire Dooe Inside Bus Emergency Equipment 29 Neutral Safety Switch 30 Shifter
56. ment points if any padding between frame rails and floor sills is missing or grossly misaligned The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any originally installed body holddown or cowl mount is missing if three 3 or more body holddowns are loose misaligned or have missing hardware if three 3 or more body holddowns have cracks or stripped nuts at floor sill securement point 2 Floor Inspect condition of floor structure sills and braces Make repairs if there are any minor cracks in floor sills braces or welds The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if there are any holes or cracks in floor sheet metal creating an opening to the passenger compartment if entire cross section of any floor sill or brace is broken if there is any broken weld or mounting of a floor sill or brace resulting in complete separation more than one 1 foot in length if there is any broken weld in the mounting of the bracing K member at the front of the body floor between stepwell and driver s area 3 Outriggers Inspect body outriggers and hardware for condition and securement Make repairs if any body outrigger is cracked or has loose or missing hardware The vehicle should be taken out of service until repairs can be made any originally installed as required by manufacturer outrigger is missing 4 Braces
57. mp is missing if there is any originally installed exhaust hanger which is 27 missing broken or detached from the exhaust system or frame mounting point 3 Muffler Inspect condition of the muffler Make repairs if the muffler is cracked or if there is other significant physical damage to the muffler The vehicle should be removed from service if the muffler is leaking and produces an audible sound and exhaust can be felt from the leaking area 4 Tailpipe Inspect the condition of tailpipe and insure that it extends beyond the rear bumper and exits to the left of the left frame rail Make repairs if the tailpipe is cracked or there is other significant damage to the tailpipe Check the tailpipe and make sure it extends at least to the edge of the rear bumper but no more than two 2 inches beyond bumper or exits to the left or right and extends to edge of bus body The vehicle should be removed from service if the tailpipe is leaking and produces and audible sound and exhaust can be felt from the leaking area UNDERNEATH BUS WHEELS AND TIRES 1 Tread Depth Inspect and measure all tires for tread depth and record on inspection form The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if the measured tread depth of either front tire is less than 4 32 inch 2 32 inch for rear tires at three 3 points spaced equally around the circumference of the tire in the same major tr
58. ng system including support brackets retaining straps and chassis frame is missing loose cracked or broken if any fuel tank mounting fasteners are loose or missing if barrier assembly if originally equipped is damaged insecurely mounted or missing Hoses Inspect all fuel lines and under bus fuel system components for routing securement and condition The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any fuel line or hose is unsecured or is routed subject to excessive heat or abrasion if any fuel line or hose is deteriorated or damaged including cracks or any damage that may cause potential leakage or clamps are loose or missing if any under bus fuel system filter water separator or other components are insecurely mounted cracked or damaged Wiring Inspect fuel tank sending unit wiring for securement routing and condition Make repairs if any wiring or connection has damaged or missing insulation The vehicle should be taken out of service until repairs can be made if any portion of sending unit wiring including ground or connections is unsecured or is routed subject to excessive heat or abrasion 22 UNDERNEATH BUS BRAKE EQUIPMENT 1 Bleed Reservoirs With air system fully charged check manual operation of safety relief valve Partially open manual petcock valve on the first wet tank Allow tank to drain until any moisture water or cont
59. ns exist if there are cuts abrasion or other damage to tire sidewall resulting in exposed or damaged cord if there is any evidence of separation bulges other than normal manufacturer bulge or other damage within the carcass of the tire if there are any cracks that run around the bead or sidewall of the tire on retreaded tire there is any separation of the tire tread from the tire carcass that could result in tire or tread failure if any valve stem is damaged or mislocated so that the tire cannot be filled with air if there is damage to the lock ring assembly or lock ring groove of a multi piece rim including rust or corrosion which could cause the lock ring not to seat fully if there are any cracks or breaks at the lugholes or any other part of a rim or cast spokes if there are any dents or bends in a rim that could result in failure of a rim or separation of the tire from the rim NOTE Weather cracking only shall not be cause for rejection 4 Matching Inspect for matching of tire construction tire design tire size and load rating on each axle Make repairs if there is mismatching of inner and outer dual tire diameter greater than 3 8 inch 28 5 6 7 The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if there is any tire marked for other than highway use if any tire is not of the proper type size and minimum load rating If any tire on an axle are not of th
60. ny other locking device except for OEM interlock system if bus will start with any emergency door locked OEM interlock system if any latch mechanism will not secure door hatch or window in closed position 2 Buzzers Check operation of buzzers for emergency door s emergency exit windows and emergency exit roof hatches Make repairs if buzzer give false alarms The vehicle should be removed from service if emergency exit buzzer circuit s fail to operate 3 Labeling and Pad Inspect for label and opening instructions for emergency door emergency windows and emergency exit ventilator roof hatch Make repairs if any of the following conditions exist if any emergency exits are not clearly labeled and visible inside and outside the bus as Emergency Door or Emergency Exit if emergency door emergency windows or emergency exit roof hatches do not have readable instructions for operation on the inside of the exit or readable from the inside if emergency exit door pad is ripped or has loose mounting if any door pad is missing or has any protruding edge INSIDE BUS WINDSHIELD SIDE amp REAR WINDOWS 1 Glass cracks Inspect windshield and all windows for cracks and other damage Make repairs if any of the following conditions exist if there are any cracks in the windshield in the driver s direct field of vision or any pock marks that obstruct the driver s vision if there are any cracks in the windshield or an
61. of excessive water or dirt contamination transmission fluid shows need of servicing discoloration and or burnt smell The vehicle should be removed from service until repairs can be made if the transmission fluid is not present on dipstick or is above the full mark overfilled 5 Windshield Washer Fluid Check windshield washer fluid level Make repairs if the reservoir is low or the windshield washer does not spray windshield 6 Coolant Check coolant antifreeze level and condition and freeze protection Make repairs if any of the following conditions exist the coolant level in radiator or reservoir is low the coolant shows evidence of excessive oil or dirt contamination or rust and corrosion the coolant freeze boil protection is inadequate acceptable freeze protection 20 F or lower the coolant pH level is too 13 high or too low the coolant additive package has deteriorated The vehicle should be taken out of service until problem can be determined if coolant cannot be seen in reservoir or in radiator tank with cap removed ENGINE COMPARTMENT BELTS 1 2 3 4 Tightness Visually and physically check all drive belts for proper tension If available use a tension gauge If a gauge is not available use a ruler to measure the deflection of the belt s up and down at the widest point between the drive and driven pulley s Make repairs if any belt exceeds tension reading recommended by manufacturer
62. oken cracked or loose on shoe if shoe platform or webbing is cracked or damaged if there is any loose damaged or if there is any loose damaged or missing foundation brake hardware within the drums Drums Inspect rear brake drum s for condition Make repairs if any of the following conditions exist if there is any grease oil or brake fluid on the inside of the drum if any drum is not mounted securely to hub or fasteners are loose Rotors Inspect rear brake rotor s for mounting and condition Make repairs if the following conditions exist If rotor mounting is not secure if friction surface is contaminated with oil grease or brake fluid if any rotor friction surface is significantly grooved or damaged Wheel Cylinders or Calipers Inspect wheel cylinder s or caliper s for leaks and mounting and condition Make repairs if any wheel cylinder or caliper is not securely mounted or has loose or missing fasteners if there is uneven brake lining or brake pad wear evidence of rotor or drum damage evidence of dragging or other evidence that any wheel cylinder or caliper may be sticking 10 Brake Adjustment a For air wedge brakes or hydraulic drum brakes adjust rear brakes at every monthly inspection as follows Brakes must be adjusted until brake drum does not turn Then back off brake adjustment until there is slight drag on drum surface 020 clearance between lining and drum The vehicle should be removed from servi
63. olt seating plate shock mount bracket or nut is loose missing cracked or stripped Shocks Inspect rear shocks for condition and securement Make repairs if any of the following conditions exist if there is any wetness around shock body due to leaking shock fluid if any shock is broken if any shock mounting or fastener is loose missing cracked or broken Shackles Inspect rear suspension shackles spring hangers and hanger pinch bolts for condition and securement The vehicle should be taken out of service until repairs can be made if any rear spring shackle or hanger is worn to the point or pinch bolt is stripped or missing so that spring pin cannot be clamped tightly Pins and Bushings Inspect rear spring pins and bushings for wear and lubrication Make repairs if any greaseable spring pin assembly will not accept lubrication or zerk grease fitting is damaged or missing The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if inner sleeve on rubber spring pin assemblies is worn through or rubber bushing is excessively worn rubber is compacted or deteriorated resulting in free play between rubber and 24 spring eye and inner sleeve if rear spring pin bushing metal type bushing is worn through if total free play up and down of pin and bushing exceeds 1 8 inch if on system that uses two 2 pins and bushings combined free play exceeds inch 9 Hanger
64. on of seat back foam is missing or damaged Cuts and other upholstery damage Inspect seat upholstery for condition and damage Make repairs if seat upholstery is cut or torn and foam is visible through cut Make repairs if seat upholstery is not repaired properly The vehicle should be removed from service if any vehicle that came equipped with fire block upholstery has been retrofitted with upholstery other than fire block Bottoms amp Flip Up Seat To remain in compliance with FMVSS222 all seat bottoms must be secured and remain secured when students are transported Inspect seat bottoms for securement and condition Make repairs if any seat bottom is not securely anchored to seat frame or if any seat bottom padding or cover has damage and deterioration Inspect flip up type seat bottom at side emergency door if equipped for proper operation There must be clear access to the emergency door with a minimum aisle width of twelve 12 inches between seats The vehicle should be removed from service if there is not a clear minimum twelve 12 inch aisle width to the side emergency door It should also be removed from service if the flip up seat bottom will not raise or lower stay in the raised position or automatically retract properly when not occupied Modesty Panels amp Courtesy Panels Inspect modesty panels and courtesy panels for condition mounting and padding Make repairs if any covering or padding is damaged or if any mount
65. or oil leaks Parking Brake With vehicle stopped apply park brake Place transmission selector in drive position and accelerate engine to a fast idle approximately 1 200 R P M s vehicle should not move forward Note Buses equipped with Rear Diesel engine and Allison World Transmission should be checked at 900 R P M Air Leaks To check the vehicle for air leaks the system should be charged to 100 p s i minimum The engine should then be turned off and the park brake released Make sure a wheel chock secures the vehicle to prevent any movement With brakes in released position check for air pressure leak pressure drop for at least one 1 minute Note pressure drop if any Firmly apply the service brake Do not release Check for air pressure leak pressure drop for at least one 1 minute Note pressure drop if any If air is leaking but the rate is less than two 2 psi per minute brakes released or 3 psi per minute with service brake applied repair the vehicle If pressure leaks more than two 2 psi per minute brakes not applied or more than three 3 psi per minute with service brake applied the vehicle should be taken out of service until repairs can be made Low Air Warning Check operation of low air warning buzzer and light by building air pressure to 100 125 psi and perform the following procedures with ignition key switch in run position drop air pressure Low air warning buzzer and light should activat
66. or replace ENGINE COMPARTMENT FLUID LEVELS 1 Brake Fluid Check brake fluid and brake power assist hydraulic fluid if applicable for level and condition If the following conditions exist make repairs as necessary level of brake fluid in either side of master cylinder reservoir is lower than 1 4 inch from top or below Add mark if equipped brake fluid or power assist fluid shows evidence of excessive water oil or dirt contamination brake power assist hydraulic fluid is below cold Add mark If fluid is low in either of these components an inspection should be made and if leaks are detected the vehicle should be placed out of service until repairs are made 2 Power Steering Fluid Check the power steering reservoir fluid levels and condition Make repairs if power steering fluid is below cold Add mark or if power steering fluid shows evidence of excessive water oil or dirt contamination 3 Oil Check the level and condition of oil Repair if engine oil is below Add mark If no oil is observed on dipstick the vehicle should be taken out of service until reason can be determined The vehicle should also be taken out of service if there is evidence of fuel or water contamination in the oil 4 Transmission Fluid Check the level and condition of transmission fluid Make repairs if any of the following conditions exist transmission fluid is below Add mark transmission fluid shows evidence
67. ound the vehicle needs to be repaired if the locking pin is loose if end cap O rings or bolts are loose or missing The vehicle should be taken out of service if the locking pin is backing out loose or missing if the kingpin movement is more than inch measured at the outside edge of the tire If the vertical up and down play in kingpin assembly is greater than 030 and or thrust bearing is damaged or missing NOTE If play is beyond specifications wear may be kingpin axle eye and or king pin bushings Vehicle should be removed from service if side play at outside edge of tire is greater than 4 inch Do not tighten kingpin lock if equipped or grease kingpin before inspecting kingpin assembly 4 Shackles Inspect condition of shackles spring hangers and pinch bolts Make repairs if any of the following conditions exist if any front spring shackle or hanger has significant side wear at the spring eye if any front spring shackle or hanger is worn or pinch bolt is stripped or missing so that spring pin cannot be clamped tightly The vehicle should be taken out of service if any front spring shackle or hanger is cracked or broken 17 5 6 7 8 9 Spring Mounts Inspect spring mount bracket s for condition and securement Make repairs if any front spring mount to frame fastener is loose or missing The vehicle should be taken out of service if any front spring mount is broken cracked or if the frame is crac
68. out if there is loose or missing hardware or if the linkage is missing one return spring or is not equipped with dual return springs external type The vehicle should be removed from service until repairs can be made if pedal and assembly are not mounted securely or if control design and mounting are not of OEM design if accelerator control and linkage sticks or doesn t operate freely if pedal is built up with extender block s or not of OEM design Engine Shutdown Only OEM approved ignition controlled is shutdown acceptable on all buses On 1985 and older buses equipped with manual engine shutdown check for free operation of shutdown over full range with minimum effort The vehicle should be removed from service until repairs can be made if the engine cannot be started or if shutdown or operation is difficult Remove the vehicle from service until repairs can be made if the bus was originally equipped with ignition switch type controlled shutdown but has been retrofitted with Bowden Cable manual type shutdown INSIDE BUS GAUGES INDICATORS DASH LIGHTS amp HORN 1 Gauges Check from drivers position the visibility OEM location readability operation accuracy and condition of the following gauges Speedometer and odometer Oil Pressure Temperature Fuel Voltmeter and ammeter Air Pressure Tachometer AmMMoOAw gt Make repairs if oil pressure temperature fuel voltmeter or ammeter gauges are in
69. pect heater system for a Heating performance and water control valve b Blower operations condition and control switches c System leaks condition and hose shielding d Condition of ductwork and heater box Make repairs if any of the following conditions exist if system is not producing adequate heat if water control valve is hard to operate if heater blowers do not work on all speeds are noisy or vibrate if blower switches are damaged loose or blower operates intermittently Repair if heater hoses are cracked swollen or badly chafed if shielding is missing or does not completely cover hoses if any portion of heating system within the passenger area creates sharp edges projections or other hazards to passengers 2 Defrosters Inspect windshield defroster system for a Airflow heat and coverage area b Blower operations condition and control switches c Condition of ductwork diffusers and fresh air control if equipped Make repairs if any of the following conditions exist if any defroster blower does not work on low or high speed if blower switches are damaged or loose if any ductwork or diffusers are loose or damaged if fresh air control if equipped does not function if airflow is not present at all defroster outlets 34 External Driver Fan Inspect driver fan for a Presence of fan mounting and condition b Blade condition c Protective cage mounting and condition d Operation and swi
70. rom service until repairs can be made if seals or weather stripping allow air fume leaks into the driver s compartment 33 INSIDE BUS WINDSHIELD WIPERS amp WASHERS 1 Operation Inspect both wipers for a Swept area field of view and effectiveness of wiping b Proper operation of both wipers on high and low speeds and condition and mounting of switch es and knob s c Condition and mounting of wiper motors and linkage d Inspect for proper washer operation Make repairs if any of the following conditions exist if either wiper does not operate on low or high speed if wiper goes past perimeter of glass if washer does not operate or is misadjusted if either blade does not effectively clear driver s field of vision if either wiper motor or linkage is visibly damaged or loose if switch or knob mounting is loose or missing The vehicle should be removed from service until repairs can be made if either wiper fails to operate 2 Park Inspect for parked position of wipers when turned off Make repairs if wipers do not automatically return to parked position out of driver s line of sight when turned off 3 Blades Inspect blades for condition mounting and tension Make repairs if blade s do not clean windshield properly Repair if either blade s is damaged deteriorated loose or does not hold proper tension against windshield INSIDE BUS HEATERS DEFROSTERS amp EXTERNAL DRIVER FAN 1 Heaters Ins
71. s Inspect hangers for mounting and condition Make repairs as soon as possible if any hanger is found with a small crack 1 2 inch or less that can be welded The vehicle should be taken out of service until repairs can be made if any spring hanger or bracket is cracked 1 2 inch or more or broken or any mounting fastener is loose or missing 10 Seals Inspect rear wheel seals for condition and leakage Make repairs if there is wetness or dripping of grease around axle flange or if any axle flange stud or nut is loose or missing The vehicle should be taken out of service until repairs can be made if either wheel seal is damaged or leaking excessively 11 Wheel Bearings Inspect rear wheel bearings for condition and proper adjustment of bearings a Raise the rear wheels wheels unloaded and release park brake b Grasp tire and attempt to rock wheel assembly to check for movement The vehicle should be taken out of service if there is any detectable looseness or roughness in rear wheel bearings UNDERNEATH BUS REAR BRAKE 1 Hoses Inspect rear brake flexible hoses for condition securement and routing Make repairs if any rear brake hose supporting bracket is damaged or has loose fasteners or if any rear brake hose is rubbing on or routed against other components The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if any rear brake hose or connection is leaking
72. s protruding metal or if bumper mounting system has cracked broken or bent brackets or braces cracked welds or missing or loose fasteners 4 Body Damage Check body exterior for accident damage scratches dents etc Make repairs if body has small dents scratches etc or has rusted spots The vehicle should be removed from service until repairs can be made if any of the following conditions exist if any body part is damaged or dislocated creating a protrusion or sharp edge if body panels rivets or other components are damaged or corroded to the point where joint strength or body structural integrity is compromised 5 Paint Check the paint on body and trim for required coloration and condition Make repairs if paint is faded to a point that no gloss is present or it is discolored rusted or damaged The vehicle should be removed from service if the paint is not National School Bus Yellow or if the bumpers warning light hoods and background are not black 6 Reflective Markings Check reflective markings for coloration reflectability and condition Make repairs if reflective markings are faded discolored damaged or peeling The vehicle should be removed from service until repairs can be made if reflective markings are missing around any emergency exit or door Reflective markings required on 1995 and newer buses 7 Lettering Check all lettering for required type size location and color The vehicle should be removed
73. se is detected If excessive noise and vibration are detected the vehicle should be removed from service until repairs can be made e Transmission Check transmission operation for upshift downshift and slippage Make repairs if rough upshift or downshift is experienced If transmission is slipping the bus should be removed from service until repairs can be made f Road Speed Control Check road speed control for proper operation Check operation for high limit cut off and low limit cut in Make repairs if high limit is 48 mph or above and if low cut in is 42 or below Remove the vehicle from service if road speed control fails to operate g Instrument Gauges Speedometer and Odometer Check all instrument gauges for proper operation Make repairs if any gauge fails to operate properly Check speedometer and odometer for proper operation Make repairs if speedometer needle is erratic or if odometer fails to operate Remove the vehicle from service if speedometer fails to operate h Hydraulic Brake Warning Light Check operation of hydraulic brake warning light Remove the vehicle from service if warning light fails to operate i Low Air Warning Buzzer and light Check low air warning buzzer and light for proper operation Remove the vehicle from service if warning buzzer and light fail to operate properly 42 NOTES 43 NOTES 44
74. seating The vehicle should be taken out of service if any portion of the slack adjuster or S cam is missing broken cracked or badly worn if S cam snap ring is missing or if slack adjuster has a frozen or stripped worm gear or ratchet assembly Pushrods Inspect pushrod assembly ies for condition securement and alignment Make repairs if the following conditions exist if any portion of pushrod is rubbing against body of chamber or chamber is misaligned if the pushrod on the left and right side is not mounted in identical same slack adjuster location hole same effective slack adjuster length The vehicle should be taken out of service if any portion of the pushrod assembly locknut pushrod clevis and pin or cotter pin is loose missing or damaged Linings Inspect brake lining through inspection cover or hole Make repairs if any of the following conditions exist If friction surface is contaminated with oil grease or brake fluid if lining is worn to within 1 8 inch of shoe table riveted type shoe if lining is worn to within 1 16 inch of shoe table bonded type lining The vehicle should be taken out of service if lining is broken cracked or loose on shoe if shoe platform or webbing is cracked or damaged if there is any loose damaged or missing foundation brake hardware within the drum Drums Inspect front brake drum s for condition Make repairs if there is any grease oil or brake fluid on the inside of the
75. sembly and mounting fasteners for condition and securement Make repairs if any transmission assembly fastener s is loose missing or damaged If any of the following conditions exist the vehicle should be taken out of service until repairs can be made transmission is not mounted securely to flywheel housing there is external indication that any torque converter bolt s are loose or missing 2 Linkage Inspect transmission linkage for routing condition and securement Make repairs if any of the following conditions exist if modulator TV cable or vacuum hose is routed where it is subject to excessive heat or abrasion if any linkage hardware or fasteners are loose if modulator TV cable is exposed or casing is damaged if modulator vacuum hose is deteriorated or loose The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if linkage is bent or damaged binding or severely misadjusted if any linkage hardware or fasteners are missing or linkage is damaged so as to cause a sticking or binding condition if modulator vacuum hose is leaking or not connected 3 Lines Inspect transmission lines for securement routing and condition Make repairs if any of the following conditions exist if any transmission line s is unsecured or routed subject to excessive heat or abrasion if any transmission line is crimped if there is any line of improper type if any transmission line is worn
76. service if the diesel air filter restriction exceeds manufacturer s specifications ENGINE COMPARTMENT POWER STEERING PUMP 1 Check securement and condition of power steering pump Make repairs if any portion of the power steering pump mounting bracketry or fasteners is cracked loose or missing ENGINE COMPARTMENT AIR COMPRESSOR AND FILTER 1 Check securement and condition of air compressor and filter assembly Make repairs if air compressor air filter if equipped is dirty Make repairs if any portion of the air compressor compressor air filter if equipped filter compressor mounting bracketry filter cover or fastener is cracked loose or missing Make repairs if hose from engine air cleaner to air compressor is damaged torn or missing ENGINE COMPARTMENT WATER PUMP 1 Check condition of water pump and pulley Make repairs if any of the following condition s exist there is evidence of coolant seepage from water pump seal gasket surface or weep hole if water pump fasteners are loose damaged or missing The vehicle should be taken out of service until repairs can be made if water pump is noisy bearing is damaged or coolant is leaking out ENGINE COMPARTMENT FAN 1 Check fan blade and fan clutch assembly for securement and condition The vehicle should be taken out of service if the fan has any cracked bent or broken blades if any portion of fan mounting is loose or if fan clutch is seized
77. t assembly if any U joint has significant cross shaft to bearing cup play or CV joint has significant play if any U joint or CV joint shows evidence of significant rusting of bearings if any bearing cup is loose in yoke 3 Yokes Inspect driveshaft yokes for condition and lubrication Make repairs if any of the following conditions exist if driveshaft splines are unlubricated if dust cap on yoke is missing if zerk grease fitting is missing or clogged if cork washer in dust cap is missing The vehicle should be taken out of service until repairs can be made if any yoke has significant play in splines or if any yoke is cracked or damaged 4 Hanger Bearings Inspect hanger bearings and rubber insulators for condition and securement Make repairs if hanger bearing rubber insulator is deteriorated and damaged or oil soaked or if hanger bearing support is misaligned The vehicle should be taken out of service until repairs can be made if any of the following conditions exist if the bearing outer race is loose in insulator or inner race is loose on shaft if there is significant play in hanger bearing if there is any missing or damaged hardware or fasteners in hanger bearing or support assembly 5 Guards Inspect for presence and condition of driveshaft guards Make repairs if any driveshaft guard is bent damaged missing or has loose or damaged mounting fasteners 6 Driveshaft Park Brake Inspect driveshaft park brake assembly
78. tch Make repairs if fan mounting is loose or fan won t stay in adjustment if fan blade is damaged if switch is loose if fan does not operate The vehicle should be removed from service if protective cage is missing loose or damaged INSIDE BUS MIRROR ADJUSTMENTS AND CONDITION 1 2 3 Interior Rearview Mirror Check interior rearview mirror for size condition and mounting All interior mirrors shall be 6 high and 30 long Make repairs if any portion of reflective surface is deteriorate or if mirror mounting is loose The vehicle should be removed from service if stickers or other items obstruct any portion of the driver s view or if driver s view of images is not clear due to distortion or other causes Outside Rearview Mirrors Check outside rearview mirrors for vision condition and mounting Check rearview mirrors to insure that the view provides the driver with a view along the left and right sides of the bus Correct mirror adjustment will provide driver a view of rear tires at ground level and a minimum of two hundred feet 200 to the rear of the bus It will also provide a view at least twelve 12 feet perpendicular to the side of the bus at a distance of thirty two 32 feet back from the front bumper Make repairs if mirrors are not in correct adjustment or if mounting brackets or mirror assembly is loose The vehicle should be removed from service if any mirror is missing or if any mirror is crac
79. ted in the engine compartment including power steering coolant air compressor intake vacuum brake hydraulic assist engine oil and transmission hoses 1 2 3 Clamp s and Connections Visually and physically check that hose connections or clamp s are tight Make repairs if any of the following conditions exist if any hose connection or clamp s is loose or is too tight digging into hose if any hose connection or clamp s is stripped or damaged Condition Visually inspect all hoses for cuts abrasions wear oil saturation dry rotting or ballooning Make repairs if any hose is cut abraded worn oil saturated dry rotted or ballooned to the point that failure could occur Routing Visually inspect routing and securement of all hoses Make repairs if any hose is misrouted or unsecured so heat damage abrasion or cuts could result in failure ENGINE COMPARTMENT AIR FILTER ASSEMBLY 14 1 Check air cleaner assembly housing lid piping gasket s seal and clamp s for securement condition and record filter restriction Check for presence of wing nut and seal if equipped Make repairs if any of the following condition s exist if any portion of the air cleaner assembly or mounting is loose or damaged including piping nuts bolts or clamps if there are any worn or damaged seals or gaskets if there are any air or vacuum leaks or missing components The vehicle should be taken out of
80. tion or will not maintain set position with steering wheel in the straight ahead position Side Marker Lights Check side marker lights if installed for operation and condition Make repairs if any side marker light fails to function or is cracked or damaged Brake Lights Check brake lights and lens for operation and condition Make repairs if any of the following conditions exist one brake light on either or both sides fails to function four 4 brake light systems only if any brake light lens is cracked damaged or white light is visible any brake light lens has darkened faded or is dirty significantly affecting the visibility or color of the light The vehicle should be removed from service until repairs can be made if any of the following conditions exist if brake light circuit fails to function if after brake pedal is released brake light switch sticks or lights stay on if any brake light lens is not red or is not proper type meeting SAE specifications Tail Lights Check tail light s and lens for operation and condition Make repairs if any of the following conditions exist if one 1 tail light on either or both sides fail to function four 4 tail light system only if any taillight lens is cracked if any tail light lens has darkened faded or is dirty significantly affecting the visibility or color of the light if any taillight lens is damaged and white light is visible The vehicle should be removed from servic
81. to check for noise and condition of bearings NOTE It is important to correctly identify the source of any play To determine if the play is in the wheel bearings have an assistant fully apply the brakes while rechecking play If movement disappears with brakes applied then play was in the wheel bearings Make repairs if any of the following conditions exist if there is minor seepage of grease or oil around the dust cover if dust cover or fasteners are loose or missing The vehicle should be taken out of service if there is any noise binding or roughness is discovered in bearings or if wheel bearing endplay exceeds manufacturer s specifications maximum of 010 in and out play measured at bearing hub 2 I Beam Inspect I beam axle assembly The vehicle should be taken out of service until repairs can be made if the I beam has been cut modified or is damaged or if there is any bluing or other evidence that the I beam has been heated 3 King Pins Inspect king pin assemblies for condition and play as follows a With front wheels raised grasp tire at top and bottom or using a pry bar for leverage attempt to move the wheel assembly in and out NOTE Wheel bearings must be adjusted properly or wheel bearing play must be eliminated by locking brakes before checking kingpins b Place a pry bar under wheel and lift tire straight up and down to determine condition of thrust bearing If any of the following conditions are f
82. tops and lock nuts Any steering arm has been bent is cracked or is damaged Any steering arm attachment point is loose or any fasteners or cotter pin is missing Either steering stop or lock is loose damaged or missing Tie Rod and Ends check the tie rod ends tie rod dust boots and clamps or fasteners as equipped for looseness damage and condition check idler arm assembly as equipped for looseness damage and condition Tie rod end dust boot is cut damaged or missing repair Tie rod end needs lubrication repair Any tie rod end grease fitting is loose or missing or will not take grease repair Idler arm needs lubrication repair Idler arm grease fitting is loose or missing or will not take grease repair Tie rod clamps fasteners or cotter pin is stripped missing or loose Any clamp as equipped is mispositioned Any tie rod end is cracked or damaged Any tie rod end has more than 1 16 inch axial play Tie rod end ball stud is loose in steering arm or idler arm Any idler arm fasteners are loose or missing Idler arm is cracked or damaged or cotter pin is missing Idler arm up and down play is greater than 1 4 inch total 1 8 inch either direction OUTSIDE BUS BATTERY CHECK Hold down Check for tightness condition and type of battery hold down Make repairs as soon as possible if battery hold down assembly or tray is loose corroded or damaged ca
83. using insecure mounting of battery 1 Battery Terminals Check terminals for cleanliness tightness and condition Make repairs as soon as possible if terminals are loose damaged 12 corroded or have missing hardware 2 Battery Cables Check cable assemblies for routing securement condition and size Make repairs if the following conditions exist cable or insulation is cracked damaged or corroded cable is misrouted unsecured or grommet is missing cable is routed against the exhaust or any other extremely hot surface cable is smaller than original equipment size 3 Cleanliness Check cleanliness of battery ies Repair if battery top or sides are corroded greasy dirty or wet with electrolyte If battery is cracked or damaged it should be replaced before operating 4 Tray Check battery tray for operation condition and securement Make repairs if the following conditions exist if battery slide tray is corroded dirty or hard to slide in and out if battery slide tray securement device or tray stop is missing or nonfunctional if battery tray does not slide in and out if battery slide tray or box is damaged or deteriorated reducing security of battery ies if battery box door does not open or will not stay latched 5 Electrolyte Level Check electrolyte level in battery ies for proper level if applicable Repair if electrolyte is low If electrolyte is too low and exposes plates repair
84. ver or belt covers are damaged or loose if seat belt does not fully extend and retract The vehicle should be removed from service until repairs can be made if seat frame and mounts are cracked broken or distorted if driver seat belt is missing or is inoperable or if seat belt is routed improperly if seat belt buckle and tongue assemblies do not latch and release properly 35 INSIDE BUS PASSENGER SEATS 1 2 3 4 5 6 Frames Inspect passenger seat frames for condition of welds tubing and hardware Check for presence of non OEM seat frames Make repairs if any seat back frame is repaired using non OEM hardware The vehicle should be removed from service until repairs can be made if seat frames or welds are broken or cracked if any seat frame hardware has been added or modified which results in projections or sharp edges if any non OEM seat frames have been installed Mounting Inspect condition of passenger seat mounting Make repairs if any seat mounting at floor or seat rail is loose Remove the vehicle from service if any seat mounting fasteners are of lower grade or different type than OEM fasteners for the specific locations Pads Inspect seat back foam for specifications and condition All North Carolina School Buses must meet FMVSS222 Check for thickness and density of foam around frame Make repairs if any portion of seat frame can be felt when pressing down on seat back top Repair if any porti
85. ware is damaged missing or not secure including cams clips pins rollers and platform fasteners Inspect wheelchair and occupant securement tie down system for condition mounting proper type and location Make repairs if track is filled with dirt and trash The vehicle should be removed from service until repairs can be made if wheelchair tie down track or fasteners are loose broken or sections of track are not continuous within each wheelchair position if wheelchair or occupant securement straps are broken frayed or will not operate if wheelchair or occupant securement track is mounted using lag type bolts or sheet metal screws Check for presence of a durable webbing cutter if equipped on all buses equipped with restraining devices or wheelchair positions securely mounted in the driver s compartment and within easy reach of the driver Repair if no durable webbing cutter is present if equipped or if webbing cutter if equipped is not securely mounted in driver s compartment within easy reach of the driver OUTSIDE BUS ALL EXTERIOR LIGHTS amp BACKUP ALARM 1 Headlights Check both headlights for brightness operation condition of sealed beams and visible misaiming Check high beam indicator operation and headlight switch Make repairs if any of the following conditions exist if left and right sealed beams are of different type halogen vs conventional if either sealed beam does not light on low and hig
86. y window greater than two 2 inches in length if there is any crack in non laminated safety glass The vehicle should be removed from service until repairs can be made if any glass is missing or if any laminated windshield or laminated window glass is broken or splintered that might cause injury when touched 2 Fogging Check windshield and windows for fogging and reduced visibility or improper level of tinting Make repairs if glass is starting to fog around the edges if there is any reduced visibility through the windshield or any windows The vehicle should be removed from service until repairs can be made if the windshield or any window that provides visibility to any mirror is fogged more than two 2 inches in from the outer border if any windshield or window fogging or clouding results in reduced visibility of a mirror if there is any tinting on the windshield or windows to the side of the driver that is not 70 light transmission or clearer if there is tinting on any windows behind the driver s location that is not 28 light transmission or clearer 37 3 4 Latches and Window Operation Check latches and windows for condition and operation Make repairs if any of the following conditions exist if latches are hard to operate or any window does not move up and down freely if windows do not stay closed if window will not move full travel up and down The vehicle should be removed from service if there are any loose

North Carolina School Bus Inspection Manual

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