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North Carolina School Bus Inspection Manual

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1. 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 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 Out of Service if 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 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 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
2. TABLE OF CONTENTS BRAKES Brak Testing Proced re geegent d e gedreet ee Brake Stroke Measurements amp Brake Adjustment Inside Bus Brake Component Checks AAA Inside Bus Hydraulic Brake System Checks oo cece eeeeeeseeeeeeeeeeeees STEERING BATTERY Inside Bus Steering Component Check A Outside Bus Steering Component Check eee eeeeeseeeneceeeeeeeeeeneens Outside Bus Battery Check jis sgegidfveieieegtee kee dgeh ege tecossedentenasons ENGINE COMPARTMENT Flecken ee BEE EE EE Bee eebe eeh eeh eege E ege EA ae Air Filter Assembly eege iinnat EE Power Steerns HEURE Air Compressor and Filter 3 4 0 0n ede Bnew ihn he Water PUMP EE SE F el System and Lines egene Eed EE UNDERNEATH BUS Front Suspension E Pront Brakes ireren na ee Engine Transmission Mounts Starter Mounting ssseseeeeeeereereesreereree Transmssion EE Fl id Leaks dereen ee EE Pret Tank eet EE Brake Ve E Driveline 2 2iadevieceaeeeedeasl seansini R a ae a S EEEE Rear Suspension geet Reat take eege edel Body Securements and Zebra Exha st Systemy EE Wheel and KEE EE INSIDE BUS Emergency Equipment EE 31 Neutral Safety EE 32 ER ee e E a aaah a ecnbeteaeds 32 Engine EE 33 Gauges Indicators Dash Lights amp Horn sesseseseseeereererserererrrrserereees 33 Engine Warning Lights and Buzzer ssesesesseeseeressiseresresseseresresseseresresss 34 Interior Wiring Cab Hoses and Fire Wall Seals eee eeeeece
3. c Check clutch master and slave cylinders for hydraulic leaks and operation The vehicle shall be removed from service until repaired if either master or slave cylinder is leaking or inoperable Clutch Adjustment if equipped Check free play travel of the clutch pedal This is the first easy movement of the clutch pedal and shall be no more than 1 inches and no less than 3 4 inch of travel FLUID LEAKS Oil Inspect for engine oil leaks at all potential locations and determine severity Make repairs if any of the following conditions exist engine oil leakage is causing deterioration of any rubber parts such as steering linkage boots hoses etc engine oil is dripping at any location except on exhaust system The vehicle shall be removed from service until repairs are made if fresh engine oil is found 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 shall be removed from service until repairs are made if the coolant leakage is excessive and could result in engine 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
4. The vehicle shall be removed from service until repairs are made if taillight circuit fails to function tail light lens is not red taillight lens is not proper type meeting SAE specs The vehicle shall be removed from service until repairs are made if backup light stays on all of the time backup lights stay on in any gear position other than reverse The vehicle shall be removed from service until repairs are made if any of the following conditions exist amber or red light does not function or is dim amber red lights both front and rear do not alternately flash side to side warning light is not red outer or amber inner or is not the proper type warning light lens is damaged and white light is visible warning light lens has darkened faded misaimed or dirty affecting the color of the light or reducing the visibility to less than 500 feet in bright sunlight warning lights do not function The vehicle shall be removed from service until repairs are made if any stop arm light does not flash or does not flash between 60 and 120 times per minute or if stop arm does not operate as required The vehicle shall be removed from service until repairs are made if any of the following conditions exist bus is not equipped with a student crossing arm assembly and arm crossing arm does not extend 60 degrees from bumper crossing arm does not deploy when stop arm is activated The vehicle shall be removed from service until repairs are made if mi
5. Inspect driver fan for a presence of fan mounting and condition b blade condition c protective cage mounting and condition d operation and switch Make repairs if any of the following conditions exist fan mounting loose or fan will not stay in adjustment fan blade damaged switch loose fan non operational The vehicle shall be removed from service if protective cage is missing loose or damaged MIRROR ADJUSTMENTS AND CONDITION Interior Rearview Mirror Check interior rearview mirror for size condition and mounting All interior mirrors shall be OEM design Make repairs if any of the following conditions exist any portion of reflective surface is deteriorated mirror mounting loose stickers or other items obstruct any portion of the driver s view driver s view of images not clear due to distortion or other causes The vehicle shall be removed from service until repairs are made if mirror is missing or will not hold a set adjustment 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 to the rear of the bus It will also provide a view at least twelve feet perpendicular to the side of the bus at a distance of thirty two feet back from the f
6. The vehicle shall be removed from service until repairs are made if compressor mounting brackets or fasteners is cracked loose or missing The vehicle shall be removed from service until repairs are made if water pump is noisy bearing is damaged or coolant is leaking out The vehicle shall be removed from service until repairs are made if fan has any cracked bent or broken blades any portion of fan mounting is loose fan clutch is seized or loose The vehicle shall be placed out of service until repairs can be made if any portion of the alternator mounting brackets or fastener is cracked loose or missing The vehicle shall 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 heat damage or if there is any burnt wiring or wiring other than ground wires missing insulation The vehicle shall be removed from service until repairs can be made if any fuel system connection is stripped loose cracked or leaking The vehicle shall be taken out of service until repairs can be made if the radiator cap is missing The vehicle shall be taken out of service until repairs can be made if there is any noise binding or roughness is discovered in bearings wheel bearing endplay exceeds manufacturer s specifications maximum of 010 in and out play measured at bearing hub The vehicle shall be taken out of service until repairs can be mad
7. 29 Engine Oil Added 7 Stop Sign amp Walking Arm 30 Drain Fuel Water Separator 8 Batteries amp Cables 31 Engine Belts Adjust All 9 Tires LF RF LRO LRI 32 Transmission Fluid Added Record Air Pressure RRO_ DI 10 Tires LF__RF__LRO__ Up 93 ____ Drive Shaft Record Tread Dept RRO RRI 34 Differential Lube Added Seen 11 Entrance Steps amp Handrails ss 35 Springs and Hangers 12 Door Controls All a 36 Lettering amp Paint Sg 13 Warning Buzzers All EE 37 Body amp Sheet Metal Damage 14 Bus Body Glass All 38 Wheel Chair Mounts If equipped lt 15 Windshield Wipers Arm Travel Washer Fluid Added 39 Wheel Chair Lift If equipped a D I Sun Visor 40 Governor MPH maximum ss 17 Horn as 41 Check Travel Angle 18 Lights All Daminas 42 __ Brake Stroke Measurement 2 19 Turn Signals amp Cancellation s LE RF 20 Mirrors All LR RR Gil Dash Instruments All Se 43 ROAD TEST COMPLETED 22 Clean Int Ext BE 44 Brake meter test reading Optional 23 Fire Ext First Aid Kit Body Fluid Kit Remarks Record labor to nearest tenth hour Labor Hours Mech S LaborHours rr Mech Brake Adjustment Labor Hours Mech VMRS 013 001 Mechanic s Signature TD 30 Rev 11 04 63 NOTES 64
8. 77 Lift hood on bus Check washer fluid level Check alignment of belts balancer and any vibration of engine accessories Begin inspecting at right rear of engine compartment and check around engine to the left side Check for loose hoses wires leaks and all engine and mounting bolts If equipped with filter minder note the reading if required inspect the air cleaner housing filter and manifold Check automatic transmission level Return to cab and turn engine off Release parking brake Inspect all hoses and pump for seepage and leaks Inspect the radiator fan shroud charge air cooler oil cooler top tank and support rods for secure mounting condition corrosion and leaks Check engine oil level Check master cylinder and fill if required and equipped Inspect the engine compartment brake lines or hoses for secure mounting condition leaks routing chafing kinked or damaged lines UNDER THE BUS 78 79 80 81 82 83 84 85 86 87 88 89 90 91 Lift front axle with bottle jack as required all small bearing axles only 7500 lb GM Inspect steering shaft u joints and slip joint Inspect steering box for mounting leaks and any rust on bolts Inspect condition of pitman arm and drag link Inspect front left brake hose Inspect condition of brake can and all mounting hardware Measure slack adjustment travel Repeat this step on all four slack adjusters See P 8 for instructions Check
9. Inspect for presence type condition and securement of all wheel hardware Check for proper spacing of rear dual wheels and tires The vehicle shall be removed from service until repairs are made if any of the following conditions exist e Improper matching of rims and lock rings Evidence of slippage of wheel assembly on cast spoke hub Stud holes are elongated Any wheel or stud is loose rusting or corrosion indicating possible looseness Wheel stud or nut is broken or missing Improper spacer has been installed between dual wheels 7 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 shall be made as soon as possible Exception will be made if OEM was equipped with gray wheels INSIDE BUS EMERGENCY EQUIPMENT 1 Fire Extinguisher Check fire extinguisher for presence correct pressure inspection sticker tag inspection date mounting and accessibility proper UL Underwriters Laboratory rating nozzle for looseness damaged parts presence of a safety pin and tamper proof seal Make repairs if any of the following conditions exist loose bracket mount to panel inspection tag will expire before next scheduled inspection pressure is above or below the green zone fire extinguisher is not accessible to driver or not secured in mounting bracket box The vehicle shall be removed from service until rep
10. Make repairs if there is leakage at or around axle housing ends The vehicle shall be taken out of service until repairs are made if any portion of axle housing is cracked or bent 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 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 lubricant level is low differential gaskets or seals are leaking any external differential hardware or fasteners are loose or missing The vehicle shall be taken out of service until repairs are made if e Lubricant is excessively low in the differential e Differential pinion yoke has endplay or side play exceeding manufacturer s specifications e 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 any loose missing broken or worn spring clips any leaf spring or air suspension ride height is less than manufacturer s specifications rubber frame bumper is missing 25 The vehicle shall be taken out of service until repairs are made if 5 6 7 8 9 Any leaf spring is broken or missing Air bag type spring assembly is damaged
11. battery slide tray or box is damaged or deteriorated reducing security of batteries battery box door does not open or will not stay latched ENGINE COMPARTMENT FLUID LEVELS 1 Brake Fluid Check fluid level and condition Make repairs if any of the following conditions exist level of brake fluid in either side of master cylinder reservoir is lower than La inch from top or below Add mark if equipped brake fluid shows evidence of excessive water oil or dirt contamination If fluid is low an inspection shall be made The vehicle shall be removed from service until repairs are made if any evidence of a fresh leak is detected or fluid is excessively low less than La full 2 Power Steering Fluid Hydraulic Brake Assist 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 The vehicle shall be removed from service until repairs are made if fluid is excessively low less than La full 3 Oil Check the level and condition of oil Repair if engine oil is below Add mark The vehicle shall be removed from service until repairs are made if no oil is observed on dipstick or 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
12. e Stop arm light does not operate e Does not flash between 60 and 120 times per minute e Stop arm does not operate as designed Crossing Control Arm Crossing arms required on all 1977 and newer buses Check front bumper mounted student crossing arm for operation condition mounting and retention device i e magnet Make repairs if any of the following conditions exist crossing arm mount bolts loose hinge bushings need lubrication or are damaged air leaks from air operated diaphragm arm does not fully extend 90 degrees arm is improper height level with bumper when out The vehicle shall be removed from service until repairs are made if any of the following conditions exist e Bus is not equipped with a student crossing arm assembly and arm e Crossing arm does not extend 60 degrees from bumper e Crossing arm does not deploy when stop arm is activated GENERAL CONDITION BUS EXTERIOR 1 Mirror Mounts and Mirror Glass Check exterior mirror mounting brackets and mirror glass for tightness and condition Make repairs if any of the following conditions exist mounting bracket bolts or mirror glass loose mounting or bracket bolts missing The vehicle shall be removed from service until repairs are made if 43 2 3 4 5 6 7 e Mirror brackets are severely bent broken or mounting is insecure e Mirror glass is discolored e Mounting of mirror or bracket made by different manufacturers e Driver
13. hoses etc or if transmission fluid is seeping at any location except on exhaust system The vehicle shall be removed from service until repairs are made if fresh transmission fluid is found 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 shall be removed from service until repairs are made if the power steering fluid is dripping FUEL TANK 1 Leaks Inspect fuel tank assembly for leaks The vehicle shall be taken out of service until repairs are made if any of the following conditions exist e Fuel leakage from the tank e Fuel cap is missing e Fuel tank has any cracks e Connections are loose at the tank 23 2 3 4 1 2 Mounting Inspect fuel tank mounting system and barrier for securement and condition The vehicle shall be taken out of service until repairs are made if e Any portion of fuel tank mounting system is missing loose cracked or broken including support brackets retaining straps and chassis frame e Fuel tank mounting fasteners are loose or missing e Crash barrier assembly is damaged insecurely mounted or missing Hoses Inspect all fuel lines and under bus fuel system components for
14. in feet from initial speed of 20 m p h 4 Emergency Brake Systems Application and Braking distance in feet from initial speed of 20 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 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 indicati
15. pair protective 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 The vehicle shall be removed from service until repairs are made if entire contents or kit are missing 4 Reflectors Check for emergency roadside reflectors These are required on all buses 2000 and newer Check quantity for three reflectors Remove the bus from service if reflectors are missing NEUTRAL SAFETY SWITCH 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 shall be removed from service until repairs are made if the starter will engage in any gear other than park or neutral SHIFTER Check that shifter operates easily that it correctly indicates the gear that the transmission is in and has a functional detent mechanism with a ball knob handle on end of shift lever Make repairs if shifter does not shift easily into all gears indicator is misaligned or shifter has a loose ball or knob handle The vehicle shall be removed from service until repairs are made if e Shifter will not shift into all available gear positions The indicator indicates wrong gear Detent is non functional or if ball or knob handle is missing from end of shifter lever 32 1 2 3 1 ENGINE CONTROLS Key Switch Check
16. 144 Notice operation of child reminder system if applicable 145 Remove key and leave in designated location 146 Complete and sign 30 day form 51 APPENDIX B OUT OF SERVICE ITEMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 The vehicle shall be removed from service until repairs are made if brake reading is below 60 percent The vehicle shall be removed from service until repairs are made if air pressure gauge s are not working The vehicle shall be removed from service until repairs are made if the cutout pressure is too low below 100 p s i or too high above 130 p s i The vehicle shall be removed from service until repairs are made if vehicle moves with parking brake applied The vehicle shall be removed from service until repairs are made if pressure leaks more than two 2 psi per minute brakes not applied more than three 3 psi per minute with service brake applied The vehicle shall be removed from service until repairs are made if either light or buzzer is inoperative or buzzer fails to operate by 50 psi or continues to operate above 70 psi The vehicle shall be removed from service until repairs are made if any leaks are found in the brake or hydraulic system The vehicle shall be removed from service until repairs are made if brake pedal reserve is less than one inch from floor The vehicle shall be removed from service until repairs are made
17. A frame mounting is cracked loose or has been welded U Bolts Inspect spring U bolts for condition and securement Make repairs if U bolt is misaligned or rust underneath any U bolt nuts indicates the possibility of looseness The vehicle shall be taken out of service until repairs are made if any shock mount bracket U bolt seating plate or nut is loose missing cracked or stripped 18 9 Shocks Inspect shocks for condition and securement Make repairs if there is wetness around shock body due to leaking shock fluid or any shock mounting or fastener is loose The bus shall be removed from service until repairs can be made if any shock is broken or missing 10 Springs Inspect front springs for condition securement and alignment Make repairs if any of the following conditions exist loose missing broken or worn spring clips coil or leaf spring has flattened and ride height is less than manufacturer s specifications rubber bumper is missing The vehicle shall be taken out of service until repairs are made if e Kither front spring saddle is missing if equipped Any leaf spring is broken cracked or missing Spring eye is worn or spread such that bushings are loose in spring eye Coil spring is broken or insecurely mounted Non OEM blocks or spacers are installed There is misalignment of spring leaves or other evidence that center pin is loose or broken Either front coil or leaf spring is worn so that the rubber frame
18. 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 The vehicle shall be removed from service until repairs are made if pressure leaks more than two 2 psi per minute brakes not applied more than three 3 psi per minute with service brake applied 6 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 a Switch ignition key switch to on position b drop air pressure Low air warning buzzer and light should activate by the time the pressure drops to 50 psi c Start the engine and build system air pressure Warning buzzer and light should deactivate by 70 psi The vehicle shall be removed from service until repairs are made if any of the following conditions exist e Low air warning light is inoperative e Low air buzzer is inoperative e Buzzer or light fails to operate by 50 psi or continues to operate above 70 psi 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 shall be checked on hydraulic brake equipped vehicles 1 Any visible leaks in the brake or hydraulic assist system The vehicle shall be removed from service until repairs are made if any leaks are found in the brake or hydraulic system Check the brake warning
19. The vehicle shall be removed from service until repairs are made 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 is felt when pressing down on seat back top or if any portion of seat back foam is missing or damaged The vehicle shall be removed from service until repairs are made if any seat foam is missing Cuts and other upholstery damage Inspect seat upholstery for condition and damage Make repairs if any of the following conditions exist seat upholstery cut or torn and foam is visible through cut seat upholstery not repaired properly The vehicle shall be removed from service if any vehicle that came equipped with fire block upholstery all lift buses and all others manufactured after late 1996 has been retrofitted with upholstery other than fire block 38 5 6 7 1 2 3 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 seat bottom is not securely anchored to seat frame or seat bottom padding cover has damage and deterioration Inspect flip up type seat bottom at side em
20. affecting the visibility or color of the light The vehicle shall be removed from service until repairs are made if e Brake light circuit fails to function e Brake pedal is in released and brake light switch sticks or lights stay on e Brake light lens is not red or is not proper type meeting SAE specifications Tail Lights Check tail light and lens for operation and condition Make repairs if any of the following conditions exist tail light fails to function taillight lens is cracked taillight lens is darkened faded or dirty significantly affecting the visibility color of the light taillight lens is damaged white light is visible The vehicle shall be removed from service until repairs are made if e Taillight circuit fails to function e Tail light lens is not red e Taillight lens is not proper type meeting SAE specs 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 shall be removed from service until repairs are made if backup light stays on all of the time backup lights 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 1
21. 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 Key switch in ON position Engine not operating pump and bulb check Key switch in START position Light OFF electric hydraulic Pump operates when service Brakes are applied Light ON and electric hydraulic Pump operation some vehicles SEE NAVISTAR MANUAL Light ON and electric hydraulic Pump operates when service Brakes are applied Light ON momentarily and Electric hydraulic pump operates Key switch in ON position and Engine operating with service Brakes applied Light OFF 2 Check brake pedal reserve distance from floor upon one firm brake application engine off hydraulic boost depleted The vehicle shall be removed from service until repairs are made if brake pedal reserve is less than one inch from floor a Check brake pedal fade continues to fall to floor after initial firm application with engine off The vehicle shall be removed from service until repairs are made if there is any brake pedal fade falling away after initial firm application b Check all brake hardware and components inside the bus for secure mounting routing and condition including
22. any portion of pushrod is rubbing against body of chamber or chamber is misaligned pushrod on the left and right side are not mounted in identical same slack adjuster location hole same effective slack adjuster length The vehicle shall be taken out of service until repairs are made 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 The vehicle shall be taken out of service until repairs are made if Lining is broken cracked or loose on shoe Shoe platform or webbing is cracked damaged There is any loose damaged or missing foundation brake hardware within the drum Friction surface is contaminated with oil grease or brake fluid Lining with a thickness less than 3 16 inch on a continuous lining or for a shoe with two pads IF EQUIPPED WITH DISC STYLE BRAKES MINIMUM IS 1 8 Drums Inspect front brake drums for condition The vehicle shall be removed from service until repairs can be made if e There is any grease oil or brake fluid on the inside of the drum e Any drum is not mounted securely to hub e Fasteners are loose e Drums have external crack or cracks that open upon brake application Rotors Inspect front brake rotors for mounting and condition The vehicle shall be removed from service until repairs can be made if e Rotor mounting is not secure e Friction surface is c
23. be removed from service until repairs are made if any of the following conditions exist any sharp edges rust through or projections from paneling that could cause injury to passengers or driver The vehicle shall be removed from service until repairs are made if there are any aerosol cans containers with flammable volatile chemicals or any unlabeled container located inside the bus The vehicle shall be removed from service until repairs are made if seals or weather stripping allow air fume leaks into the driver s compartment The vehicle shall be removed from service until repairs are made if either wiper fails to operate The vehicle shall be removed from service until repairs are made if any portion of heating system within the passenger area creates sharp edges projections or other hazards to passengers The vehicle shall be removed from service if protective cage around driver fan is missing loose or damaged The vehicle shall be removed from service until repaired if any mirror is missing or if any mirror is cracked pitted clouded or deteriorated to the extent that vision is obscured or will not hold a set adjustment The vehicle shall be removed from service until repairs are made if any crossover mirror is missing any mirror is cracked pitted clouded or deteriorated to the extent that vision is obscured or will not hold a set adjustment mounting of any mirror and bracket made by different manufacturers The vehicle shall be remo
24. free play Check wheel bearing and kingpin play Examine under the left front tire area check the condition of kingpins and front axle Inspect left tie rod end Visually inspect tie rod tube for straightness Inspect and note the remaining shoe or pad thickness Inspect front left spring u bolts and hangers 49 92 Inspect all around the oil pad and underneath of engine 93 Inspect right front spring u bolts and hangers 94 Inspect and note the remaining shoe or pad thickness on the right front 95 Inspect the right front tie rod end 96 Check condition of right kingpin and front axle 97 Check the right front free play 98 Inspect the brake hose brake can and all brake hardware 99 Check wheel bearing and kingpin play 100 Inspect engine crossover and engine mounts for condition 101 Inspect front out riggers and wheelhouses 102 Insect around transmission Check for leaks loose wires and mounting 100 Visually check front u joint check down drive shaft for proper alignment 101 Follow battery cables to box check routing clamps and frame insulators 102 Follow frame down left side of bus Checking all lines floors body clamps outriggers and cross members for condition 103 Inspect air tanks and drain 104 Inspect air dyer if equipped 105 Inspect the front half of the left rear spring hanger and u bolts 106 Inspect the pinion seal and rear u joint 107 Follow drive shaft forward inspec
25. from service until repairs are made if any of the following conditions exist emergency door latch mechanism is stuck or requires more than 40 pounds to release emergency door handle is mounted horizontally to allow hitching onto the bus The vehicle shall be removed from service until repairs are made if any of the following conditions exist hood cannot be opened as designed safety latch does not secure hood hood prop rod or hold open feature does not function properly The vehicle shall be removed from service if the bus is dirty to the point that visibility through any window or light lens is significantly reduced The vehicle shall be taken out of service until repairs are made if travel angle is uneven 59 165 166 167 168 169 170 171 172 The vehicle shall be removed from service until repairs are made if free play exceeds maximum allowable amount excessive tire shimmy occurs roughness is detected in steering gear The vehicle shall be removed from service if excessive noise is detected or if engine fails to operate properly The vehicle shall be removed from service until repairs are made if excessive noise and vibration are detected during road test The vehicle shall be removed from service until repairs are made if transmission is slipping The vehicle
26. is not a violation LONG STROKE CLAMP TYPE BRAKE CHAMBER DATA TYPE OUTSIDE DIAMETER BRAKE ADJUSTMENT LIMIT 12 5 11 16 14 5cm 1 3 4 4 5cm 16 6 3 8 162mm 2 0 51mm 20 6 25 32 172mm 2 0 51mm 24 7 7 32 184mm 2 0 51mm 24 7 7 32 184mm 2 5 64mm 30 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 INSIDE BUS BRAKE COMPONENT CHECK Air Brakes All of the following items shall be inspected on Air Brake Equipped Vehicles 1 Air Pressure Gauges On buses built after March 1975 check for the presence of two gauges or single gauge with dual needles One gauge or needle should indicate air pressure available to the primary air brake system and the other should indicate air pressure available to the secondary brake system Both gauges must be accurate to within 7 at 100 lbs x 7 bs The vehicle shall be removed from service until repairs are made if gauge s are not working Note If bus is equipped with anti lock braking system refer to appropriate Manufacturer s Service Manual for inspection criteria 2 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 agai
27. leaking Air lines or valves are damaged leaking Misalignment of spring leaves or other evidence that centering pin is loose or broken 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 shall be taken out of service until repairs are made if any U bolt seating plate or shock mount bracket nut is loose missing cracked or stripped Shocks Inspect shocks for condition and securement Make repairs if any of the following conditions exist wetness around shock body due to leaking shock fluid shock mounting or fastener is loose The bus shall be removed from service until repairs are made if any shock is broken or missing Spring Hanger Inspect condition of spring hangers and pinch bolts Make repairs if any of the following conditions exist spring hanger has significant side wear at the spring eye spring hanger is worn pinch bolt is stripped or missing so that spring pin cannot be clamped tightly The vehicle shall be taken out of service until repairs are made if spring shackle hanger is loose cracked or broken Pins and Bushings Inspect condition of pins and bushings Inspect front spring pins and bushings for wear lubrication and securement The vehicle shall be removed from servi
28. 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 e Recapped tire has been re grooved e Front tire is a recapped or re grooved tire e There is evidence that any tire has been re grooved using unapproved procedure Pressure With tire cold check pressures on all tires and record on inspection form Make repairs if any of the following conditions exist pressure in tire is less than the maximum cold inflation pressure stated on the sidewall of the tire minus 20 pressure in tire is greater than 5 above maximum cold inflation pressure stated on sidewall of the tire Adjust pressure if there are more than 20 differences in tire pressure on a particular axle Damage Inspect for damage to wheels and tires Make repairs if any of the following conditions exist tire is mounted so it cannot be filled with air foreign material in the tire tread which could cause damage or loss of air pressure valve cap or extension is missing minor dents or bends in a rim The vehicle shall be taken out of service until repairs are made if any of the following conditions exist e Cuts abrasion or other damage to tire sidewall resulting in exposed or damaged cord e Separation bulges other than normal manufacturer bulge or other damage within the carcass of the tire e Cracks that run around the bead or sidewall of the tire are present e Retread tire that has any sep
29. 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 1 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 causing insecure mounting of battery 2 Battery Terminals Check terminals for cleanliness tightness and condition Make repairs as soon as possible if terminals are loose damaged corroded or have missing hardware 13 3 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 and cable is smaller than original equipment size 4 Cleanliness Check cleanliness of batteries Repair if battery top or sides are corroded greasy dirty or wet with electrolyte If battery is cracked or damaged it shall be replaced before operating 5 Tray Check battery tray for operation condition and securement Make repairs if the following conditions exist battery slide tray is corroded dirty or hard to slide in and out battery slide tray securement device or tray stop is missing or nonfunctional battery tray does not slide in and out
30. or if any yoke is cracked or damaged Hanger Bearings Inspect hanger bearings and rubber insulators for condition and securement Make repairs if hanger bearing rubber insulator is deteriorated damaged oil soaked or hanger bearing support is misaligned The vehicle shall be taken out of service until repairs are made if e Bearing outer race is loose in insulator e Inner race is loose on shaft e Significant play in hanger bearing e Missing or damaged hardware fasteners in hanger bearing or support assembly Guards Inspect for presence and condition of drive shaft guards Make repairs if any drive shaft guard is bent damaged loose or has damaged mounting fasteners The vehicle shall be taken out of service until repairs are made if guard is missing Drive Shaft Park Brake Inspect drive shaft park brake assembly for adjustment and condition Check mounting securement linkage drum and all other related hardware Make repairs if lining is worn down to 2 32 inch from top of rivet head lining is contaminated with grease oil The vehicle shall be taken out of service until repairs are made if e Lining is broken cracked or loose e Drum is cracked or has excessive heat damage or scoring of friction surface e Actuating mounting hardware or fastener is damaged loose missing e Park brake is not adjusted per manufacturer s specifications REAR SUSPENSION Axle Housing Inspect axle housing for condition and leakage
31. or repair of any activity bus 474 1979p Cx 150 61 19557 e Ss 25 L t Ga A237 S La APPENDIX D 30 Day Inspection Video An instructional video produced in 2000 was provided to each school bus garage in North Carolina as an educational tool for new technicians and a refresher for others performing 30 day inspections North Carolina Thirty Day Bus Inspection With an introduction from Ned Jarrett this video serves asa guide and reference for the required 30 day inspection of North Carolina s school buses Inspection Preparation Bus Interior Engine Compartment Bus Exterior Bus Underside Road Test 62 APPENDIX E TD 30 Inspection Form Note The work order for a 30 day inspection is generated by the computer system Following is a representation of the items contained on the technician s copy of the work order 30 DAY SCHOOL BUS INSPECTION WORK SHEET ORDER MILEAGE BUS NO MAKE MODEL SCHOOL DATE Needs Needs OK Items Inspected Repairs OK Items Inspected Rapalrs 1 Steering Fluid Added See 24 Seats All covers foam pads frames seat cushions secure 2 Brake Foot Check amp Adjust ng 25 Seat Belts All 3 Clean Slacks w wire brush e 26 Exhaust System 4 Drain Air Tanks Completely n 27 Cooling System Added D 5 Brake Fluid Added 28 A Freeze Protection 6 Brake Park Check amp Adjust
32. pushrod and clevis assembly brake pedal assembly and rubber cover pad 10 if originally equipped Repair rubber cover if it is worn The vehicle shall be removed from service until repairs are made if rubber cover pad is missing or worn out c Check the emergency brake control assembly The vehicle shall be removed from service until repairs are made if emergency brake control assembly is hard to operate or doesn t latch and release properly 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 The vehicle shall be removed from service until repairs are made if park brake doesn t hold or functions improperly 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 is 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 Repair steering wheel if cracked plastic or worn in the contact area The vehicle shall be removed from service until repairs are made if free play lash exceeds the amounts specified in
33. repairs are made if any of the following conditions exist e Any belt tensioner that does not pivot or move freely and apply spring pressure on belt e Any tension on belts that is too loose based on specifications of type tension gauge used e Tension of any belt using ruler method that is too loose when firm pressure is applied greater than 34 inch deflection e Any slippage is detected 2 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 belt is glazed belt is oil saturated dry rotted cut or plies of belt s are separated belt is distorted or twisted 3 Routing Visually inspect belt for rubbing or contact with objects other than pulleys and for routing around correct pulleys Make repairs if any of the following conditions exist belt is making contact with objects other than pulley or belt is routed around incorrect pulley 4 Belt Alignment Visually inspect belts for proper alignment Make repairs if any belt is not inline or if any belt is misaligned that could result in failure HOSES NOTE References to hoses includes all types of hoses located in the engine compartment including power steering coolant air compressor intake vacuum brake hydraulic assist engine oil and transmission hoses 1 Clamps and Connections Visually and physically check
34. section are based upon Federal Motor Carrier Safety Regulations An inspector or technician on all school buses shall perform a brake performance test when PM services are conducted A consistent method for brake testing is to use a brake testing device during each 30 day inspection and record braking efficiency on an inspection form A reading between 60 65 percent should result in further investigation of the braking system by the technician This brake performance test will not override any other defect found during the brake inspection 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 vehicle shall be removed from service until repairs are made if brake reading is below 60 percent The purpose of requiring 60 percent braking efficiency is to be able to test the bus while unloaded Sixty 60 percent braking efficiency is the equivalent of the 43 5 percent braking efficiency required by law with a full load Best results will be obtained if brakes are depressed fully but not locked during meter testing 393 52 Brake Performance 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 c of this section 2 De
35. service until repairs are made if the low oil pressure warning light or buzzer is inoperative either constant or momentary The vehicle shall be removed from service until repairs are made if any wire or connector is cut or severely chafed wire conductor is exposed or routed against a sharp edge any interference with the driver controls The vehicle shall be removed from service until repairs are made if there are any open holes or unsealed area in the firewall The vehicle shall be removed from service until repairs are made if the following exist unsealed holes or cracks through the underside of the bus aisle molding strip is not securely fastened to the floor or aisle or if cover molding presents a sharp edge or protrusion any damage to the rubber floor covering which could cause a tripping hazard The vehicle shall be removed from service until repairs are made if step well support structure is broken or step well is rusted through 57 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 The vehicle shall be removed from service until repairs are made if entrance handrail is missing or not securely mounted handrail fails the NHTSA String and Nut Test The vehicle shall
36. size e Chamber is not matched both sides to be 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 slack adjuster is dirty and prevents technician from inspecting for cracks or prevents the lock sleeve from seating slack adjuster is mounted so that adjuster bolt is facing chamber older model Chevrolet and Ford manual slacks S cam shaft and or S cam bushing total wear up and down is greater than 040 S cam in and out endplay is more than 060 The vehicle shall be taken out of service until repairs are made if e Any portion of slack adjuster or S cam is missing broken cracked or badly worn e S cam snap ring is missing e Slack adjuster has frozen or stripped worm gear or ratchet assembly Pushrods Inspect pushrod assembly for condition securement and alignment Make repairs if pushrod is rubbing against body of chamber or chamber is misaligned The vehicle shall be taken out of service until repairs are made if e Any portion of pushrod assembly locknut pushrod clevis and pin or cotter pin is loose missing or damaged e Pushrod on left and right sides are not mounted in identical same slack adjuster location holes same effective slack adjuster length 27 6 7 8 9 Linings Inspect brake lining through inspection cover or hole Make repairs if any of the following conditions
37. that hose connections or clamp s are tight Make repairs if any of the following conditions exist hose connection or clamp s is loose or too tight digging into hose hose connection or clamp s is stripped damaged 2 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 3 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 AIR FILTER ASSEMBLY Check air cleaner assembly housing lid piping gasket seal and clamp s for securement condition and check filter minder Check for presence of wing nut and seal if equipped Make repairs if any of the following conditions exist any portion of the air cleaner assembly or mounting is loose or damaged 15 including piping nuts bolts or clamps worn or damaged seals gaskets any air or vacuum leaks or missing components Vehicle shall be removed from service if the diesel air filter restriction exceeds manufacturer s specifications POWER STEERING PUMP Check securement and condition of power steering pump The vehicle shall be removed from service until repairs are made if any portion of the power steering pump mounting brackets or fasteners is cracked loose or miss
38. the chart below STEERING WHEEL PLAY LASH MEASUREMENTS Free Play Lash Measurements Power Assist 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 shall be placed out of service until repaired To check power assist operation run the engine at fast idle turning the steering wheel a full right and left turn to feel for binding jamming or belt slippage 2 Steering column Check steering column inside bus for up and down play perpendicular to shaft and for proper mounting The firewall rubber boot should also be checked for proper seal Make repairs if the boot is found damaged or torn The vehicle shall be taken out of service until repairs are made if any of the following conditions exist e Side to side play in steering column exceeds 1 4 inch or up and down play exceeds one 1 inch e Column assembly mounting including floor mounting plate or fasteners are loose 11 e Tilt telescopic assembly if equipped will not stay in the locked position e Steering column U joint inside the bus if equipped is loose damaged or noisy after lubrication e Flexible coupling if equipped rag joint has loose or missing fasteners damaged flexible disc or elongated holes e Any column U joint pinch bolt other c
39. two inches in from the outer border e Windshield window fogging or clouding results in reduced visibility of a mirror e Tinting on the windshield or windows to the side of the driver that is not 70 light transmission or clearer e Tinting on any windows behind the driver s location that is not 28 light transmission or clearer Latches and Window Operation Check latches and windows for condition and operation Make repairs if any of the following conditions exist latches are hard to operate or any window does not move up and down freely windows do not stay closed window will not move full travel up and down The vehicle shall be removed from service if there is any loose damaged or protruding window hardware that would be a hazard to passengers Sun Visor Check drivers sun visor for condition and operation Make repairs if any of the following conditions exist sun visor is too tight and cannot be adjusted driver sun visor is cracked damaged clouded dirty will not stay in position or has unauthorized stickers Cannot be altered from OEM The vehicle shall be removed from service until repairs are made if sun visor is missing or has sharp protruding edges that could cause personal injury WHEELCHAIR LIFT DOOR AND SECUREMENT SYSTEM Operate lift through complete cycle and inspect for proper operation condition safety features manual backup system fluid leaks mounting barrier operation warning light buzzer operati
40. 0 in and out play measured at bearing hub 2 I Beam Inspect I beam axle assembly The vehicle shall be taken out of service until repairs can be made if I beam has been cut modified or damaged other than qualified machine shop 17 3 4 5 6 7 8 to repair axle eye there is any bluing or other evidence that the I beam has been heated King Pins Inspect king pin assemblies Make repairs if any of the following conditions are found locking pin is loose end cap O rings or bolts are loose or missing The vehicle shall be taken out of service until repairs can be made if Locking pin is backing out loose or missing Kingpin movement is more than LA inch measured at the outside edge of the tire Vertical up and down play in kingpin assembly is greater than 030 Thrust bearing is damaged or missing NOTE If play is beyond specifications wear may be kingpin axle eye and or king pin bushings Vehicle shall 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 Spring Hanger Shackles and Attachments Inspect condition of spring hangers and pinch bolts Make repairs if any of the following conditions exist front spring hanger has significant side wear at the spring eye front spring hanger is worn pinch bolt is stripped or missing so that spring pin cannot be clamped tightl
41. 6 17 18 19 20 21 22 23 24 Enter the driver door Check condition of hinges panels and door bumpers Inspect condition of handrails steps and floor covering Operate the driver seat and the seat belt for secure mounting condition and proper operation Adjust the seat through all positions and operate the seat belt Inspect the ignition switch driver s key should not be in ignition Check the ignition switch for proper operation Check to ensure air gauge is below ten pounds if air brake vehicle With the ignition switch in the off position depress the brake pedal on hydraulic brake buses and inspect the brake motor for proper operation With the ignition switch in the on position check the operation of the low air light brake warning light buzzer and any engine lights With the transmission in drive check the operation of the neutral safety switch With the transmission in neutral and parking brake applied turn the ignition switch to start and check the starter for proper engagement and disengagement Inspect the engine for noise idle misfire and smoke Inspect volt gauge and oil pressure gauge for immediate reaction Notice reaction in the air gauge for proper build Inspect the interior roof rear view mirror and sun visor for secure mounting condition and proper operation Inspect the windshield wipers and washer for proper operation Inspect all front glass for cracks clarity glazin
42. 8 Emergency Door Operation Check emergency door for operation from exterior of bus Make repairs if emergency door latch mechanisms or hinges need lubrication The vehicle shall be removed from service until repairs are made if any of the following conditions exist emergency door latch mechanism is stuck or requires more than 40 pounds to release 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 hood is misaligned or rubbing cowl hood is rubbing air filter assembly hood hinges are not lubricated or are damaged bumper or securement device is damaged or missing The vehicle shall be removed from service until repairs are made if any of the following conditions exist e Hood cannot be opened as designed e Safety latch does not secure hood e 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 The vehicle shall be removed from service if the bus is dirty to the point that visibility through any window or light lens is significantly reduced ROAD TEST Road Test Every bus is required to have a road test when monthly inspections are performed The following items shall be checked during the road test a Travel angle The travel angle shall be checked w
43. 997 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 broken darkened CLEARANCE LIGHTS REFLECTORS amp STROBE LIGHT Clearance and Marker Lights Check lights and lens for operation condition and location Make repairs if any of the following conditions exist clearance light fails to function clearance light lens damaged or white light visible rear clearance light lens not red intermediate or front lens not amber clearance light lens has darkened faded or dirty which significantly affects the visibility or color of the light 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 reflector is damaged or cracked required reflectors are missing reflector is faded significantly affecting its original color 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 42 EIGHT LIGHT SYSTEM STOP ARM amp CROSSING ARM Eight Light Warning Lamps Require 100 of L
44. EDs Operating 1 Eight Light Warning System Lights Check eight light warning system lights for operation and 2 3 ww condition Make repairs if any of the following conditions exist amber or red pilot light fails to function light hood if equipped is damaged so that it obstructs visibility of the light The vehicle shall be removed from service until repairs are made if any of the following conditions exist e Amber or red light does not function or is dim Amber red lights both front and rear do not alternately flash side to side Warning light is not red outer or amber inner or is not the proper type Warning light lens is damaged and white light is visible Warning light lens has darkened faded misaimed or dirty affecting the color of the light or reducing the visibility to less than 500 feet in bright sunlight e Warning lights do not function Stop Arm Check stop arm for specifications operation fully extends to 90 degrees and condition Make repairs if any of the following conditions exist wiring ground strap loose or not properly routed and secured hinge or bushing is dry of lubrication stop arm assembly or blade mounting loose stop arm extends more or less than 90 degrees stop arm does not fully extend or retract or is slow air operated stop arm diaphragm has air leak stop arm paint or decal is significantly faded or discolored The vehicle shall be removed from service until repairs are made if
45. IVELINE Drive shaft Inspect drive shaft for condition Make repairs if drive shaft balancing weight if originally equipped is missing or drive shaft has foreign material wrapped around it The vehicle shall be taken out of service until repairs are made if drive shaft is bent or seriously dented Cracks or other damage in the drive shaft which could cause structural failure U Joints Inspect U joints or constant velocity 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 shall be taken out of service until repairs can be made if e Hardware or fasteners are missing in any U joint or CV joint assembly e U joint has significant cross shaft to bearing cup play or CV joint has significant play e U joint or CV joint shows evidence of significant rusting of bearings e Bearing cup in yoke is loose 24 3 4 5 6 1 2 3 4 Yokes Inspect drive shaft yokes for condition and lubrication Make repairs if any of the following conditions exist drive shaft splines are unlubricated dust cap on yoke is missing zerk grease fitting is missing or clogged cork washer in dust cap is missing The vehicle shall be taken out of service until repairs are made if any yoke has significant play in splines
46. ND BELT Check driver seat and belt for condition mounting and operation Make repairs if any of the following conditions exist seat air or manual adjustment binds or difficult to operate seat adjustment loose or adjustment hardware missing seat upholstery or foam deteriorated or damaged seat bottom loose in frame or mispositioned if seat belt retractor cover belt covers are damaged or loose seat belt does not fully extend and retract The vehicle shall be removed from service until repairs are made if any of the following conditions exist e Seat frame and mounts are cracked broken or distorted e Seat moved from OEM position unless repositioned using written OEM approved mounting instructions e Driver seat belt is missing or inoperable e Seat belt is routed improperly e Seat belt buckle and tongue assemblies do not latch and release properly PASSENGER SEATS Frames Inspect passenger seat frames for condition of welds tubing and hardware Check for presence of non OEM seat frames Make repairs if seat back frame is repaired using non OEM hardware The vehicle shall be removed from service until repairs are made if e Seat frames or welds are broken or cracked e Seat frame hardware has been added or modified which results in projections or sharp edges e Non OEM seat frames have been installed Mounting Inspect condition of passenger seat mounting Make repairs if seat mounting at floor or seat rail is loose
47. North Carolina School Bus Inspection Manual Regulations And Procedures Public Schools of North Carolina January 2005 ATTENTION This manual has been developed for those engaged in school bus or activity bus inspection with the goal of inspection uniformity thereby increasing the likelihood that fewer buses will be operated in an unsafe condition From this point forward activity buses are referred to as school buses A committee from a variety of Federal amp State resources developed the regulations described herein 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 technical 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 every 30 calendar days A computer database operated by the state schedules buses for inspection and causes them to appear 10 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 shall be directed to the North Carolina Department of Public Instruction Transportation Services
48. Section Phone 919 807 3570 All North Carolina School Systems may copy and reproduce this document for their personnel Anyone else wishing to copy this manual is requested to contact the North Carolina Department of Public Instruction Transportation Services Section A copy of this manual must be present during each 30 day inspection MESSAGE TO TECHNICIANS This manual has been prepared by the statewide committee as a guideline for the proper inspection of school buses It includes federal and state regulations and procedures identified in previous editions of this manual and others identified by the committee It is intended for adoption by the State Board of Education under G S 115C 240 c These regulations and procedures are designed to provide the safest transportation possible for the precious cargo being transported by North Carolina school districts Any deviation from these regulations and procedures could result in the injury or death of our passengers The Transportation Department plays a vital role in the education and development of North Carolina s school children By maintaining a safe school bus the bus technician helps provide a means for a child to get to school and obtain an education This publication attempts to cover a majority of the items that are required to be inspected and serviced on school buses for the 30 day inspection Due to evolving specifications and make up of schools buses it would be virtually imp
49. a cracked brace underneath the body or bumper brace is broken cracked or missing Skirts Inspect body skirts for securement and condition Make repair if body skirt brace has cracked broken sheet metal or mounting points Frame Rails Inspect condition of chassis frame rails cross members and all hardware attaching points Make repairs if ONE bolt is missing from front cross member The vehicle shall be taken out of service until repairs are made if there are cracks in either frame rail or cross member there are any loose missing rivet or other fastener securing a cross member to the frame missing more than one front cross member bolt EXHAUST SYSTEM 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 missing or if there is any physical damage to exhaust system The vehicle shall be taken out of service until repairs are made if there is leakage which is audible or felt around any portion of the exhaust system including manifold pipe sections or junctions Mounting Inspect mounting of the exhaust system Make repairs if any of the following conditions exist exhaust system hanger not securely mounted loose exhaust pipe or clamp clamp is missing originally installed exhaust hanger missing broken or detached from the exhaust system frame mounting point Muffler Inspect condition
50. abeled inside and outside the bus as Emergency Door or Emergency Exit emergency door emergency windows or emergency exit roof hatches do not 39 have readable instructions for operation on the inside of the exit or readable from the inside emergency exit door pad is ripped or has loose mounting door pad is missing or has any protruding edge WINDSHIELD SIDE amp REAR WINDOWS 1 2 3 4 1 Glass cracks Inspect windshield and all windows for cracks and other damage Make repairs if any of the following conditions exist windshield cracks in the driver s direct field of vision or any pock marks that obstruct the driver s vision or any pock mark larger than a quarter anywhere on windshield cracks in the windshield or any window greater than two inches in length crack in non laminated safety glass The vehicle shall be removed from service until repairs are made if any of the following conditions exist glass is missing laminated windshield or laminated window glass is broken or splintered that might cause injury when touched 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 or is reduced in visibility through the windshield or any windows The vehicle shall be removed from service until repairs are made if e Windshield or any window that provides visibility to any mirror is fogged more than
51. airs are made if there is any crack in either frame rail or cross member there is any loose missing rivet or other fastener securing a cross member to the frame The vehicle shall be taken out of service until repairs are made if there is any leakage which is audible or felt around any portion of the exhaust system including manifold pipe sections or any junction The vehicle shall be removed from service until repairs are made if the muffler is leaking and produces an audible sound or exhaust is felt from the leaking area weephole is excluded The vehicle shall be removed from service until repairs are made if the tailpipe is leaking and produces an audible sound or exhaust is felt from the leaking area The vehicle shall be taken out of service until repairs are made if tread depth of either front tire is less than 4 32 inch 2 32 inch for rear tires at three points spaced equally around the circumference of the tire in the same major tread groove 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 recapped tire has been re grooved front tire is a recapped or re grooved tire there is evidence that any tire has been re grooved using unapproved procedure The vehicle shall be taken out of service until repairs are made if any of the following conditions exist cuts abrasion or other damage to tire sidewall resulting in exposed or dama
52. airs are made if any of the following conditions exist e Rating is less than 2 2 pound minimum 2002 and newer must have 5 lb minimum and 10BC rating e No fire extinguisher on bus e Tamper proof seal material cannot be broken NOTE Six years from the manufacturing date all type ABC BC or Halon fire extinguishers require a six year maintenance They are also required to have a hydro test twelve 12 years 31 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 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 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 The vehicle shall be removed from service until repairs are made 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 LL S C powder sanitizes deodorizes encapsulates 1 odor reducing mask 1
53. airs if any of the following conditions exist wiring or connectors are unsecured corroded or improperly routed any connector connection is unsecured The vehicle shall be removed from service until repairs are made if e Any wire or connector is cut or severely chafed e Wire conductor is exposed or routed against a sharp edge e Any interference with the driver controls 2 Cab Hoses Inspect all hoses for leaks condition routing abrasion and presence of heater hose 3 shielding Make repairs if hoses are weathered cracked worn or improperly routed hose is unshielded in the driver s compartment Firewall Seals Inspect firewall for cracks unsealed openings and sound insulation material Make repairs if sound deadening insulation package is unsecured or deteriorated The vehicle shall be 34 removed from service until repairs are made if there are open holes or unsealed area in the firewall 1 2 3 4 5 6 7 BUS INTERIOR Floor Inspect floor covering plywood sub floor if installed aisle and cover molding strips for condition adhesion and or fastening holes or cracks and ribbed rubber aisle Make repairs if any of the following conditions exist Watch Your Step decal missing or unreadable rubber floor covering loose deteriorated or cracked plywood rotten or soft cover molding loose or fasteners are missing The vehicle shall be removed from service until repairs are made if th
54. al engine shutdown check for free operation of shutdown over full range with minimum effort The vehicle shall be removed from service until repairs are made if e Engine cannot be started e Shutdown or operation is difficult e Bus was originally equipped with ignition switch type controlled shutdown and has been retrofitted with manual type shutdown GAUGES INDICATORS DASH LIGHTS amp HORN 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 AmMOAWD gt Make repairs if any of the following conditions exist oil pressure temperature fuel voltmeter or ammeter gauges are inoperable inaccurate damaged or difficult to read odometer inoperable or is not working properly odometer unreadable tachometer fails to function properly The vehicle shall be removed from service until repairs are made if 33 2 3 1 2 3 1 Oil or temperature warning system is not functioning or is unreadable Speedometer doesn t work or is confirmed to be inaccurate Speedometer is unreadable or damaged Air pressure gauge is inaccurate unreadable or not working Indicators and Dash Lights Check for the presence and operation of the following indicators Low air pressure High beam light Left and right turn signal a
55. anufacturer s specifications The vehicle shall be taken out of service until repairs are made if any portion of axle housing is cracked or bent any portion of axle housing is leaking lubricant due to cracks porous metal or defective weld The vehicle shall be taken out of service until repairs are made if lubricant is excessively low in the differential differential pinion yoke has endplay or side play exceeding manufacturer s specifications pinion yoke end nut is loose or missing The vehicle shall be taken out of service until repairs are made if any leaf spring is broken or missing air bag type spring assembly or air bag is damaged leaking airlines or valves are damaged leaking misalignment of spring leaves or other evidence that centering pin is loose or broken either rear leaf spring is worn to the point that suspension bottoming has damaged rubber frame bumper The vehicle shall be taken out of service until repairs are made if any U bolt seating plate or shock mount bracket nut is loose missing cracked or stripped The bus shall be removed from service until repairs are made if any shock is broken or missing The vehicle shall be taken out of service until repairs are made if front spring shackle hanger is loose cracked or broken The vehicle shall be removed from service until repairs are made if wear exceeds 1 4 inch or bushing is missing The vehicle shall be taken out of service until repairs are made if front spring s
56. aration of the tire tread from the tire carcass that could result in tire or tread failure e Valve stem is damaged e 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 e Cracks or breaks at the lugholes or any other part of a rim or cast spokes e 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 shall not be only cause for rejection 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 30 The vehicle shall be taken out of service until repairs are made if any of the following conditions exist e Any tire marked for other than highway use is found Tire is not of the proper type size and minimum load rating Any tire on an axle that is not of the same type e g lug or rib and size Tire is below minimum load rating Radial and bias ply tires are intermixed on the same axle 5 Alignment Inspect tires for evidence of proper alignment Make repairs if tire is feather edged cupped tread wear is uneven or if lateral run out of tire rim assembly exceeds 1 4 inch The vehicle shall be removed from service until repairs are made if tires rim are grossly misaligned affecting steering 6 Wheel Hardware
57. bumper is damaged or worn due to frequent bottoming of front suspension Alignment wedge is loose or damaged e Air bag type spring assembly is damaged leaking 11 Wheel Seals Check for condition and leakage Make repairs if either front wheel seal is damaged or leaking Remove bus from service until repairs can be made if evidence of fresh oil is found on the brake linings drums or rotors FRONT BRAKES 1 Brake Hoses Inspect front brake flexible hoses for condition securement and routing Make repairs if any of the following conditions exist any front brake flex hose supporting brackets are damaged or have loose fasteners any front brake flex hose is rubbing or routed against other components The vehicle shall be taken out of service until repairs can be made if e Any front brake hose or connection is leaking fluid or air pressure e Any front brake hose is kinked collapsed or bulging e Any front brake hose has damaged plies cords or is damaged below outer covering 2 Lines Inspect air and hydraulic brake lines for routing securement and condition Make repairs if any of the following conditions exist brake line bracket or securement system is loose or missing brake line is rubbing on other components or abraded brake line is not of OEM material size or type The vehicle shall be taken out of service until repairs are made if brake line is crimped or damaged significantly and restricting air pressure or hydraulic fl
58. c type brakes Automatic slack adjusters DO NOT ADJUST BRAKES ON VEHICLES WITH AUTOMATIC SLACK ADJUSTERS UNLESS THE BRAKE ADJUSTMENT LIMIT EXCEEDS MAXIMUM ADJUSTMENT LIMITS Refer to page 8 IF LIMIT IS EXCEEDED SELF ADJUSTING MECHANISM NEEDS TO BE REPAIRED OR REPLACED Follow slack adjuster manufacturer s adjustment procedure when adjustments must be made AUTOMATIC SLACKS MUST BE CHECKED EVERY 30 DAYS PUSHROD TRAVEL MUST BE MEASURED AND RECORDED ON THE TD 30 PROCEDURE i CHOCK TIRES ii RELEASE ALL BRAKES iii VERIFY AIR PRESSURE IS BETWEEN 90 100 PSI iv MARK ALL PUSH RODS WITH CHALK v FULLY APPLY BRAKE vi MEASURE THE DISTANCE THE PUSH ROD TRAVELS AT EACH CHAMBER vii RECORD PUSH ROD TRAVEL viii COMPARE MEASUREMENTS TO PAGE 8 OF THIS MANUAL The vehicle shall be removed from service until repairs can be made if any automatic slack adjuster arm or mechanism is damaged or loose 21 1 2 1 2 3 4 5 6 ENGINE TRANSMISSION MOUNTS STARTER MOUNTING Engine Transmission Mounts Inspect engine and transmission mounts for condition and securement Repairs shall be made if the following conditions exist mounting fasteners are loose missing or broken 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 loose heat shield
59. ce until repairs are made if wear exceeds 1 4 inch or bushing is missing Spring Hanger Shackles Attachments Inspect condition of spring hangers and pinch bolts Make repairs if any of the following conditions exist front spring hanger has significant side wear at the spring eye front spring hanger is worn pinch bolt is stripped or missing so that spring pin cannot be clamped tightly if any hanger is found with a small crack 1 2 inch or less that are welded steel only The vehicle shall be taken out of service until repairs are made if e Front spring shackle hanger is loose cracked or broken Front spring mount to frame fastener is loose missing broken or cracked The frame is cracked at any spring mounting location Spring hanger or bracket is cracked or broken 1 2 inch or more 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 axle flange stud or nut is loose or missing The vehicle shall be taken out of service until repairs are made if evidence of fresh oil is found on the brake linings or drums rotors 11 Wheel Bearings Inspect rear wheel bearings for condition and proper adjustment 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 shall be taken out of service if there is any de
60. celerating 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 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 Type of Motor Vehicle Braking force as a Percentage of gross Vehicle or combination Service Brake Systems Deceleration in feet per second per second 3 Application and braking distance
61. ductwork and heater box condition of heater filter and clean if necessary D a cS P Make repairs if any of the following conditions exist system is not producing adequate heat water control valve hard to operate heater blowers do not work on all speeds are noisy or vibrate blower switches are damaged loose or blower operates intermittently heater hoses are cracked swollen or badly chafed shielding missing or does not completely cover hoses The vehicle shall be removed from service until repairs are made 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 3 Air Conditioner Inspect A C for a A C performance for cooling 36 4 1 2 3 blower operations condition and control switches system leaks condition and hose shielding condition of ductwork check condition of evaporator filter and clean if necessary nm pn Make repairs if any of the following conditions exist defroster blower does not work on low or high speed blower switches are damaged or loose ductwork or diffusers are loose or damaged fresh air control if equipped does not function airflow is not present at all defroster outlets External Driver Fan
62. e compartment Make repairs if any of the following conditions exist any loose damaged or corroded wiring connector or terminal end if any repair has been made using improper gauge wiring The vehicle shall be taken out of service until repairs can be made if e There is any unsecured or poorly routed wiring that could cause a potential short or fire due to abrasion e Heat damage Burnt wiring or wiring missing insulation other than ground wires is present 16 FUEL SYSTEM AND LINES 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 conditions exist evidence of dirt algae or water in the fuel water separator if equipped any unsecured poorly routed loose fuel line or hose that could cause potential fire due to abrasion or heat damage The vehicle shall be removed from service until repairs can be made if any fuel system connection is stripped loose cracked or leaking RADIATOR 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 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 rad
63. e following exist e Unsealed holes or cracks through the underside of the bus e Aisle molding strip is not securely fastened to the floor or aisle or if cover molding presents a sharp edge or protrusion e Any damage to the rubber floor covering which could cause a tripping hazard Step well Check condition of step well and tread Make repairs if any of the following conditions exist step tread not secure or sealed at inside edge where it meets the next step step well tread and leading edge at aisle not flush and securely adhered step well tread worn more than four inches in width The vehicle shall be removed from service until repairs are made if step well support structure is broken or step well is rusted through Handrails Check for the presence and secure mounting of entrance handrails The vehicle shall be removed from service until repairs are made if entrance handrail is missing or not securely mounted handrail fails the NHTSA String and Nut Test 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 unauthorized items affixed to the interior paneling of the bus graffiti or unauthorized stickers seating charts and safety information are approved on interior panels loose or missing attachment screws on any maintenance access panel interior paneling is mildewed or pai
64. e hardware or fasteners are missing or linkage is damaged so as to cause a sticking or binding modulator vacuum hose is leaking or not connected The vehicle shall be taken out of service until repairs are made if the body of the transmission filter housing including all hose connections are cracked or damaged The vehicle shall be taken out of service until repairs are made if the clutch cannot be adjusted to specifications release bearing is excessively noisy clutch is slipping grabbing or has excessive chatter when engaging clutch linkage or return spring is binding or sticking transmission is hard to shift The vehicle shall be removed from service if the clutch pedal cover pad is missing or built up with extender block not of OEM design The vehicle shall be removed from service until repaired if either the master or slave cylinder is leaking or inoperable The vehicle shall be removed from service until repairs are made if fresh engine oil is dripping on any portion of exhaust system The vehicle shall be removed from service until repairs are made if the coolant leakage is excessive and could result in engine failure The vehicle shall be removed from service until repairs are made if fresh transmission fluid is dripping on any portion of the exhaust system The vehicle shall be removed from service until repairs are made if the power steering fluid is dripping The vehicle shall be taken out of service until repairs are made if any
65. e if I beam has been cut modified other than qualified machine shop to repair axle eye or damaged there is any bluing or other evidence that the I beam has been heated The vehicle shall be taken out of service until repairs can be made if locking pin is backing out loose or missing kingpin movement is more than 4 inch measured at the outside edge of the tire the vertical up and down play in kingpin assembly is greater than 030 thrust bearing is damaged or missing Vehicle shall be removed from service if side play at outside edge of tire is greater than La inch The vehicle shall be taken out of service until repairs can be made if any front spring shackle or hanger is loose cracked broken front spring mount to frame fastener is loose missing broken cracked the frame is cracked at any spring mounting location The vehicle shall be removed from service until repairs can be made if wear exceeds 1 4 inch or bushing is missing The vehicle shall be taken out of service until repairs are made if A frame assembly is bent missing or broken fasteners u bolts are loose or missing mounting of bushing assembly is not secure rubber bushing is missing A frame bushing or pivot arm has more than 050 free play at pivot point The vehicle shall be taken out of service until repairs are made if the following conditions exist ball joint mounting is loose missing or cotter pin is missing ball joint to A frame mounting is cracked loos
66. e or has been welded The vehicle shall be taken out of service until repairs are made if any shock mount bracket U bolt seating plate or nut is loose missing cracked stripped The bus shall be removed from service until repairs can be made if any shock is broken or missing The vehicle shall be taken out of service until repairs are made if either front spring saddle if equipped is missing or any leaf spring is broken cracked or missing spring eye is worn or spread such that bushings are loose in spring eye coil spring is broken or insecurely mounted non OEM blocks or spacers are installed there is misalignment of spring leaves or other evidence that center pin is loose or broken 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 alignment wedge is loose or damaged air bag type spring assembly or bag is damaged leaking Remove bus from service until repairs can be made if evidence of fresh oil is found on the brake linings drums or rotors The vehicle shall be taken out of service until repairs can be made if any front brake hose or connection is leaking fluid or air pressure any front brake hose is kinked collapsed bulging has damaged plies cords or is damaged below outer covering The vehicle shall be taken out of service until repairs are made if any brake line is crimped or damaged significantly and restricting air pressure or hydraulic f
67. ed dislocated creating a protrusion or sharp edge body panels rivets or other components are damaged corroded to the point where joint strength or body structural integrity is compromised Paint Check the paint on body and trim for required coloration and condition Make repairs if paint is faded discolored rusted or damaged The vehicle shall be removed from service until repairs are made if the paint is not National School Bus Yellow or warning light hoods and background are not black Reflective Markings Check reflective markings for coloration reflectivity and condition Make repairs if reflective markings are faded discolored damaged or peeling The vehicle shall be removed from service until repairs are made if reflective markings are missing around any emergency exit or door Reflective markings required on 1995 and newer buses Lettering Check all lettering for required type size location and color The vehicle shall be removed from service until repairs are made if bus is not equipped with the following lettering or they are not legible e School Bus 8 letters on front and rear e North Carolina Public Schools 6 letters on both sides 5 before 1997 44 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
68. eeteeeeneees 34 General Condition Bus Interior cccccccccccccccccececececececeeececeeeeeeeeees 35 Windshield Wipers amp Washers AER eAGh ieee tenes 36 Heaters Defrosters A C amp External Driver Fan 36 Mirror Adjustments amp Condition ee ceeceeeeeeseeeseceseceseeeeseessaeeneeneees 37 Driver s Seat and Belt ji hepetes eedicdeveneaceedcatieutecans sii 38 Passenger Seats 38 Emergency Door Windows Hat ches 0 eeceecceeseesseceseeeseeeeneesnaeenseensees 39 Windshield Side amp Rear Windows ccccccssessssssessssesssssssssesssesesssrsees 40 Wheelchair Lift Door and Securement System ce eeeeeeseeeeeeeeeeeee 40 OUTSIDE BUS All Exterior Lights amp Backup Alarm cccescecseeeserseccenseesoneescersees 41 Clearance Lights Reflectors amp Strobe Light esssesesrsesssressersreeresss 42 Eight Light Warning System Stop Arm amp Crossing Arm ee 43 General Condition Bus Exterior ccccccccccccccccccccececececececseecececeeeeeeeeees 44 ROAD TEST Road KE 45 APPENDIX A 30 Day Inspection Step By Step 47 APPENDIX B Out Of Service Items 00 00000 52 APPENDIX C Public School Law IISC 2408 D APPENDIX D School Bus Inspection Training Video 63 APPENDIX E TD 30 Inspection Fum 64 SO PPD rs C O N T E N T S BRAKES BRAKE TESTING PROCEDURE Inspection criteria for this
69. equipped on all buses equipped with restraining devices or wheelchair positions Must be securely mounted in the driver s compartment and within easy reach of the driver Repair if no durable webbing cutter is present and properly mounted within easy reach of driver if equipped OUTSIDE BUS ALL EXTERIOR LIGHTS amp BACKUP ALARM For LED lights make repairs if 20 of LED bulbs are not operating in a light unit Eight Light Warning Lamps Require 100 of LEDs Operating 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 left and right sealed beams are different type halogen vs conventional sealed beam does not operate on low and high sealed beam lens foggy cracked or light is dim high beam indicator does not function any obvious misaiming of headlights dimmer switch sticks hard to operate or doesn t function headlight switch is damaged and or not securely mounted knob is missing The vehicle shall be removed from service until repairs are made if lights go out after being on a short time operation is intermittent headlight circuit fails to operate 2 Turn Signals Check turn signals including bulbs and lenses for operation and condition Make repairs if any of the following conditions exist front rear or side mounted turn signal lens is c
70. ergency 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 shall be removed from service until repairs are made if any of the following conditions exist e Nota clear minimum twelve 12 inch aisle width to the side emergency door e Flip up seat bottom will not raise or lower e Will not 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 of the following conditions exist covering or padding damaged mounting frame or attaching hardware missing damaged The vehicle shall be removed from service until repairs are made if e 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 e Fire blocking crash barrier fabric is repaired or replaced using unapproved procedures or non fire blocking material EMERGENCY DOOR WINDOWS HATCHES 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 rear door opens too far and damages lights door handle latch or mounting hardware loose mountin
71. exist friction surface is contaminated with oil grease or brake fluid lining is worn to within 1 8 inch of shoe table riveted type shoe lining is worn to within 1 16 inch of shoe table bonded type lining The vehicle shall be taken out of service until repairs are made if e Lining is broken cracked or loose on shoe e Shoe platform or webbing is cracked or damaged e Any loose damaged or missing foundation brake hardware is within the drums Drums Inspect rear brake drum for condition The vehicle shall be taken out of service until repairs are made if grease oil or brake fluid is on the inside of the drum drum is not mounted securely to hub or fasteners are loose Rotors Inspect rear brake rotor for mounting and condition The vehicle shall be taken out of service until repairs are made if e Rotor mounting is not secure e Friction surface is contaminated with oil grease or brake fluid e Rotor friction surface is significantly grooved or damaged Wheel Cylinders or Calipers Inspect wheel cylinder or caliper for leaks and mounting and condition Make repairs if there is uneven brake lining or brake pad wear wheel cylinder The vehicle shall be taken out of service until repairs are made if e Caliper is not securely mounted or has loose or missing fasteners e There is rotor or drum damage e Evidence that any wheel cylinder caliper may be sticking 10 Brake Adjustment 1 a Manual Slack Adjuster or ai
72. exist transmission fluid is below Add mark transmission fluid shows evidence of excessive water or dirt contamination transmission fluid shows need of servicing discoloration and or burnt smell The vehicle shall be removed from service until repairs are 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 Make repairs if any of the following conditions exist coolant level in radiator or reservoir is low coolant shows evidence of excessive oil dirt contamination rust and corrosion The vehicle shall be taken out of service until repairs are made if coolant cannot be seen in reservoir or in radiator tank with cap removed 14 BELTS 1 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 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 shall be taken out of service until
73. fety latch when door handle is closed 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 mounting of switches knobs c condition and mounting of wiper motors and linkage d inspect for proper washer operation Make repairs if any of the following conditions exist either wiper does not operate on low or high speed wiper goes past edge of glass washer does not operate or is misadjusted blades do not effectively clear driver s field of vision wiper motor or linkage is visibly damaged or loose switch knob mounting is loose or missing The vehicle shall be removed from service until repairs are 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 blades do not clean windshield properly Repair if either blade is damaged deteriorated loose or does not hold proper tension against windshield HEATERS DEFROSTERS A C amp EXTERNAL DRIVER FAN 1 Heaters Inspect heater system for heating performance and water control valve blower operations condition and control switches system leaks condition and hose shielding condition of
74. for presence of key Remove if key is found in ignition switch Make repairs if the key sticks is loose or not mounted in OEM location The vehicle shall be removed from service until repairs are made if e Switch operates without a key Bus equipped with a push button or a device other than key type switch Engine will not crank start Switch doesn t function properly in start run off or accessory position Switch is intermittent in any position Accelerator Check and insure the accelerator pedal control design and mounting securement are OEM Inspect the pedal assembly and linkage for loose missing hardware All engine types must have two 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 out linkage is missing one return spring or is not equipped with dual return springs external type The vehicle shall be removed from service until repairs are made if e Pedal and assembly are not mounted securely e Control design and mounting are not of OEM design e Accelerator control and linkage sticks or doesn t operate freely e Pedal is built up with extender block 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 manu
75. g and secure mounting Check the inspection sticker for expiration date and condition Inspect the heater defroster unit fan output and temperature control lever for proper operation Lubricate the control lever if needed Inspect the condition of water valves and hoses Check condition of brake and accelerator pad condition Inspect the dash for secure mounting and condition Inspect all the accessories and radio for proper operation mounting and condition While in the drivers seat check and measure the steering play 47 25 26 27 28 29 30 Turn on headlights check the operation of the dimmer switch Check the operation of the high beam indicator Leave park lights on Operate directional lights turning wheel to left and right checking the auto return of switch if equipped Operate four way flashers and leave on Turn on interior lights Observe step light for proper operation Check operation of air build both needles If adequate place transmission in drive and test parking brake Check e brake warning lights if equipped 31 Place brake holding tool on pedal An assistant is recommended during 30 day inspection process 32 Step up in cab check for fire extinguisher condition first aid kit and spill kit reflectors if equipped 33 Check for condition of all required decals on bulkhead 34 Release door switch from emergency to normal 35 Activate eight way lighting system place shifter in reve
76. g of guard for inside rear door handle loose emergency door latch does not operate smoothly and easily when closing or opening door hold open feature if equipped does not function or secure door in the open position inside door handle is not equipped with a guard emergency door does not open and close from the inside and outside easily weather strip seal is damaged or does not seal properly roof hatch seal is damaged or dislodged roof hatch does not open easily to full emergency open position The vehicle shall be removed from service until repairs are made if e Emergency door or window will not open properly e Is equipped with any type of a hasp lock or any other locking device except for OEM interlock system e Bus will start with any emergency door locked OEM interlock system e Latch mechanism will not secure door hatch or window in closed position Buzzers Check operation of buzzers for emergency doors emergency exit windows and emergency exit roof hatches Make repairs if buzzer fails to operate or gives false alarms The vehicle shall be removed from service until repairs are made if emergency exit buzzer circuit fails to operate emergency door fails to operate panel buzzer 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 emergency exits are not clearly l
77. ged cord separation bulges other than normal manufacturer bulge or other damage within the carcass of the tire cracks that run around the bead or sidewall of the tire retread tire that has any separation of the tire tread from the tire 56 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 carcass that could result in tire or tread failure valve stem is damaged 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 cracks or breaks at the lugholes or any other part of a rim or cast spokes dents or bends in a rim that could result in failure of a rim or separation of the tire from the rim The vehicle shall be taken out of service until repairs are made if any of the following conditions exist any tire marked for other than highway use tire is not of the proper type size and minimum load rating any tire on an axle are not of the same type e g lug or rib and size tire is below minimum load rating if radial and bias ply tires are intermixed on the same axle The vehicle shall be removed from service until repairs are made if tires rim are grossly misaligned affecting steering The vehic
78. hackle hanger is loose cracked or broken front spring mount to frame fastener is loose missing broken or cracked the frame is cracked at any spring mounting location spring hanger or bracket is cracked 1 2 inch or more or broken any mounting fastener is loose or missing The vehicle shall be taken out of service until repairs are made if evidence of fresh oil is found on the brake linings or drums rotors The vehicle shall be taken out of service if there is any detectable looseness or roughness in rear wheel bearings The vehicle shall be taken out of service until repairs are made if rear brake hose or connection is leaking fluid or air pressure rear brake hose is kinked collapsed bulging or has damaged plies or cord any damage below outer covering The vehicle shall be taken out of service until repairs are made if brake line is bent crimped damaged significantly restricting air pressure or hydraulic fluid brake line or connection is leaking air pressure or hydraulic fluid any brake line is not of proper size or type 55 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 The vehicle shall be taken out of service until repairs are made if rear brake chamber mounting bracket is cracked bent or broken either cha
79. he school to which such bus is assigned hall be the du to the principal of the defect or other defect defect comes to the a b It s school ty of the driver which may affect ttention of the driver report such defect to the superintendent such bu the safe to which of each school bus to report promptly s is assigned any mechanical of the unit It shall be the du administra c assigned or by ty of the superi tive unit to cause any and all such defec If any school bus is found by the principal the superintendent of the local school be so defective tha shall be t bus to be principal different employees d The discon of the school assigned ntendent t the bus may not be operated wi he duty of such principal or superinte tinued until such defect is remedied to which such bus is assigned may permit t bus assigned to such school in the tra to the bus found to be defective superintendent of each local school and the principal admi operation of the bus when such shall thereupon local school administrative of the local school ts to be corrected promptly of the school to which it is administrative unit to th reasonable safety it ndent to cause the use of such in which event the he use of a he pupils and nsportation of t nistrative unit sha cause each activity bus which is used for the
80. hile the vehicle is being driven Observe centerline on highway and check for side evenness to centerline The vehicle shall be taken out of service until repairs are made if travel angle is uneven 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 The vehicle shall be removed from service until repairs are made if e Free play exceeds maximum allowable amount e Excessive tire shimmy occurs e Roughness is detected in steering gear 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 The vehicle shall be removed from service 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 noise is detected The vehicle shall be removed from service until repairs are made if excessive noise and vibration are detected 45 e Transmission Check transmission operation for up shift downshift and slippage Make repairs if rough up shift or downshift is experienced The vehicle shall be removed from service until repairs are made if transmission is slipping f Road Speed Control Check road speed control for proper operation Check operation for high limit cut off and low limit cut in Make repai
81. ian should review this manual often in order to achieve the best possible results 30 DAY MANUAL REVISION COMMITTEE MEMBERS The preparation of this manual was a cooperative effort between the North Carolina Pupil Transportation Association NCPTA and the North Carolina Department of Public Instruction NCDPI Transportation Services Section The committee would like thank those around the state the provided input and feedback during the preparation of this manual NCPTA NAME DISTRICT COUNTY Ronnie Baldwin District 1 Buncombe Rich Laird District 2 Mecklenburg Robert Boggs District 3 Iredell Jay Temple District 4 Davidson Jeff Garmon District 5 Cabarrus Ralph Trango District 6 Wake Mickey Beasley District 7 Johnston David Twiddy District 8 Dare Frankie Floyd District 9 Craven Charles Ball NCDPI James Hawkins NCDPI Randy Henson NCDPI Committee Chair ex oficio members Derek Graham NCDPI Jean Strickland NCDPI editing Craig Warren NCDPI EMAIL ADDRESS ronaldbaldwin bcsmail org rd laird cms k12 nc us tcampbell iss k12 nc us jtemple davidson k12 nc us jgarmon cabarrus k12 nc us rtrangol wepss net mickeybeasley johnston k12 nc us david twiddy dare k12 nc us frankie floyd craven k12 nc us cball dpi state nc us jhawkins dpi state nc us rhenson dpi state nc us dgraham dpi state nc us jstrickl dpi state nc us cwarren dpi state nc us SO PD rd C O N T E N T S
82. iator cap is the wrong pressure rating visible damage to the pressure seat or vacuum relief seat of the cap The vehicle shall be taken out of service until repairs can be made if the radiator cap is missing 3 Reservoir Check coolant reservoir including any 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 damaged leaking 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 loose missing fasteners or fan shroud is missing UNDERNEATH BUS FRONT SUSPENSION CHECKS 1 Wheel Bearings Inspect front wheel bearings and related components for condition and proper adjustment 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 minor seepage of grease or oil around the dust cover dust cover or fasteners is loose or missing The vehicle shall be taken out of service until repairs can be made if there is any noise binding or roughness discovered in bearings wheel bearing endplay exceeds manufacturer s specifications maximum of 01
83. if there is any brake pedal fade falling away after initial firm application The vehicle shall be removed from service until repairs are made if rubber cover pad is missing or worn out The vehicle shall be removed from service until repairs are made if emergency brake control assembly is hard to operate or doesn t latch and release properly The vehicle shall be removed from service until repairs are made if park brake doesn t hold or functions improperly The vehicle shall be taken out of service until repairs are made if any of the following conditions exist side to side play in steering column exceeds 1 4 inch or up and down play exceeds one 1 inch column assembly mounting including floor mounting plate or fasteners are loose tilt telescopic assembly if equipped will not stay in the locked position steering column U joint inside the bus if equipped is loose damaged or noisy after lubrication flexible coupling if equipped rag joint has loose or missing fasteners damaged flexible disc or elongated holes any column u joint pinch bolt other column fasteners or input shaft coupling is loose damaged or missing steering gearbox is loose on frame or fasteners or lock tabs are loose or missing The vehicle shall be removed from service until repairs are made if any evidence of a leak is detected or fluid is excessively low less than full The vehicle shall be removed from service until repairs are made if fluid is e
84. ing AIR COMPRESSOR AND FILTER Check securement and condition of air compressor and filter assembly Make repairs if air compressor air filter if equipped is dirty or cover is missing Make repairs if hose from engine air cleaner to air compressor is damaged torn or missing The vehicle shall be removed from service until repairs are made if compressor mounting brackets or fasteners is cracked loose or missing WATER PUMP Check condition of water pump and pulley Make repairs if any of the following condition s exist evidence of a coolant leak from the water pump seal gasket surface or weep hole water pump fasteners are loose damaged or missing The vehicle shall be removed from service until repairs are made _if water pump is noisy bearing is damaged or coolant is leaking out FAN Check fan blade and fan clutch assembly for securement and condition The vehicle shall be removed from service until repairs are made if e Fan has any cracked bent or broken blades e Any portion of fan mounting is loose e Fan clutch is seized or loose ALTERNATOR 1 Check securement and condition of alternator assembly Make repairs if alternator is noisy The vehicle shall be placed out of service until repairs can be made if any portion of the alternator mounting brackets 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 engin
85. is worn or deteriorated to the point that failure could occur Auxiliary Filter Inspect transmission external filter assembly if equipped for securement and condition Make repairs if external filter mounting is loose or missing fasteners or filter canister is damaged The vehicle shall be taken out of service until repairs are made if the body of the transmission filter housing including all hose connections are cracked or damaged Cooler Inspect transmission cooler as equipped for securement and condition Make repairs if the mounting of separate transmission cooler is loose leaking or has loose missing fasteners Clutch Operation if equipped a Check pedal linkage clutch and release bearing for wear slippage and abnormal noises in the engaged and released positions Make repairs if the following conditions exist loose bolts or nuts noisy release bearing clutch is out of adjustment 22 The vehicle shall be taken out of service until repairs are made if The clutch cannot be adjusted to specifications Release bearing is excessively noisy Clutch is slipping grabbing or has excessive chatter when engaging clutch Linkage or return spring is binding or sticking Transmission is hard to shift b Visually check clutch pedal pad for wear Make repairs if the pedal cover pad is worn The vehicle shall be removed from service if the clutch pedal cover pad is missing or built up with extender block not of OEM design
86. le shall be removed from service until repairs are made if any of the following conditions exist improper matching of rims and lock rings evidence of slippage of wheel assembly on cast spoke hub stud holes are elongated any wheel or stud is loose rusting or corrosion indicating possible looseness wheel stud or nut is broken or missing improper spacer has been installed between dual wheels The vehicle shall be removed from service until repairs are made if any of the following conditions exist rating is less than 2 1 2 pound minimum 2002 and newer must have 5 lb minimum and 10BC rating no fire extinguisher on bus tamper proof seal material cannot be broken The vehicle shall be removed from service until repairs are made if entire contents or kit are missing The vehicle shall be removed from service until repairs are made if entire contents or kit are missing Remove the bus from service if reflectors are missing The vehicle shall be removed from service until repairs are made if the starter will engage in any gear other than park or neutral The vehicle shall be removed from service until repairs are made if shifter will not shift into all available gear positions the indicator indicates wrong gear detent is non functional or if ball or knob handle is missing from end of shifter lever The vehicle shall be removed from service until repairs are made if switch operates without a key bus is equipped with a push button or a device o
87. les This fact accounts for the variation from 20 to 40 feet in the values in column 4 for the various classes of vehicles The term GVWR refers to gross vehicle weight rating and the term GVW refers to gross vehicle weight BRAKE STROKE MEASUREMENT 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 This 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 Then check the chart for the appropriate brake chamber and determine if the brake needs adjusting Refer to manufacturer s 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 TYPE OUTSIDE DIAMETER BRAKE ADJUSTMENT LIMIT 6 4 1 2 114mm 1 1 4 32mm 9 5 1 4 133mm 1 3 8 35mm 12 5 11 16 145mm 1 3 8 35mm 16 6 3 8 162mm 1 3 4 45mm 20 6 25 32 172mm 1 3 4 45mm 24 7 7 32 184mm 1 3 4 45mm 30 8 3 32 206mm 2 51mm 36 9 229mm 2 1 4 57mm NOTE A brake at the adjustment limit
88. luid any brake line or connection is leaking air pressure or hydraulic fluid 53 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 The vehicle shall be taken out of service until repairs can be made if front brake chamber mounting bracket is cracked bent broken or if either chamber is not of the original size size of chambers is not matched left and right both sides must be the same size non manufactured holes are found in the spring brake housing The vehicle shall be taken out of service until repairs are made if any portion of the slack adjuster or S cam is missing broken cracked or badly worn S cam snap ring is missing slack adjuster has a frozen or stripped worm gear or ratchet assembly The vehicle shall be taken out of service until repairs are made if any portion of the pushrod assembly ocknut pushrod clevis and pin or cotter pin is loose missing or damaged The vehicle shall be taken out of service until repairs are made if lining is broken cracked or loose on shoe shoe platform or webbing is cracked damaged there is any loose damaged or missing foundation brake hardware within the drum friction surface is contaminated with oil grease or brake fluid lining with a thickness less than 3 16 inch
89. mber is not original size or size of chamber is not matched both sides to be same size The vehicle shall be taken out of service until repairs are made if any portion of slack adjuster or S cam is missing broken cracked or badly worn S cam snap ring is missing slack adjuster has frozen or stripped worm gear or ratchet assembly The vehicle shall be taken out of service until repairs are made if any portion of pushrod assembly locknut pushrod clevis and pin or cotter pin is loose missing or damaged pushrod on left and right sides are not mounted in identical same slack adjuster location holes same effective slack adjuster length The vehicle shall be taken out of service until repairs are made if lining is broken cracked or loose on shoe shoe platform or webbing is cracked or damaged any loose damaged or missing foundation brake hardware is within the drums The vehicle shall be taken out of service until repairs are made if grease oil or brake fluid is on the inside of the drum drum is not mounted securely to hub or fasteners are loose The vehicle shall be taken out of service until repairs are made if rotor mounting is not secure friction surface is contaminated with oil grease or brake fluid rotor friction surface is significantly grooved or damaged The vehicle shall be taken out of service until repairs are made if caliper is not securely mounted or has loose or missing fasteners there is rotor or drum damage e
90. n Note Repairs should be made if cutout pressure is below 120 p s i The vehicle shall be removed from service until repairs are made if the cutout pressure is too low below 100 p s i or too high above 130 p s i 3 Air Compressor Operation Air reservoir shall 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 shall be made if time for system buildup 85 100 p s 1 exceeds 40 seconds Air compressor should also be checked for oil leaks 4 Parking Brake With vehicle stopped apply park brake Place transmission selector in drive position and accelerate engine to a fast idle approximately 1 200 rpm s vehicle should not move forward The vehicle shall be removed from service until repairs are made if vehicle moves with parking brake applied Note Buses equipped with Rear Diesel engine and Allison World Transmission shall be checked at 900 R P M 5 Air Leaks To check the vehicle for air leaks the system shall 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 Note pressure drop if any
91. n that is not 28 light transmission or clearer The vehicle shall be removed from service if there is any loose damaged or protruding window hardware that would be a hazard to passengers 58 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 The vehicle shall be removed from service until repairs are made if sun visor is missing or has sharp protruding edges that could cause personal injury The vehicle shall be removed from service until repairs are made if elevator lift platform is not flush with floor in up position any part of the lift mechanism or hardware is damaged missing or not secure including cams clips pins rollers and platform fasteners The vehicle shall be removed from service until repairs are made if headlights go out after being on a short time operation is intermittent headlight circuit fails to operate The vehicle shall be removed from service until repairs are made if rear turn signal fails to operate The vehicle shall be removed from service until repairs are made if brake light circuit fails to function brake pedal is released brake light switch sticks or lights stay on brake light lens is not red or is not proper type meeting SAE specifications
92. nd 4 way hazard All dash and control panel lights for illumination at gauges and switches ABS braking system indicator light if equipped E Stroke monitor if equipped Su IS Ge Make repairs if dash lights are inoperable one or more lights for the control switches are inoperable one or more panel lights is inoperable Horn Check horn and horn button for proper operation must be OEM design The vehicle shall be removed from service until repairs are made if horn fails to function as designed ENGINE WARNING LIGHTS AND BUZZER Check for presence and operation of the following warning lights and buzzer High coolant temperature dash warning light or buzzer on diesel buses The vehicle shall be removed from service until repairs are made if high coolant temperature warning light or buzzer is inoperative either constant or momentary Low oil pressure dash warning light and buzzer on bus The vehicle shall be removed from service until repairs are made if the low oil pressure warning light or buzzer is inoperative either constant or momentary Low air warning buzzer The vehicle shall be removed from service until repairs are made if air brake warning light and buzzer are simultaneously non functioning either constant or momentary INTERIOR WIRING CAB HOSES AND FIRE WALL SEALS Interior Wiring Inspect visible wiring for mounting condition chafing abrasion corrosion loose connectors or improper repairs Make rep
93. ng condition and tightness of steering gear box and check frame frame braces and associated rivets or fasteners for looseness and condition Pitman Arm Check the pitman arm for looseness or misalignment at sector shaft splines and looseness at all joints Check looseness of pinch bolt and fasteners and condition of pitman arm Pitman arm grease fitting if originally equipped is loose or missing repair 12 Qut of Service if Steering gear box loose or any mounting bolts loose or missing There is any binding in steering gear box Any play is observed between pitman arm and sector shaft Pinch bolt at sector shaft is loose or missing Pitman arm to sector shaft timing marks are misaligned Inspection Procedures Drag Link Check the drag link ends shaft and fasteners for looseness and condition on vehicles with I beam suspension 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 stops and lock nuts Tie Rod and Ends check the tie rod ends tie rod dust boots and clamps or fasteners as equipped for looseness damage and condition Idler Arm check idler arm assembly as equipped for looseness damage and condition Repair or note If Any drag link end grease fitting as equipped is loose or missing or will not take grease repair
94. nts where required is missing or damaged The vehicle shall be removed from service until repairs are made if any of the following conditions exist sharp edges rust through or projections from paneling that could cause injury to passengers or driver Loose Objects Secured Check to insure that all objects within the bus are secure The vehicle shall be removed from service until repairs are made if there are any aerosol cans containers with flammable volatile chemicals or any unlabeled container located inside the bus Dog House Engine Cover Inspect dog house engine cover for seals soundproofing weather stripping prop rod and latch operation Make repairs if any of the following conditions exist soundproofing not present or deteriorated latch is hard to operate or does not secure dog house engine cover properly The vehicle shall be removed from service until repairs are made if seals or weather stripping allow air fume leaks into the driver s compartment Entrance Door Entrance Controls Manual and air electric Inspect for presence of safety pad above door door bumpers and weather stripping around the door Check air door release valve for leaks Check to see that amber lights do not activate before door is opened Make repairs if any of the following exist manual door handle locks when in opened position amber lights activate before 35 door safety latch is released There should be no more than 3 16 inch play in sa
95. of the following conditions exist fuel leakage from the tank connections or cap fuel tank has any cracks connections are loose at the tank The vehicle shall be taken out of service until repairs are made if any portion of fuel tank mounting system including support brackets retaining straps and chassis frame is missing loose cracked or broken fuel tank mounting fasteners are loose or missing barrier assembly is damaged insecurely mounted or missing 54 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 The vehicle shall be taken out of service until repairs are made if fuel line or hose is unsecured or is routed subject to excessive heat or abrasion fuel line or hose is deteriorated or damaged including cracks or damage that may cause potential leakage or clamps are loose or missing under bus fuel system filter water separator or other components are insecurely mounted cracked or damaged The vehicle shall be taken out of service until repairs are made if any portion of sending unit wiring including ground or connections is unsecured or is routed subject to excessive heat or abrasion The vehicle shall be taken out of service until repairs are made if safety valve leaks or does not release p
96. of the muffler Make repairs if the muffler is cracked or if there is other significant physical damage to the muffler The vehicle shall be removed from service until repairs are made if the muffler is leaking and produces an audible sound or exhaust is felt from the leaking area weephole is excluded 29 4 1 2 3 4 Tailpipe Inspect the condition of tailpipe and insure that it extends beyond the rear bumper Check the tailpipe and make sure it extends at least to the edge of the rear bumper but no more than two inches beyond bumper or exits behind the rear tires to the left or right and extends to edge of bus body Make repairs if the tailpipe is cracked or other significant damage to the tailpipe The vehicle shall be removed from service until repairs are made if the tailpipe is leaking and produces an audible sound or exhaust is felt from the leaking area WHEELS AND TIRES Tread Depth Inspect and measure all tires for tread depth and record on inspection form Measurement shall be taken at the most worn groove of the tire Measurement shall not be taken at a wear bar Make repairs if front tire has reached 4 32 and rear tire has reached 2 32 The vehicle shall be taken out of service until repairs are made if e Tread depth of either front tire is less than 4 32 inch 2 32 inch for rear tires at three points spaced equally around the circumference of the tire in the same major tread groove e Measured tread depth
97. olumn fasteners or input shaft coupling is loose damaged or missing e Steering gearbox is loose on frame or fasteners or lock tabs are loose or missing OUTSIDE BUS STEERING COMPONENT CHECK Steering Gear Box and other external components will be checked using the following procedure 1 Vehicle shall be on the ground and not suspended Have an assistant move the steering wheel back and forth repeatedly to load steering components Visually observe the following external steering and related suspension frame components for looseness while the assistant works the 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 Check the vehicle frame cross members and frame cross members and frame braces including associate rivets and fasteners for looseness and condition 2 Have the assistant carefully operate steering to full left and right turn 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 Steering Gear Box Mounting Check mounti
98. on a continuous lining or 4 for a shoe with two pads IF EQUIPPED WITH DISC STYLE BRAKES MINIMUM IS 1 8 The vehicle shall be removed from service until repairs can be made if there is any grease oil or brake fluid on the inside of the drum any drum is not mounted securely to hub fasteners are loose drums with external crack or cracks that open upon brake application The vehicle shall be removed from service until repairs can be made if rotor mounting is not secure friction surface is contaminated with oil grease or brake fluid any rotor friction surface is significantly grooved or damaged Vehicle shall be removed from service until repairs can be made if any wheel cylinder or caliper is not securely mounted has loose or missing fasteners has rotor drum damage wheel cylinder caliper is sticking The vehicle shall be removed from service until repairs are made if there is any damage or condition that prevents proper adjustment of S cam or air disc type brakes The vehicle shall be removed from service until repairs can be made if any automatic slack adjuster arm or mechanism is damaged or loose The vehicle shall be taken out of service until repairs are made if transmission is not mounted securely to flywheel housing there is external indication that any torque converter bolt is loose or missing The vehicle shall be taken out of service until repairs are made if linkage is bent damaged binding or severely misadjusted linkag
99. on and overall condition Make repairs if any of the following conditions exist dome light at inside lift area inoperative lift door or latch does not operate smoothly fluid seepage at the lift white light if equipped at exterior lift area inoperative lift control cable or wiring damaged or routed improperly lift does not fold unfold lift and lower properly lift jerks or binds lift leaks fluid onto or below floor there is excessive side play more than two inches in the lift mechanism when the platform is partially or fully extended lift jacks up the vehicle manual backup system does not function properly The vehicle shall be removed from service until repairs are made if elevator lift 40 platform is not flush with floor in up position any part of the lift mechanism or hardware is damaged missing or not secure including cams clips pins rollers and platform fasteners 2 Inspect wheelchair and occupant securement tie down system for condition mounting proper type and location Make repairs if any of the following conditions exist track filled with dirt and trash wheelchair tie down track or fasteners are loose broken or sections of track are not continuous within each wheelchair position wheelchair or occupant securement straps are broken frayed or will not operate wheelchair or occupant securement track mounted using lag type bolts or sheet metal screws 3 Check for presence of a durable webbing cutter if
100. on 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 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 vehic
101. ontaminated with oil grease or brake fluid e Any rotor friction surface is significantly grooved or damaged Wheel Cylinders or Calipers Inspect wheel cylinders or calipers for leaks mounting and condition Make repairs if brake lining pad indicates tapered wear Vehicle shall be removed from service until repairs can be made if Any wheel cylinder or caliper is not securely mounted Loose or missing fasteners are present Rotor drum damage is observed Wheel cylinder caliper is sticking 20 10 Brake Adjustment a b For hydraulic drum brakes Check front brake adjustment at every inspection For S cam or air disc brakes at every monthly inspection brake chamber pushrod travel must be checked at all four wheel positions and brakes must be adjusted as necessary to achieve less than or equal to the maximum pushrod travel PUSHROD TRAVEL MUST BE MEASURED AND RECORDED ON THE TD 30 PROCEDURE c d e i CHOCK TIRES ii RELEASE ALL BRAKES iii VERIFY AIR PRESSURE IS BETWEEN 90 100 PSI iv MARK ALL PUSH RODS WITH CHALK vi FULLY APPLY BRAKE vi MEASURE THE DISTANCE THE PUSH ROD TRAVELS AT EACH CHAMBER vii RECORD PUSH ROD TRAVEL viii COMPARE MEASUREMENTS TO PAGE 8 OF THIS MANUAL If adjustment is needed wheels must be raised off of the ground The vehicle shall be removed from service until repairs are made if there is any damage or condition that prevents proper adjustment of S cam or air dis
102. or passenger mirror is missing 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 The vehicle shall be removed from service until repairs are made if e Windshield glass is cracked and could be dislodged e Glass is discolored and prevents driver from having clear visibility e Glass is missing e Any piece of glass is non OEM Bumpers Check bumpers for mounting condition color reflective tape if equipped and body seal rear bumper If bus is equipped with reflective strip on rear bumper no other stickers are allowed to cover reflective strip except vinyl reflective type Make repairs if any of the following conditions exist bumper is not black bumper is equipped with any unauthorized stickers or decals only stickers approved by DPI Transportation Services are to be installed bumper has bent brackets braces The vehicle shall be removed from service until repairs are made if e Bumper is significantly bent Bumper has protruding metal Bumper mounting system is cracked or broken Bumper has cracked welds Bumper has missing or loose fasteners 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 shall be removed from service until repairs are made if any of the following conditions exist body part damag
103. ossible to include every single item that could malfunction When a problem is encountered that is not covered in this manual the safety of the bus driver passengers and motoring public should always be the most important factor considered It will be up to the mechanic doing the inspection to make the decision whether the bus should be allowed to stay in service or be replaced by a spare until repairs are made It is highly recommended that a technician and an assistant inspect a school bus One person will assist in various light checks braking checks and steering checks from the driver seat The technician will be outside of the bus to verify that the different systems are working properly The inspection and repair of a school bus is to be broken down into two steps 1 The bus must be properly inspected for defects This process should not be interrupted once an inspection has begun The inspectors must carefully check all the items listed on the TD 30 inspection form If a defect is found the problem must be noted at the proper place on the form No repairs shall be made until the inspection process is completed 2 After completing the inspection the technicians should review the defects found and repair them A TD 18 shall be filled out to indicate repairs made If it becomes apparent that a bus with an out of service defect cannot be repaired before it is to be dispatched on the next route a spare vehicle must be secured The technic
104. r disc brakes must be checked at every monthly inspection Brake chamber pushrod travel must be checked at all four wheel positions and if travel is out of specification see Air Brake Chamber Stroke Measurements on page 8 brakes must be adjusted to achieve minimum pushrod travel The vehicle shall be taken out of service until repairs are made if there is damage or condition that prevents proper adjustment of S cam or air disc type brakes any brake adjustment is out of specification b Automatic Slack Adjusters ASA must be checked as follows Check the pushrod travel before any adjustment is made If needed manually adjust the ASA following the manufacturers adjustment procedures NOTE If an automatic slack adjuster is out of adjustment check inspect the ASA for a malfunction and make repairs The vehicle shall be removed from service until repairs are made if any automatic slack adjuster arm or mechanism is damaged or loose adjusted stroke pushrod travel of any automatic slack adjuster equipped brake exceeds maximum shown in charts on page 8 BODY SECUREMENTS and STRUCTURE Body Hold Downs Inspect for securement and condition of all body hold downs chassis cowl mounts and frame pads Body hold downs include any J bolt U bolt or clamp type hold down used to secure body to chassis frame Make repairs if any of the following conditions exist body hold down is loose or misaligned cracks or stripped fasteners at floor sill secu
105. r test drive Wear seat belt 127 Place transmission in drive and move vehicle forward 128 Hold wheel loosely in hands and apply brakes checking for any pulls 129 Test brake several times during the teat drive checking for excessive noise growls pulls and pedal travel Record brake meter reading optional on 30 day sheet 130 Proceed with test drive and feel for any pulling in wheel Check for shakes and vibrations Check return of wheel after turns and travel alignment 131 Ensure transmission is shifting smoothly and at the correct time 132 Operate bus to max speed and test the governor operation 133 Check all mirrors for clear vision and adjustment 134 Check speedometer and odometer for normal operation 135 Listen for body snaps and floor noises 136 Listen for rear axle noise and vibration 137 Check operation of water temp gauge charging gauge for voltage fuel gauge for bouncing oil pressure dropping and steady air pressure 138 Listen for air governor cut out and air dryer operation if equipped 139 Check exhaust for excessive smoking Notice engine power for proper engine condition 140 Operate at least one stop operate eight way lighting and walk stop arm Check door switches and handles for proper operation 141 Park bus let engine cool down shut engine down 142 Step on brake pedal and check pressure listen for pressure leaks 143 Set parking brake and drain air to less than ten pounds
106. racked front top of fender rear or side mounted turn signal does not flash or is dim turn signal indicator does not properly indicate right and left turn signal switch does not function properly or will not maintain set position turn signal switch does not cancel or return to neutral position front rear or side mounted turn signal lens is damaged or white light is visible any turn signal lens has darkened faded or dirty significantly affecting visibility or color of the light front signals fail to operate The vehicle shall be removed from service until repairs are made if rear turn signal fails to operate 3 Hazard Lights Check hazard lights for operation and condition Make repairs if any of the following conditions exist lens is cracked darkened or dirty four way hazard light fails to function hazard switch does not function or will not maintain set position with steering wheel in the straight ahead position 4 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 damaged darkened 41 5 6 7 8 9 1 2 3 Brake Lights Check brake lights and lens for operation and condition Make repairs if any of the following conditions exist Three or less brake lights fail to function brake light lens is cracked damaged white light is visible brake light lens is darkened faded or dirty significantly
107. rement points padding between frame rails and floor sills is missing or grossly misaligned The vehicle shall be taken out of service until repairs are made if 28 2 3 4 5 6 1 2 3 e Originally installed body hold down or cowl mount is missing e Three or more body hold downs are loose misaligned or have missing hardware e Three or more body hold downs have cracks or stripped nuts at floor sill securement point 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 shall be taken out of service until repairs are made if e Holes or cracks in floor sheet metal create an opening to the passenger compartment e Entire cross section of any floor sill or brace is broken e Any broken weld or mounting of a floor sill brace resulting in complete separation more than one 1 foot in length e Any broken weld in the mounting of the bracing K member at the front of the body floor between step well and driver s area Outriggers Inspect body outriggers and hardware for condition and securement Make repairs if any body outrigger is cracked loose or missing hardware The vehicle shall be taken out of service until repairs are made if the originally installed as required by manufacturer outrigger is missing Braces Inspect for condition and securement of all chassis and body braces Make repairs if there is
108. ressure excessive sludge or oil contamination in the reservoir more than 8 fluid ounces reservoir leaks due to corrosion or is cracked The vehicle shall be taken out of service until repairs are made if drive shaft is bent or seriously dented there are cracks or other damage in the drive shaft which could cause structural failure The vehicle shall be taken out of service until repairs can be made if hardware or fasteners are missing in any U joint or CV joint assembly U joint has significant cross shaft to bearing cup play or CV joint has significant play U joint or CV joint shows evidence of significant rusting of bearings bearing cup is loose in yoke The vehicle shall be taken out of service until repairs are made if any yoke has significant play in splines or if any yoke is cracked or damaged The vehicle shall be taken out of service until repairs are made if bearing outer race is loose in insulator or inner race is loose on shaft there is significant play in hanger bearing there are missing or damaged hardware fasteners in hanger bearing or support assembly The vehicle shall be taken out of service until repairs are made if drive shaft guard is missing The vehicle shall be taken out of service until repairs are made if lining is broken cracked or loose drum is cracked or has excessive heat damage or scoring of friction surface actuating mounting hardware or fastener is damaged loose missing park brake is not adjusted per m
109. ront bumper Make repairs if mirrors are not in correct adjustment or mounting brackets mirror assembly is loose All mirror systems must meet criteria of and be in compliance with FMVSS111 The vehicle shall be removed from service until repairs are made if any of the following conditions exist e Mirror is missing e Mirror is cracked pitted clouded or deteriorated to extent vision is obscured e Mirror will not hold set adjustment Crossover Mirror System Check crossover 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 12 feet and the entire width of the bus 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 All mirror systems must meet criteria of and be in compliance with FMVSS111 37 1 1 2 3 4 The vehicle shall be removed from service until repairs are made if e Mirror is missing e Mirror is cracked pitted clouded or deteriorated to the extent that vision is obscured e Will not hold a set adjustment e Mounting of any mirror and bracket made by different manufacturers DRIVER S SEAT A
110. routing securement and condition The vehicle shall be taken out of service until repairs are made if e Fuel line or hose is unsecured or is routed subject to excessive heat or abrasion e Fuel line or hose is deteriorated or damaged e Clamps are loose or missing including cracks or damage that may cause potential leakage e 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 been damaged or missing insulation The vehicle shall be taken out of service until repairs are made if any portion of sending unit wiring including ground or connections is unsecured or routed subject to excessive heat or abrasion BRAKE EQUIPMENT 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 all moisture and contamination are 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 shall be taken out of service until repairs are made if e Safety valve leaks or does not release pressure e Excessive sludge or oil contamination in the reservoir more than 8 fluid ounces e Reservoir is cracked or leaks due to corrosion DR
111. rror brackets are severely bent broken or mounting is insecure mirror glass is discolored driver or passenger mirror is missing mounting of any mirror or bracket made by different manufacturers The vehicle shall be removed from service until repairs are made if windshield glass is cracked and could be dislodged glass is discolored and prevents driver from having clear visibility glass is missing any piece of glass is non OEM The vehicle shall be removed from service until repairs are made if bumper is significantly bent bumper has protruding metal bumper mounting system is cracked or broken bumper has cracked welds missing or loose fasteners The vehicle shall be removed from service until repairs are made if any of the following conditions exist body part is damaged or dislocated creating a protrusion or sharp edge body panels rivets or other components are damaged corroded to the point where joint strength or body structural integrity is compromised The vehicle shall be removed from service until repairs are made if the paint is not National School Bus Yellow or warning light hoods and background are not black The vehicle shall be removed from service until repairs are made if reflective markings are missing around any emergency exit or door Reflective markings required on 1995 and newer buses The vehicle shall be removed from service until repairs are made if all exterior lettering is not readable The vehicle shall be removed
112. rs if high limit is 48 mph or above and if low cut in is 42 or below The vehicle shall be removed from service until repairs are made if road speed control fails to operate or allows vehicle to exceed 50 MPH 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 The vehicle shall be removed from service until repairs are made if speedometer fails to operate h Hydraulic Brake Warning Light Check operation of hydraulic brake warning light The vehicle shall be removed from service until repairs are made if warning light fails to operate i Low Air Warning Buzzer and light Check low air warning buzzer and light for proper operation The vehicle shall be removed from service until repairs are made if warning buzzer or light fail to operate properly 46 APPENDIX A 30 DAY INSPECTION step by step Following is one suggested approach for conducting the 30 day inspection It is important to conduct the inspection first then to make repairs as needed Do not make repairs until inspection is completed 1 2 3 Review last inspection sheet Visually inspect under the vehicle for leaks Place wheel chock under front right tire INSIDE THE BUS 4 5 6 10 11 12 13 14 15 1
113. rse 36 Walk to rear of bus and activate all roof buzzers and emergency exit levers listening for buzzer operation Open all emergency exits and check for binding and sticking Inspect all emergency exit decals and lettering 37 Operate rear door to full open position and check operation of holdback 38 Check warning lights flashers and reverse lights and buzzer if equipped Listen for roof warning light operation 39 Inspecting seats for cover damage loose seat bottoms secure mounting and any weak cushions 40 Indicate if cleanliness of bus is not acceptable on the 30 day form 41 Remove the brake holding tool sit in seat 42 Place transmission in neutral check operation of front warning lights 43 Activate door switch and check operation of entrance door Leave red warning lights on 44 Replace brake holding tool an assistant is recommended to aid with outside checks OUTSIDE THE BUS 45 Exit entrance door and inspect right rear view mirrors 46 Inspect right side hood hold down strap 47 Visually inspect reflectors headlights markers and body condition as you go around the bus 48 Check tire tread Check the right front tire pressure wheel condition Check hub and wheel holding hardware for cracking or rust Remove plug and check fluid if equipped 49 Check extended walk arm mounting diaphragm and return cables and springs 50 Inspect bumper bolts and grill as you go around 51 Inspect left side hood hold do
114. shall be removed from service until repairs are made if road speed control fails to operate or allows vehicle to exceed 50 MPH The vehicle shall be removed from service until repairs are made if speedometer fails to operate The vehicle shall be removed from service until repairs are made if hydraulic brake warning light fails to operate The vehicle shall be removed from service until repairs are made if low air warning buzzer or light fails to operate properly UNDER NO CIRCUSTANCES SHALL A SCHOOL BUS BE USED TO TRANSPORT PASSENGERS WITH A KNOWN DEFECT THAT HAS BEEN DEFINED AS AN OUT OF SERVICE ITEM 60 APPENDIX C PUBLIC SCHOOL LAW G S 115C 248 115C 248 drivers each school bus owned or operated by such local schoo inspected at least once each 30 days during the schoo or other defects which may affect the saf together wit defects report of such inspection Inspection of school buses and activity buses discontinuing use until defects remedied a The superintendent of each local school administrative unit report of defects by shall cause administrative unit to be l year for mechanical h the rec operation of such bus A ommendations of the person making the inspection shall be filed promptly in the office of the superintendent of such local school administrative unit and a copy thereof shall be forwarded to the principal of t
115. starter mounting bolts studs or nuts are loose damaged missing or broken loose or damaged starter missing heat shield if equipped TRANSMISSION CHECKS Transmission Bolts Inspect transmission assembly and mounting fasteners for condition and securement Make repairs if any transmission assembly fastener is loose missing or damaged The vehicle shall be taken out of service until repairs are made if transmission is not mounted securely to flywheel housing external indication that any torque converter bolt is loose or missing Linkage Inspect transmission linkage for routing condition and securement Make repairs if any of the following conditions exist modulator cable or vacuum hose routed where it is subject to excessive heat or abrasion linkage hardware or fasteners are loose exposed modulator cable or damaged casing deteriorated or loose modulator vacuum hose The vehicle shall be taken out of service until repairs are made if Linkage is bent damaged binding or severely misadjusted Linkage hardware or fasteners are missing Linkage is damaged so as to cause it to stick or bind Modulator vacuum hose is leaking or not connected Lines Inspect transmission lines for securement routing and condition Make repairs if any of the following conditions exist transmission line unsecured or routed subject to excessive heat or abrasion transmission line crimped transmission line of improper type transmission line
116. tectable looseness or roughness in rear wheel bearings 26 1 2 3 4 5 REAR BRAKE Hoses Inspect rear brake flexible hoses for condition securement and routing Make repairs if rear brake hose supporting bracket is damaged has loose fasteners or rear brake hose is rubbing or routed against other components The vehicle shall be taken out of service until repairs are made if e Rear brake hose or connection is leaking fluid or air pressure e Rear brake hose is kinked collapsed or bulging e Has damaged plies or cord e Any damage below outer covering Lines Inspect air and hydraulic brake lines for routing securement and condition Make repairs if any of the following conditions exist brake line or securement system is loose missing brake line is rubbing on other components or is frayed worn The vehicle shall be taken out of service until repairs are made if e Brake line is bent crimped damaged significantly restricting air pressure or hydraulic fluid e Brake line or connection is leaking air pressure or hydraulic fluid e Any brake line is not of proper size or type Chambers Inspect rear brake chamber assembly for securement condition and proper size Make repairs if rear brake chamber or mounting fastener is damaged or loose The vehicle shall be taken out of service until repairs are made if e Rear brake chamber mounting bracket is cracked bent or broken e Either chamber is not original
117. ther than key type switch engine will not crank start switch doesn t function properly in start run off or accessory position switch is intermittent in any position The vehicle shall be removed from service until repairs are made if pedal and assembly are not mounted securely control design and mounting are not of OEM design accelerator control and linkage sticks or doesn t operate freely pedal is built up with extender block or not of OEM design The vehicle shall be removed from service until repairs are made if engine cannot be started shutdown or operation is difficult bus was originally equipped with ignition switch type controlled shutdown and has been retrofitted with manual type shutdown The vehicle shall be removed from service until repairs are made if oil or temperature warning system is not functioning or is unreadable speedometer doesn t work or is confirmed to be inaccurate speedometer is unreadable or damaged pressure gauge is inaccurate unreadable or not working The vehicle shall be removed from service until repairs are made if horn fails to function as designed The vehicle shall be removed from service until repairs are made if high coolant temperature warning light or buzzer is inoperative either constant or momentary The vehicle shall be removed from service if air brake warning light and air brake buzzer are simultaneously non functioning either constant or momentary The vehicle shall be removed from
118. ting u joints and carrier bearings 108 Inspect exhaust as you travel up the drive shaft 109 Follow exhaust up to engine clamp 110 Follow frame down right side of bus Checking all lines floors body clamps outriggers cross members for condition 111 Inspect fuel tank Check all mounting bolts cages lines and wiring 112 Inspect the front half of the right rear spring hanger and u bolts 113 Inspect condition of right rear tire sidewalls 114 Inspect the condition of the rear half of the right rear spring hanger and u bolts 115 Inspect the condition all right rear hoses brake cans calipers spider bolts and brake hardware for condition 116 Check the free play on the right rear brake 117 Inspect and note the remaining shoe or pad thickness on the right rear 118 Check differential vent for cleanliness 119 Inspect for brake hoses rubbing frame 120 Inspect and note the remaining shoe or pad thickness on the left rear 121 Check the free play on the left rear brake 122 Inspect the condition all left rear hoses brake cans calipers spider bolts and brake hardware for condition 123 Inspect the condition of the rear half of the left rear spring hanger and u bolts 124 Inspect condition of left rear tire sidewalls 125 Loop the rear floor section from the left side to the right side inspecting the frame bumper mounting exhaust hangers and joints 50 ROAD TEST 126 Remove wheel chock Prepare fo
119. transpor local schoo operation of such activity bus as the regular public school buses for the normal school pupils are i principal o shall be forwarded to th administrative unit or any public school system therein inspected for mechanical defects or other defec at the same time nspected A report of such inspection recommendations of the person making the inspection f the school which uses and operates involved superintendent of the It shall be the duty of the driver of tation of students by such to be ts which may affect the safe and in the same way and manner transportation of public together with the shall be filed with the such activity bus and a copy local school administrative unit same reports to the principal of the school usin bus as is required by this section If any publi ach activity bus to make the g and operating such activity c school activity bus is found to be so defective that the activity bus may not be operated with reasonable safety it shall be the duty of such principal to cause the use of such activity bus to be discontinued until such defect is remedied to the satisfaction of the person making the inspection and a report to this effect has been filed in the manner herein prescribed Nothing in this subsection shall authorize the use of State funds for the purchase 13727 ert 21 S 8 1961 C operation
120. uid brake line or connection is leaking air pressure or hydraulic fluid 3 Chambers Inspect front brake chamber assembly for securement condition and proper size Make repairs if front brake chamber or mounting fastener is damaged loose The vehicle shall be taken out of service until repairs can be made if Front brake chamber mounting bracket is cracked bent or broken If either chamber is not of the original size Size of chambers is not matched left and right both sides must be the same size Non manufactured holes are found in the spring brake housing 19 4 5 6 7 8 9 Slacks Inspect slack adjusters and S cam assemblies for wear condition operation and securement Make repairs if any of the following conditions exist slack adjuster mounted so that adjuster bolt is facing chamber S cam shaft and S cam bushing total wear up and down is greater that 040 S cam in and out endplay is more than 060 slack adjuster is dirty and prevents the lock sleeve from seating and the technician from inspecting for cracks The vehicle shall be taken out of service until repairs are made if e Any portion of the slack adjuster or S cam is missing broken cracked or badly worn e S cam snap ring is missing e Slack adjuster has a frozen or stripped worm gear or ratchet assembly Pushrods Inspect pushrod assembly for condition securement and alignment Make repairs if the following conditions exist
121. ved from service until repairs are made if 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 fire blocking crash barrier fabric is repaired or replaced using unapproved procedures or non fire blocking material The vehicle shall be removed from service until repairs are made if emergency door will not open properly is equipped with any type of a hasp lock or any other locking device except for OEM interlock system bus will start with any emergency door locked OEM interlock system latch mechanism will not secure door hatch or window in closed position The vehicle shall be removed from service until repairs are made if emergency exit buzzer circuit fails to operate emergency door fails to operate panel buzzer The vehicle shall be removed from service until repairs are made if any of the following conditions exist glass is missing laminated windshield or laminated window glass is broken or splintered that might cause injury when touched The vehicle shall be removed from service until repairs are made if windshield or any window that provides visibility to any mirror is fogged more than two inches in from the outer border windshield window fogging or clouding results in reduced visibility of a mirror tinting on the windshield or windows to the side of the driver that is not 70 light transmission or clearer tinting on any windows behind the driver s locatio
122. ved from service until repairs are made if any of the following conditions exist seat frame and mounts are cracked broken or distorted seat moved from OEM position unless repositioned using written OEM approved mounting instructions driver seat belt is missing or inoperable seat belt is routed improperly seat belt buckle and tongue assemblies do not latch and release properly The vehicle shall be removed from service until repairs are made if seat frames or welds are broken or cracked seat frame hardware has been added or modified which results in projections or sharp edges non OEM seat frames have been installed The vehicle shall be removed from service until repairs are made if any seat mounting fasteners are of lower grade or different type than OEM fasteners for the specific locations The vehicle shall be removed from service until repairs are made if any seat foam is missing The vehicle shall be removed from service if any vehicle that came equipped with fire block upholstery all lift buses and all others manufactured after late 1996 has been retrofitted with upholstery other than fire block The vehicle shall be removed from service until repairs are made if any of the following conditions exist not a clear minimum twelve 12 inch aisle width to the side emergency door flip up seat bottom will not raise or lower will not stay in the raised position or automatically retract properly when not occupied The vehicle shall be remo
123. vidence that any wheel cylinder caliper may be sticking The vehicle shall be taken out of service until repairs are made if there is damage or condition that prevents proper adjustment of S cam or air disc type brakes any brake adjustment is out of specification The vehicle shall be removed from service until repairs are made if any automatic slack adjuster arm or mechanism is damaged or loose adjusted stroke pushrod travel of any automatic slack adjuster equipped brake exceeds maximum shown in charts on page 8 The vehicle shall be taken out of service until repairs are made if originally installed body hold down or cowl mount is missing three or more body hold downs are loose misaligned or have missing hardware three or more body hold downs have cracks or stripped nuts at floor sill securement point The vehicle shall be taken out of service until repairs are made if holes or cracks in floor sheet metal create an opening to the passenger compartment entire cross section of any floor sill or brace is broken any broken weld or mounting of a floor sill brace resulting in complete separation more than one 1 foot in length any broken weld in the mounting of the bracing K member at the front of the body floor between step well and driver s area The vehicle shall be taken out of service until repairs are made if originally installed as required by manufacturer outrigger is missing The vehicle shall be taken out of service until rep
124. wn strap 52 Check tire tread Check the left front tire pressure wheel condition Check hub and wheel holding hardware for cracking or rust Remove plug and check fluid if equipped 53 Inspect left side rear view mirrors 54 Check condition of drivers window slides and latch 55 Check condition of extended stop arm base and diaphragm 56 Open electrical box and inspect condition or wiring and mounting Lock after inspecting 57 Open battery box slide out batteries and inspect cable and mounting 58 Inspect for proper lettering and condition of bus body paint on right side 48 59 60 61 62 63 64 65 66 Check rear tire tread Check the left rear tire pressures and wheel condition Check hub and wheel holding hardware for leaks cracking or rust Go around rear of bus checking all lights reflectors Check exhaust tip for extending past bumper Inspect for proper lettering and condition of bus body paint at rear of bus Check tire tread Check the right rear tire pressures and wheel condition Check hub and wheel holding hardware for leaks cracking or rust Inspect for proper lettering and condition of bus body paint on left side Inspect condition of fuel cap and fuel tank area Indicate if exterior cleanliness of bus is not acceptable on the 30 day form Step up into bus and shut off eight way lighting park lights and hazards ENGINE COMPARTMENT 67 68 69 70 71 72 73 74 75 76
125. xcessively low less than 1 4 full The vehicle shall be removed from service until repairs are made if no oil is observed on dipstick evidence of fuel or water contamination in the oil The vehicle shall be removed from service until repairs are made if the transmission fluid is not present on dipstick or is above the full mark overfilled The vehicle shall be taken out of service until repairs are made if coolant cannot be seen in reservoir or in radiator tank with cap removed The vehicle shall be taken out of service until repairs are 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 3 4 inch deflection or if any slippage is detected Vehicle shall be removed from service if the diesel air filter restriction exceeds manufacturer specifications The vehicle shall be removed from service until repairs are made if any portion of the power steering pump mounting brackets or fasteners is cracked loose or missing 52 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
126. y The vehicle shall be taken out of service until repairs can be made if e Any front spring shackle or hanger is loose cracked broken e Front spring mount to frame fastener is loose missing broken cracked e Frame is cracked at any spring mounting location Pins and Bushings Inspect pins and bushings as follows Inspect front spring pins and bushings for wear lubrication and securement The vehicle shall be removed from service until repairs can be made if wear exceeds 1 4 inch or bushing is missing A Frames and Bushings Inspect A frames and bushings for condition and securement Make repairs if rubber bushing is split badly deteriorated or badly extruded from suspension joints The vehicle shall be taken out of service until repairs are made if A frame assembly is bent missing or broken Fasteners u bolts are loose or missing Mounting of bushing assembly is not secure Rubber bushing is missing A frame bushing or pivot arm has more than 050 free play at pivot point Ball Joints Inspect ball joints for condition securement and lubrication Make repairs if any of the following conditions exist zerk grease fitting is missing damaged or ball joint will not take lubrication any ball joint has more than 3 32 inch axial play The vehicle shall be taken out of service until repairs are made if the following conditions exist e Ball joint mounting is loose or missing e Cotter pin is missing e Ball joint to

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