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Saf-T-Liner EFX Operator`s Manual School Bus

1. NEN Start engine Check operation of the following EE a Check engine light SEEN De DIANE 624 5 aon ye sedan e EN c Sound of engine noise knock miss squeal etc EE d ALNSTUMOMIS oS ey Rows xp Rap us dosis d A d EN e Heater Air EN f Windshield wiper and washer EN g All Interior lights kk KK kam ho sie en o KIR KI K KIR ode ee ZEN h Turn signals stop lampS EN i Headlights clearance lights EE j All warning devices warning lights horn BEEN Maximum air system pressure 110 120 5 EE Is DOCOMO hone nase za Depress brake pedal check for leaks while depressed SEN Check operation of parking spring brakes EE Inspect seat backs and cushions for cuts rips EN Check condition of all rear view mirrors adjust mirrors as necessary EE Move bus to ready line En route check operation of brakes and steering BEEN Check to make sure al
2. DEF TANK FILL ACCESS DOOR CAUTION USE DEF ONLY La 9 4 DIESEL EXHAUST USE DEF ONLY u ig my nier Idr m vell DIESEL EXHAUST FLLAD Degrade Sed ACCESS DOOR ACCESS DOOR LABEL OLITSIDE VIEW LABEL INSIDE VIEW FUEL DEF GAUGE The DEF levels are measured by a gauge consisting e Between 50 and 75 full three bars are of a four segment LED bar graph illuminated green Figure 6 e Between 75 and 100 full four bars are illuminated green Figure 5 gt m uM aL p CONTINUED ON NEXT PAGE FIGURE 5 Page 2 5 SAF T LINER EFX OPERATOR S MANUAL FUEL DEF GAUGE CONTINUED e Between 25 and 50 full two bars are illuminated green Figure 7 T TI FIGURE 7 DEF WARNINGS AND ENGINE DERATES There are safety controls that warn the driver and derate the engine when the DEF level registers below 10 or if the DEF tank is contaminated NOTICE Under no circumstances will the engine be suddenly shut down due to running the vehicle out of DEF or putting the improper fluid in the DEF tank NOTICE Tampering with any portion of the DEF system or diluting the fluid will result in a system fault detection and a possible major engine derate DEF LEVEL WARNING When the DEF level in the tank drops to 10 full the DEF Low Level Lamp in the gauge is illuminated solid amber and on
3. EN 17 Inspect engine mounts condition and security EN 18 Inspect air intake ducts hoses for condition amp for chafing ____ Looseclamps 19 Check air cleaner restriction indicator Service filter if necessary Form 2 PREVENTIVE MAINTENANCE INSPECTION 1 CONTINUED OK Not OK 20 Inspect cooling system for leaks Radiator Hoses ___ 21 Inspect fan assembly Mounting Fan blades 22 Check coolant level Freeze protection and SCA levels ppm or units Important Check with Engine Manufacturer for their SCA recommendations and maintenance schedule 23 Check Hydraulic fluid 24 Grease rear suspension Drive shaft Brake mechanism 25 Check lube level Rear axle Tans Sid s sau x qd d neues ran 26 Adjust rear brakes 27 Clean rear axle vent Inspect lining wear eene 28 Inspect rear springs broken leaves Loose U bolts ____ 29 Inspect air suspension for cracks Wear Hangers leaks 30 Bleed air tanks Check moisture ejector Heat operation 31 Inspect battery installation hold down clamps security clean as required 32 Inspect battery cables for corrosion chafing
4. J DIKEL GGUWERADEC F li Dimensions in millimeters JA C MAJA E25 N a Rear Door Opening 1143 Floor line lt 4536 ke Wheelchair anchorages Rear Door Emergency Exit No Wheelchair Anchorages within the shaded region Page 6 20 GENERAL INFORMATION TRACK SEATING GENERAL INSTALLATION AND REMOVAL GUIDELINES CONTINUED 14 Different seat types and or styles have different installation criteria Care should be taken to identify the specific seat style and type per the seat installation section of this manual Seats equipped with ISO Latch infant carrier attachment options should be located in the first row of a school bus If more than two seats have been ISO Latch equipped they may be located anywhere behind the first rows and the rear most row on the vehicle Tests have shown infant carriers with the infant secured rearward facing is the safest way to transport infants ISO Latch equipped tracked seats infant carrier capable should be spaced at 27 minimum regardless of seat type and minimum spacing allowed by the seat type chart This minimum spacing is to protect the infant from contacting the seat back or barrier due to infant carrier belt stretch in a frontal collision 18 If one seat is installed in a TBB product with seat belt option all seats in the vehicle should be equipped with seat belts 1
5. 33 Check state of charge in batteries Fill if applicable Battery voltage 34 Inspect fuel tank mounting brackets for cracks security 35 Clean fuel tank vents Inspect filler cap seals __ 36 Jack front axle Check tires for toe in wear a Grease suspension king pin steering linkage ER b Check lube level of front wheels Bearing adjustment __ SEN c Check steering linkage for lost motion Checkking pins J _ d Inspect front springs for broken leaves Loose U Bolts Shackles e Adjust front brakes Grease brake mechanism Checklining wear 37 Inspect steering gear box mounting for security 38 Inspect wheel rim lug nuts for security llli 39 Inspect wheels rims for cracks 5 40 Inspect tires for cuts tread depth 41 Inflate tires to recommended pressure 42 Inspect body mounting bolts and clips for security 43 Consult repair order for following a Change engine oil ____ Replace oil filters __ ___ 44 Start engine Check filters for leaks b
6. PASSENGER ADVISORY SYSTEM BUZZER ACTIVATION B2001 28 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard Bus Scan When the Ignition is turned off the buzzer sounds continuously and Active Pilot Lamp illuminates on the control unit The buzzer will continue until Driver walks back to the back of the bus and presses button in rear bulkhead Once the button is pressed the buzzer ceases and Pilot lamp turns off If button is not pressed in 60 seconds the Bus horn will sound You must turn Ignition back on then off and then press button in rear bulkhead for the horn to stop Time to alarm 60 seconds Type of Alarm Buzzer and Chassis Horn System Activation Ignition amp Warning Light activation Alarm Activation Driver turns off ignition Alarm Indication Buzzer sounds upon alarm activation Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Buzzer ceases Operation without Deactivation Buzzer and Chassis Horn Dome Light N A Pilot Light Location Operation On Bus Scan Module Lights Labeling N A Page 6 46 GENERAL INFORMATION CHILD REMINDER SYSTEM EP2 B2001 29 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard When the bus is started there
7. The following are minimum preventive maintenance inspections that should be performed as shown on the forms or more often as operational and climatic conditions dictate A Any addition of accessories which exceed the capacity of the electrical system or any modification of the system such as bypassing a circuit breaker could cause premature failure of electrical components Any such addition of accessories or modifications may affect your rights under the warranty Page 7 1 SAF T LINER EFX OPERATOR S MANUAL TOUCH UP Retouch damaged areas as soon as possible to benefit vehicle appearance and control corrosion Exposed metal quickly corrodes and repair may WASHING For the first 30 days wash the vehicle only with clean water Do not use a high pressure hose or detergent during this period Operating conditions will dictate washing frequency Special attention must be given to WAXING Waxing is recommended to eliminate any weathered appearance A good automotive wax may be applied after the first 30 days of service Annual waxing should Page 7 2 develop into a major expense Your Thomas dealer may be your paint source removing salt deposits when vehicle is operated in areas that use salt Failure to do so may cause serious damage to sheet metal and painted surfaces which could invalidate your warranty be standard procedure for additional corrosion protection and longer paint life and to mainta
8. Cummins ISB 1 Open all gate valves 2 Open valve on front heater using controls 3 Remove radiator cap WINDSHIELD WASHER To add windshield washer fluid locate the fluid reservoir behind the left windshield wiper access panel below the windshield Use a suitable washer fluid not water and fill to the cap 4 With engine NOT running turn on booster pump 5 Add coolant as required 6 Total volume of coolant added should be 2 to 2 1 2 gallons 7 Start engine and add coolant as required 8 Install radiator cap Two 2 to 2 1 2 gallons is an average required to filla dry heater system after the engine is already filled When performing heater or engine maintenance the volume of coolant required to fill the system will vary Page 7 22 MAINTENANCE AIR CLEANER The air cleaner is located in the forward section ahead of the stepwell An elastic seal is attached to the top inlet adapter sealing the area where the air cleaner contacts the incoming air plenum A restriction indicator has been installed behind the grill assembly at the top of the radiator installed viewed from the front Maximum restriction is 25 H2O at full load and rated engine RPM This will occur during normal operation on the road Replace the element every 2 years 45 000 miles or 25 of restriction whichever comes first Do not attempt to clean or reuse it DRAINING AIR RESERVOIR TANKS The air reservoir tanks should be draine
9. Page ii INTRODUCTION To THE OPERATOR This manual has been prepared to acquaint you with the necessary information for the proper operation of your Thomas Bus body and chassis A thorough knowledge of the operating controls is essential to the proper transit and comfort of passengers The information and illustrations contained in this manual are based on the latest product information available at the time of publication Some procedures and illustrations will pertain to optional equipment Thomas Built Buses Inc reserves the right to make changes at any time without notice We would like to say Thank You for choosing the Thomas product line to fill your transportation needs This manual should remain with the vehicle when sold to provide the next owner with important operation and maintenance information GENERAL INFORMATION HAZARD ALERT TYPES amp USES Service literature includes a new type of hazard alert the NOTICE This new hazard type allows a distinction between potential injury and property or component damage which were formerly grouped DANGER under CAUTION The use of DANGER and WARNING hazard alerts are the same as before For more information see each definition below DANGER indicates an immediately hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or seri
10. SAF T LINER EFX OPERATOR S MANUAL LUBRICATION CHARTS The following information has been extracted from the supplied with the Thomas Maintenance Manual service manuals of manufacturers providing should be studied as they contain additional components for Thomas Built Buses All manuals lubrication and maintenance information ENGINE OIL CAPACITY AND CLASSIFICATION CUMMINS ENGINE OiL CAPACITY RECOMMENDED LUBRICANT Rm TT See Manufacturer s recommendation ISB 200 260 17 6 Qts 16 7L kk for approved lubricant It is normal to add some oil between oil changes Check your engine oil level before start up or while refueling or at least every 500 miles 800km To Do not handle a hot oil filter with bare hands check the engine oil level park your vehicle on level ground and turn engine off Wait a few minutes for oil to drain back to oil pan Protect yourself from engine heat then pull out the dipstick Wipe it clean and reinsert fully Pull the dipstick out and check level Keep the oil level above the ADD mark on the dipstick by adding oil as required DO NOT OVERFILL Change engine oil and filter according to the Maintenance Schedule Page 7 10 MAINTENANCE ENGINE OIL AND FILTER CHANGE INTERVAL CUMMINS ENGINE ENGINE MILEAGE INTERVAL NTERVAL TIME INTERVAL 00 NTERVAL ISB 200 260 6 000 miles 9600km 6 months or 500 hours ENGINE OIL VISCOSITY CHART 0 to 1209F
11. SAF T LINER EFX OPERATOR S MANUAL SERVICE INSPECTION POINTS ada 1 7 C i i 1 di 52 _ TR maf e 4 n bs mE Ea Y c GO OO de 8 Ta s mf b 4 FX Qe M n ANS nn afer Automatic Stack Adjusters Air Brakes Bees _ Engine Reservoir Drweshafs Udom amp SipYes Emme Bds TT Engine Ol Fiter Engine Ol fill Tube _ Tan _ Front Axle Wheel Bearings King Pins FuelMater Separar Power Steering Resenor Rede _ Steering Transmission Fil Tube Transmission lt Fiter Edema Transmission Fiter nema Uds TT WhellugRus _ Fe Engine Coolant Fiter Air Tanks 4 Air Brakes DEF Tak _ Windshield Washer Reservoir Wr ye _ MN EN LR EN N ue LM LM LOS M EN Bn ww Es Page 7 12 MAINTENANCE OIL LUBRICATED WHEEL BEARINGS Use only gear type oil Base stock from solvent refined high viscosity index petroleum oil e Corrosion and oxidation inhibitors e Extreme pressure EP additive e Pour Point 10 C Maximum Generally use SAE 90 viscosity oil which meets or exceeds API GL 5 requirements BRAKE SYSTEM The vehicle is equipped with a dual br
12. Saf T Liner EFX Operator s Manual School Bus If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately submit a complaint to the Administrator National Traffic Safety Administration 400 Seventh Street SW Washington DC 2059 or call the toll free Vehicle Safety Hotline at 1 888 327 4236 TTY 1 800 424 9153 or go to http www safercar gov in addition to notifying THOMAS BUILT BUSES INC If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or THOMAS BUILT BUSES INC TABLE OF CONTENTS SECTION INTRODUCTION S 525 R3 3 1ROP pep e ee ee e e e e e e e e e e 9 e e e e e e e e e e e e e e e e e 1 EPA10 EXHAUST SYSTEM 4 es e e 054555 e eee eee e e e e e e e e e e e e 2 OPERATOR S COMPARTMENT 3 OPERATING THE VEHICLE ccc ccc ccc cece cc e ee e e e e e e e e e ee e e e e e e e e ee 4 EMERGENCY EQUIPMENT ss ee e e e e e e e e e e e e e e e e e e e e e e e e e e 5 GENERAL INFORMATION 5 i e e e e e e 6 IVLAINTENANCE amp amp APR c a amp onum ca 7 Page i SAF T LINER EFX OPERATOR S MANUAL
13. 732 6600 e Freedman Seating Company 4043 N Ravenswood Chicago IL 60613 773 929 6100 e The C E White Company P O Box 308 New Washington OH 44854 419 492 2157 RESTRAINING BELTS Restraining belts are only available on seats specifically designed for their use All should be checked for proper operation daily and fasteners should be checked monthly To fasten the belt pull the belt across the occupant and insert the tongue into the buckle until it clicks Pull to make sure it is latched snug the belt by pulling slack out Press the button on the buckle to release Wax should only be used on Chemical Coated Fabrics and Film if manufacturer recommends its use Many waxes contain dyes and dyes will stain The main thing to remember is to use good judgement when choosing any cleaning substance other than soap and water e Transportation Seating P O Box 595 Montezuma GA 31063 616 732 6600 e Syntec Inc 200 Swarthmore Ave High Point NC 27263 336 861 9023 IMMI 18881 US 31 N Westfield IN 46074 800 586 7839 Seat belts must only be used on seat assemblies designed for their use C 6 12 GENERAL INFORMATION IMMI SEAT CUSHION LATCHES NOTICE Some buses are equipped with seat cushions 1 Always lock seat cushions in place after lifting Always place seat belts on top of the seat cushions before latching TRACK SEATING GE
14. Do not seal the lower outside window sash Page 6 7 Saf T Liner EFX OPERATOR S MANUAL GLASS REPLACEMENT The glass used in your bus must meet certain Federal Motor Vehicle Safety Standards Therefore whenever a glass is broken or must be replaced it should be replaced with identical glass The following instructions are for replacing glass in split sash 1 Remove sash as per section Sash Removal 2 a To replace the lower stationary glass loosen the center screw on each end of the center rail Remove the screw on each end of the lower rail 2 b Remove lower rail and slide glass out 3 a To replace the upper sliding section glass stand window on it s side and remove three 3 screws from the sidemember 3 b Remove the sidemember 3 c Remove the screw on each end of the lower rail of the sliding section and slide glass out Always wear heavy gloves and eye protection when handling glass to minimize the risk of injury 4 Checkthe glazing rubber If the seal is damaged or has deteriorated replace the one piece rubber seal available from your Thomas Dealer 5 Check the new glass to be installed Sharp corners will cut the glazing rubber seal and lead to glass breakage due to glass contacting metal The corners should be ground to a smooth radius of 1 8 6 Reverse Steps 1 5 to reassemble sash Be careful not to twist or cut the gasket as you slide it into place WINDOWS SPLIT SAsH PUSHOUT GLASS REP
15. Replace fuel filters 45 Engine idling amp at operating temperature check automatic transmission fluid level 46 Road test Check brake operation unusual noises etc 47 Wipe grease off steering wheel and driver s seat 48 Fill out all required work orders forms Mechanic s Signature Comments Form 3 Unit Number Mileage Repair Order Date Time Location J gt 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Steam clean engine compartment if necessary Perform 1 Inspection a eos re USA kk a a a al rreri b l an aa ll ahaa a ak and a Inspect hoses for deterioration replace as required Check condition of antifreeze replace as required set for 309F 349C PREVENTIVE MAINTENANCE INSPECTION 2 45 000 Miles 75 000 Km Annual Check OK X Attention Required R Repair Not Applicable OK Not OK Important Check with Engine Manufacturer for their SCA recommendations and maintenance schedule Check shutters for opening and closing fully if so equipped Service shutter system filter if so equipped Clean front of radiator module mud dirt debris R
16. Type of Alarm Chassis Horn System Activation When red warning lamps are used for first time Alarm Activation When Ignition is turned off Alarm Indication Dome Lamps are turned on Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Dome lamps flash when deactivated Operation without Deactivation Chassis Horn Dome Light Yes Approximately 30 seconds Pilot Light Location Operation LED pilot light located in switch cabinet lights steady upon system activation Labeling PASSENGER CHECK REMINDER SYSTEM Located at pilot light on switch cabinet Page 6 39 Saf T Liner EFX OPERATOR S MANUAL CHILD REMINDER SYSTEM MODEL CR2A OPTION B2001 20 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard oystem is armed after being in run for 10 minutes It is activated when the bus Ignition is turned off The Pilot Lamp on the dash lights as well as the Passenger Dome Lamps For the first 60 seconds after turning the Ignition off the alarm cannot be disarmed When the Lights flash two times then the driver can press the button at the back of the bus When the button is pressed the passenger dome lamps flash 2 times and the Pilot Lamp cuts off The Driver can now leave the bus If the system is not disarmed within 1 minute then the horn will start blowing When this happens th
17. With the door in the open position put a wrench on the flats of the air cylinder output shaft and rotate as necessary Facing the shaft end of the cylinder clockwise rotation will lengthen the rod or decrease opening Counterclockwise rotation will shorten the rod or increase door opening 4 Remove and check operation Use appropriate size wrench on flat part of shaft only Do not use any other tool on the air cylinder shaft This will cause damage to the cylinder and may cause failure Care should be used when operating doors while making adjustments Keep hands clear of moving parts Personal injury could result o Adjust Flow Control Valves by tightening clockwise until snug back off 1 1 2 turns counterclockwise for initial adjustment of Opening and closing speed Adjust as necessary 6 Start engine to maintain air pressure Cycle door several times to ensure opening and closing speed is at desired speed 7 Reinstall access panel Return bus to service NOTICE Service Filter annually CONTINUED ON NEXT PAGE Page 6 4 GENERAL INFORMATION Page 6 5 Saf T Liner EFX OPERATOR S MANUAL SIDE EMERGENCY DOOR An emergency door is usually located on the street side of the vehicle The opening hardware for the emergency door is protected to prevent accidental opening Instructions for opening the emergency door are clearly displayed on the door face This door should be opened daily to ensure tha
18. or lubricants electrical system component alteration addition of after market components such as e Retarder e Air conditioning e Battery disconnect e Traction devices Page 1 3 SAF T LINER EFX OPERATOR S MANUAL CERTIFICATION AND DATA PLATE The computer generated Certification and Data Plates are attached to the inside roof liner above the driver s window or on the front bulkhead The Certification Plate certifies compliance with all Federal Motor Vehicle Safety Standards in effect at time of manufacture Other information included are Date of Manufacture GAWR Front GAWR Rear GVWR Tire Data VIN Vehicle Type and Body ID Whenever contact is made with a dealer authorized service agent or Thomas Built Buses concerning warranty parts or service these numbers must be given to identify the unit The three sets of numbers are VEHICLE IDENTIFICATION NUMBER VIN a i 1 INC MFD BY 59 We Move GVWR 38 KG 12 LB GAWR FRONT 34 9 LB W 20 RIMS 22 TIRES f 32 24 PSI COLD 36 GAWR REAR 35 KG 10 LB W 21 5 23 TIRES amp 33 25 PSI COLD 37 MFD BY THOMAS BUILT BUSES INC 1 Chassis Identification Number When concerning the chassis of a Thomas product 2 Order Number The first five digit number in the Body Identification number 3 Body Number The last seven digit number i
19. shorting connector is installed under the left dash next to the diagnostic port that performs this function Page 3 12 PANEL DIMMER SWITCH OPTIONAL Enables the driver to dim or brighten the light on the dash panel by sliding the button to the desired brightness HEADLIGHT SWITCH The headlight switch is a three position switch that controls the main lighting circuit Position 1 lower position is the OFF position Position 2 center energizes the parking lights tail lights marker clearance lights instrument and panel lights Position 3 upper position energizes the headlights PILOT LIGHT WITH WARNING LIGHT SYMBOL Amber and red flashing lights coordinated with eight light warning system OPERATOR S COMPARTMENT Page 3 13 SAF T LINER EFX OPERATOR S MANUAL EIGHT LIGHT WARNING Eight light warning system controls the amber and red warning lights mounted on the four corners of the exterior of the vehicle These lights are activated at various times by the driver as necessary This system requirements vary from state to state Follow your state requirements for proper operation DOOR CONTROL SWITCH The electric door control switch controls the operation of the front door In the lower position the entrance door is closed In the upper position the door will open This switch is connected directly to the battery ree allowing entrance and exit of the vehicle at all times The operator shou
20. B2001 23 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard oystem is activated when the Red warning lamps are used the first time Once the route is complete and the Ignition is turned off the Pilot Lamp on the dash lights as well as the Passenger Dome Lamps The Driver then has 60 seconds to check the bus for passengers and press the button at the back of the bus When the button is pressed the passenger dome lamps flash 2 times and the Pilot Lamp cuts off The Driver can now leave the bus If the system is not disarmed then the horn will start blowing and headlamps will flash When this happens the driver must go to the front and turn the Ignition back on then off and then return to rear of the bus to press button to deactivate Time to alarm 60 seconds Type of Alarm Chassis horn System Activation When red warning lamps are used for first time Alarm Activation When Ignition is turned off Alarm Indication Interior Lamps are turned on Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Interior lamps flash when deactivated Operation without Deactivation Pilot lamp and dome lights ON If not disarmed within 1 Minute chassis horn will blow and headlamps will start flashing Dome Light Yes Approximately 30 seconds Pilot Light Location Operation LED pilot light loc
21. Message Menu Screen The display the EE prom upon key off messages menu should contain the following configurable categories 25 Diesel Exhaust Fluid DEF Gauge Refer to EPA10 Exhaust System section for operation a Odometer 26 Low Fuel Level Gauge LOW FUEL Ultra b Chassis Battery Voltage Low Sulfur Diesel Fuel only Indicates the c Instantaneous Fuel Economy amount of fuel in the tank d Average Fuel Economy 2 Park Brake On Indicator Red The e Gear Attained Status warning parking brake on indicator light BRAKE f Transmission Temperature legend activates whenever the parking brake is g Hour Meter engaged If the vehicle is moving at a speed of 2 h Trip Odometer 1 mph 3 km h or more the emergency buzzer will l Trip Odometer 2 sound until the parking brake is released j Boost Pressure 28 High Beam Headlight Indicator Blue k Engine RPM Indicator light sideways beam icon illuminates l Percent Engine Load when the headlight high beams are on m Fuel Level n Coolant Temperature o Engine Oil Pressure Page 3 9 SAF T LINER EFX OPERATOR S MANUAL DisPLAY MESSAGE SCREEN OPERATING EXAMPLE FOR MAINTENANCE MENU The maintenance menu shall contain three sub menus These three sub menus are maintenance intervals transmission oil life remaining and transmission oil filter life monitor A fourth sub menu is needed for older pre 2010 service version clusters Screen 1 Auxil
22. T Liner EFX OPERATOR S MANUAL 11 Wheelchair anchorages should be kept well away from the exit aisle to side emergency exit doors No anchorages are allowed within 12 of the centerline of the exit aisle 305 305 305 Floor line Wheelchair Anchorages Center of Restricted Area Side Emergency Exit No Wheelchair Anchorages within the indicated region Page 6 18 12 The rear exit door deserves special attention in a school bus Fully tracked units with removable seats adjacent to the rear exit door must allow enough clear area in the door opening to accommodate a 305 mm deep x 610 mm wide x 1143 mm high volume for vehicles with a GVWR greater than 4336 kg GENERAL INFORMATION TRACK SEATING GENERAL INSTALLATION AND REMOVAL GUIDELINES CONTINUED 10 000 Ib For vehicles with a GVWR of less than 45336 kg the opening should accommodate a volume of 152 mm deep x 558 mm wide x 1143 mm high These dimensions are measured from the top of floor to the outside of the rear bus wall at floor level with the rear emergency door open Rear Door Opening NR ROME N i Center of Bus hom E m owr Te Dimensions in millimeters Rear Door Emergency Exit No Wheelchair Anchorages within the shaded region Page 6 19 Saf T Liner EFX OPERATOR S MANUAL 13 Wheelchair anchorages should be excluded from this area fue COCHE CT JUNG AG
23. an anti restart feature to prevent engaging the starter with the engine running Ignition switch keys have numbers Record your key number for reference if lost Page 3 16 OPERATOR S COMPARTMENT PASSENGER HEATER SWITCH LO HI OPTIONAL The underseat heater fan switches enable the vehicle operator to control the fan speed of the underseat heaters The fans operate at either Low High speed or Off REAR ViEW MIRROR CONTROL SWITCHES OPTIONAL Controls remote adjustment for both upper flat and lower convex mirrors left side and right side independently Switches are located on the lower left dash RADIO CONTROLS SEE RADIO OPERATOR S MANUAL A separate operators manual is supplied when vehicle is equipped with Radio or PA LEFT HEATER SwitcH LO HI Orr OPTIONAL The underseat heater fan switches enable the vehicle operator to control the fan speed of the underseat heaters The fans operate at either Low High speed or Off Page 3 17 SAF T LINER EFX OPERATOR S MANUAL BOOSTER Pump ON OFF The booster pump switch energizes an auxiliary coolant booster pump to circulate coolant to the heaters when engine is idling or when stop and go driving conditions reduce coolant flow due to low engine rpm EXHAUST COMPRESSION BRAKE HI LOW OPTIONAL When switch is set to LOW position exhaust brake is active When set to HIGH position both exhaust brake and compression brake are act
24. and excessive vibrations In addition to broken or misaligned clamps brackets or pipes inspecting the exhaust system at the scheduled maintenance interval inspect the exhaust system if the noise level of the vehicle has increased Replace parts that show leakage wear or damage with genuine Freightliner Thomas parts EPA10 EXHAUST SYSTEM DEFINITIONS OF AFTERTREATMENT SYSTEM ATS TERMS Refer to the following list of definitions of ATS terms e DEF Pump filters and supplies DEF to the and components DEF metering unit DEF Tank holds DEF and regulates its e Aftertreatment System ATS the entire exhaust system from the turbocharger to the tail pipe including the Selective Catalytic Reduction SCR components Aftertreatment Device ATD a device that removes pollutants from exhaust gas after the gas leaves the combustion chamber BlueTec amp Daimler s X proprietary SCR technology Diesel Oxidation Catalyst DOC a flow through devise that enhances the oxidation of hydrocarbons in the ATD Diesel Particulate Filter DPF a component in the ATD that traps particulate matter from the exhaust gas Diesel Exhaust Fluid DEF the chemical agent that reacts with the exhaust gases in the SCR to reduce NOx temperature DEF Metering Unit mixes DEF with compressed air and meters this mixture into the exhaust flow via an injection nozzle SCR Catalyst the housing containing a treated ceramic flow th
25. and tether belts as follows 1 Check the web for fraying cuts or extreme wear especially near the buckle latch plate and in the D loop guide area Check the web for extreme dirt or dust and for severe fading from exposure to sunlight Check the buckle and latch for operation and for wear or damage Check buckle cable for damage sharp bends kinks frayed or exposed strands and loose or corroded fasteners Check the Komfort Latch for function and cracks or other damage Check the web retractor for function and damage Check the mounting bolts for tightness and tighten any that are loose Page 3 41 SAF T LINER EFX OPERATOR S MANUAL ENGINE ACCESS DOORS UPPER ACCESS DooR LOWER Access DOOR FOR EASE OF CHECKING ENGINE OIL LEVEL TRANSMISSION FLUID LEVEL AND POWER STEERING FLUID RESERVOIR Page 3 42 OPERATING THE VEHICLE This section provides the operator with important operational information The following pages contain helpful driving tips information for daily operation and procedures for operation in emergency or inclement weather conditions It is important to carefully read and understand the following pages before operating the vehicle A proper DAILY CHECKLIST The vehicle should be inspected daily prior to operation to ensure safe operation and reliable service The following is a minimum daily checklist Additional checklist items may be added acc
26. brake should be applied or the vehicle could begin to move and cause bodily harm To activate the windshield washers press the wiper knob The washers will operate on both wet arms Wet arms provide for the washer fluid to be plumbed to the spray tips located on the wiper blades at the pivot point PARKING BRAKE PUSH TO RELEASE Page 3 15 SAF T LINER EFX OPERATOR S MANUAL IGNITION SwITCH WITH ANTI RESTART FEATURE The ignition switch is a four position key switch that controls the cold ignition circuits The four positions are as follows Position 1 vertical is the OFF position The key can be removed only at this position Position 2 one click counterclockwise is the accessory position This position energizes the accessory circuits only Position 3 one click clockwise from off is the ON or RUN position This position energizes the ignition alarm and accessory circuits Position 4 energizes the engine starter This position is spring loaded The switch automatically returns to Position 3 upon release KEYLESS IGNITION SWITCH OPTIONAL The keyless ignition switch with anti restart is offered as an alternative to the standard keyed switch Turn the keyless ignition switch clockwise to start vehicle engine Release switch as engine starts Once the switch is turned to Position 4 and released it must be returned to Position 1 before attempting to restart the engine The ignition switch contains
27. complete be sure to plug connector back together 3 This method uses the Cummins Software Tool INSITE version 6 52 or later to initiate a Stationary Regen Interface to the nine pin diagnostic connector located under the left side of the dash to the PC Open INSITETM and go to the After Treatment section Follow the software instructions to complete the Regen For Stationary Regen following parameters must be met 3 1 start engine and let idle 3 2 the transmission must be in Neutral 3 3 the parking brake must be set 3 4 vehicle speed must be 0 When in Stationary Regen engine speed will be elevated to approximately 1200 rpms After regen is complete the engine idle will return back to normal The DPF lamp and the HEST lamp turn off and the bus is returned to service Page 4 21 SAF T LINER EFX OPERATOR S MANUAL REMOTE MANUAL AIR TANK DRAIN VALVES OPTIONAL Manual Drain valves allows the driver to drain the air tanks without reaching under the unit The access door is located left side of the unit behind the battery box CLOSE PRIMARY SECONDARY ACCESSORY SPECIAL Page 4 22 EMERGENCY EQUIPMENT This section provides the operator with important information about the vehicle s emergency equipment Safety equipment on the Thomas vehicle varies according to local state Federal and operator requirements EMERGENCY DOOR An emergency exit door is located at the rear of the vehicle Most
28. disconnect switch is accessible The main starter alternator cable branches from inside this enclosure keeping its terminals protected from the environment Avoid extended or unnecessary idling Extended idling of the engine ten minutes or more particularly at high engine speeds could produce excessive system temperatures that could damage your vehicle MEGA FUSE JUNCTION BLOCK Page 4 6 OPERATING THE VEHICLE DRIVING TiPS AUTOMATIC TRANSMISSIONS The vehicle operator should use care when accelerating or downshifting on slippery road surfaces Sudden acceleration or engine braking caused by shifting to a lower gear range can result in a loss of vehicle control This is very important on snow or ice covered roads If the vehicle is stuck in sand or mud do not attempt to pull the bus out under its own power it will only mire itself deeper Request professional towing assistance ROCKING THE VEHICLE A Rocking the vehicle is moving it forward and backwards in a steady rhythm If the vehicle is stuck have it pulled out Do not attempt to rock the vehicle SPECIAL DRIVING INSTRUCTIONS Warning To reduce the risk of personal injury before going down a steep or long grade reduce speed and down shift the transmission Do not hold the brake pedal down too long or too often while going down a steep or long grade This could cause the brakes to overheat reducing their effectiveness As
29. doors have a locking capability in the open position to allow a clear exit from the vehicle The opening hardware for the emergency exit door is protected to prevent accidental opening Instructions for opening the emergency exit door are clearly displayed on the door face Opening of the emergency exit activates a warning buzzer in the operator s compartment It is important to carefully read and understand the following pages before operating the vehicle A proper understanding of component location function and operation is important to the competent operation of the vehicle and the protection of all passengers NOTICE The vehicle should not be driven if an emergency exit buzzer is sounding Page 5 1 SAF T LINER EFX OPERATOR S MANUAL EMERGENCY WINDOW EXITS The vehicle s emergency push out windows also function as emergency exits To open the windows in 2 emergency situations follow the instructions that are EMERGENC Y EXI E p pe EMERGENCY EXIT LIFT HANDLE TO OPEN PUSH OUT clearly displayed on the window frame EMERGENCY EX rr nz n ERES _ F ue ente T oF The vehicle should not be driven if an emergency PUSH OU NOTICE exit buzzer is sounding NOTICE Some states require that operating instructions be located on glass Page 5 2 EMERGENCY EQUIPMENT EMERGEN
30. dry Paint the retainer assembly if needed to prevent rusting Check that foreign objects such as stones bolts and nuts are removed from the battery box After cleaning connect the cables to the batteries and tighten them to the torque specifications listed on the battery generally 10 to 15 Ibf ft 14 to 20 N m Coat the battery terminals with dielectric grease Page 4 9 SAF T LINER EFX OPERATOR S MANUAL Emergency Starting With Jumper Cables When using jumper cables follow the instructions below Batteries release explosive gas Do not smoke when working around batteries Put out all flames and remove all sources of sparks or intense heat in the vicinity of the battery Do not allow the vehicles to touch each other Do not lean over the batteries when making connections and keep all other persons away from the batteries Failure to follow these precautions could lead to severe personal injury as a result of an explosion or acid burns NOTICE Make sure that both starting systems are the same voltage Electronic devices on both vehicles can be damaged when connected to a vehicle with a different operating voltage 1 Apply the parking brakes and turn off all lights and other electrical devices IMPORTANT Do not attempt to jump start a damaged battery 2 Open the battery door location will vary to access the batteries Slide the battery tray out NOTICE Always connect the batter
31. pressure drops below 60 72 psi 41 50 kPa If one needle suddenly drops pressure and stays below 65 psi 448 kPa the other system can still safely stop the vehicle but it may take longer stopping distances may be increased and the brakes can only be applied a limited number of times Have the vehicle repaired immediately if this occurs NOTICE On Hydraulics units a single needle air gauge is installed for air operated accessories Page 3 3 SAF T LINER EFX OPERATOR S MANUAL TRANSMISSION SHIFTER WITH OPTIONAL 3000 PTS TRANSMISSION PUSHBUTTON The pushbutton shift selector has R N D Up Arrow Down Arrow Mode Button and a digital display Select R Reverse to back the vehicle The vehicle must come to a complete stop before shifting from R Reverse to D Drive N Neutral is selected when starting the engine for extended periods of engine idle operation and when checking vehicle accessories With the pushbutton selector N Neutral is selected by the ECU at start up unlike the lever shifter This button has a raised edge to enable the driver to touch without looking at the display Do not race the engine when shifting from Neutral into another gear Set the gear selector to Neutral engage the parking brake and turn off the ignition even momentarily Never leave the vehicle unattended while the engine is running Unexpected sudden vehicle movement may occur if these pre
32. pressure to the edge of the rubber seal from inside the bus to seat the seal and position the assembly on the metal flange This will ensure a proper seal Page 6 9 Saf T Liner EFX OPERATOR S MANUAL Windshield Replacement The windshield is installed by a bonded process This requires no maintenance by the operator If problems arise requiring the replacement of the windshield the vehicle should be taken to a professional glass installer Page 6 10 GENERAL INFORMATION THOMAS SEATS AND BARRIERS All seats and barriers used in the manufacture of bus bodies must meet many federal requirements One requirement commonly overlooked is the seat back foam for impact energy absorption This is directed primarily where the head and knees will strike the seat back in the event of an accident Styrofoam is used in this critical area where its impact resistance is determined by its density and thickness The seat back is designed so that the styrofoam will crunch or collapse under a predetermined force This absorbs much of the force generated by the child s head or knees when he is thrown into the seat Once this occurs the styrofoam is damaged and the seat back would not serve the same purpose for which it was designed Unless you removed the upholstery you would not know whether the foam should be replaced or not Only OEM seat back foam should be used to ensure FMVSS compliance There are suppliers of seat backs o
33. reservoir Do not overfill Use DEXRON III Automatic Transmission Fluid or equivalent NOTICE To avoid loss of reservoir cap and or loss or contamination of fluid be sure that the cap is properly installed NOTICE Flush the system with recommended fluids only Do not mix oil types Using mixed oils or any unapproved oil could lead to seal deterioration and leaks which could ultimately result in the loss of power steering assist Page 7 14 MAINTENANCE TRANSMISSION FLUID UTOMATIC TRANSMISSIONS The following procedure should be used when checking the transmission fluid in the automatic transmission 1 Operate the transmission in a drive range until transmission oil reaches normal operating temperature of 1609 2009F 719 939C The transmission oil must be warm to ensure a proper reading 2 Shift through all drive ranges to fill the clutches and oil passages 3 Park the vehicle on a level surface shift transmission to NEUTRAL and apply the parking brake Allow engine to run at idle speed 4 Wipe the dipstick clean and check oil level The safe operating level is any level within the add and full range on the dipstick 5 If oil is not within the range indicated in step 4 add or drain oil as necessary to bring the level near the full mark Do not overfill severe transmission damage results Overfilling results in oil breakdown due to excessive heat and aeration from the churning acti
34. the opening It should be 28 1 2 If this is incorrect adjust as follows 28 1 2 _ 1 Bleed air from system by activating the emergency air release rocker switch located above the door 2 Remove the access panel above the entrance door to expose the adjusting rod 3 Loosen the two 2 jam nuts that secure the turn buckle in place N Care should be used when operating doors while making adjustments Keep hands clear of moving parts Personal injury could result Rotating the turn buckle will lengthen or shorten the arm thus increasing or decreasing the door opening Do not exceed the door opening This also controls the sequence of the front and rear doors closing The rear door leaf must come in first allowing the front door leaf to contact and seal the door and stepwell opening and upper door stop seal Tighten both jam nuts Check door for proper opening and closing EMERGENCY DOOR RELEASE FLPSWITCH j PUSH LEFT DOOR LEF Page 6 3 Saf T Liner EFX OPERATOR S MANUAL AIR OPERATED DOOR CLOSURE ADJUSTMENT 1 Bleed air from system by activating the emergency air release rocker switch located above the door Check that air is absent by moving door control valve back and forth several times before proceeding EMERGENCY DOR RELEASE FLPSWITCH P PUSH LEFT DOOR LEV 2 Remove the access panel above the entrance door to expose the adjusting rod 3
35. 0 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard Bus Scan When the Ignition is turned off the buzzer sounds continuously and Active Pilot Lamp illuminates on the control unit The buzzer will continue until Driver walks back to the back of the bus and presses button in rear bulkhead Once the button is pressed the buzzer ceases and Pilot lamp turns off If button is not pressed in 60 seconds the Bus horn will sound You must turn Ignition back on then off and then press button in rear bulkhead for the horn to stop Time to alarm 60 seconds Type of Alarm Chassis Horn system Activation Ignition Alarm Activation Driver turns off ignition Alarm Indication Buzzer sounds upon alarm activation Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Buzzer ceases Operation without Deactivation Chassis horn Dome Light N A Pilot Light Location Operation On Bus Scan Module Lights Labeling N A Service Mode By key switch on unit Page 6 44 GENERAL INFORMATION PASSENGER ADVISORY SYSTEM HORN ACTIVATION CHECK MATE B2001 26 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard The Child Checkmate system is active when the Ignition is turned on the firs
36. 00 is recommended The instructions are included with the kit and are printed in the engine operation and maintenance manuals The pH balance should be maintained between 6 5 and 9 0 for the ELC and 8 5 11 for the Fully Formulated anything lower is corrosive to cast iron steel and aluminum and causes rapid depletion of additives Anything over can cause the over concentration to precipitate from the coolant onto heat transfer surfaces reducing the systems ability to dissipate absorb and radiate heat Use the following guidelines when adding or refilling the cooling system e Do not use methoxy propanol base antifreeze as it may damage engine seals Never exceed 65 antifreeze in any coolant solution f engine overheats do not add water or coolant until engine has cooled Add coolant with engine running The use of a permanent antifreeze with a high silicate content should be avoided to prevent radiator and cooling system plugging This can lead to overheating with resulting engine damage e Always top off the cooling system after operating the engine for 15 minutes when the cooling system has been drained e Ifthe cooling system must be drained to service or repair the engine close the heater shut off valves to prevent draining the entire system The vehicle is equipped with a surge tank to store coolant that would normally overflow when the cooling system is hot Coolant is also added to the system through the reservo
37. 1 All federal state and local laws regarding such items as warning signals night illumination speed etc must be followed 2 Safety chains must be used 3 No vehicle should ever be towed over 45 mph 70 kph 4 Loose or protruding parts of the damaged vehicle should be secured prior to moving 5 A safety chain system completely independent of the primary lifting and towing attachment must be used 6 Operators should refrain from going under a vehicle which is being lifted by the towing equipment unless the vehicle is adequately supported by safety stands NOTICE This is to prevent the possibility of the emergency brake being applied during towing 3 Remove the drive shaft from the unit Care should be taken to ensure the U Joint bearings are not lost NOTICE If the unit is to be towed more than 10 miles the rear axle shafts should be removed instead of the drive shaft 4 f axle shafts are removed cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects 7 No towing operation which for any reason jeopardizes the safety of the wrecker operator other motorists or bystanders should be attempted Page 4 17 SAF T LINER EFX OPERATOR S MANUAL AFTER TOWING After towing the vehicle block the rear wheels Remove the covers from the hub openings and install the axle shafts Apply the emergency brake system DIESEL FUEL SPECIFICATIONS CUMMINS Use only
38. 110 120 psi EE j Check heater operation Air conditioner _____ serene SEN Check alternator output on voltmeter _____ Check operation of parking spring brakes ____ Park brake warning light ___ ___ m Check hydraulic fluid level EE 4 Depress brake pedal check for leaks in brake system EN o Inspect condition of windshield Side glasses Mirrors at esu oe baies BEEN 6 Inspect condition of wiper blades Fil washer container BEEN f Inspect front door assembly hinges Controls Adjustments __ mine al al did S al a Eg EN 8 Inspect seat back and cushion for damage ____ Check frames _ BEEN 9 Inspect condition of floor covering Upholstery Ln EE 10 Inspect and operate all emergency exits opening locking EE 11 Check operation of all door and window warning buzzers EN 12 Check operation of all roof hatches and warning buzzers EE 13 Inspect exterior sheet metal for damage Corrosion Paint Condition BEEN 14 Inspect lock condition all external access doors TEN 15 Check condition and adjust all Belts Alternator A Airconditioner SM 16 Inspect condition of throttle for proper operation
39. 179 to 49 C 5w 40 or 15W 40 10 to 1189F 23 to 48 C 10W 30 ISB 200 260 10 to 70 F 23 to 21 C 10W 30 18 to 70 F 28 to 21 C oW 30 20 to 32 F 29 to 09C 0W 30 For temperature below 109F 239C it may be necessary to warm the oil so the engine can be cranked and the oil can circulate freely GENERAL LUBRICATION NOTES The following notes are helpful when performing lubrication procedures on the vehicle These notes apply to the Lubrication Location Chart Clean grease fitting before lubricating component with dry clean towel Lubricate at each point every 3 000 miles 4800km or monthly with lubricant to meet MIL L 2105 WHEEL BEARINGS GREASE PACKED LUBRICATED e Lubricate every 12 000 miles 19200km e Soap Type Lithium 12 Hydroxy stearate or equivalent e Consistency NLGII No 1 e Corrosion and Oxidation Inhibitors e Base Oil Solvent Refined Petroleum Oil e Base Oil Viscosity at 2109F 75 SUS e Pour Point 10 F e Consult your MVP EFX Service Manuals e Adjust service interval as necessary for local conditions e The front axle is a sealed knuckle type and does not require raising off the ground for lubrication Pack the grease by hand forcing the grease into the cavities between the rollers and cage from the large end of the cone Pack the wheel or hub cavity between the bearing cups with grease to the level of the smallest diameter of the cups Page 7 11
40. 18 MAINTENANCE ANTIFREEZE Your bus is equipped with a 50 50 solution of antifreeze and water The antifreeze is an SCA pre charged heavy duty coolant antifreeze which is a blend of ethylene glycol and a specially formulated inhibitor package designed for heavy duty cooling system applications It meets or exceeds all requirements of RP 329 Truck Maintenance Council This mixture protects the bus to 349F 379C Prior to taking the bus into a cold climate the driver should check the antifreeze For protection to 629F 529C and below the mixture should be 60 antifreeze and 40 water Never have more than 65 antifreeze in the system Freeze point protection and cooling capabilities are dependent on the correct mixture Antifreeze should be used in the cooling system all year to assist in corrosion control Rust scale and solder bloom are typical examples of problems normally associated with cooling systems utilizing water only during the summer months NOTICE Optional Extended Life Antifreeze is available which does not contain SCA Check label on the vehicle to be sure which type is in the vehicle Alliance pre charged antifreeze part OWI ALAOO3 is recommended NOTICE Check with Engine Manufacturer for their SCA recommendations and maintenance schedule Nitrate levels need to be checked and maintained every time coolant is added to the system A Penray Test Kit part PIC TS 100 is recommended to c
41. 21 Slauson Avenue Santa Fe Springs CA 90670 221 562 464 0099 Automotive Innovations Inc Braun Lifts 4 First Street Bridgewater MA 02324 508 697 8324 Page 6 35 Saf T Liner EFX OPERATOR S MANUAL AIR ELECTRIC STOP ARMS CROSSING ARMS All stop arms and crossing arms air or electric draw from the on board chassis air or electrical system The connection to the chassis system should never be changed since it is located so that a defective stop arm crossing arm could never deplete an air brake brake system or short the electrical system The plumbing or wiring varies widely for different makes of chassis Problems may occur with leaks or shorts in this plumbing or wiring Stop arm crossing arm assemblies are purchased as a kit with many different kits available with blades to meet all state requirements The assembly is attached to the outside of the outside of the body or bumper with sheet metal screws This assembly requires occasional cleaning and lubrication of moving parts Stop arms crossing arms are most commonly operated by a manual switch mounted in the switch panel For air controlled arms the manual switch activates an electric solenoid valve controlling the air flow Optionally the solenoid valve may be activated by the warning lamp system or a switch in the header above the entrance door Electrically controlled arms are completely self contained They may be activated by the warning lamp sys
42. 31004 International Truck amp Engine Company Fleetrite Synthetic ATF AN 071006 John Deere amp Company HD SynTran TO CHECK THE LATEST ALLISON APPROVED FLUIDS GO TO www allisontransmission com Lubricants listed in order of preference Do not mix types of oil Page 7 16 MAINTENANCE REAR AXLE FLUID Check the lubricant every 3000 miles 4800km or once a month Check the lubricant level in the rear axle according to the following sequence 1 Locate rear filler plug on rear axle 2 Remove filler plug and check lubricant level Lubricant should be level with plug opening 3 Add lubricant as necessary to level of filler plug opening Install rear filler plug Drain and refill axle housing at 25 000 miles 40000km or 12 months whichever occurs first Draining the rear axle is best accomplished immediately after the vehicle has completed a trip The warm lubricant will run freely allowing full drainage in minimum time This practice works well in cold weather Page 7 17 SAF T LINER EFX OPERATOR S MANUAL COOLANT LEVEL Check the cooling system daily such as during fuel stops You do not need to remove the radiator cap to check the coolant level Look through the translucent coolant reservoir tank or the sight glass near the top of the radiator When the engine is cold the coolant level should be at or slightly above the Full Cold mark on the reservoir tank when the engine has fully warmed up the le
43. 9 Again Thomas Built Buses is dedicated to helping our customers operate our products in the safest way possible and is ready to assist them in any way we can If there is any doubt as to the safety and or compliance of a particular seating configuration or track seat removal install please ask a TBB expert to help at 336 841 5911 Page 6 21 Saf T Liner EFX OPERATOR S MANUAL IMPACT ZONE NOTICE Refer to FMVSS 217 for additional Information School buses with a GVWR of more than 10 000 pounds In the case of a rear emergency exit door an opening large enough to permit unobstructed passage of a rectangular parallelepiped 114 centimeters high 61 centimeters wide and 30 centimeters deep keeping the 114 centimeter dimension vertical the 61 centimeter dimension parallel to the opening and the lower surface in contact with the floor of the bus at all times School buses with a GVWR of 10 000 pounds or less In the case of a rear emergency exit door the rectangular parallelepiped dimensions shall be 45 inches high 22 inches wide and six inches deep Disregarding the GVWR of School buses In case of a side emergency exit door an opening of at least 114 centimeters high and 61 centimeters wide is required No portion of a seat or a restraining barrier shall be installed within the area bounded by the opening of a side emergency exit door a vertical transverse plane tangent to the rearward edge of the d
44. CY ROOF ESCAPE HATCH OPTIONAL The vehicle may contain an emergency roof escape hatch The location of the hatch is subject to vehicle build specifications according to Federal or State Regulations variations On vehicles equipped with an emergency roof escape hatch the opening instructions are clearly displayed on the hatch cover FIRST AID KIT OPTIONAL It is important that a first aid kit is maintained with the vehicle If items or components are used they should be replaced immediately A need cannot be predicted thus be prepared at all times FLUID CLEAN UP Kir OPTIONAL The body fluid clean up kit is used when any type of body fluid comes in contact with the bus It is important that this kit be maintained with the vehicle at all times If items are used they should be replaced immediately FIRST AID PREMIERS SECOURS mie IT ILI n J JBUILT BU S E ST We Move People N Page 5 3 SAF T LINER EFX OPERATOR S MANUAL SEAT BELT CUTTER OPTIONAL Seat belt cutting knife used for the purpose of cutting seat belt and wheelchair securement belts in emergency situations Located with other safety equipment FIRE EXTINGUISHER OPTIONAL The fire extinguisher should be inspected monthly to verify that it contains sufficient charge Observe gauge on fire extinguisher fo
45. DRAULIC BRAKES CONTINUED 6 Use a pull scale graduated in pounds and 10 Discontinue adjusting the knob when the scale attach it to the brake handle one inch from the is reading a force of 120 2 pounds to apply end of the lever the hand brake The hand brake is now adjusted correctly 11 Remove the scale and wheel chocks the bus is ready for service ull Force is 4 Rapid or forced release of the hand lever for the driveline park brake could result in damage to the cable A damaged cable could lead to cable failure resulting in the inability to apply the driveline park brake which could result in a vehicle roll away that could cause property damage or severe personal injury 7 Take measurements of the force required applying the brake 8 Release the parking brake by controlling the handle to the off position 9 Continue to gradually turn the adjusting knob clockwise apply the brake and take readings on the force required to apply the brake and release the brake Page 3 31 SAF T LINER EFX OPERATOR S MANUAL OPERATOR S COMPARTMENT CONTROLS The following pages provide information on the controls in the operators compartment The design location and mounting position of these controls TURN SIGNAL LEVER DIMMER SwITCH The turn signal lever serves the dual purpose of energizing the vehicle turn signals and changing the vehicle headlights from one setting to the other To activate
46. For a driver performed Parked Regeneration vehicle must be equipped with a dash mounted Regeneration Switch See Engine Operator s Manual for complete Regeneration Instructions 24 01583 000B FIGURE 2 FIGURE 3 FIGURE 4 3 1 After the parked regen has run for 20 to 40 NOTICE minutes the regen cycle is completed The engine idle speed will drop to normal and the vehicle may be driven normally The HEST lamp may be illuminated but will go out when the vehicle speed exceeds 5 mph 8 km h or the system has cooled to normal operating The driver must remain with the vehicle during the entire regeneration cycle 2 Set the parking brake If the parking brake was already set you must release it then set it temperature 3 2 To stop a parked regen at any time during the process engage the clutch brake or throttle pedal or turn off the engine again 3 Press and hold the regeneration switch for 4 seconds The engine will increase rpm and initiate the regen process Page 2 3 SAF T LINER EFX OPERATOR S MANUAL ATS DIESEL PARTICULATE FILTER DPF MAINTENANCE Eventually ash will accumulate in the DPF and the filter will require servicing DPF servicing must be performed by an authorized technician following the engine manufacturer s instructions A record must be maintained for warranty purposes that includes e date of cleaning or replacement e vehicle mileage e particulate filter part number and s
47. IGURE 1 CUMMINS ATD SENSOR LOCATIONS 1 DOC INLET TEMPERATURE SENSOR 7 SCR INLET TEMPERATURE SENSOR 2 DOC OUTLET TEMPERATURE SENSOR 8 SCR TEMPERATURE SENSOR 3 DPF OUTLET TEMPERATURE SENSOR 9 OUTLET NOx SENSOR 4 DPF TEMPERATURE SENSOR INTERFACE 10 SCR OUTLET TEMPERATURE SENSOR 5 DPF PRESSURE SENSOR INTERFACE 6 DOSER INTERFACE Page 2 11 SAF T LINER EFX OPERATOR S MANUAL DIESEL EXHAUST FLUID DEF FILTER The Environmental Protection Agency s 2010 regulations require lower nitrogen oxide NOx exhaust emissions Selective catalytic reduction SCR uses diesel exhaust fluid DEF to lower NOx emissions in the vehicle exhaust A filter in the DEF pump prevents clogging of the DEF metering unit injection nozzle EPA07 EXHAUST SYSTEM DEFINITIONS OF ATS COMPONENTS Refer to the following list of definitions of ATS terms and components e Aftertreatment System ATS the entire exhaust system from the turbocharger to the exhaust stack or tail pipe e Aftertreatment Device ATD the muffler like canister that houses a DPF and sensors INSPECTION NOTICE The Environmental Protection Agency s 2007 regulations require lower exhaust emissions thus requiring new exhaust system components See Figure 2 In particular the aftertreatment device ATD which is part of the aftertreatment system ATS requires special attention during regularly scheduled maintenance inspections If any discrepancies are d
48. IL The indicator is illuminated for all active engine emission related faults including but not limited to after treatment devices Retarder Active Lamp Lamp illuminates when the transmission retarder is engaged It serves to slow vehicles or maintain a steady speed on declines and help prevent the vehicle from running away on downhill declines Hydraulic Brake Fault Warning indicator is used to indicate that hydraulic brake fluid pressure is low Wait to Start Optional Indicates to the driver turning the ignition key he needs to wait a few moments with the key in the accessory position before cranking the ignition Traction Control Prevents the drive wheels from spinning when on slippery roads 12 13 14 15 16 17 18 19 20 21 A B S Warning The warning lamp blinks once then goes OFF and stays OFF unless the system detects a problem For more information refer to the service manual Shift Inhibit SHIFT INHIBIT Yellow The indicator and message will be activated by the ICU if a message is received from the transmission Check Trans CHECK TRANSMISSION Amber Transmission Fault indicator When a problem is detected by the transmission s electronic system a diagnostic code is generated Diesel Particulate Filter DPF Yellow Lamp indicates that a manual regen is required soon and should be scheduled for the earliest convenient time Right Turn Signal Indicator
49. L TIRE When a wheel is changed or any time the wheel lug nuts have been loosened the lug nuts should be properly torqued Refer to the Maintenance Section for proper torque value Retighten at 100 miles 160 km and at 500 miles 800 km Page 4 13 SAF T LINER EFX OPERATOR S MANUAL CHASSIS JACKING POINTS 4 b Do not raise vehicle using a bumper jack Use y HM 2 TIT i only jack or equivalent supplied by vehicle v Es manufacturer with your vehicle Position jack only at prescribed jacking points If you must raise the vehicle for servicing use adequate jack stands Never service a vehicle while it is supported only by a jack To prevent inadvertent vehicle movement while changing a tire always block the wheel diagonally opposite the wheel being changed Be sure the park brake is engaged REAR WHEEL JACKING POINT Do not put any portion of your body under the vehicle while vehicle is supported by a jack Never start engine while vehicle is supported by a jack AIR RIDE JACKING POINT On units equipped with rear air suspension one should use a minimum of a 4 x 4 block of wood or steel on top of the jack and locate the jack beneath the 1 beam directly below axle housing To prevent inadvertent movement while jacking the vehicle always block the wheel diagonally opposite pum the wheel being raised Be sure
50. LACEMENT The glass used in your bus must meet certain Federal Motor Motor Vehicles Safety Standards Therefore whenever a glass is broken or must be replaced it should be replaced with identical glass The following instructions are for replacing glass in split sash 1 Open the sash approximately 15 to 20 degrees and secure in that position A rubber tie down works well in holding the sash out 2 Remove the screws in the bottom rail and remove the stationary lower rail and glass 3 Remove the screws in the center rail and remove the center rail 4 Release both window latches and lower the sliding glass and frame out the bottom of the rails Page 6 8 It is suggested that you remove only one section of glass at a time It is more difficult to replace if both are removed 5 Check the glazing rubber If it is damaged or has deteriorated replace it with the one piece rubber seal available from your Thomas Dealer 6 Check the new glass to be installed Sharp corners will cut the glazing rubber seal and lead to glass breakage due to glass contacting metal The corners should be ground to a smooth radius of 1 8 7 Reverse procedure to reassemble sash GENERAL INFORMATION STATIONARY GLASS This section applies to entrance doors emergency doors and rear stationary windows 4 Always wear heavy gloves and eye protection when handling glass to minimize the risk of injury To remove the glass for rep
51. Lamps Green Indicates that the driver intends to turn right and flashes at a rate determined by the flasher module Fasten Seat Belt Warning Red The warning light Seat belt icon illuminates for 15 seconds after the ignition switch is turned on Speedometer Indicates vehicle speed in miles per hour mph and kilometers per hour kph Transmission Fluid Temperature Optional Indicates the temperature of oil in the transmission Maintenance Menu Contains three sub menus Maintenance Intervals Transmission Oil Life remaining and Transmission Oil Filter Life Monitor High Coolant Temperature Gauge Red The warning light thermometer icon and emergency buzzer activate whenever the coolant temperature goes above a preset maximum specified by the engine manufacturer CONTINUED ON NEXT PAGE Page 3 8 OPERATOR S COMPARTMENT EPA10 INSTRUMENT CLUSTER CONTINUED 22 Cruise Control CRUISE ON Green The The display messages menu has three visible lines indicator or message will be activated by the The top line displays the odometer and chassis ICU when the associated input is activated battery voltage while the second and third lines 23 Low Engine Oil Pressure LOW display other driver selectable parameters The lines PRESSURE Indicates the oil pressure in the can be adjusted to show any of the optional display engine is low messages The menu configuration will be stored in 24 Display
52. NERAL INSTALLATION AND REMOVAL GUIDELINES Removal and installation of track seating in school buses is the responsibility of the school bus operator and maintenance staff these guidelines are provided by Thomas Built Buses to assist owners and operators to help insure safe and compliant seating arrangements Because the number of variations and combinations of removable seating in a school bus is almost limitless these recommendations and guidelines are not intended to cover every possible configuration that might be required in service If there is any doubt as to the safety and or compliance of a particular seating configuration please ask TBB to help at 336 841 5911 1 Thomas Built Buses TBB recommends that units be ordered with maximum seating capacity installed at the factory to ensure that gross axle weight ratings GAWR and gross vehicle weight ratings GVWR are not exceeded If seating is added to a school bus that was not ordered or delivered on the bus as configured by Thomas Built Buses care should be taken to ensure that axle weight ratings and gross vehicle weight ratings are not exceeded Actual weight of the unit with full fluid capacities full of fuel with 120 Ib per seating position for all seats on the vehicle and 150 Ib for driver and each wheelchair position should not be greater than the GAWR or GVWR printed on the vehicle federal data label For capacity calculations the full passenger load should be a
53. OR S COMPARTMENT WARNING BUZZER Mounted on the driver s switch cabinet to alert the driver when the emergency exit is opened MIRROR DEFROSTER SWITCH OPTIONAL The mirror defroster switch energizes the defroster strips in the exterior mirrors DESTINATION SIGN SWITCH OPTIONAL The destination sign switch energizes the vehicle destination sign light Page 3 27 SAF T LINER EFX OPERATOR S MANUAL MICROPHONE JACK OPTIONAL When a remote mounted microphone is ordered Hole will be plugged when not ordered SANDER SWITCH OPTIONAL Switch located in the driver s area enables vehicle operator to energize the wheel sanders that mount forward of the rear wheels Sand is released onto the street to increase traction OVERRIDE SWITCH ON OFF OPTIONAL Will override the eight light warning system and activate de activate it as required per option content ON This switch may be located on the dash as well as the z side panel D OVERRIDE Page 3 28 OPERATOR S COMPARTMENT AUXILIARY RESERVE AIR TANK DRAIN OPTIONAL Momentary switch that allows the driver to activate the solenoid drain valve located on the auxiliary reservoir CHIME ON OFF OPTIONAL Vehicle operator has the option of having the chime switch ON or OFF If the operator chooses to have the chime OFF a Passenger Stop Request Sign mounted facing passengers under the bulkhead above the windshield will lig
54. Operation without Deactivation Dome lights ON for approx 1 minute 8 second delay Chassis horn will blow Note After 1 minute with the bus empty the theft mate will activate After 30 minutes if motion is sensed the chassis horn will blow 5 times until system is deactivated Dome Light Yes Approximately 60 seconds Pilot Light Location Operation N A Labeling N A Page 6 47 Saf T Liner EFX OPERATOR S MANUAL Page 6 48 MAINTENANCE This section provides the operator with important information about vehicle maintenance Proper vehicle maintenance is essential to ensuring vehicle reliability and dependability Proper maintenance should start with a good preventive maintenance program Periodic inspections by qualified personnel are the key to eliminating costly and expensive failures and downtime ELECTRICAL CiRCUIT PROTECTION Your vehicle s electrical system is protected from overload damage by circuit breakers Should an electrical component fail to operate check the appropriate circuit breaker Always replace a circuit breaker with the same rating as specified Never replace with a higher amperage rating because severe wiring damage and possible fire can result Circuit Breakers that open blow may be reset but will continue to open until the cause of the overload condition is corrected If a circuit breaker needs to be replaced use only a new circuit breaker rated according to specifications
55. R DOOR OPENING ADJUSTMENT CONTINUED 5 Do not exceed the door opening dimension of 28 1 2 This also controls the sequence of the front and rear doors closing The rear door leaf must come in first allowing the front door leaf to overlap the rear leaf and seal the door and ES stepwell opening 6 Reinstall linkage and tighten all jam nuts 7 Check door for proper opening and closing MANUAL DOOR CLOSURE ADJUSTMENT 1 Loosen jam nuts at both ends of control rod The door control mounting bracket located at the 2 Remove one end by removing clevis bolt nut or approximate center of the cowl should be tightened in spherical rod end the first thirty 30 days and at least every six 6 3 Adjust by turning the clevis or spherical rod end months thereafter counterclockwise to lengthen and clockwise to shorten 4 Turn the clevis clockwise to shorten or increase door opening Turn clevis counterclockwise to lengthen or decrease opening 5 Reinstall clevis pin and check operation Tighten jam nuts Page 6 2 GENERAL INFORMATION DooR MAINTENANCE The door hinge fasteners should be tightened periodically to ensure proper door operation It is very important that drain holes in the bottom of the outward opening door leaves be cleaned every thirty 30 days Use a short piece of welding rod or stiff wire for a cleaning probe AIR OPERATED DOOR OPENING ADJUSTMENT Open the doors fully and check the measurement across
56. Refer to the Operator s Compartment section of this manual for information concerning the Hydraulic Brake For either application make sure rod is installed in center of brake chamber Turn rod 1 4 turn clockwise and install nut on rod Turn nut clockwise on either chamber to cage or release the spring parking brake OPERATING THE VEHICLE BATTERY CARE MAINTENANCE FREE BATTERY Batteries release explosive gas as a by product of their chemical activity Do not smoke when working around batteries Put out all flames and remove any source of sparks or intense heat Make sure the battery compartment is completely vented before disconnecting or connecting battery cables Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear a face shield and protective clothing when working around batteries Damaged chafed or kinked wiring can cause electrical short circuits and lead to fires causing property damage injury or death Clean inspect and maintain wiring and connections carefully 1 Inspect the battery cables for wear and replace as needed Clean the cable connector terminals with a wire brush Clean and tighten the battery ground cable terminal and clamps Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged parts Remove any corrosion with a wire brush and wash with a weak solution of baking soda and water Rinse with clean water the
57. T SYSTEM INSPECTION CONTINUED 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed Check the DPF exterior surface for dents or other damage See Figure 2 Reference A A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal 2 damage to the DPF causing it to malfunction Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or re route as needed x 7 6 FIGURE 2 AFTERTREATMENT DEVICE TYPICAL Inspect this area of the canister for dents DOC Area DPF Area Inlet Temperature Sensor Marmon Fitting at Inlet from Turbocharger Sensor Housing XA m DPF V Band Mounting Clamps Inlet Temperature Sensor Exhaust Outlet to Diffuser Outlet Temperature Sensor DPF Outlet Pressure Sensor DPF Intake Pressure Sensor Page 2 13 SAF T LINER EFX OPERATOR S MANUAL Page 2 14 OPERATOR S COMPARTMENT This section provides the operator with important operational and general information The following divides the Operator s Compartment into four major parts The first part of this section covers the Instrument Panel the second part covers the Side Console Switch Panel the Operator s Compartment Controls forms the third part and information abou
58. Thomas Built Buses recommends that when an MVP EF requires towing that it be towed from the front whenever possible If the need arises for the unit to be towed from the rear the towing operator should make sure the steer axle tires are rated high enough to support the unit weight when towing from the rear It is also recommended that when towing from the rear the distance towed is less than 30 miles at 45 mph DELIVERY INSPECTION NEW VEHICLE Each new Thomas bus has been inspected before delivery Every precaution has been taken to provide the user with a complete and trouble free bus There are certain steps that must be taken to continue the assurance of a trouble free bus Proper inspection and maintenance of the bus is a necessity from the time of delivery and throughout its service life If the bus is not processed through a dealer before delivery to the operator the need to perform the Delivery Inspection is greater Any discrepancies or omissions should be reported to the selling dealer immediately Page 1 7 SAF T LINER EFX OPERATOR S MANUAL FIRST THIRTY DAYS In addition to the Delivery Inspection a one time These are areas that should receive attention on any preventive maintenance inspection should be new vehicle performed after the first thirty days of operation Tighten all mounting clips bolts then retighten every six months thereafter Tighten all cowl mounting bolts then re
59. To minimize the risk of personal injury do not put any portion of your body under the vehicle while the vehicle is supported by a jack The jack is for emergency wheel and tire changing only If you wish to service the vehicle use jack stands Never start the engine while the vehicle is on the jack 9 Raise vehicle only to a height that permits tire removal 10 Remove all 10 lug nuts 11 Remove wheel and tire 12 Install replacement wheel and tire by reversing steps 1 10 Reinstall lug nuts hand tightening until snug 13 Lower vehicle to ground by slowing turning valve on jack counterclockwise Do not lower vehicle until all clamps or lug nuts are tight 14 After wheels are on ground tighten nuts as shown in the section entitled Tightening Wheel Nuts following procedure closely 15 Return jack and all equipment to tool box CONTINUED ON NEXT PAGE Page 7 6 MAINTENANCE CHANGING TIRES CONTINUED Use the following procedure for changing the outside rear axle tire A qualified tire service center should be contacted to change an inside rear axle tire due to the safety hazards involved 1 Make sure vehicle is parked on a level surface and is not obstructing traffic 2 Turn on emergency flashers 3 Place a run up block in front of inside rear axle tire 4 Drive vehicle forward until inside rear axle tire is on top of chock 5 Block diagonally opposite wheel Use chocks if possible to prev
60. Ultra Low Sulfur Diesel ULSD fuel ULSD is required for correct operation of the After Treatment system otherwise the engine may not meet emission regulations and may damage the After Treatment System ULSD contains 15ppm sulphur Refer to the Cummins Owners Manual for more information on this subject FUEL TANK FILLING 4 4 Y LJ Handle fuel with care it is highly flammable Do not refuel the vehicle while smoking or when near open flames or sparks Always stop engine before refueling vehicle Fill fuel tank outdoors Prevent fires by keeping vehicle clean of accumulated trash grease and other debris Always clean up spilled fuel If fuel is observed overflowing from cap remove cap with caution Internal pressure may cause fuel expulsion before disconnecting the towing vehicle Check and fill rear axle with oil as described in the lubrication chart Page 4 18 OPERATING THE VEHICLE WATER IN FUEL During refueling it is possible for water and other contaminants to be pumped into your fuel tank along with fuel Fuel that is contaminated by water or dirt can cause severe damage to engine Drain water from separator until clear fuel is observed INSPECTING FOR ROAD DAMAGE The suspension and steering linkage in your vehicle should be inspected periodically for abnormal looseness and damaged seals Also be alert for any changes in steering action Hard steering excessive free play or unusual sounds w
61. WERE CONNECTED a OW gt DISCHARGED BATTERY NEGATIVE GROUND POSITIVE JUMPER CABLE 1ST CONNECTION POSITIVE JUMPER CABLE TO DISCHARGED BATTERY 2ND CONNECTION POSITIVE JUMPER CABLE TO BOOSTER BATTERY 3RD CONNECTION NEGATIVE JUMPER CABLE TO BOOSTER BATTERY 4TH CONNECTION NEGATIVE JUMPER CABLE TO NEGATIVE GROUND STUD DISCHARGED BATTERY Attempt to start the engine of the vehicle with the batteries receiving the charge When the engine starts let it idle for a few minutes Do the next step exactly as instructed and do not allow the clamps of one cable to touch the clamps of the other cable Otherwise a spark could occur near a battery possibly resulting in severe personal injury from explosion or acid burns 10 D NEGATIVE JUMPER CABLE E BOOSTER BATTERY Disconnect the negative jumper cable from the negative cable stud on the jump started vehicle Disconnect the negative jumper cable from the booster battery Disconnect the positive cable from the booster battery Disconnect the other end of the positive jumper cable from the jump started vehicle Slide the battery tray back into position and close the battery door Page 4 11 SAF T LINER EFX OPERATOR S MANUAL BATTERY REPLACEMENT Wiring batteries backwards can cause serious damage to the electrical system Battery posts terminals and related accessories contain lead and lead compounds chemical
62. a result the vehicle will not slow down at the usual rate Failure to take these steps could result in the loss of vehicle control To avoid skidding on slippery roads do not down shift into 1 Low at speeds above 20 mph 32 kph Do not coast the vehicle in neutral Severe transmission damage may result and vehicle will not have benefits of engine braking If rocking the vehicle is necessary even at low speeds it may cause engine overheating axle damage transmission damage or failure or tire damage On slippery surfaces avoid quick movements of steering wheel Decrease your speed and allow for extra stopping distance required by these conditions Apply the brakes by pumping the pedal steadily and evenly to avoid wheel lock up and loss of vehicle control Avoid driving through flooded areas unless you are sure the water is no higher than the bottom of the wheel rims Drive through slowly Allow adequate stopping distance since wet brakes do not grip well After driving through water gently apply the brakes several times while the vehicle is moving slowly to dry the brakes When driving on icy or gravelled surfaces reduce speed Avoid sharp turning maneuvers Page 4 7 SAF T LINER EFX OPERATOR S MANUAL PARKING When parking the vehicle use the following sequence 1 Shift transmission lever to Neutral or Park with engine running With Push Button select the Neutral position while
63. ake system that consists of separate systems for the front axle and rear axle service brakes The complete brake system should be checked at regular intervals for valve leaks condition of air lines compressor governor adjustment and brake adjustment Check the brake system for leaks according to the following procedure 1 Run engine to build up system pressure to governor cut off of 115 125 psi 79 86 kPa BRAKE LUBRICATION Care must be exercised when lubricating components near the brake linings Over lubrication could cause the brake linings to become saturated with lubricant and impair their ability to properly stop the vehicle For extreme cold weather use SAE 80W and for hot climates use SAE 140 Oil lubricated bearing in lieu of grease packed wheel bearing should be check for lubrication every 3 000 miles 4800km or monthly 2 Shut down engine and release service brakes Observe dual brake air system gauge on dashboard Pressure drop should not exceed 20 psi in 10 minutes Apply service brakes 5 Observe dual brake air system gauge on dashboard Pressure drop should not exceed 3 psi per minute 6 Leakage above limits requires a complete system inspection and immediate correction of cause Page 7 13 SAF T LINER EFX OPERATOR S MANUAL AUTOMATIC SLACK ADJUSTERS A Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mecha
64. al N Park COLD WEATHER STARTING To start the vehicle during cold weather use the following procedure 1 Apply parking brake if not already applied 2 Place transmission shift control in neutral N Park IMPORTANT Do not depress accelerator during step 3 3 Turn ignition key to ON Wait until the Instrument Cluster performs self check then start 4 On units equipped with a master control switch turn switch to DAY and press engine start button DANGER DO NOT USE VOLATILE STARTING AIDS SUCH AS ETHER PROPANE OR GASOLINE IN THE ENGINE AIR INTAKE SYSTEM EXPLOSION HAZARD CAN CAUSE SEVERE ENGINE DAMAGE AND PERSONAL INJURY 3 Turn ignition key ON 4 Wait until the Instrument Cluster performs self check then start If engine fails to start within 30 seconds wait 1 to 2 minutes and repeat step 4 When engine starts reduce engine speed to fast idle rpm Do not apply load or increase engine speed until oil pressure gauge indicates normal approximately 15 seconds NOTICE After starting a turbocharged engine do not accelerate engine above 1000 rpm until oil pressure gauge indicates normal Page 4 4 OPERATING THE VEHICLE BLock HEATERS Block heaters are heating elements installed in the engine water jacket to aid in cold starting by keeping the engine coolant warm while the engine is not operating The heater should be plugged in anytime the ambient temperature is expected
65. alert other motorists of the vehicle s position in the road Pulling the knob out activates the emergency flashers Pushing the knob in deactivates the emergency flashers The emergency flashers should be activated when the vehicle is disabled in the street and obstructing traffic stopping due to an emergency in tow or proceeding at very reduced speed Never use an abrasive cleaner Keep mounting brackets tight Page 3 35 SAF T LINER EFX OPERATOR S MANUAL DEFROSTER FANS OPTIONAL The defroster fans are used to help clear the windshield and driver s window for better visibility The fans run at either low or high speed The fans must be cleaned and the fasteners tightened occasionally Doran Monitor Exterior 4 or 8 Light Optional The Doran exterior light monitoring system 4 8 12 16 monitors the condition of those exterior vehicle INCANDESCENT lights identified by the type of monitor board The A LIGHT MONITOR monitor provides the operator with the location of any malfunctioning light In the event that a bulb has become damaged or burned out or the circuit is DO REAR OO int ted onding light on the Doran panel interrupted corresp ing lig p G3 55 O O goes off The Doran panel should be checked daily to verify the operation of all warning lights Page 3 36 OPERATOR S COMPARTMENT DRIVER S SEAT The d
66. alling seats a minimum 12 clear aisle must be maintained Figure 5 shows an example of measuring aisle space Typically two 39 seats side by side are the largest two seats that can be placed beside one another and still allow for a 12 clear aisle Aisle Width Measurement All track seats must be mounted forward facing When reinstalling a track mounted seat it is recommended that it is installed in the same location with the same hardware as it was originally installed Seats must conform to the allowable knee room spacing for each particular seat Please refer to the knee room section of the manual If you are unsure of the knee room required please contact the manufacturer Not all track seats are installed with the same number of fasteners Please contact the manufacturer if you are unsure of how many fasteners are required Track mounted fasteners are required to be torque to 20 25 ft lbs to insure proper installation Track seats will be installed in 17 increments Seat Spacing will be determined Federal and State specifications Most seats will have a Min knee room of 24 and a Max knee room of 24 plus H point See example of an IMMI seat track installation on the next page Page 6 30 GENERAL INFORMATION INSTALLING TRACK SEATING CONTINUED See Detail A Detail A IMMI Seat Track Installation Page 6 31 Saf T Liner EFX OPERATOR S MANUAL MEASURING KNEE ROOM It is very importa
67. as outlined under Release Parking Brake Manually This is to prevent the possibility of the emergency brake being applied during towing 3 Remove the drive shaft from the unit Care should be taken to ensure the U Joint bearings are not lost Page 4 16 NOTICE If the unit is to be towed more than 10 miles the rear axle shafts should be removed instead of the drive shaft 4 f axle shafts are removed cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects OPERATING THE VEHICLE FRONT END TOWING FRONT WHEELS OFF GROUND Proper equipment must be used to prevent damage to the vehicle during the towing procedure Connect the towing equipment to the main structural parts of the vehicle chassis The chain should be hooked around the front axle outboard of the springs DO NOT attach to bumpers tow hooks or brackets Use only equipment designed for this purpose following directions of the wrecker manufacturer A safety chair that is completely independent of the primary towing attachment must be used To prepare a disabled vehicle for front end towing with the front wheels off the ground the following steps are necessary 1 Block the wheels of the disabled vehicle 2 Release the emergency brake system by compressing the brake chamber springs as outlined earlier in this section entitled Release Parking Brake Manually SPECIAL TOWING INSTRUCTIONS
68. ated in switch cabinet lights steady upon system activation Labeling PASSENGER CHECK REMINDER SYSTEM Located at pilot light on switch cabinet Air or Electric Door Covers the Air door or electric door Page 6 43 Saf T Liner EFX OPERATOR S MANUAL PASSENGER ADVISORY SYSTEM BUZZER ACTIVATION B2001 24 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard Post Trip inspection When the Ignition is turned off the buzzer sounds continuously and Pilot Lamp illuminates on the dash The buzzer will continue until Driver walks back to the back of the bus and presses button in rear bulkhead Once the button is pressed the buzzer ceases and Pilot lamp turns off Time to alarm N A Type of Alarm Buzzer System Activation Ignition Alarm Activation Driver turns off ignition Alarm Indication Buzzer sounds upon alarm activation Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Buzzer ceases and pilot light goes out Operation without Deactivation Buzzer and pilot light ON Dome Light N A Pilot Light Location Operation LED pilot light located in switch cabinet flashes upon system activation Labeling PERFORM POST TRIP INSPECTION DISABLE ALARM AT REAR OF BUS Located at pilot light on switch cabinet PASSENGER ADVISORY SYSTEM BUZZER ACTIVATION B2001 25 00
69. cautions are not taken Do not allow the vehicle to coast in Neutral When D Drive is selected the transmission will initially engage the lowest gear programmed for the D Drive position usually 1 First gear As the speed increases it will automatically upshift As the vehicle slows down the transmission will downshift The vehicle must come to a complete stop before shifting from D Drive to R Reverse Occasionally there will be a need to limit the transmission to the lower gears To do this utilize the Up Arrow and Down Arrow buttons to select a specific range The digital display will Indicator your choice This will not change until vehicle speed is reduced sufficiently to allow the transmission to downshift The Display Mode button allows the driver to enable a secondary shift schedule To access the Diagnostic Codes press the up and down arrows at the same time To clear active fault codes hold the mode button three seconds until mode LED flashes CONTINUED ON NEXT PAGE Page 3 4 OPERATOR S COMPARTMENT TRANSMISSION SHIFTER WITH OPTIONAL 3000 PTS TRANSMISSION PUSHBUTTON CONTINUED The Display Mode button allows the driver to enable a secondary shift schedule To access the Diagnostic Codes press the up and down arrows at the same time To clear active fault codes hold the mode button three seconds until mode LED flashes Never depend on the transmission as an engine brake The transmiss
70. connect the hoses to the radiator Torque the clamps 33 to 38 Ibf in 370 to 430 N cm 11 Fill the radiator with coolant Use a mixture of 50 percent water and 50 percent corrosion inhibiting antifreeze to protect the engine to 34 F 379 C year round NOTICE Flushing a coolant system that has ELC Extended Life contaminate the system if all of the water is not Coolant with water will removed it is recommended that you flush an ELC system with ELC coolant Continued on next page Page 7 20 MAINTENANCE COOLING SYSTEM CONTINUED If the system is dirty showing mineral build up scale rust or oil use a heavy duty radiator cleaner following the engine manufacturer s directions Maintaining the correct coolant additive concentration level requires an initial charge after cleaning and a service charge at the scheduled maintenance interval There are two methods for charging a diesel cooling system when performing maintenance 1 The filter change method if equipped that uses an initial charge filter containing a pre measured amount of dry additives 2 Pouring a pre measured amount of liquid additive into the radiator and adding a service filter if equipped There are various test kits available to check SCA concentration levels They are used to check the nitrite level of the chemical Nitrite is the additive that aids in the prevention of corrosion and cavitation The Penray Kit part PIC TS 1
71. d it must be replaced 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting bands for tightness Tighten to 30 Ibfeft 41 Nem if needed Do not overtighten 5 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD No leaks are allowed anywhere in the system 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 7 Check the DPF exterior surface for dents or other damage A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to malfunction 8 Check the SCR catalyst for dents and other damage 9 Check for heat discoloration on the surface of the Heat discoloration may indicate internal damage especially around the DPF NOTICE Diesel exhaust fluid creeps causing white crystals to form around the line fittings The presence of crystals does not mean the system has a leak Replacing the fittings or troubleshooting the components is not necessary unless there is a system failure or a fault code 10 Check the DEF tank pump metering unit and lines for leaks 11 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed Page 2 10 EPA10 EXHAUST SYSTEM INSPECTION F
72. d daily The drain cocks should be left open until all moisture escapes Many operators open the drain cocks at the end of the day to permit thorough purging of the system The drain cocks are closed prior to placing the vehicle back into service This automatically causes the engine to be warmed up while rebuilding air pressure in the system A LJ Failure to maintain air tanks properly can result in excessive water sludge and other contaminants entering the air brake system This can clog air passages which can result in slower brake operation or brake failure Replacement is simple e Secure the vehicle e Remove the four fasteners from the bottom the filter drops down Replace filter Page 7 23 SAF T LINER EFX OPERATOR S MANUAL BERG CABLE OPERATED DRAIN VALVES Cable operated Berg drain valves mounted on all air reservoir tanks Remote mounted cables are located on the right side of the body To drain the tanks pull on cables below the side sheet Tanks should be drained daily PROPER DisPOSAL OF FLUIDS A Be mindful of the environment and ecology Before you drain any fluids find out the proper way to dispose of the fluid Do not pour oil onto the ground down a drain or into a stream pond or lake Consult local ordinances that govern the disposal of wastes UNIQUE DRIVING CONDITIONS Engine Oil amp Oil Filter Change every three months or 3 000 miles 4800 km whichever occurs
73. d more often NOTICE When cleaning areas containing electrical components and connections take care to protect these items from water intrusion When using a pressure washer to clean these areas use the lowest possible pressure setting MAINTENANCE TIRES GENERAL INFORMATION Tire size and inflation pressures are recorded on the vehicle certification plate For greater riding comfort prolonged tire life and to reduce wear and tear on the vehicle the tires should be inflated as specified When checking tire inflation pressure it is important to use an accurate gauge and check the pressure when the tires are cold Cold inflation pressures must not exceed the recommended pressure specification Exceeding this pressure specification will exceed the design capability of the tire Before driving each day glance at all tires If one looks lower than the others have the pressure of all tires TIRE AND WHEEL REPLACEMENT A When you replace tires use only tire and wheel combinations as recommended the Certification Plate in the driver s area Refer to this plate to help determine what type of tires your vehicle has Make sure that all tires and wheels are of the same size and load carrying capacity Never mix radial bias belted or bias type tires Use only wheels recommended for the tire size selected Replacement of tires with specifications size load ranges and in some cases brands other than w
74. d on and runs for 10 minutes Once the route is complete and the Ignition is turned off the Pilot Lamp on the dash lights as well as the Passenger Dome Lamps The Driver then has 60 seconds to check the bus for passengers and press the button at the back of the bus When the button is pressed the passenger dome lamps flash 3 times and the Pilot Lamp cuts off The Driver can now leave the bus If the system is not disarmed then the horn will start blowing and headlamps will flash When this happens the driver must go to the front and turn the Ignition back on then off and then return to rear of the bus to press button to deactivate Time to alarm 60 seconds Type of Alarm Chassis horn System Activation 10 minutes after the bus is started Alarm Activation When Ignition is turned off Alarm Indication Interior Lamps are turned on Location of Deactivation Switch Last bulkhead section Drivers side Confirmation of Deactivation Interior lamps flash when deactivated Operation without Deactivation Pilot lamp and dome lights ON If not disarmed within 1 Minute chassis horn will blow and headlamps will start flashing Dome Light Yes Approximately 30 seconds Pilot Light Location Operation LED pilot light located in switch cabinet lights steady upon system activation Labeling PASSENGER CHECK REMINDER SYSTEM Located at pilot light on switch cabinet Page 6 42 GENERAL INFORMATION CHILD REMINDER SYSTEM
75. dded to the rear axle of the vehicle If there is any doubt as to the capacity of the vehicle and allowable weight loading please contact the Thomas Built Buses Inc Engineering Services staff for help at 336 841 5911 TBB tracked school bus seat options are designed for forward facing orientation on the vehicle wheelchairs should be secured in the forward facing orientation on the vehicle and secured per the wheelchair restraint manufacturer s instructions knee room measurements should be referenced at the center of the seat and at the seat reference point height which is typically 25 above the seat cushion s highest point Page 6 13 Saf T Liner EFX OPERATOR S MANUAL KNEEROOM KNEEROOM H PoiNr HORIZONTAL H H PoiNr VERTICAL SBT SEAT BACK THICKNESS H PoiNT HIP POINT CONTINUED ON NEXT PAGE Page 6 14 GENERAL INFORMATION TRACK SEATING GENERAL INSTALLATION AND REMOVAL GUIDELINES CONTINUED 9 School bus seating is designed to accommodate student encapsulation for primary crash protection Encapsulation uses the seat backs and barriers as a passive restraint system to absorb kinetic energy in a crash situation and protect passengers Seat spacing is critical to passive encapsulation to protect passengers in the event of vehicle impacts It is essential that removable seats be installed to maintain spacing that ensures safe configurations The minimum seat spacing is limi
76. de glass ELECTRONIC HEATER DEFROSTER CONTROLLER The heater control panel enables the operator to control the dash heating system by adjusting the temperature setting and the fan speed SWITCH BLANKS Blank panels are used to fill in openings in the switch panel where switches are not used Page 3 2 OPERATOR S COMPARTMENT AIR PRESSURE GAUGE The air pressure gauge indicates the levels of air pressure in the primary or rear axle brake system green needle An optional secondary or front axle brake system red needle is available If you have dual air pressure gauges they should indicate the same pressure reading Common cut out pressures are between 105 125 psi 72 86 kPa Common cut in pressures are between 90 105 psi 62 72 kPa The pressure range between cut in and cut out is not adjustable The rear brakes will gradually begin to apply when air pressure drops below 65 psi 45 kPa At 40 psi 28 kPa the rear brakes will automatically lock up by actuating the PP 1 valve and allowing the air in the spring brake side of the brake chamber to be released Determine and correct cause of pressure loss before returning vehicle to service In the event that a pressure loss occurs the operator can identify the affected system by observing the gauge needles Stop the vehicle immediately if either of the following conditions Occur Lower air warning buzzer sounds and or indicator light comes on when the air
77. driver s seat belt has a wall mounted retractor with a single belt that runs through a bracket located over the window and back down to the driver s seat The buckle should slide freely on the belt as the driver pulls the belt across his body to the push button latch on the door side of the seat DRIVER S WINDOW Application Hold buckle in one hand and pull connector belt across pelvic region hip bone Make sure neither belt is twisted Insert connector belt into open end of buckle A snap sound indicates the connector belt is properly engaged with the buckle However tug on the belt to ensure that the connector belt is properly engaged with the buckle The belt retractor automatically eliminates belt slack for a snug but comfortable fit A shoulder adjustment strap is incorporated into the belt It consists of a sleeve that slides on the belt close to the overhead bracket See illustration The sleeve is connected to a loop that limits the movement of the seat belt as it crosses the driver s shoulder CONTINUED ON NEXT PAGE Page 3 40 OPERATOR S COMPARTMENT DRIVER S SEAT BELT CONTINUED Release The seat belts contain a push button located on the buckle To release the belt push in on the button and the latch will disconnect from the buckle Dell driver must always wear seat belt when operating the vehicle Inspection Inspect the seat belts
78. e bar of the DEF level lightbar is illuminated solid amber Figure 9 When the DEF level in the tank drops to 5 full the DEF Low Level Lamp in the gauge is illuminated e Between 10 and 25 full one bar is illuminated green Figure 8 a FIGURE 8 gt FIGURE 9 flashing amber and one bar of the DEF level lightbar is illuminated flashing red Figure 10 i Z V S FIGURE 10 Page 2 6 EPA10 ExHAUST SYSTEM DEF WARNINGS AND ENGINE DERATES CONTINUED DEF LEVEL WARNING AND MINOR ENGINE DERATE When the DEF level drops to 2 596 the DEF warning lamp in the gauge is illuminated flashing amber one bar of the DEF level lightbar flashes red and the CHECK engine lamp amber illuminates The engine will perform a minor torque derate of approximately 25 Figure 11 FIGURE 11 DEF TANK IS EMPTY WARNING AND MINOR ENGINE DERATE When the DEF tank registers empty the DEF warning lamp flashes and one bar of the DEF level lightbar flashes red The CHECK engine lamp illuminates the malfunction indicator lamp amber illuminates and the engine remains at a minor derate Figure 12 FIGURE 12 DEF TANK EMPTY WARNING IGNORED WARNING AND MAJOR ENGINE DERATE After the DEF tank registers empty if the DEF is not refilled after a fuel fill or engine stop the CHECK engine lamp malfunction indicator lamp and the STOP engine lamp red will be illuminated The engine rema
79. e driver must go to the front and turn the Ignition back on then off and then return to rear of the bus to press button to deactivate If driver attempts to leave through Entrance door then the horn will sound as well Time to alarm 60 seconds Type of Alarm Chassis Horn System Activation Timer 10 minutes Alarm Activation When Ignition is turned off Alarm Indication Chassis Horn Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Interior Dome lights will flash two times Operation without Deactivation Pilot lamp and dome lights ON If not disarmed within 4 Minutes chassis horn will blow Dome Light Yes Pilot Light Location Operation LED pilot light located in switch cabinet lights steady upon system activation Labeling A PASSENGER CHECK REMINDER SYSTEM Located at pilot light on switch cabinet B Operating instructions to be attached to compartment above driver Page 6 40 GENERAL INFORMATION PASSENGER ADVISORY SYSTEM HORN ACTIVATION B2001 21 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard oystem is activated when the Red warning lamps are used the first time Once the route is complete and the Ignition is turned off the Pilot Lamp on the dash lights as well as the Passenger Dome Lamps The Driver then has 60 seconds to check the bus for pa
80. e precise speed control is desirable and for climbing and descending long grades To prevent excess engine speed do not exceed 45 mph 72 kph in this gear 1 First For driving up very steep hills and engine braking at low speeds 25 mph 40 kph or less when going downhill To prevent excessive engine speed do not exceed 25 mph 40 kph in this gear A red indicator light will illuminate if the transmission is unable to shift at the appropriate time This indicates a failure in the transmission and should be checked by a qualified technician Pull the bus over to a safe location and get assistance Never depend on the transmission as an engine brake The transmission will upshift no mater what gear is selected when the internal pressure reaches a certain level A shift point will be created by high engine rpm OPERATOR S COMPARTMENT EPA10 INSTRUMENT CLUSTER DIESEL e 09 9 XL og Geo 10 11 12 13 14 15 TACHOMETER OPTIONAL MAINTENANCE LEFT TURN SIGNAL HIGH EXHAUST SYSTEM TEMPERATURE CHECK ENGINE STOP ENGINE MALFUNCTION INDICATOR LAMP TRANSMISSION RETARDER ACTIVE AIR BRAKE HYDRAULIC BRAKE DEPENDING ON UNIT CONFIGURATION WAIT TO START TRACTION CONTROL ABS WARNING SHIFT INHIBIT CHECK TRANSMISSION DIESEL PARTICULATE FILTER REGENERATION RIGHT TURN SIGNAL FASTEN SEAT BELT WARNING SPEEDOMETER MPH amp METRIC HIGH TRANSMISSION TEMP INDICATOR a
81. e stop and using light pressure will result in increased brake pad life BRAKE PEDAL AIR The brake pedal controls the application of the vehicle service brake Downward pressure on the brake pedal decreases the vehicle speed by applying air to the brake chambers at each wheel and stops the vehicle when desired by the operator Anticipating the stop and using light application of the brakes will result in increased life of brake linings and drums Continuous heavy applications result in premature wear due to excess heat Overheating the brakes may increase the distance required to stop the vehicle Page 3 34 OPERATOR S COMPARTMENT SUN VISOR Six inches x 30 plastic with finished edge mounted to windshield header Optional sun visor is available in three versions 1 A plexiglass 6 x 30 with aluminum legs mounted over the driver s window and or over the right side of windshield 2 6 x 30 California sun visor black non transparent mounted in pivot brackets over the driver s window 3 A6 x 30 visor mounted right side of windshield in addition to standard left side visor Clean with plexiglass cleaner and a soft dry towel Horn Button The electric horn alerts other motorists pedestrians and waiting passengers of vehicle presence Push down on center part of steering wheel to activate horn Release pressure to deactivate horn EMERGENCY FLASHERS The emergency flashers enable the operator to
82. e stretched threads with cross threading and lower their ability to hold a specific torque The U bolts on your vehicle s leaf springs should be checked and retightened every 5 000 miles 8000km A M 7 25 SAF T LINER EFX OPERATOR S MANUAL CUMMINS ENGINE OPERATING SPECIFICATIONS Oil Pressure psi 10 30 kPa 69 207 Coolant Temperature F 1809 2129 C 829 1009 Engine Idle RPM Rated Speed RPM 2500 governed Charging Voltage 13 14 Volts Lower oil pressure is normal at idling speed Higher than normal oil pressure at start up with engine cold is acceptable If no oil pressure is indicated warning light and buzzer will activate Shut down engine immediately and determine cause Coolant temperature will vary with air temperature and conditions Page 7 26 MAINTENANCE GENERAL VEHICLE SPECIFICATIONS NOTICE All height dimensions are based on an average of measurements taken All measurements are based on 11R22 5 Tires 41 1 2 outside diameter Standard e 1 1 e Window Wheelbase Height Height Turning F Axle Section 73 HR 78 HR Radius 2905 23 10 10 10 366 5 23 10 11 355 3 26 5 11 10 D995 37 26 5 12 414 0 29 12 10 424 0 29 13 442 7 DE 13 10 452 7 14 467 0 34 2 14 10 477 0 34 2 1 ROOF MOUNTED ITEMS THAT REQUIRE ADDITIONAL HEIGHT Static Vent 2 1 32 or 5 159 cm Roof Hatch Low Prof
83. earn seat installation requirements and determine proper seat spacing for each seat It is always recommended that you only re install the seats that were originally installed in the vehicle and that they be installed in the same location as they were removed If you are unsure of any step in installing track seating please contact Thomas Built Buses Page 6 25 Saf T Liner EFX OPERATOR S MANUAL TRACK SEAT IDENTIFICATION When installing a track mounted seat it is important that you know what seat you are installing You must be able to identify each seat being installed to maintain the proper seat spacing A seat can be identified by following these three steps 1 Determine the make of the seat 2 Determine the type of seat 3 Determine what options if any are on the seat 1 Determine the make of the seat Track seating is offered in two makes IMMI and SynTec The easiest way to distinguish between the two is the distinct outer perimeters Example of IMMI Sea All IMMI seats will have a similar appearance The IMMI seat has two different variations the Gen ll and SSA The difference between the Gen II and the SSA are the seat backs The SSA has a concave back and the Gen II has a straight back CONTINUED ON NEXT PAGE IMMI Gen Il straight back Page 6 26 GENERAL INFORMATION TRACK SEAT IDENTIFICATION CONTINUED The SynTec seat can be seen below All SynTec seats will be similar in s
84. ed tire pressure Protect tires from heat and sunlight Thoroughly clean vehicle Touch up any painted surfaces that are scratched or chipped Lubricate all grease fittings Add a commercially available fuel stabilizer to the fuel tank following manufacturer s instructions then idle the engine long enough to ensure complete circulation of the fuel stabilizer throughout the fuel system Page 4 20 OPERATING THE VEHICLE INITIATING A STATIONARY PARKED REGENERATION REGEN A Before attempting to initiate a Stationary Regen be sure to turn off Fast Idle Switch There are three possible methods of initiating a Stationary Regen 1 DPF Regen Switch located on the dash For the switch to activate stationary regeneration the following parameters must be met 1 1 start engine and let idle 1 2 the transmission must be in Neutral 1 3 the parking brake must be set 1 4 vehicle speed must be 0 1 5 regeneration must be required 1 6 the switch must be held down for 4 seconds 2 Omit Exhaust System Regen Switch service connector located near the 9 pin diagnostic connector under the left side of dash In order to initiate a regen with service connector the following parameters must be met 2 1 start engine and let idle 2 2 unplug the two piece service connector 2 3 the transmission must be in Neutral 2 4 the parking brake must be set 2 5 vehicle speed must be 0 The engine will begin Stationary Regen When regen is
85. emove covers all heaters clean cores clean 5 Check operation of all heater motors defrosters Replace power steering filter in reservoir Replace water filter if not done previously Check operation block oil heaters if applicable Check operation of ether start device Tighten all hose clamps air intake system Air cleaner element replace every 2 years 45 000 miles or 25 of restriction whichever comes first 000 cee eee Rss Check operation of restriction indicator remove and test operation Service crankcase breathers 000 cee eee sh Check exhaust system for leaks security Check operation of engine protection system Test batteries for full charge Clean batteries and battery Test alternator regulator setting 14 to 14 2 must be checked with a fully charged battery Remove starter inspect brushes at 90 000 mile intervals Clean dust from magnetic switch lever end Remove backing plates if equipped Inspect rear brakes linings Re
86. en all lug nuts all wheels 10 ExHAUST SYSTEM AFTERTREATMENT SYSTEM ATS PRINCIPLES OF OPERATION CUMMINS NOTICE EPA10 emissions regulations apply to vehicles domiciled in Canada and the USA at the time of printing this manual Vehicles that are domiciled outside of the USA and Canada may not have EPA10 compliant engines with an emission aftertreatment system depending upon local statutory emissions guidelines The EPA mandates that all engines built after December 31 2009 must reduce the level of emissions exhausted by the engine to the following levels Nitrogen Oxides NOx 0 2 g bhp hr Particulate Matter PM 01 g bhp hr To meet EPA guidelines diesel engines installed in Thomas Built Buses Inc chassis for domicile in Canada and the USA use an Aftertreatment System ATS with an Aftertreatment Device ATD and Selective Catalytic Reduction SCR technology to reduce NOx downstream of the engine Using non specification fluids can result in serious damage to the ATS It is extremely important that the following guidelines be followed for vehicles with EPA10 compliant engines or damage may occur to the ATD and the warranty may be compromised e Use ultralow sulfur diesel with 15 ppm sulfur content or less e Do not use fuel blended with used engine lube oil or kerosene e Engine lube oil must have a sulfated ash level less than 1 0 wt currently referred to as CJ 4 oil e Use
87. engine is running 2 Apply parking brake Let unit idle approximately five minutes 3 Shut off engine 4 Place chock blocks under at least one wheel Air Brake The parking brakes are mechanically applied via the action of a heavy coil spring against the service brake push rod assembly on the rear axle brakes only Air pressure within the spring brakes chamber holds the parking brake in the released position Pulling the parking brake control valve out releases the pressure RELEASE PARKING BRAKE MANUALLY The following procedure is provided for manually releasing the parking brake 4 Block the wheels before beginning this procedure The vehicle will roll when the parking brake is manually released Determine the type of brake chamber on the vehicle Certain types have release rods that are permanenitly installed in the rear of the chamber housing Others have the rod stored on the side of the chamber housing Page 4 8 within the chamber allowing the spring to set the brakes In the event the air system is below 60 psi the parking brakes cannot be released until the air system is recharged either by the running engine to charge the system with the engine driven air compressor or by charging system from an external source such as a shop air supply If this is not possible the spring parking brakes must be released manually before moving the bus Refer to Release Parking Brake Manually below
88. ent vehicle move ment 6 Apply parking brake 10 11 12 13 Place automatic transmission vehicles in NEUTRAL Shut down engine Remove all 10 lug nuts Remove wheel and tire Install replacement wheel and tire by reversing steps 1 9 Reinstall lug nuts hand tightening until snug Drive vehicle down block Do not drive vehicle down block until all clamps or lug nuts are tight After wheels are on ground tighten nuts as shown in the next section Tightening Wheel Nuts Follow procedure closely Page 7 7 SAF T LINER EFX OPERATOR S MANUAL TIGHTENING WHEEL NUTS Before tightening the wheel nuts the following points should be understood NOTICE Stud Pilot Wheels Lug nuts on the right side of the vehicle have right hand turn clockwise to tighten threads and on the left side of the vehicle have left hand turn counterclockwise to tighten threads For rear axle wheels make sure the valve stems are 180 apart 1 2 turn to facilitate inflating and checking tires Never apply grease or oil to wheel studs or nuts Use a torque wrench to tighten nuts Re torque wheel nuts every 1 000 miles 1600km Use the following procedure for tightening disc type wheels 1 Install all 10 wheel nuts loosely 2 Finger tighten only the nuts indicated by arrows in the illustration below 10 BOLT DISC WHEELS 2 Torque all wheel nuts to 450 525 ft Ibs 608 7098 Nm The presence
89. er and birth defects or other reproductive harm INTRODUCTION VEHICLE MODIFICATION DISCLAIMER POLICY Thomas Built Buses Inc is not responsible for any direct or indirect consequence of any modification or alteration made to its products by anyone other than the Thomas factory Please be advised that such modifications may VOID the Federal and or State Certification and the Thomas Body and Chassis warranty The limited warranties of Thomas exclude Components or systems which have been altered or modified without the express prior written authorization of the company Examples of such modifications are but are not limited to the following e after market alternate fuel conversions chassis wheelbase changes e mounting a Thomas body on a different chassis than the original e mounting a different body than original on a Thomas chassis any component alteration that affects GAWRF GAWRR and or GVWR any component alteration that affects any FMVSS certification power train replacement or alteration other than original specification steering braking or Suspension alteration other than original specification seating capacity or configuration modification addition or deletion of any passenger entrance or exit basic body structural alteration modification of the body to chassis mounting system exhaust system alteration or replacement other than original specification use of un approved fluids fuels
90. erial number DIESEL EXHAUST FLUID DEF CUMMINS DEF is used in the aftertreatment system to lower NOx in the exhaust stream DEF is colorless and close to odorless It may have a slightly pungent odor similar to ammonia It is nontoxic non flammable and biodegradable It is mildly corrosive to aluminum but it will not affect the strength or structure of the aluminum Constant DEF contact will result in white powder residue Around 12 F 11 C DEF freezes to slush but is not damaged or destroyed if frozen and is fully usable when thawed The DEF supply lines are electrically heated and are purged when the engine is Page 2 4 shut down At start up normal operation of the vehicle is not inhibited if the DEF is frozen an immersion heater with engine coolant flowing through it will warm the DEF once the engine is running to allow the SCR system to operate EPA10 ExHAUST SYSTEM DEF TANK LOCATION AND FiLLING REQUIREMENTS On the MVP EFKX the tank is located on the right side The MVP EFxX School Bus has a 10 gallon tank rearward of the front entrance door The DEF tank has capacity DEF consumption is approximately 296 of a 19 mm filler neck inlet that prevents the hose from a fuel consumption dependent on vehicle operation diesel outlet from being inserted and has a blue cap For every 50 gallons of diesel fuel consumed for easy identification approximately 1 gallon of DEF will be consumed
91. et the interval for engine oil changes use the down button to scroll to ENGINE OIL in the maintenance menu to select ENGINE OIL press the Right button Screen 4 Auxiliary Screens Maintenance ENGINE OIL CHANGE INTERVAL 5000 Miles PRESS TO CHANGE To change the interval to 6000 miles continue to press the Down button until 6000 miles is selected Page 3 11 SAF T LINER EFX OPERATOR S MANUAL DPF DIESEL PARTICULATE FILTER MANUAL REGEN SWITCH The DPF Regen Switch located on the dash may have three selectable positions e Request Regeneration e Default can include appropriate normal state condition either in an automatic regeneration or inhibit state e Inhibit regeneration optional when available NOTICE The DPF Regen Switch is standard An optional CRUISE CONTROL SWITCH SET RESUME OPTIONAL Momentary switch that allows the driver to set the desired vehicle speed When this speed is reached it is maintained by pressing the switch to the SET position to lock in Touching the brake or accelerator pedal will override the SET function To return the vehicle to the desired speed press the switch to the RESUME position The vehicle will return to its preset speed CRUISE CONTROL SWITCH ON OFF OPTIONAL Activates or deactivates the cruise control Switch must be in ON position for the Cruise Control Set Resume Switch to operate Omit Exhaust System Regeneration Switch
92. first if your driving habits FREQUENTLY include Operating when outside temperature remains below freezing and most trips are less than 5 miles 8km Operating during hot weather above 909F 329C and making frequent stops driving in stop and go rush hour traffic continuously driving above normal highway speeds operating in dusty conditions carrying maximum loads extensive idling and or low speed operation Air Cleaner f operating in severe dust conditions ask your dealer for proper replacement intervals Automatic Transmission Lubricant Must be changed whenever there is evidence of dirt contamination or high temperature condition indicated by discoloration or strong odor Page 7 24 MAINTENANCE DRIVE BELT REPLACEMENT AND ADJUSTMENT NOTICE Belts must be cool when tension is checked Disconnect the negative cable from the battery when replacing belt Check belts for wear cracks and other damage Replace the belt if it is frayed or has pieces of material missing With engine stopped check belt tension with a reliable gauge Drive belt tension should be 80 100 ft Ibs 360 490 N LEAF SPRINGS When properly tightened the U bolts on your vehicle s leaf springs should stretch by 003 per inch of original length Since the U bolts have stretched during installation they should not be re used for repairs The very act of removing their fastening nuts will cut th
93. gt 2 inches rt Floor Beneath Emergency Exit VIEW PARALLEL TO SEAT BACK Clearance area around seat back arm rests and other obstructions Window Handle Clearance All emergency window release handles must have a two inch minimum clearance to allow unobstructed access in the event of an emergency This is especially important when positioning track seats NOTICE Refer to FMVSS 217 for additional information Seats must be positioned so that emergency window release handles are located outside the 2 clear zone shown below 2 inches Floor Beneath Emergency Exit VIEW PERPENDICULAR TO SEAT BACK Access region is the spatial volume created by the intersection of the projections of the areas shown in the two views Page 6 34 GENERAL INFORMATION WHEELCHAIR TIEDOWN Several combinations of wheelchair securement systems are available through Thomas Each one has unique characteristics while accomplishing the same goal For information on the proper use and care of the specific setup on your vehicle consult the manufacturer s Instruction Guide supplied with the vehicle VENDOR LIFTS For information on the proper use and care of the specific setup on your vehicle consult the manufacturer s Instruction Guide supplied with the vehicle Below is a list of these manufacturers e Ricon Corporate Headquarters 7900 Nelson Road Panorama City CA 91402 800 322 2884 e Maxon Lift 119
94. hape Another difference between the two is the SynTec frame All SynTec seats will be constructed with round tubing unlike the IMMI seats Example of SynTec Seat 2 Determine the type of seat To identify the seat types you must measure the length of the seat cushion Listed below are the measurements of each type of seat The seat cushion is measured across the width of the cushion The following picture shows how to measure the seat cushion Both the SynTec and IMMI seat can be identified using the same method IMMI track seats are offered in 5 types 30 36 39 FLEX and 45 SynTec track seats are offered in 3 types 30 36 and 39 30 seat will have an approximate seat cushion width of 30 36 seat will have an approximate seat cushion width of 36 39 seat will have an approximate seat cushion width of 39 The 39 seat will not have three lap and shoulder belts FLEX seat will have an approximate seat cushion width of 39 The FLEX seat will also have three lap and shoulder belts 45 seat will have an approximate seat cushion width of 45 Measuring Cushion Width Page 6 27 Saf T Liner EFX OPERATOR S MANUAL 3 Determine what options if any are on the seat Review each option in the manual to determine what options if any are on the seat It is important that you determine what options are present to install the seat properly The IMMI track seat is offered wi
95. hat is specified may result in a reduction of GAWR and GVWR Failure to follow these precautions can adversely affect the safety and handling of your vehicle 4 L Use of after market wheel assemblies may not be compatible with your vehicle and may result in equipment failure and possible injury A wheel of the wrong size or type may adversely affect load carrying capacity wheel and bearing life brake checked Otherwise check pressure every few weeks Check spare tire regularly When loading your vehicle the weight on each axle should be evenly distributed so that the weight on any wheel does not exceed 1 2 the GAWR Gross Axle Weight Rating for the axle on which that wheel is mounted Inspect the tire side walls for cuts bruises and other damage If internal damage to the tire is suspected have the tire dismounted and inspected for need to repair or replace cooling speedometer odometer calibration stopping ability headlight aim bumper height vehicle ground clearance steering stops and tire or tire chain clearance to the body and chassis Replacement with used wheels is not advised The use of wheels and or tires with load carrying limits higher than the limits of the wheels tires originally installed on your vehicle does not in itself increase the GAWR or the GVWR of the vehicle Only wheel assemblies approved and released for your vehicle model should be used Alterations to the vehicle suspension
96. heck with The ideal level is 1200 ppm parts per million Anti leak antifreezes are not recommended for use in Cummins engines Although these antifreezes are chemically compatible with DCA water treatment the anti leak agents may clog the coolant filters Page 7 19 SAF T LINER EFX OPERATOR S MANUAL COOLING SYSTEM The cooling system in the vehicle contains approximately 52 U S quarts 49 2L The antifreeze is an SCA pre charged heavy duty coolant antifreeze which is a blend of ethylene glycol and a specially formulated inhibitor package designed for heavy duty cooling system applications It meets or exceeds all requirements of RP 329 Truck Maintenance Council The original factory installed solution of antifreeze and water protects the engine cooling system and vehicle heating system to 349F 379C The cooling system is pre charged to the correct SCA level upon leaving the factory When adding coolant to the vehicle a 5096 ethylene glycol antifreeze and 50 water solution is recommended A 50 50 antifreeze to water ratio will protect the engine cooling system and heating system to 349F 379C The coolant must be checked before driving in a colder climate or season The quality of the make up water also affects the efficiency of the coolant additives and components When untreated all water is corrosive Therefore we recommend using de ionized water Water with an extremely high mineral content is u
97. hen turning or parking indicate a need for inspection or servicing NOTICE After any severe impact such as striking large potholes inadvertent sliding into curbs on icy roads or a collision involving the front end observe the steering wheel alignment If the steering wheel spokes seem to be in a different position while going down the road have the front suspension and steering checked for possible damage Periodically check for broken springs or shock absorber mounts Page 4 19 SAF T LINER EFX OPERATOR S MANUAL EXTENDED VEHICLE STORAGE Any time vehicle will be out of use over an extended period of time 60 days or more the following steps should be taken to give it maximum protection 1 Change engine oil Used oil does not give adequate protection 2 Service air cleaner 3 Cooling system was initially protected with antifreeze to 349F 19C If colder temperatures are expected adjust antifreeze mixture If coolant has been in vehicle for 36 months or 30 000 miles 48 000km flush cooling system Fill system with mixture of antifreeze and softened water and be sure coolant contains a rust inhibitor Do not use additional rust inhibitors or anti rust products as they may not be compatible with a radiator coolant that already contains rust inhibitors 4 Remove and clean battery Store in a cool dry place and keep it charged 5 Cover dash with opaque material 6 Check and maintain recommend
98. hown below Knee room Inch Inch Check your state and local guidelines for how to measure the knee room Seat back thickness SBT is measured at H point when all air is compressed from the seat back Seat spacing is the Seat Back Thickness plus knee room Page 6 15 All seats in a school bus should have another seat or a barrier installed immediately in front above minimum seat spacing and below maximum seat spacing In no circumstances should seats be removed from the middle of a seat row n general seats should be removed from the rear of the bus in school buses with a rear lift door position and from the front of the bus in vehicles configured with a front lift door location When seats are removed from the front of a seat row a track mounted barrier should be moved rearward to allow above the minimum knee room and above the maximum knee room between the barrier and the first seat Seat rows should be removed to allow at least a 46 clear space for the addition of a wheelchair passenger Track options that allow for different seat widths in the same seat row should always have the wider seats located in front of narrower seats Never install a narrow seat in front of a wider seat Care should be used to install seating to allow clear access to emergency exits especially push out window exits and emergency exit doors Seat backs must allow for a 2 clearance for emergency exit handle access and the seat back should
99. ht up If the chime is ON the vehicle operator will be alerted by a single chime sound for non mobility aid passengers double chime sound for mobility aid passengers requesting to disembark PUSH BUTTON EIGHT LIGHT WARNING SYSTEM OPTIONAL Used as part of an eight light warning system that controls the entrance door As vehicle approaches stop this switch energizes amber warning lights when pressed Amber lights remain on until red lights are energized A decal with operating instructions is mounted below the switch Page 3 29 SAF T LINER EFX OPERATOR S MANUAL HAND BRAKE HYDRAULIC BRAKES The driveline parking brake is designed to hold the vehicle securely in a parked position This is accomplished by locking the driveline in place preventing its rotation Never use the parking brake to stop a moving vehicle The control or hand lever located beside the driver is an overcenter locking type It has an adjustment knob on the end for the operator to adjust the amount of brake application To apply the parking brake depress the brake pedal and pull on the park brake lever When properly adjusted the lever should have an increased resistance until it passes over center to the fully applied position To release the parking brake depress the brake pedal and push the lever forward passing over center Hold the lever to the end of travel If the parking brake does not hold the vehicle securely when appl
100. iary Screens Maintenance SETUP MLAIN TENANCE DIAGNOSTICS Maintenance Screens are next Screen 2 Maintenance Screens The maintenance intervals menu allows the driver to set the change intervals of the Engine Oil and Engine Air Filter The maintenance warnings must be disabled if the intervals are set to zero There are a minimum of two maintenance screens In select cases depending on the vehicles transmission type you may see four maintenance screens In this case the cluster S W receives a message from the engine ECU and the transmission maintenance screen are then activated Otherwise only the two default maintenance screens are available MAINTENANCE MENU EMINE OIL ENGINE AIF FILTER CONTINUED ON NEXT PAGE Right amp Engine Oil Highlighted 2 Fight amp Engine Air Fiter Highlighted Right amp Transmission il Life Highlighted Right amp Transmission wil Filter Highlighted EMSINE OIL CHANGE INTERWAL ddddd MILES PRESS 4 TO CHANGE gt AIR FILTER CHANGE INTERVAL ddddd MILES PRESS 4 TO CHANGE TRANSMISSION OIL LIFE REMAINING HOLD gt TO RESET TRANSMISSION OIL FILTER IS FUNCTIONAL HOLD gt TO RESET Page 3 10 OPERATOR S COMPARTMENT DisPLAY MESSAGE SCREEN OPERATING EXAMPLE FOR MAINTENANCE MENU CONTINUED Screen 3 Auxiliary Screens Maintenance MAINTENANCE MENU ENGINE OIL ENGINE AIR FILTER To s
101. ied depress the brake pedal and release the parking brake Turn the adjustment knob clockwise as viewed from the end of the lever to increase the braking force Turning the knob clockwise will also increase the resistance needed to move the lever over center Do not allow the driveline park brake hand lever to snap to the release position The operator must maintain control of the lever during its full travel Allowing the lever to move unaided could allow damage to the pin or cable or both causing the brake to not hold the vehicle securely when reapplied allowing the vehicle to roll away that could cause property damage or severe personal injury To properly adjust the driveline park brake 1 Park the bus on level ground 2 Chock the vehicle wheels 3 From underneath the bus locate the transmission mounted park brake drum assembly 4 Adjust the distance from the center of the yoke pin at the lever of the parking brake drum to the end of the cable at the face of the mounting clamp of the parking brake cable to 8 1 2 1 16 This will eliminate the free play of the parking brake lever Make sure there is no drag at this setting if so increase dimension until brake is just prior to brake drag 5 From the drivers seat gradually turn the adjustment knob on the parking brake handle clockwise until resistance is felt CONTINUED ON NEXT PAGE Page 3 30 OPERATOR S COMPARTMENT HAND BRAKE HY
102. ies and jumper cables correctly positive to positive and negative to negative Connecting a charging device backwards positive to negative can severely damage the vehicle electrical content and cause non warrantable failures 3 Connect the positive jumper cable to the positive terminal on the discharged battery See Jumper Connections diagram on next page 4 Connect the other end of the positive jumper cable to the positive terminal on the booster battery providing the charge Do the next step exactly as instructed and do not allow the clamps of one cable to touch the clamps of the other cable Otherwise a spark could occur near a battery possibly resulting in severe personal injury from explosion or acid burns 5 Connect the negative jumper cable to the negative terminal on the booster battery 6 Connect the other end of the negative jumper cable to the negative ground stud on the vehicle requiring the jump start 7 Start the engine of the vehicle providing the jump start and let the engine run for a few minutes to charge the batteries of the other vehicle NOTICE Do not crank the engine for more than 30 seconds at a time during any of the following procedures Wait two minutes after each try to allow the starter to cool Failure to do so could cause starter damage Continued on next page Page 4 10 OPERATING THE VEHICLE DISCONNECT JUMPER CABLES IN THE REVERSE ORDER THAT THEY
103. ile 2 1 4 or 5 715 cm Strobe Light 4 1 2 or 11 43 cm Roof Hatch 5 1 4 or 13 335 cm Metric Window Wheelbase Body Length Body 1 Height Section w Bumpers 73 HR 9 94 10 10 10710 11 11 10 12 12 10 13 13 10 14 14 10 R Axle 12 23 72 22 pss 12123 72 227 dz T 1222 2 20 Page 7 27 SAF T LINER EFX OPERATOR S MANUAL Page 7 28 Form 1 DRIVER S DAILY INSPECTION amp CONDITION REPORT Bus Number Date Time Mileage Location po SL oue zz dies Q O all c 13 14 15 16 17 18 19 MAINTENANCE DEPARTMENT OK Fill fuel tank Gallons Liters _ EN Check engine oil level Quarts Liters added _ Inspect engine for oil coolant and fuel leaks ZEN Check fuel water separator for water EE Check coolant EN Fill windshield washer container EN Inspect tires for cuts damage inflation wear EN Visual inspection of exterior for EN Drain Am TANKS 622454 dE CU kan ea ke s b SEN Inspect engine belts for 1 lt NEN Visual inspection of engine compartment
104. ilot light indicates that the Child Check System is armed when illuminated C PASSENGER CHECK REMINDER SYSTEM NOISE SUPPRESSION SWITCH OPTIONAL With the noise suppression switch in the active position it enables the driver to eliminate any noise from radio heaters and fans that may be in use when the bus is approaching railroad crossings Page 3 21 SAF T LINER EFX OPERATOR S MANUAL DEFROSTER FAN SwiTCH Enables the defroster fan for windshield cleaning The fans run at either low or high speed HORN OPTIONAL Momentary switch that activates the air horn mounted beneath the driver s vestibule floor When switch is released it returns to the off position ID MARKER LIGHTS SWITCH OPTIONAL The marker light switch energizes the bus marker lights Page 3 22 OPERATOR S COMPARTMENT DRIVER S DOME LIGHT SwiTcH ON OFF OPTIONAL The driver s dome light switch enables the vehicle operator to energize the dome light above the operator s compartment INTERIOR LIGHT SWITCHES The interior light switches energize all the vehicle interior dome lights except the one directly above the driver LIFT SWITCH ON OFF OPTIONAL Controlled by the bus operator switch must be ON to operate the lift Page 3 23 SAF T LINER EFX OPERATOR S MANUAL OUTSIDE SPEAKER HORN SWITCH OPTIONAL Outside speaker horn mounted beneath front area of bus Located on left side rear of the inne
105. in your current warranty status MAINTENANCE FLOOR COVERING Cleanliness is important to you and your passengers and will give you longer floor life Allowing dirt and other abrasive materials to accumulate on the floor Will shorten the life of the vehicle floor covering Daily sweeping and cleaning is recommended Do not use floor sweeping compounds as it may cause floor covering to separate or lift from the floor The recommended sweeping procedure is to start in the front of the body and sweep toward the rear and side emergency door This method ensures a check of emergency door operations and ensures removal of dirt pencils etc which cause the emergency door to improperly seal Do not use harsh detergents and excessive amounts of water Mop with a mild soap solution then remove excess water Oil and grease quickly deteriorate the floor covering Remove as soon as possible HEATING SYSTEM All heaters have removable aluminum filters These filters prevent debris from accumulating on the heater core and causing inefficient heat transfer Use an air hose to remove all foreign material from the filters every 30 days Check the condition of all hoses to the heaters as well as the tightness of the hose clamps The heater hoses should not be kinked All heater hose clamps should be tightened after 30 days When system coolant is replaced it is important to bleed all air from the heater units Wax floor occasionally fo
106. indow This track is designed for use with securement equipment supplied by TBB approved vendors Q Straint and Sure Lok Use with any other straps or tiedowns is not recommended The restraint system consists of wheelchair tiedowns and occupant restraint belts The wheelchair restraints secure the wheelchair to the floor and the occupant restraint belts secure the passenger to the wheelchair NOTICE Refer to the operation instructions supplied with the restraint system for proper use and safety information Securing the Wheelchair The wheelchair must be forward facing It should be centered between the four attachment points on the floor track The wheelchair must be secured with two front and two rear tiedowns If there are more than two track segments in front of the wheelchair use the outer two tracks If there are more than two track segments behind the wheelchair use the inner two tracks It is important to refer to the instructions provided by the manufacturer of the tiedowns for use and safety information Page 6 33 Saf T Liner EFX OPERATOR S MANUAL Securing the Occupant The occupant must be secured with an upper torso belt occupant tiedown and pelvic belt occupant tiedown The torso occupant tiedown must be secured to the overhead track above the window It is important to refer to the instructions provided by the manufacturer of the occupant restraints for use and safety information i 2 inches
107. ins at a minor derate until the electronic sensors indicate a safe situation then a major engine derate will occur Vehicle speed may be limited to 5 mph 8 km h Figure 13 oo Z Pau LIEN FIGURE 13 DEF CONTAMINATED WARNING AND MAJOR ENGINE DERATE Once a contaminant is detected in the DEF tank your vehicle must be taken to an authorized Cummins service center to ensure no permanent damage has occurred to the SCR system the system will function properly with the correct reducing agent and to reset the appropriate fault codes If a contaminant is detected in the DEF tank the NOx sensors in the SCR system will activate the DEF warning lamp the CHECK engine lamp and the malfunction indicator lamp and a minor engine derate CONTINUED ON NEXT PAGE Page 2 7 SAF T LINER EFX OPERATOR S MANUAL DEF WARNINGS AND ENGINE DERATES CONTINUED will occur After driving 20 hours or 1000 miles 1600 km without remedy the STOP engine lamp will illuminate and a major engine derate will occur as soon as the electronic sensors indicate a safe situation After the DEF tank is refilled with DEF and the SCR system senses proper NOx levels the engine Will return to normal operation Page 2 8 10 ExHAUST SYSTEM EXHAUST SYSTEM INSPECTING NOISE EMISSION CONTROL The exhaust system must be free of leaks binding These conditions are usually caused by loose grounding
108. ion will upshift no matter what gear is selected when the internal pressure reaches a certain level A shift point will be created by high engine rpm NOTICE R Reverse or D Drive position may be prevented when a damaging or undesirable range engagement would occur due to a vehicle logic or engine speed condition For more information refer to your Allison Transmission Operator s Manual Page 3 5 SAF T LINER EFX OPERATOR S MANUAL TRANSMISSION SHIFTER WITH OPTIONAL 2500 PTS TRANSMISSION LEVER To put the transmission into gear move the selector lever from Neutral to the desired drive position Do not race the engine when shifting from Neutral into another gear The available gears are R Reverse Vehicle must be completely stopped before engaging this gear N Neutral Use when vehicle is standing for prolonged periods with engine running Set the parking brake if you leave the vehicle Engine may be started in this gear Set the gear selector to Neutral engage the parking brake and turn off the ignition even momentarily Never leave the vehicle unattended while the engine is running Unexpected sudden vehicle movement may occur if these precautions are not taken Do not allow the vehicle to coast in Neutral Page 3 6 D Overdrive For most highway driving D Drive For most city driving 2 Second For driving slowly in heavy city traffic or on mountain roads where mor
109. ir tank Do not open the surge tank filler cap when the engine and radiator are hot Cooling system pressure may force extremely hot coolant by the filler cap opening and cause serious personal injury Allow engine and radiator to cool and release system pressure at pressure release cap before opening cooling system The reservoir tank contains a pressure release valve that is designed to safely release cooling system pressure Lift the pressure release valve to discharge any remaining cooling system pressure or steam before attempting to open the reservoir tank filler cap A safety latch prevents complete removal of the filler cap in one operation Continued on next page Page 7 21 SAF T LINER EFX OPERATOR S MANUAL COOLING SYSTEM CONTINUED During filling air must be vented from the engine coolant passages Some engines are equipped with a vent to allow the air to escape The system must be filled slowly to prevent air locks Wait 2 to 3 minutes to allow air to be vented then add mixture to bring the level to the bottom of the filler neck HEATER COOLANT FILL PROCEDURES The following procedures have been established to help improve the purging of air from the heater system and engine when cooling system repairs are performed A procedure has been written for each engine Use the one that best suites your particular application NOTICE Procedure should be performed on cold engines only
110. iscovered refer to the engine manufacturer s service literature for repair instructions or take the vehicle to an authorized Freightliner or Thomas Built Bus service facility for repair 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe and each exhaust seal clamp for leakage wear cracks or e Diesel Particulate Filter DPF a filter that collects and holds particulate matter soot and ash e Diesel Oxidation Catalyst DOC oxidizes hydrocarbons and reduces NOx Sensors detect temperatures and pressure within the ATS damage Replace damage components as needed If leakage exists at the clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be replaced 3 f present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 M m if needed Do not overtighten 5 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD No leaks are allowed anywhere in the system CONTINUED ON NEXT PAGE Page 2 12 10 ExHAUS
111. ive RETARDER SWITCH ON OFF OPTIONAL This switch activates retarder in the transmission The retarder in the transmission becomes activate when the vehicle operator applies pressure to the brake treadle There are three switches that control the amount of retarder capacity used Light pressure on the brake treadle will activate one third braking capacity of the retarder while a moderate amount of pressure will utilize two thirds of the breaking capacity of the retarder Heavy brake application will use all retarder capacity to slow and stop the vehicle A hand control is also available on some models which gives the vehicle operator six different levels of retardation Page 3 18 OPERATOR S COMPARTMENT SECONDARY RESERVE AIR TANK DRAIN OPTIONAL Momentary switch that allows the driver to activate the solenoid drain valve located on the secondary reservoir SECONDARY RES AIR TANK OOOO OOOO WET RESERVE AIR TANK DRAIN OPTIONAL Momentary switch that allows the driver to activate the solenoid drain valve located on the wet tank reservoir WET RES AIR TANK OO O O O O OO PRIMARY RESERVE AIR TANK DRAIN OPTIONAL Momentary switch that allows the driver to activate the solenoid drain valve located on the primary reservoir PRIMARY RES AIR TANK O O O QO O O 00 Page 3 19 SAF T LINER EFX OPERATOR S MANUAL SIDE CONSOLE SWITCH PANEL The Side Console Switch Panel contains
112. l exterior doors are closed securely SN Inspect driver s seat belt for condition and operation mE Driver s Signature Comments Form 2 PREVENTIVE MAINTENANCE INSPECTION 1 4 000 Miles 6 400 Km 60 Days whichever occurs first Unit Number Check OK Mileage X Attention Required Repair Order R Repair Date Time N A Not Applicable Location OK Not OK 1 Check driver s reports for problems previously reported BEEN 2 Ignition switch On air pressure warning signals SEEN 3 Start engine Check operation of the following a b Check operation of Intake Air EE All gauges Oil pressure Temp Trans Temp lach BEEN Voltmeter Ammeter Air pressure Speedometer EN d Check interior lights Dash lights Ceilinglights EN e Check exterior lights Headlights High beam indicator NEED Tail Stop Stepwell Clearance _ EE f Check turn signals 4 wayflashers g Check 4 light warning system 8 light warning system____ EN h Check Windshield wiper operation Washer EN i Check max air pressure should be
113. lacement or structural repair follow the steps listed below 1 Apply pressure against the glass from the outside of the body Start at one top corner and work your way around outer edge of rubber seal pushing glass and seal together off the metal flange Remove the glass and rubber seal intact Remove rubber seal from glass and inspect seal for cuts and deterioration If any are found replace rubber seal to avoid future leaks and glass breakage Inspect metal flange for burrs and sharp edges that could cut rubber seal Inspect flange for rust and deterioration Repair and repaint before reinstalling glass and rubber seal Inspect new or replacement glass and install rubber seal around outer edge glass used by Thomas meets FMVSS 205 requirements Use of OM glass is recommended when replacing any glass on the bus o Apply a soapy solution silicone or rubber lubricant to the outside diameter of the seal This will aid in installation of the glass and seal e e e lt 332 Using a nylon cord approximately 2 longer than the total circumference of the rubber seal wrap the cord around the seal and glass Rest the assembly on the bottom flange of the window opening from the inside of the bus Pull the cord slowly from the outside of bus while an assistant applies light pressure to the glass from inside the bus Work rubber seal onto the metal flange Apply even
114. ld ensure that the door is closed when shutting down the vehicle and leaving it parked If ignition key is turned off and door switch is left in open position an alarm buzzer will sound An emergency release valve is mounted over the windshield beside the door which allows the door to be opened without air pressure Air doors have two or three postion switches Page 3 14 OPERATOR S COMPARTMENT WINDSHIELD WIPER WASHER CONTROL AND INDICATOR Electric windshield wiper washer is standard The electric windshield wiper washer controls the wipers The wiper knob is located on the lower right dash The wiper control is a multi position switch which operates clockwise OFF INTERMITTENT LOW HIGH INTERMITTENT wiper control is integrated into the switch To activate turn the wiper knob one click or position clockwise from OFF and the wiper will operate on INTERMITTENT The closer to the OFF position the longer the interval The further away from the OFF position the shorter the interval The next position to the right or clockwise is LOW and the last position operates the wipers on HIGH To deactivate turn the knob counterclockwise to the OFF position PARK BRAKE VALVE AIR BRAKES The parking brake applies or releases the vehicle parking brake Pulling out on the parking brake knob applies the parking brake Pushing the knob in releases the parking brake Whenever the vehicle is put in to neutral the parking
115. ly when chassis transmission is placed in reverse It is wired into the back up lights AIR RESTRICTION INDICATOR The restriction indicator is a progressive locking type located directly behind the grille The air cleaner element should be changed when the maximum PARTIAL restriction is indicated on the gauge RESTRICTION FULL RESTRICTION TIME TO CHANGE THE FILTER Front Access Latch Key Location The front access headlamp wiper panel latch key is located in the dash storage compartment Page 6 38 GENERAL INFORMATION PASSENGER ADVISORY SYSTEM HORN ACTIVATION OPTION B2001 19 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard e System is activated when the Red warning lamps are used the first time Once the route is complete and the Ignition is turned off the Pilot Lamp on the dash lights as well as the Passenger Dome Lamps The Driver then has to check the bus for passengers and press the button at the back of the bus When the button is pressed the passenger dome lamps flash 2 times and the Pilot Lamp cuts off The Driver can now leave the bus If the system is not disarmed then the horn will start blowing When this happens the driver must go to the front and turn the Ignition back on then off and then return to rear of the bus to press button to deactivate Time to alarm N A
116. move the key avoiding the possibility of personal injury Avoid touching fan blades with hands ENGINE COMPARTMENT CHECKLIST Make sure the vehicle engine is off and parking brake is engaged before performing the following tasks e Check engine oil level before starting and when refueling e Check belt for cracks breaks frayed edges and proper tension INTERIOR CHECKLIST People sometimes damage unattended buses e Aisles and stepwells must always be clear of objects e Emergency exit handles must be in safe working condition e Check all emergency exits for proper operation e The Emergency Exit sign on an emergency door must be clearly visible Check coolant level only with engine cool As necessary fill with a 50 50 water antifreeze solution Fill to the cold max line do not over fill You may lock some emergency roof hatches in a partly open position for fresh air Do not leave them open as a regular practice Keep in mind the bus higher clearance while driving with them open Page 4 2 OPERATING THE VEHICLE FINAL CHECK Adjust driver s seat and steering wheel Start engine look and listen for signs of trouble Check all gauges and warning lights Check and adjust mirrors Adjust the vehicle mirrors according to the following procedures before vehicle begins daily service Crossview Mirrors Swivel the mirror head to give a clear view of area directly in front of the vehicle Inte
117. mp GAUGE MAINTENANCE MENU HIGH COOLANT TEMP INDICATOR amp GAUGE CRUISE CONTROL ON Low PRESSURE INDICATOR amp GAUGE DASH DRIVER DISPLAY SCREEN DIESEL EXHAUST FLUID DEF GAUGE Low FUEL INDICATOR amp FUEL LEVEL GAUGE ULTRA Low SULFUR DIESEL FUEL ONLY PARKING BRAKE HIGH BEAM HEADLIGHT INDICATOR CONTINUED ON NEXT PAGE Page 3 SAF T LINER EFX OPERATOR S MANUAL EPA10 INSTRUMENT CLUSTER CONTINUED 1 10 11 Tachometer Indicates engine speed in revolutions per minute rpm Maintenance Intervals Indicator Yellow Will activate when either of the following conditions have been met The oil change interval has been met and the change air filter input has been set low This menu allows the driver to set the change intervals The maintenance warnings must be disabled if the intervals are set to zero Left Turn Signal Indicator Lamp Green Indicates that the driver intends to turn left and flashes at a rate determined by the flasher module High Exhaust System Temperature HEST Alerts the driver that the exhaust temperature is out of the desired range Check Engine CHECK ENGINE When a problem is detected by the engine s electronic system a diagnostic code is generated and the Check Engine lamp is turned ON Stop Engine STOP ENGINE This acts as the Engine Warning Lamp The bus will shut down in 30 seconds after light illuminates Malfunction Indicator Lamp M
118. n EFX requires towing that it be towed from the front whenever possible If the need arises for the unit to be towed from the rear the towing operator should make sure the steer axle tires are rated high enough to support the unit weight when towing from the rear It is also recommended that when towing from the rear the distance towed is less than 30 miles at 45 mph Thomas Built Buses recommends that when an EFX requires towing that it be towed from the front whenever possible If the need arises for the unit to be towed from the rear the towing operator should make sure the steer axle tires are rated high enough to support the unit weight when towing from the rear It is also recommended that when towing from the rear the distance towed is less than 30 miles at 45 mph Page 4 15 SAF T LINER EFX OPERATOR S MANUAL FRONT END TOWING ALL WHEELS ON GROUND This is the preferred way of towing The vehicle may be towed on all wheels provided the steering is operating normally Remember that the power steering will not have power assist and the air brakes are disabled There must be an appropriate tow bar installed between the towing vehicle and the disabled vehicle To prepare a disabled vehicle for front end towing with all wheels on the ground the following steps are necessary 1 Block the Wheels of the disabled vehicle 2 Release the emergency brake system by compressing the brake chamber springs
119. n the Body Identification number The Data Plate lists items such as Chassis Yard Number Model Year Engine and Serial Number Transmission and Serial Number Axles and Model Numbers The VIN Vehicle Identification Number is assigned by the chassis manufacturer and contains information such as manufacturer engine type body style and order number 3 6 THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON 3 VIN 30 VEH TYPE 28 BODY ID 2 Page 1 4 TEB PART NUMBER 63011847 INTRODUCTION VEHICLE EMISSION CONTROL INFORMATION LABEL MANUFACTURED BY THOMAS BUILT BUSES INC HE DM HIGH POINT NORTH CAROLINA LE WELT MFO BY THOMAS BUILT BUSES INC INC WEH MAD BY 3 VEHICLE EMISSION CONTROL INFORMATION IDENTIFICATION HUMBER 301 VEHICLE FAMILY CODE 77 REGULATORY SUBCATEGORY 78 SION CONTROL IDENTIFIERS 7B THES VEHICLE COMPLIES WITH EPA REGULATIONS FOR 3 HEAVY DUTY VEHICLES BODY ID 12 SEE CHNNER S MANUAL FOR PROPER MAINTENANCE OF THES TES PART HUMBER 176984 Page 1 5 SAF T LINER EFX OPERATOR S MANUAL VEHICLE LOADING The Thomas vehicle is designed to provide excellent service if not loaded in excess of either the Gross Vehicle Weight Rating GVWR or the maximum front and rear Gross Axle Weight Rating GAWR These ratings are listed on the vehicle certificati
120. ndow to its maximum position as determined by the props so that the sides and bottom of the inner window frame are visible and accessible With a stiff fiber brush do not use a wire brush and or an air hose remove any dirt or debris from the latch area channels across the bottom of the window and back frame opray or otherwise apply a solvent cleaner with dissolved oil like WD 40 on the latch parts on the bottom of the window and back frame Cycle the latch mechanism a couple of times with the inside and outside handles to allow the lubricant to work in Wipe down the latch area and back frame with a cloth to remove excess oil and liquid 6 With the same cloth wipe the seals on the sides and across the bottom of the window and around the seal contact area of the back frame so that dirt is removed and a light oil film is left on the metal and seals Silicone spray or graphite spray may also be used WD 40 or silicone spray will provide better corrosion and seal protection Close and open the window to verify latch operation and force When done close the window Page 5 6 EMERGENCY EQUIPMENT MAINTENANCE INTERVALS HEHR OFFERED AS OPTION If the vehicle is in daily use Hehr recommends maintenance every time the bus is washed or monthly which ever is shorter Proportionately longer periods may be used if the vehicle is not used every day or if it is operated only a clean dry environment N
121. nfit for cooling system use If water hardness registers in excess of 200 PPM part per million or if chloride and sulfate register 100 PPM or more use an alternate water source or have your water supply professionally treated The cooling system should not be operated without antifreeze even in hot weather conditions In addition to antifreeze and good quality make up water the diesel cooling system requires the use of supplemental coolant additives and filters to protect the system from oil fouling corrosion products scale rust and dirt Check with Engine Manufacturer for their recommendations When treating the cooling system with chemical additives always start clean To flush the system 1 Place a large container under the radiator 2 Remove the surge tank cap 3 Open the petcock at the bottom of the radiator to drain the engine coolant 4 Disconnect the radiator inlet and outlet hose connections 5 Attach a flushing gun nozzel to the radiator outlet 6 Add water to the radiator until it is full When flushing the radiator do not apply more than 20 psi 138 kPa air pressure Excessive pressure can damage the radiator or heater core 7 Apply no more than 20 psi 138 kPa air pressure intermittently to help dislodge sediment buildup in the core 8 Drain the radiator then flush the radiator until clean water flows from the radiator Remove the flushing gun 9 Close the petcock 10 Using clamps
122. nical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged components Improperly maintaining the vehicle braking system may lead to brake failure resulting in property damage personal injury or death POWER STEERING LUBRICATION The lubricant used in this vehicle s power steering system is the medium by which hydraulic pressures are applied and relieved under control to effect steering assist In addition the oil lubricates moving parts and dissipates heat which reduces efficiency and accelerates wear Change oil twice a year or every 5 000 miles 8000 km Severe service requires more frequent intervals Block the rear tires and apply the parking brake when filling the reservoir while the engine is running The power steering pump reservoir must be kept full and free of air Run the engine and turn the steering wheel from side to side while filling the reservoir to its proper level A replaceable filter element is located in the power steering reservoir Change the filter element whenever the oil in the steering system is changed Carefully clean any built up oil around the reservoir cover Remove the cover and filter element Clean the inside of the reservoir with a lint free cloth Install a new filter element refill the reservoir and replace its cover The level must be between the MAX and MIN mark on the
123. not obstruct the Ellipsoid gauge passing in front of seat back Page 6 16 Saf T Liner EFX OPERATOR S MANUAL clear opening of the emergency exit such that an ellipsoid with major axis of 50 centimeters and minor axis of 33 centimeters keeping a major axis horizontal at all times can pass through the opening without contact with the seat back u a E mu j E Ti 2201 ji ha PN Ellipsoid gauge passing above seat back CONTINUED ON NEXT PAGE GENERAL INFORMATION TRACK SEATING GENERAL INSTALLATION AND REMOVAL GUIDELINES CONTINUED 9 Wheelchair anchorages should allow passage of the ellipsoid in front of the torso or behind the shoulder belt attachment as shown below Pushouts not permissible in this area ni Emergency Exit E f 58 E iium AIS j ll z7 Ellipsoid dy This is typically achieved by the position of a 10 Removable barriers and seats should allow for a 12 clear aisle to emergency exit doors without exceeding maximum seat spacing barrier immediately at the door opening and far enough behind the forward seat to allow a 12 clear aisle for side emergency doors 30 cm minimum E M Jdis j Floor line No seat or barrier may extend past door opening No obstruction of door latch mechanism Minimum Side Emergency Exit Clearance Specifications Page 6 17 Saf
124. nt that each seat be placed in the location for which it was designed By not properly placing the seat in its correct location you may be in violation of state and or federal regulations and could cause injury to a passenger in the event of an accident Seat Spacing If both seats are identical seat spacing should be measured to determine the proper seat placement Seat spacing can be measured by measuring the distance between two seats using the same reference point A good place to measure the seat spacing is the forward most seat bolt pictured below Measuring Seat Spacing NOTICE When measuring seat spacing both seats must be identical Knee Room Knee room should be used in seat placement when the two seats are not identical Knee room is measured from the front of the seat back to the rear of the seat back of the next seat in front of it passing through the H point This is also the same as seat spacing minus the seat back thickness For the most common spacing measurements please refer to the Seat Spacing Chart If you do not see the combination of seats you have or are unsure of the proper seat spacing please contact Thomas Built Buses for proper seat spacing Page 6 32 GENERAL INFORMATION WHEELCHAIR RESTRAINTS General information If this unit is equipped with wheelchair placements each wheelchair placement will have two or four track segments in the floor and one track segment above the w
125. of rust streaks emanating from the lug nuts is evidence of the lug nuts not being torqued to specification Failure to correct this condition will lead to damaged wheels or rims and can result in the loss of wheels involved if permitted to operate in this condition for any extended period of operation If your vehicle is equipped with a spare tire check the spare tire inflation pressure at the same time as the other tires The spare tire and wheel should be of the same size and quality as the others on your vehicle Page 7 8 MAINTENANCE WHEEL INSPECTION amp MAINTENANCE Whenever a wheel is removed and then reinstalled always remove any corrosion that might be present on the mounting surface of the wheel and or the surface of the hub drum or rotor that contacts the wheel MOUNTING amp DISMOUNTING TIRE When remounting and inflating a tire use only appropriate equipment and adhere to prescribed safety precautions to avoid damage to the tire and possible injury to yourself If you are not properly equipped or experienced in this work take the tire to a tire repair shop Installing wheels without good metal to metal contact at the wheel mounting surface can cause the wheel lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion causing loss of control 13 did IMPROPERLY INFLATED PROPERLY INFLATED BIAS OR BIAS BELTED TIRE PROPERLY INFLATED RADIAL TIRE Page 7 9
126. on of the gears Early breakdown of the oil will result in heavy varnish and sludge deposits that plug oil ports and build up on splines and bearings Under these conditions the transmission will overheat and severe damage will result Overheating Extended operation at low road speeds with engine at full throttle can cause excessively high oil temperatures in the transmission If overheating is encountered shift transmission to NEUTRAL and accelerate the engine to 1200 1500 rpm This should reduce the sump temperature to normal operating range of 1609 2209F 719 939C N The engine should never be operated for more than 30 seconds at full throttle with transmission in any gear and output stalled Page 7 15 SAF T LINER EFX OPERATOR S MANUAL TRANSMISSION LUBRICANT ALLISON TRANSMISSION CAPACITY RECOMMENDED LUBRICANT 2500 PTS 20 Qts Dexron lll or C 4 3000 PTS 29 Qts Dexron lll or C 4 Dry fill not including coolers and external filter TRANSMISSION OIL AND OIL FILTER CHANGE CHART ALLISON TRANSMISSION MILEAGE INTERVAL TIME INTERVAL 2500 PTS 25 000 miles 12 months 3000 PTS Whichever occurs first Initial Change only APPROVED ALLISON TRANSMISSION LUBRICANTS NUMBER AN 051005 ExxonMobil Lubricants and Petroleum Specialties Company Mobil Delvac Synthetic AN 011001 Castrol Heavy Duty Lubricants TranSynd Autran Syn 295 AN 031002 AN 031003 Cognis Corporation Emgard 2805 AN 0
127. on plate with the tires required to obtain these ratings GAWR Gross Axle Weight Rating is the maximum weight the axle can carry and reflects the combined capacity of axle brakes tires wheel equipment full fuel burden included and suspension GVWR Gross Vehicle Weight Rating is the maximum loaded weight of the vehicle Passenger and cargo loads should be distributed proportionately over both the front and rear axles full fuel burden included and sides of the vehicle Actual loads at the front and rear axles can only be determined by weighing the vehicle at highway weigh stations or other similar facilities Overloading create the potential for safety hazards and places excessive loads on vehicle components Vehicle warranty is void on any vehicle which has been subject to misuse Overloading the vehicle is misuse Vehicle Loading Example Vehicle equipped with standard axles and suspension 10 00 x 20 Load Range G or 11R22 5 Load Range G Rear GAWR 21 200 Ib 9616 kg Front GAWR 12 000 Ib 5479 kg GVWR 33 200 Ib 15095 kg Rear curb weight cargo and passenger load cannot exceed 21 200 Ib 9616 kg Front curb weight cargo and passenger load cannot exceed 12 000 Ib 5479 kg Maximum total weight cannot exceed 33 200 Ib 15095 kg CONTINUES ON NEXT PAGE REAR GAWR FRONT GAWR Page 1 6 INTRODUCTION VEHICLE LOADING CONTINUED y Y LJ
128. only certified diesel exhaust fluid DEF in the DEF tank After exhaust gasses leave the engine they flow into the ATS First they flow into a two part ATD comprised of a diesel oxidation catalyst DOC and a Diesel Particulate Filter DPF The DPF traps soot particles then exhaust heat converts the soot to ash in the DPF in a process called regeneration regen The harder an engine works the better it disposes of soot When the engine is running under load and regen occurs without input it is called passive regen If the engine isn t running hot enough the electronic controls may initiate an active regen whereby extra fuel is injected into the exhaust stream before the diesel particulate filter to superheat the soot trapped in the filter and burn it to ash Both types of regen occur without driver input pancer Active regeneration can occur automatically any time the vehicle is moving The exhaust gas temperature could reach 1500 F 800 C which is hot enough to ignite or melt common materials and to burn people The exhaust can remain hot after the vehicle has stopped moving Operating at reduced engine load will allow soot to accumulate in the DPF When this occurs the DPF lamp illuminates indicating that a regen must be performed and the driver must either bring the vehicle up to highway speed to increase the load or park the vehicle and initiate a parked regen See Parked Regen later in this chapter for ins
129. oolant temperature is at least 150 F 66 C CONTINUED ON NEXT PAGE Page 2 2 10 ExHAUST SYSTEM ATS PARKED REGENERATION CONTINUED EXHAUST AFTERTREATMENT SYSTEM INFORMATION INDICATOR EH i zi ay f A WARNING C EY Qu CERO 2 Solid Flashing Flashing Flashing P Level 1 Level 2 Level 3 Level 4 Indicator Filter Regeneration Filter Regeneration Parked Regeneration Parked Regeneration Required HEST High Exhaust Message s Recommended Necessary Required Engine Engine Shut Down System Temperature Derate Diesel Particulate Filter is reaching Filter is now Filter has reached Filter has exceeded Flashing Filter Condition capacity reaching maximum maximum capacity maximum capacity regeneration is in capacity progress Required Action Bring vehicle to To avoid engine Vehicle must be Vehicle must be parked and a highway speeds to derate bring vehicle parked and a Parked Parked Regeneration or Service Solid allow for an Automatic gi to highway speeds Regeneration must Regeneration must be performed Ill Exhaust Components Regeneration or to allow for an be performed Check engine operators manual and exhaust gas are perform a Parked Automatic engine will begin for details engine will shut down at high temperature Regeneration Regeneration or derate When stationary keep perform a Parked away from people and Regeneration Bs flammable materials soon as possible or vapors
130. oor opening frame a vertical transverse plane parallel to that plane at a distance of 30 centimeters forward of that plane and a longitudinal vertical plane passing through the longitudinal centerline of the bus CONTINUED ON NEXT PAGE Sides of Bus Body 2 Side Emergency Exit TS P a i minimum Centerline of Bus Minimum Side Emergency Exit Clearance Specifications Plan View Page 6 22 GENERAL INFORMATION DOOR IMPACT ZONE CONTINUED However a seat bottom may be located within the area as described if the seat bottom pivots and automatically assumes and retains a vertical position when not in use so that no portion of the seat bottom is within the area as described above When the seat bottom is vertical see below 30 cm minimum Floor line No seat or barrier may extend past door opening No obstruction of door latch mechanism Minimum Side Emergency Exit Flip Up Seat Clearance Specifications Page 6 23 Saf T Liner EFX OPERATOR S MANUAL No portion of a seat or restraining barrier located forward of the area described above and between the door opening and a longitudinal vertical plane passing through the longitudinal centerline of the bus shall extend rearward of a vertical transverse plane tangent to the forward most portion of a latch mechanism on the door 30 cm minimum uU j Floor line No seat frame or barrier ma
131. or steering can adversely affect vehicle handling and may lead to loss of vehicle control TIRE TREAD WEAR TREAD INDICATOR Page 7 5 SAF T LINER EFX OPERATOR S MANUAL CHANGING TIRES To avoid personal injury and or property and equipment damage call for expert tire service NOTICE Use a clip on chuck and stand to one side of any tire you are inflating Always use a tire inflation cage when inflating a tire that is not mounted on the vehicle Do not inflate a flat tire and place vehicle into service Have the flat tire checked and repaired or replace the tire before placing the vehicle into service NOTICE Stud Pilot Wheels Lug nuts on the right side of the vehicle have right hand turn clockwise to tighten threads and on the left side of the vehicle have left hand turn counterclockwise to tighten threads Use the following procedure for changing front tires 1 Make sure vehicle is parked on a level surface if possible and is not obstructing traffic 2 Apply parking brake 3 Place automatic transmission gear selector in neutral 4 Shut down engine 5 Turn on emergency flashers 6 Block diagonally opposite wheel Use chocks if possible to prevent vehicle movement 7 Slightly loosen all ten lug nuts 8 Place jack underneath axle at spring pad Make absolutely sure that jack sits on a firm level surface Close valve on jack by turning it clockwise
132. ording to local operating conditions Any items that fail to meet the checklist should be reported immediately to the EXTERIOR CHECKLIST e Clean windshield driver s window door glass mirrors and headlights e Inspect vehicle exterior Make sure all vehicle identification is clear clean and operates properly Verify that all compartments are secure under vehicle e Inspect tires for sidewall or tread damage excessive or uneven tread wear and proper inflation Inspect wheels and rims for cracks etc Check lug nuts for tightness e Drain moisture from air reservoir tanks Check for oil fuel coolant and power steering fluid leaks understanding of component location function and operation is important to the safe operation of the vehicle and the protection of all passengers maintenance supervisor and repaired as necessary before placing vehicle in service e Unplug block heater and oil heater if so equipped e Inspect steering mechanism for proper operation e Inspect for any damage to the After Treatment Device and the Mitigation Device Page 4 1 SAF T LINER EFX OPERATOR S MANUAL ENGINE COMPARTMENT SERVICE Do not service the engine until the transmission gear shift selector lever is in N Neutral and the parking brake is engaged Unless the particular procedure requires you to run the engine while working in the engine compartment you should always turn off the ignition and re
133. ormal bus operating procedure is to check egress window operation at the beginning of every driver shift If during these daily checks the forces start to become excessive shorter maintenance intervals may be required Page 5 7 SAF T LINER EFX OPERATOR S MANUAL Page 5 8 GENERAL INFORMATION OUTWARD OPENING DOOR There are two 2 adjustments for the standard The adjustments are pre set and should not require outward opening entrance doors adjustment for many years under normal use However should it become necessary to readjust use Door opening adjustment the following procedures Door closure adjustment MANUAL DOOR OPENING ADJUSTMENT Open the doors fully and check the measurement 3 Remove the cotter pin located in the curved end across the opening The measurement should be 28 of the transfer link connected to the rear door 1 2 If this is incorrect adjust as follows leaf Disconnect transfer link from door cam 4 Loosen adjustment rod jam nut and turn rod clockwise to increase door opening or turn counterclockwise to decrease opening 1 Remove the door control rod at the clevis 2 Remove the access panel above the entrance door to expose the adjusting rod An optional hinged access panel is available Option B5015 CONTINUED ON NEXT PAGE 02 000 gu x A le E a C rF El Page 6 1 Saf T Liner EFX OPERATOR S MANUAL MANUAL DOO
134. oth dampened with turpentine or kerosene Rinse Nail Polish or Lacquer Remove immediately for best results Pick up as much as possible with dry cloth taking care not to spread stain Go over quickly and lightly with non flammable cleaning fluid Rinse thoroughly Tar Asphalt Remove immediately Lengthy contact will cause a permanent stain Using cloth dampened with kerosene rub gently from outside edge of stain to center This will prevent stain from spreading Rinse Chewing Gum Car Grease Shoe Polish Scrape off as much as possible chewing gum will come off more easily if rubbed with ice cube and go over lightly with cleaning fluid to remove remainder No time should be lost in removing shoe polish as it contains dye which can cause permanent staining Rinse thoroughly CONTINUED ON NEXT PAGE Page 6 11 Saf T Liner EFX OPERATOR S MANUAL THOMAS SEATS AND BARRIERS CONTINUED Ball Point Ink Remove immediately to avoid permanent staining Use cloth dampened with alcohol Rinse thoroughly Powdered abrasives steel wool and strong cleaning preparations are not recommended They usually cause dulling especially of glossy finishes VENDOR SEATS If your bus is equipped with passenger seats other than Thomas you can contact them direct for information on care and maintenance Below is a list of these manufacturers American Seating Company 401 American Seating Center Grand Rapid MI 49504 616
135. ous injury CAUTION indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury NOTICE NOTICE indicates a procedure that could cause property and or equipment damage Page 1 1 SAF T LINER EFX OPERATOR S MANUAL NOTICE Your Thomas Built Bus has been manufactured in strict compliance with all the applicable Federal Motor Vehicle Safety Standards FMVSS and Canadian Motor Vehicle Safety Standards CMVSS We strongly advise against making any changes or CALIFORNIA PROPOSITION 65 WARNING This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm MODIFICATIONS OR ADDITIONS TO YOUR VEHICLE Installation of additional or non standard components or attachments as well as alteration or removal of components can adversely affect the safety or performance of your vehicle Be sure to observe the limitation and specifications set forth in your Operator s Manual Page 1 2 modifications that will in any way violate this compliance Thomas Built Buses will not be responsible for any change or modification occurring to the vehicle after its purchase that violates these FMVSS and Canadian Motor Vehicle Safety Standards CMVSS standards Engine Exhaust some of its constituents and certain vehicle components contain or emit chemicals known to State of California to cause canc
136. oute At the end of the route the driver has to walk back to the rear and press the Stop and Check button on the rear bulkhead and hold down until the unit chirps to let the driver know it has been deactivated If Horn starts blowing Ignition has to be turned back on then the button at back must be pressed again In California the driver must leave the vehicle to accompany students across the road the driver should simply turn off the engine and remove the key remembering to leave the overhead flashing lights on The system will remain active but will not sound the alarm as long as the overhead lights remain on Once the driver returns to the bus the engine should be started prior to turning off the Overhead lights Once the lights have been turned off the driver may repeat this procedure until the run is completed at which time the system should be deactivated following the procedures described above Time to alarm 60 seconds Type of Alarm Chassis Horn System Activation When red warning lamps are used for first time Alarm Activation When Ignition is turned off Alarm Indication Chirping from control unit Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Rapid chirp sound from control box Operation without Deactivation Chassis Horn Dome Light N A Pilot Light Location Operation None Labeling N A California option Yes Page 6 45 Saf T Liner EFX OPERATOR S MANUAL
137. ows for proper latching Inspect fuel tanks by a trained inspector every third year CNG units Check fuel sender unit connections and renew dielectric grease if necessary Check fuel fill hose for tightness Mechanic s Signature Comments OK Not OK Form 4 MAINTENANCE GENERAL MAINTENANCE RECORDS The maintenance service record is for your services performed on your vehicle This record log convenience Record the services performed on your should remain with the vehicle at all times vehicle in the record log You should retain copies of your receipts for the services You also should keep records of any emission systems maintenance MAINTENANCE PERFORMED DATE MILEAGE KM SHOP NAME AND ADDRESS 1408 Courtesy Road Post Office Box 2450 High Point NC 27261 336 889 4871 www thomasbus com 2012 Thomas Built Buses Inc rights reserved No portion of this catalog may be reproduced by any means without express permission from the copyright holder 2012 Part ZTBB 176060
138. place if less than 1 4 Form 3 25 26 2f 28 29 30 31 32 33 34 35 36 3f 38 39 PREVENTIVE MAINTENANCE INSPECTION 2 CONTINUED Inspect slack adjusters for worn splines Remove plug and grease all 4 if sealed YPE sios wanada d k kd Oe So BRAN dik s oe Tighten rear U bolts Torque Values ____ Tighten front U bolts Torque Values __ Remove front wheel Inspect lining Replace if within 1 8 of rivet head Clean and repack wheel bearings if not oil lubricated Drain and refill differential Check lube for metal chips Drain and refill manual transmission if equipped Check lube for contaminants Drain automatic transmission drop pan Replace internal filter Renew transmission Refill with ATF Dexron 111 Check operation of air dryer renew filter or desiccant if so equipped Inspect rubber seals on emergency exits Lubricate all access and emergency door hinges Replace entrance door inline Inspect all wind
139. r best appearance and floor life The use of a non skid type floor wax is suggested To renew the luster and close the pores of the floor covering after extended use mix 10 Clorox or commercial bleach to 90 water and mop the floor NOTICE Silicone hoses require special constant torque clamps For fill procedures see Heater Coolant Fill Procedures in this section Page 7 3 SAF T LINER EFX OPERATOR S MANUAL FLOOR UNDERNEATH BUS Accumulations of mud snow and road salts should be removed with a high pressure hose Follow this procedure at intervals of 30 days to 6 months depending upon your operation and environmental conditions This cleaning procedure will also give you the opportunity to make an efficient check of your mounting clips and bolts Mounting clips and bolts should be inspected for secure fit every thirty days Excessive amounts of chemicals salt and other snow and ice controls materials add to the deterioration of metal on all vehicles on our highways and roads today We suggest using the guidelines in our service manual relating to preventive maintenance of the underside of the floor As an added method you should clean the entire Page 7 4 underside of the floor of all foreign elements annually and re undercoat if chemical action is apparent or separation of undercoat to body floor is visible Climatic and operating conditions should dictate if underfloor inspection should be performe
140. r bumper Enables the outside speaker horn LUGGAGE COMPARTMENT LIGHT SWITCH OPTIONAL Located on the side panel enables driver to activate the light in the luggage compartment STROBE LIGHT OPTIONAL These lights are used in some eight light warning systems some stop arm assemblies and as a separate warning light affixed to the top of the bus in various locations These strobes improve the visibility of a stopped school bus in all driving conditions Page 3 24 OPERATOR S COMPARTMENT LIGHTS SWITCH ON OFF OPTIONAL Controlled by the vehicle operator and activates fog lights for better visibility in inclement weather CROSSING ARM DEACTIVATION SWITCH OPTIONAL Switch deactivates the crossing control arm after warning lights have been activated EMERGENCY DOOR LIGHT SWITCH OPTIONAL Turns on lights mounted above the emergency door and or rear pushout hatch Page 3 25 SAF T LINER EFX OPERATOR S MANUAL AIR CONDITIONING MASTER SWITCH OFF LOW HIGH OPTIONAL The air conditioning switch enables the bus operator to energize or de energize the air conditioning system A C AIR VENT SWITCH ON OFF OPTIONAL In A C position air conditioning system operates and cold air is available In vent position air conditioning system is off and outside air is available STEP DOOR LIGHT SWITCH OPTIONAL Energizes the step door lights without activating the door Page 3 26 OPERAT
141. r current condition Recharge fire extinguisher as necessary The chemical content of the fire extinguisher can be corrosive to any metal it contacts Excess chemical from the fire extinguisher must be brushed or vacuumed off Washing the chemical off will cause a severe corrosion problem TRIANGLES OPTIONAL Three reflectorized triangles complete with carrying case Triangle unfolds and locks firmly in place Standard mounting location left side floor under first seat Page 5 4 EMERGENCY EQUIPMENT FUSEES FLARES OPTIONAL Three 30 minute fusees in a cylindrical container mounted with easy access by the driver Operator should be familiar with the proper use of the fusees FIRE AXES OPTIONAL Fire axes are maintained with the bus for use in case of emergency Usually located in driver s area or safety equipment compartment WRECKING BAR OPTIONAL Wrecking bar is maintained with the bus for use in case of emergency Usually located in driver s area or safety equipment compartment e Page 5 5 SAF T LINER EFX OPERATOR S MANUAL SAFETY EQUIPMENT BOXES AND ACCESSORY COMPARTMENT Located over windshield with glass lettered Emergency Equipment Inside May be equipped with lock and buzzer if so desired Hinge must be lubricated occasionally EMERGENCY EQUIPMENT INSIDE T MAINTENANCE PROCEDURE HEHR HEHR OFFERED AS OPTION 1 Open the wi
142. rior Rearview Mirrors Adjust mirror to provide a clear view of passenger area and roadway Convex Mirrors Optional These mirrors provide a wider view of the adjacent lane However cars and other objects will appear smaller and further away than when viewed from a flat mirror Use care when judging distances with this type of mirror BEFORE DRIVING OFF Secure all doors Check operation of defroster and heater blowers windshield wipers washers and horn Fasten seat belt Check air pressure gauges for maximum pressure Check operation of service brake and parking brake Verify parking brake is applied and check operation of doors emergency escape hatches and emergency exits Check operation of interior lights and stepwell lights Visually inspect vehicle while engine is running for fluid or exhaust leaks Check operation of all exterior lights safety equipment and signal devices Visually check all gauges for normal operation readings Page 4 3 SAF T LINER EFX OPERATOR S MANUAL NORMAL STARTING It is important that the vehicle operator be familiar with all operating controls and indicators before attempting to operate the vehicle The following must apply before starting the vehicle All vandalocks if applicable must be in unlatched position To start the vehicle use the following procedure 1 Apply parking brake if not already applied 2 Place transmission shift control in neutr
143. river s seat is designed to accommodate a variety of driver builds and seating preferences The MECHANICAL BASE SEAT 1 DO NOT adjust seat while vehicle is in motion Backrest Tilt Rotate the knob for infinite selection of settings Cushion Height Front Lift handle pull up and forward Choice of two settings Seat Fore and Aft Move the lever left and slide seat Provided for locked in settings in 1 2 increments Rear Cushion Adjuster Rotate lever to adjust height Choice of three settings Seat Height Adjustment Pull paddle rearward following adjustments enable the seat to be moved for maximum driver comfort to adjust height To raise seat pull handle while body weight is removed from seat To lower seat pull handle while sitting in seat Release handle at desired height infinite selection of settings Lumbar Adjustment To fully inflate lumbar depress valve button while all body weight is removed from seat back To deflate lumbar depress valve button while maintaining desired seating position Page 3 37 SAF T LINER EFX OPERATOR S MANUAL AIR BASE SEAT 1 DO NOT adjust seat while vehicle is in motion Backrest Tilt Rotate knob for infinite selection of settings Cushion Height Front Lift handle pull up and forward Choice of two settings Seat Fore and Aft Move lever left and slide seat Provided for locked in settings in 1 2 increments Rear Cushion Adjuster Ro
144. rough block where the DEF and exhaust gases undergo selective catalytic reduction Selective Catalytic Reduction SCR a process used to reduce NOx emissions Engine Derate when the engine power is reduced by 25 to protect the engine This warns the driver that the DEF level registers below 10 or if the DEF tank is contaminated Page 2 9 SAF T LINER EFX OPERATOR S MANUAL INSPECTION NOTICE The Environmental Protection Agency s 2010 regulations mandate lowered exhaust emissions thus requiring exhaust system components that reduce emissions In particular the aftertreatment device ATD which is part of the aftertreatment system ATS requires special attention during regularly scheduled maintenance inspections See Figure 1 for Cummins ATD sensor locations If any discrepancies are discovered refer to the engine manufacturer s service literature for repair instructions 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each exhaust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or remove
145. s known to the State of California to cause cancer and reproductive harm Wash hands after handling Page 4 12 OPERATING THE VEHICLE TIRE INFLATION PRESSURE Over or underinflated tires can affect vehicle handling Pressure can fall suddenly resulting in loss of vehicle control Do not drive over posted speed limits or at excessive speeds This vehicle is not equipped with high speed capability tires and should never be operated in excess of 74 mph 119 kph for even a short time Doing so can result in tire failure loss of control and possible injury Ir You GET A FLAT TIRE A To minimize the risk of personal injury do not put any portion of your body under the vehicle while the vehicle is on the jack A jack is for emergency wheel and tire changing only If you wish to service the vehicle use jack stands Never start the engine while the vehicle is on the jack To prevent inadvertent vehicle movement while changing a tire always block the wheels diagonally opposite the wheel being changed Be sure the park brake is engaged Do not raise the vehicle using a bumper jack Bumper components can be damaged and the bumper jack can slip resulting in personal injury Make sure the jack is on a solid surface Brace up the vehicle with jack stands or equivalent at jacking points so that the jack cannot fail PROPERLY INFLATED BIAS OR BIAS BELTED TIRE PROPERLY INFLATED IMPROPERLY INFLATED RADIA
146. should be an audible chip from the EP2 module When the Red lamps are used for the first time in route the EP2 will emit an audible sound to let you know it is armed When the route is over with the door closed you must turn key to off position for 1 second then turn it back to Ignition or Accessory Once that is done the driver must walk back to back and push button on rear bulkhead for 3 seconds The unit will chirp to let you know that it has been deactivated Dome lights will then stay on for approximately 60 seconds Note If when the bus is cut off and tone is heard from unit and the bus is not turned back to IGN or ACC then after 8 seconds the horn will start blowing Theftmate section gt Walk onto bus Dome lights should come on and initial passive alarm will sound after 15 seconds gt The dome lights will pulsate off and on and the EP2 will sound a loud voice gt Turn the ignition key to the on position this will silence the alarm gt The EP2 system is equipped with a RF receiver to disable the alarm for a predetermined time by the mechanic for maintenance Time to alarm 8 seconds Type of Alarm Chassis horn System Activation When red warning lamps are used for first time Alarm Activation When Ignition is turned off Alarm Indication Interior Lamps are turned on Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Interior lamps flash when deactivated
147. ssengers and press the button at the back of the bus When the button is pressed the passenger dome lamps flash 2 times and the Pilot Lamp cuts off The Driver can now leave the bus If the system is not disarmed then the horn will start blowing When this happens the driver must go to the front and turn the Ignition back on then off and then return to rear of the bus to press button to deactivate Time to alarm 60 seconds Type of Alarm Chassis horn System Activation When red warning lamps are used for first time Alarm Activation When Ignition is turned off Alarm Indication Interior Lamps are turned on Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Pilot lamp and dome lights ON If not disarmed within 1 Minute chassis horn will blow Operation without Deactivation Buzzer and pilot light ON Dome Light Yes Approximately 30 seconds Pilot Light Location Operation LED pilot light located in switch cabinet lights steady upon system activation Labeling PASSENGER CHECK REMINDER SYSTEM Located at pilot light on switch cabinet Air or Electric Door Covers the Air door or electric door Page 6 41 Saf T Liner EFX OPERATOR S MANUAL CHILD REMINDER SYSTEM B2001 22 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard System is activated when the bus is turne
148. t the Driver s Seat completes the section It is important to carefully read and understand the following pages before operating the vehicle A proper understanding of component location function and operation is important to the proper operation of the bus INSTRUMENT CONTROL UNIT WITH OPTIONAL 3000 PTS TRANSMISSION 1 AIR VENT 2 HEATER DEFROSTER FAN CONTROL 3 SWITCH BLANKS 4 AIR PRESSURE GAUGE 5 3000 TRANSMISSION KEYPAD CONTROLLER OPTIONAL 2500 TRANSMISSION SHIFTER OPTIONAL 6 EPA10 INSTRUMENT CLUSTER DIESEL 7 MANUAL REGEN SWITCH OPTIONAL 8 CRUISE CONTROL SWITCH SET RESUME OPTIONAL 9 CRUISE CONTROL SWITCH ON OFF OPTIONAL 10 PANEL DIMMER SWITCH 11 HEADLIGHT SWITCH DO MOMS ii 12 PiLor L GHT w WARNING LIGHT SYMBOL OPTIONAL 13 WARNING SWITCH ON OFF AMBER LED OPTIONAL 14 Door SWITCH 15 WIPER WASHER SWITCH 16 PARK BRAKE VALVE AIR BRAKES 17 IGNITION SWITCH 18 REAR PASSENGER HEATER SWITCH 19 REMOTE MIRROR CONTROLS 20 RADIO OPTIONAL 21 LEFT HEATER SWITCH 22 BOOSTER PUMP Page 3 1 SAF T LINER EFX OPERATOR S MANUAL DRIVER S IR VENT Located on the dash at the driver s window and directs air from the defrosters to the driver s si
149. t it will open freely when it is needed Grease hinge as necessary You should also examine the door seal and ensure that it is not damaged or obstructed with any foreign material Opening the side emergency door activates a warning buzzer in the operator s compartment 3 POINT LOCK INSIDE DOOR OPTIONAL Lock for center or side emergency door Required by some states A single handle when turned secures the door at top bottom and center Check operation at maintenance intervals Page 6 6 GENERAL INFORMATION WINDOWS SPLIT SASH REMOVAL AND INSTALLATION The sash is installed in the window opening and is securely anchored on both sides to the one piece bow frames with four 4 clips two 2 on either side of the window 1 Remove four 4 screws two on each side of the window and remove the clips Interior and exterior caulking will have to be cut 2 Pull the top of the sash to the interior of the bus body 3 Disassembly of the sash for glass replacement will be covered in the next section Glass Replacement 4 Prior to reinstalling sash in opening seal both lower corners of the window opening This will assist in keeping moisture out of the body sidewalls Use silicone Thomas Part 01013370 or equivalent 5 Reassemble by reversing Steps 1 4 Reseal sash inside and outside using silicone Thomas Part 401013370 or equivalent This will ensure that moisture does not enter the side of the body
150. t time There Will be a brief audible chirp confirming it is active It remains unarmed until the Red warning lights are used the first time on a route At the end of the route the driver turns off the ignition key and has to walk back to the rear and press the Stop and Check button on the rear bulkhead and hold down until the unit chirps to let the driver know it has been deactivated If Horn starts blowing Ignition has to be turned back on then the button at back must be pressed again Time to alarm 60 seconds Type of Alarm Chassis Horn System Activation When red warning lamps are used for first time Alarm Activation When Ignition is turned off Alarm Indication Chirping from control unit Location of Deactivation Switch Rear bulkhead Confirmation of Deactivation Rapid chirp sound from control box Operation without Deactivation Chassis horn timed to activate after 60 seconds Dome Light N A Pilot Light Location Operation None Labeling N A PASSENGER ADVISORY SYSTEM HORN ACTIVATION CHECK MATE B2001 27 000 Alarm system that requires the driver to deactivate it by walking through the interior of the bus to turn it off and verify that no passengers are still aboard The Child Checkmate system is active when the Ignition is turned on the first time There will be a brief audible chirp confirming it is active It remains unarmed until the Red warning lights are used the first time on a r
151. tate lever to adjust height Choice of three settings Seat Height Adjustment Push rocker up to inflate Push rocker down to deflate Infinite height and weight selection Lumbar Adjustment Push rocker up to inflate lumbar Push rocker down to deflate lumbar Optional Triple Chamber Air Lumbar Lower middle and upper chambers individually adjustable Optional Air Bolsters Cushion and back individually adjustable Optional Height Adjuster with Memory Rotate lever to select desired ride height infinite selection Page 3 38 OPERATOR S COMPARTMENT DRIVER S SEAT WITH Box PEDESTAL 1 Backrest Tilt Rotate the knob for infinite selection of settings 2 Cushion Height Front Lift handle pull up and forward Choice of two settings 3 Seat Fore and Aft Move the lever left and slide seat Provided for locked in settings in 1 2 increments DO NOT adjust seat while vehicle is in motion Seat Height Adjustment Rotate the four 4 knobs on the box pedestal two on each side to loosen and select slot for desired height Tighten knobs to secure in position Page 3 39 SAF T LINER EFX OPERATOR S MANUAL DRIVER S SEAT BELT The driver s seat belt should be worn at all times when operating the vehicle Prior to adjusting or fastening the seat belt adjust the seat to a comfortable driving position Refer to the Driver s Seat part of this section for adjustment information The
152. ted to protect occupants from rear end collisions and ensures that there is adequate room for rearward seat back Track seats 16 75 16 75 W W sen ll ANIM Gen H ISO IMM Gen l T Gen Il TA MMSSA 19 18 19 Each seat has a unique absolute minimum knee room spacing per FMVSS 222 Generally this minimum is less than recommended Most states require a minimum knee room of 24 It is also recommended by Thomas Built Buses that a minimum knee room of 24 be maintained If you require a knee room of less than 24 contact Thomas Built Buses to get the seats absolute minimum spacing All ISO seats should have a minimum knee room of 26 8 Notes for measuring Track seats must be spaced in 1 increments Measurements should be rounded up for minimum knee A room and rounded down for maximum knee room Min Knee room 24 H deflection in the knee area and to facilitate ingress and exit from the seat row The maximum seat spacing is limited to protect occupants from front end collisions and ensures that there is sufficient forward deflection to absorb collision energy TBB recommends that seats be marked or mapped when removed from a school bus and reinstalled exactly where removed When this is not possible and to support the numerous configurations often allowed by removable seat options care should be taken to make sure seats are within minimum and maximum spacing as s
153. tem a switch in the driver s area or a switch at the entrance door Drivers should be familiar with the function and proper operation of the stop sign arm Page 6 36 GENERAL INFORMATION SPARE TIRE CARRIER OPTIONAL The spare tire carrier on the vehicle is located in the To re install the tire onto the carrier use the following rear overhang of chassis on the right side procedure 1 Load tire onto carrier bracket Use the following procedure to remove the spare tire 2 urn crank handle clockwise to raise tire It may from the carrier be necessary to back off crank handle to 1 Locate crank handle in the operator s engage safety latch compartment 3 Reinstall safety security chain and safety pins 2 Remove safety security chain and remove Verify security of safety security chain safety pins from rods 3 Place crank handle on crank rod Release and hold safety latch while cranking counterclockwise to lower tire to ground 5 Remove tire from carrier bracket FRAME RAIL A a a HH l Hp n SPARE TIRE SIDE SHEET lt LL soe ae FOLDING STEPS ON FRONT BUMPER Folding steps mounted on the front bumper to assist in cleaning the windshield The steps should be clean and lubricated Page 6 37 Saf T Liner EFX OPERATOR S MANUAL BACKING HORN amp HEAVY DUTY BACKING ALARM The backing horn or heavy duty backing alarm is mounted at the rear underbody and signals automatical
154. th ISO latch ICS lap and shoulder belts and lap belts Each seat can have one none or a combination of these options The SynTec track seat is offered in low back high back ISO latch and lap belts The following pictures show each individual option with each make of seat If you are unsure or can not find the option in this manual please contact Thomas Built Bus for assistance IMMI Lap Shoulder Belt number of belts may vary CONTINUES ON NEXT PAGE 2 3 255 IMMI ICS number of ICS may vary Page 6 28 GENERAL INFORMATION TRACK SEAT IDENTIFICATION CONTINUED Se qmm uw Et b x F a IMMI Lap Belt number of belts may vary IMMI FLEX Seat SynTec Lap Belt number of belts may vary SynTec ISO Seat number of ISO latches may vary Page 6 29 Saf T Liner EFX OPERATOR S MANUAL INSTALLING TRACK SEATING It is important that you follow each bullet point listed below to insure that the seat is installed in a safe manner When installing track seating all federal regulations must be followed Any information that contradicts federal regulation please disregard and contact Thomas Built Bus When installing track seating all federal regulations must be followed Each seat must be installed behind another seat or barrier of matching or greater width For example a 30 seat can be installed behind a 39 seat but a 39 seat cannot be installed behind a 30 seat When inst
155. the controls for bus heaters and defrosters destination sign lights and other standard and optional body group controls All switches are easily accessed by the operator A typical side console switch panel is shown below The ge IY Do OU uev b n DM x N gt p amp 5 5 9 9 9 O 5 0 5 9 iS e gt layout of your side console switch panel may differ slightly due to vehicle specifications and selected options UXILIARY POWER QULET 12 VOLT OPTIONAL SWITCH BLANKS PASSENGER CHECK REMINDER SYSTEM PILOT LIGHT NoisE SUPPRESSION CTIVE NORMAL OPTIONAL DEFROSTER FAN Lo Hi OFF OPTIONAL HORN ON NORMAL OPTIONAL ID MARKER ON OFF OPTIONAL DRIVERS DOME ON OFF OPTIONAL INTERIOR ON OFF LiFT ON OFF OPTIONAL SPEAKER OUTSIDE INSIDE OPTIONAL COMPARTMENT LUGGAGE ON OFF OPTIONAL STROBE ON OFF OPTIONAL FOG ON OFF OPTIONAL Page 3 20 OPERATOR S COMPARTMENT AUXILIARY POWER OUTLET 12 VOLT OPTIONAL Supplies a 12 volt power supply source for driver add on accessories such as cellular phones and two way radios Located on the switch cabinet the outlet is wired directly to the battery with a 10 amp in line fuse SWITCH BLANKS Blank panels are used to fill in openings in the switch panel where switches are not used PASSENGER CHECK REMINDER SYSTEM PILOT LIGHT The p
156. the park brake is p engaged gt lt L j uU Page 4 14 OPERATING THE VEHICLE VEHICLE TOWING AND CONNECTING INSTRUCTIONS Towing rules and regulations vary from federal state local and transit authority These laws must be followed when towing the vehicle Proper equipment must be used to prevent damage to vehicles during the towing procedure Use a safety chain that is completely independent of the primary towing attachment Climatic conditions road conditions equipment wrecker operator experience etc will dictate towing speed however it should never exceed 45 mph Connect the towing equipment to the main structural parts of the vehicle chassis The chain should be hooked around the front axle outboard of the springs Do not attach to bumpers tow hooks or brackets Use only equipment designed for this purpose following directions of the wrecker manufacturer TOWING A Block the disabled vehicle s wheels with chock blocks before preparing it for towing Failure to do so will result in a hazardous condition where the vehicle could roll uncontrollably Either removal of the driveshaft or removal of the axle shafts are acceptable procedures prior to towing Do not use the two tow hooks under the front of the vehicle to lift it off the ground The tow hooks are designed to tow the vehicle with all of its wheels on the ground 4 Thomas Built Buses recommends that when a
157. the turn signals move lever downward for a left hand turn or upward for a right hand turn turn signal lever automatically cancels after turn is complete To switch headlights from the low beam setting to the high beam setting pull the turn signal lever upward and release To return vehicle headlights to the low beam setting pull turn signal lever upward again and release enable the operator to perform a variety of tasks without moving from the driver s seat The vehicle s headlights have an optional high beam flash provision With the headlight switch in the ON or OFF position pull upward on the turn signal lever and release to flash high beams Page 3 32 OPERATOR S COMPARTMENT POWER STEERING Power steering uses energy from your engine to assist you in steering the vehicle When the engine is off or if the power system becomes inoperative the vehicle can still be manually steered but requires increased driver effort Should you notice any change in effort required to steer during normal vehicle operation have the power steering system checked A hissing sound at full left or full right steering wheel position is normal Never hold the steering wheel against the stops extreme right or left for more than five seconds If you hold the wheel against the stops longer than five seconds the power steering pump could be damaged TILT TELESCOPING STEERING COLUMN The tilt steering column enables the operator
158. ther than the manufacturers dealer that are serving the after market The maintenance director should check these companies for complete compliance with the Federal standards prior to purchase and installation of this material To remove seat backs for inspection and or replacement of the cover or foam the following should be performed 1 Pull the staples from the vinyl fabric under the plate 2 Slide the cover and foam envelope up and off the frame 3 Inspect and replace as necessary 4 Reverse procedure to reinstall There are many types of tape and vinyl repair materials on the after market for minor cuts and seat cover repair Torn seams in the cushion or back Covers can be easily repaired by removing the covers re sewing the seams and reinstalling Seat cleaning and care recommendations are from the Chemical Fabrics and Film Association Chemical Fabrics and Film are made to withstand scuffing cracking peeling and hard use They will come up fresh and sparkling after a mild soap and water bath a clear water rinse However certain stains if allowed to remain may become set making removal more difficult It is important to remove these stains as soon as possible Day to Day Soil Most stains can be removed with a neutral soap warm water and if necessary a good stiff brush Fabric should be thoroughly rinsed with clear water then blotted dry Paint or Enamel Remove immediately with a sponge or cl
159. tighten every six months thereafter Tighten driver s seat bolts then retighten every six months thereafter Tighten seat leg and wall rail bolts then retighten every ninety days thereafter Tighten door control mounting bracket then retighten every six months thereafter CHASSIS Check toe in Reset if necessary Check the steering operation Tighten power steering items Check power steering reservoir level Clean and lubricate all fittings Inspect front and rear engine mounts and bolt condition Tighten front and rear spring U bolts Drain and refill differential lubricant Check transmission oil level Drain and refill if manual transmission Change engine oil and filters per PM schedule Tighten radiator hoses Check coolant level Tighten steering gear mounting to frame Inspect tie rod pitman arm and drag link connections Inspect for correct clutch adjustment if equipped Check brake master cylinder fluid level hydraulic brakes Inspect for correct brake adjustment Page 1 8 Remove heater hose covers and tighten all hose clamps Wash bus only with clean water for the first thirty days Wax bus with a good automotive wax after the first thirty days Adjust belt tension all belts Tighten the After Treatment System Inspect for any damage to the After Treatment Device and the Mitigator Device Exhaust Gauge tires for correct air pressure Inspect for air leaks air brake models Tight
160. tional regeneration switch located on the dash is used to initiate a parked regeneration of the aftertreatment device Figure 3 A slow 10 second flashing of the Heat Exhaust System Temperature HEST lamp alerts the driver that a parked regen is in progress but the exhaust temperatures are still relatively cool It also indicates that the high idle speed is being controlled by the engine software not the driver A steadily illuminated HEST lamp alerts the operator of high exhaust temperatures when vehicle speed is below 5 mph 8 km h while it is performing an automatic regen and during a parked regen An illuminated DEF warning lamp in the gauge indicates that the DEF tank should be refilled at the next opportunity NOTICE The regeneration switch can initiate a parked regen only when the DPF lamp is illuminated because the engine software is signaling for a parked regeneration The regen inhibit switch optional when available provides additional control over the aftertreatment regeneration process Depressing the regeneration inhibit switch will prevent a regen from occurring during a drive cycle After the vehicle has been shut down and restarted regens will occur normally unless the inhibit switch is pressed again Figure 4 To initiate a parked regeneration perform the following steps 1 Park the vehicle away from all combustible and flammable materials Chock the tires Start and warm the engine until the c
161. to adjust the angle and height of the steering column to a more comfortable driving position To adjust the angle of the steering column locate the small lever underneath the turn signal lever Pull lever towards steering wheel and hold while tilting the steering wheel at a comfortable position Release lever to lock column in position To adjust the height of the steering column locate the small lever underneath the turn signal lever Push the lever and hold while telescoping the steering wheel to the desired position Release lever to lock column in position NOTICE After any severe impact such as striking large potholes inadvertent sliding into curbs on icy roads or a collision involving the front end observe the steering wheel alignment If the spokes of the wheel seem to be in a different position while driving have the front suspension and steering checked for possible damage Do not adjust while vehicle is in motion Page 3 33 SAF T LINER EFX OPERATOR S MANUAL ELECTRONIC ACCELERATOR PEDAL The accelerator pedal is an electric rheostat type control that sends a gradually increased current to the engine to control engine rpm and vehicle speed BRAKE PEDAL HYDRAULIC The brake pedal controls the application of the vehicle service brake Downward pressure forces the movement of hydraulic fluid from a booster or master cylinder to each wheel Anticipating th
162. to be 409F 49C or below The heater must be connected to an external source of electrical current Heaters are available for 120 AC and possess a 750 watt capacity ENGINE WARM UP After the engine starts time is needed for an oil film to re establish between moving parts Operate the engine at low load until all systems reach normal operating temperature Observe all gauges during warm up period to verify that vehicle is ready to enter service An optional weather proof plug in receptacle is mounted in the exterior panel above the front bumper Make sure that cover stays closed to prevent damage to connection pd Page 4 5 SAF T LINER EFX OPERATOR S MANUAL ENGINE IDLING FAST IDLE SYSTEM Idling the vehicle s diesel engine in cold temperatures will not result in desired engine temperature Actually a diesel engine cools down when left idling The vehicle operator should activate the fast idle feature The vehicle operator should activate the fast idle switch to automatically increase engine idle speed to 950 rpm This higher idle speed aids vehicle warm up and air pressure build up MAIN CIRCUIT BREAKER The main body and chassis power supply cables are circuit protected by a Mega Fuse Junction Block MFJB The MFJB and main power disconnect switch are housed in a NEMA enclosure for protection from the environment and debris The NEMA enclosure is mounted to the side of the battery box through which the main power
163. tructions After the exhaust stream passes through the ATD it flows through another canister housing the SCR device A controlled quantity of diesel exhaust fluid DEF is injected into the exhaust stream where heat converts it to ammonia NH3 gas This mixture flows through the SCR device where the ammonia gas reacts with the NOx in the exhaust to produce harm less nitrogen N2 and water vapor H2O which then exits out of the tailpipe Page 2 1 SAF T LINER EFX OPERATOR S MANUAL ATS WARNING LAMPS The Malfunction Indicator Lamp MIL illuminates to indicate a fault that affects the emissions Figure 1 Warning lamps in the driver s message center alert the driver of situations with the aftertreatment system An illuminated DPF lamp indicates a regen is needed FIGURE 1 ATS PARKED REGENERATION During parked regeneration exhaust temperatures are very high and could cause a fire heat damage to objects or materials or personal injury to persons near the exhaust outlet Before initiating a parked regeneration make certain the exhaust outlets are directed away from structures trees vegetation flammable materials and anything else that may be damaged or injured by prolonged exposure to high heat A reference label is included with the driver s documentation package that explains the ATS warnings and actions required to avoid further engine protection sequences Figure 2 The op
164. vel should be at or slightly above the Full Hot mark on the reservoir tank Do NOT remove radiator cap to check coolant level If the coolant level is low remove the cap on the coolant reservoir tank Fil the surge tank to the MAXIine with a 50 50 mixture of water and the type of antifreeze currently installed in your vehicle If the surge tank was empty start the engine after refilling and check the level again when the engine is at operating temperature Put the cap back on the reservoir tank Overflow Coolant Reservoir Tank Optional COOLANT FILTER REPLACEMENT Mechanical over tightening of the water filter during replacement may destroy the threads or damage the filter head If you have to add coolant more than four times a year see your dealer for a cooling system check When additional coolant is needed add the recommended concentration of antifreeze to the reservoir tank Do not overfill Never add coolant to radiator when engine is overheating Do not loosen or remove radiator cap to cool overheating engine The radiator cap should not be removed while the system is hot under pressure When the cooling system gets hot pressure builds up inside the system Suddenly removing the cap will allow scalding steam or coolant spray to escape possibly resulting in painful injuries NOTICE To ensure the proper level of cooling system additive is maintained refer to Engine Manual Page 7
165. y f No obstruction of door latch extend past door opening mechanism Minimum Side Emergency Exit Clearance Specifications Page 6 24 GENERAL INFORMATION DEFINITIONS Compartmentalization The concept of protecting each child within the passenger compartment of a school bus with a padded barrier that would prevent injury H point Also known as the SRP or Seating Reference Point It is the calculated location of a point that would be the hip pivot point of a test dummy designed for this purpose This point will vary between seat design and manufacturers Knee room The distance measured from the front of the seat back to the rear side of the seat back in front passing through the H point Also the same as seat spacing minus the seat back thickness Seat spacing The distance measured from the same point on two adjacent seats Track seating Seats that are installed on a track in the floor to allow for flexibility in mounting locations FMVSS Federal Motor Vehicle Safety Standards CMVSS Canadian Motor Vehicle Safety Standards ICS Integrated Child Seat This section of the manual will provide important information for installing and reinstalling track seats It is important that each seat be properly installed to comply with state and federal law Each step is important to follow the laws set forth to keep each passenger safe By following the outline of this section you will be better able to identify your seat l

Saf-T-Liner EFX Operator`s Manual School Bus

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