STATE OF FLORIDA SCHOOL BUS SAFETY INSPECTION MANUAL

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STATE OF FLORIDA
SCHOOL BUS
SAFETY INSPECTION
MANUAL
2017
Edition
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i
PREFACE
The purpose of this manual is to standardize safety inspection criteria for school bus inspectors,
technicians, maintenance supervisors and transportation directors to ensure that maintenance personnel
know which components to inspect, how to inspect each component, how to identify which items are in
need of repair and which defects constitute an out-of-service condition. The Florida School Bus Safety
Inspection form number (2017-IF), which is incorporated by reference in rule 6A-3.0171, Florida
Administrative Code (F.A.C.), correlates inspection items with those found in this manual. A copy of form
2017-IF is found on page 173 of this manual and may also be obtained from the School Transportation
Management Section, Department of Education, 325 West Gaines Street, Tallahassee, Florida 32399, at
a cost not to exceed actual production and distribution cost.
This manual was prepared to clarify many of the issues pertaining to school bus safety inspections. This
manual will not answer all technical questions and will not eliminate the need for trained personnel to
exercise professional judgment. The emphasis of this manual is on “SAFETY,” which should be the
foremost consideration when inspecting school buses in Florida.
Sources used in preparing this manual include Florida School Bus Specifications, National School
Transportation Specifications and Procedures, Federal Motor Vehicle Safety Standards (FMVSS),
manufacturers’ maintenance and shop service manuals, other states’ inspection standards and other
industry standards for maintenance and repair procedures.
i
SPECIFICATIONS NOTES
1.
The school district may upgrade school buses to current specifications and revise inspection
procedures according to the applicable specifications.
2.
Inspection procedures for pilot test items approved by the Florida Department of Education (FDOE)
and the Florida Association for Pupil Transportation (FAPT) School Bus Specifications
Subcommittee may not be covered in this manual. Please refer to the school bus manufacturer
and/or the equipment suppliers for inspection procedures for these items.
3.
All Florida specifications dates that appear in this manual correspond to the dates vehicles were
ordered or to the procurement invitation to bid (ITB) under which vehicles were purchased. Actual
production dates cannot always be used to determine applicable specifications due to lead-time
between ordering and build dates.
4.
All FMVSS dates listed in this manual refer to the chassis build date. Any public school bus not
meeting all applicable FMVSS must be removed from service until all non-compliance items are
corrected.
5.
Section 1006.25, Florida Statutes (F.S.), requires that all school buses transporting public school
students must meet applicable federal motor vehicle safety standards and other specifications as
prescribed by rules of the State Board of Education.
NOTE:
The inspection form and manual were first approved by the FAPT, incorporated by reference, and made
part of the F.A.C. in November 1994. All school transportation providers regulated under section 1006.22,
F.S., and rule 6A-3.0171, F.A.C., shall implement this manual. Please send any comments regarding this
manual to the following address:
FAPT School Bus Inspection Committee
Attn: School Transportation Management Section
Florida Department of Education
325 West Gaines Street, Room 834
Tallahassee, Florida 32399-0400
schtrans@fldoe.org
ii
INSTRUCTIONS
This manual must be used in conjunction with the Florida School Bus Safety Inspection Form 2017-IF
(page 173) when inspecting school buses as required by rule 6A-3.0171, F.A.C. Districts are encouraged
to ensure that copies of all applicable Florida School Bus Specifications manuals are available for use by
inspectors during their inspections. Instructions on proper use of the state inspection form and the Florida
School Bus Safety Inspection Manual are as follows:
The Florida School Bus Safety Inspection Form
1. Heading
Fill in completely, including the local bus number, mileage, repair order number (RO#), date of
inspection, chassis/body manufacturer, seating capacity, model year of bus and shop location (if
district has more than one shop).
2. Status Code Indicators
a) A " " (check mark) indicates that the items inspected meet all requirements of this manual and
are in proper working order.
b) An “X” denotes a type of defect that does not affect the safe operation of the bus. Repair the item
prior to returning the bus to service (if in district policy) or put a note on the form and repair the
item within a reasonable amount of time.
c) The letter “O” indicates safety-related defects. Repairs of this nature are required prior to placing
the bus back in service.
3. Status Code Column
Place a status code indicator (, X or O) indicating the inspection results for each row in this column
as each row is inspected. See page 175 for an inspection form with the examples described below:
a) Section A - Inside Bus, Item 2, “Registration and Insurance Card,” is okay; therefore, A. 2. Is
marked with a check ().
b) Section B - Outside Bus, Item 2 is marked with an “X” for a nonfunctional clearance light. Identify
the deficiency by placing a circle around the words “clearance light” and providing a brief
description in the comments for B. 2.
c) Section D - Underneath Bus, Item 13, “Wheels and Tires” is marked with an “O” for R/F tire tread
depth and low air pressure, which are both out-of-service conditions. Note how the deficiencies
are correctly identified and the actual measurements are recorded in the provided space near the
bottom of the form.
iii
4. Inspection Items Column
All items on the form are to be inspected. Items in bold print are the main areas to be inspected.
All other items pertain to the main areas.
Example: “Section A-Inside Bus,” Item “1. Emergency Equipment” would cover such items to
be inspected as the fire extinguisher, first aid kit, body fluid cleanup kit and roadside reflectors.
Inspection procedures for A-1 are found in the inspection manual.
5. Comments Column
This column must indicate the nature of the problem with the item circled in the “Inspection Items”
column. See example on page 175.
6. Technician’s Initials Column
The repairing technician or inspector is required to place his/her initials in the corresponding “Tech
Initials” box to indicate the repairs are complete or use the “Tech Initials” box to reference a repair
order number that documents and addresses the concern.
7. Section E, “Lubrication and Maintenance” is optional and provided for the district’s convenience.
8. The “Comments” space on the back page of the form may be used to provide additional information
related to the inspection. When writing additional comments, the inspector should label each comment
with the corresponding section and number. Document any deficiency not covered on the form in this
space. See example on page 175.
9. Enter the tread depth and air pressure of each tire in the space provided at the bottom of the form.
Measure the tread depth according to the procedures in this manual. Record the initial air pressure
reading prior to any necessary adjustment.
10. The inspector must sign the inspection form to indicate the inspection is complete.
11. The “Inspector’s Certification Number” must be the FDOE-assigned number as shown on the
inspector’s certificate.
12. “Service Manager’s Initials” and “Bus Returned to Service Date” are required to document the service
manager’s approval to return the bus to service.
iv
Repair Order Example
1. Verify all repairs noted on the inspection form on a repair order, including complete parts information
and labor descriptions (see example repair order on page 178).
2. The technician who makes the correction should initial the repair order in the “Tech Initials” box
corresponding to the item corrected.
3. It is recommended that the inspection form and associated repair order be kept together in the vehicle
record.
Manual
The Florida School Bus Safety Inspection Manual provides detailed information and instructions
corresponding to the individual items listed on the state inspection form.
On the following pages, the subject matter is in the upper left-hand corner of each page by section and
subsection, such as “Section A-Inside Bus,” then 1. Emergency Equipment. There are three columns on
each page with the following headings, “Inspection Procedures,” “Repair (or note) if ” and “Out-of-service
if.” The columns should be used as follows:
1. Inspection Procedures
This column outlines the methods to inspect each component for presence, condition, operation,
mounting and specifications.
2. Repair (or) note
This column is for documenting non-safety related deficiencies found meeting the repair or note failure
criteria. Repair items should be addressed within a reasonable period of time. A note item is okay
currently, but may need repair soon.
3. Out-of-service
This column describes deficiencies that, if found, would place the bus out-of-service. Repair out-ofservice items prior to placing the bus back in service.
Role of the School Bus Safety Inspector
The role of the school bus safety inspector is to identify and document deficiencies on buses
according to the procedures and criteria described within this manual. Results of those
inspections are to be reviewed by the district service manager, who shall make the final
determination regarding whether buses are safe or unsafe to operate, unless this authority has
been specifically delegated to another individual.
v
TABLE OF CONTENTS
Preface---------------------------------------------------------------------------------------------------------
i
Specifications Notes ---------------------------------------------------------------------------------------
ii
Instructions ---------------------------------------------------------------------------------------------------
iii
A. INSIDE BUS
1.
Emergency Equipment -------------------------------------------------------------------------
1
2. Registration and Insurance Card ------------------------------------------------------------
6
3. Shifter, Noise Abatement Switch and Neutral Safety Switch--------------------------
7
4. Engine Controls ----------------------------------------------------------------------------------
9
5. Gauges, Indicators, Dash and Switch Panel Lights, Engine Warning Lights/
Buzzers and Anti-lock Brake System (ABS) Warning Light ---------------------------
11
6. Air Brake System --------------------------------------------------------------------------------
14
7. Hydraulic Brakes---------------------------------------------------------------------------------
20
8. Windshield Wipers and Washers ------------------------------------------------------------
33
9. Heaters, Defrosters, Auxiliary Dash or Header Fan(s) ---------------------------------
34
10.
Dome and Step Well Lights -------------------------------------------------------------------
37
11.
Service Door --------------------------------------------------------------------------------------
38
12.
Horns -----------------------------------------------------------------------------------------------
40
13.
Mirror Adjustment and Condition----------------------------------------------------------- --
41
14.
Driver’s Seat and Seat Belt------------------------------------------------------------- -------
44
15.
Passenger Seats --------------------------------------------------------------------------------
45
16.
Emergency Doors, Windows, Hatches and Passenger Check System ------------
50
17.
Windshield, Side and Rear Windows -------------------------------------------------------
53
18.
Wheelchair Lift, Door and Securement System ------------------------------------------
56
19.
Two-Way Radio Operation --------------------------------------------------------------------
59
20.
Interior Wiring, Cab Hoses and Fire Wall Seals------------------------------------------
60
21.
General Condition of Bus Interior ------------------------------------------------------------
61
vi
B. OUTSIDE BUS
1. Headlights, Turn Signals, Hazard, Brake, Tail, Backup Lights, Backup Alarm
and Park Lights ----------------------------------------------------------------------------------
67
2. Clearance, Side Marker, Identification (ID) Lights, Reflectors and Strobe Light--
73
3. Pupil Warning Lights----------------------------------------------------------------------------
75
4. Stop Arm(s) and Student Crossing Arm----------------------------------------------------
77
5. General Condition of Bus Exterior -----------------------------------------------------------
79
C. ENGINE COMPARTMENT
1. Steering --------------------------------------------------------------------------------------------
85
2. Batteries -------------------------------------------------------------------------------------------
94
3. Fluid Levels and Condition --------------------------------------------------------------------
98
4. Belts and All Hoses -----------------------------------------------------------------------------
102
5. Accessory Mounting and Condition ---------------------------------------------------------
105
6. Wiring-----------------------------------------------------------------------------------------------
107
7. Fuel System and Lines -------------------------------------------------------------------------
108
8. Radiator--------------------------------------------------------------------------------------------
109
D. UNDERNEATH BUS
1. Front Suspension--------------------------------------------------------------------------------
111
2. Front Brakes --------------------------------------------------------------------------------------
118
3. Engine Mounts, Transmission Mounts and Starter Mounting -------------------------
128
4. Transmission -------------------------------------------------------------------------------------
129
5. Fluid Leaks----------------------------------------------------------------------------------------
131
6. Fuel and Diesel Exhaust Fluid (DEF) Tank------------------------------------------------
133
7. Brake Equipment --------------------------------------------------------------------------------
135
8. Driveline -------------------------------------------------------------------------------------------
137
9. Rear Suspension --------------------------------------------------------------------------------
140
10.
Rear Brakes --------------------------------------------------------------------------------------
145
11.
Body Securement and Structure -------------------------------------------------------------
154
12.
Exhaust System----------------------------------------------------------------------------------
156
13.
Wheels and Tires --------------------------------------------------------------------------------
158
E. LUBRICATION and MAINTENANCE (Optional)-------------------------------------------------
163
vii
F. ROAD TEST
1.
Brake Performance -----------------------------------------------------------------------------
165
2.
Engine, Transmission and Driveline --------------------------------------------------------
167
3.
Steering and Handling--------------------------------------------------------------------------
168
Chart and Figure Contents --------------------------------------------------------------------------------
171
Statutory Requirement for Safe Transportation of Students --------------------------------------
172
State Board of Education Rule on School District Responsibilities for the Safe
Transportation of Students------------------------------------------------------------------------------ ---
172
Florida School Bus Safety Inspection Form ----------------------------------------------------------
173
Florida School Bus Safety Inspection Form, example ----------------------------------------------
175
Repair Order --------------------------------------------------------------------------------------------------
177
Repair Order, example ------------------------------------------------------------------------------------
178
School Bus Safety Inspection Certification Program ------------------------------------------------
179
School Bus Safety Inspection Recertification Program ---------------------------------------------
183
District Online Test Administrator Guidelines and Requirements---------------------------------
185
District Online Test Administrator Application---------------------------------------------------------
186
State of Florida, School Bus Safety Inspector Application-------------------------------------------
187
2017 Table of Changes --------------------------------------------------------------------------------------
189
viii
A.
INSIDE BUS
1. Emergency Equipment
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Fire Extinguisher
Check for the presence of a fire extinguisher
and for the following:
No fire extinguisher is on bus.
1) Pressure: Check gauge.
Pressure is above or below the green zone.
2) Tag (Inspection Date): Check for the
presence of inspection sticker or tag
and inspection date.
Inspection sticker or tag will expire before next
scheduled inspection.
Tag or sticker is missing or does not verify
inspection was performed within the previous
twelve months. Exception: Buses less than
one year old with original fire extinguisher
do not need a tag or sticker.
3) Mounting: Check for accessibility and
secure mounting.
Bracket mount is loose.
Fire extinguisher is not accessible to driver,
not mounted securely or mounted in a
lockable compartment not equipped with an
operational ignition-warning buzzer or
interlock.
4) Rating: Check for proper Underwriters
Laboratory (UL) rating.
Rating is less than 2A-10BC.
(Continued on Next Page)
1
A.
INSIDE BUS
1. Emergency Equipment
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
5) Nozzle/hose: Check for loose or
damaged parts.
Hose or nozzle is loose, missing or there is
excessive damage to any part of the
extinguisher.
6) Safety Pin: Check for presence of
safety pin and breakable, nonreusable tamper seal.
Safety pin is missing and/or tamper seal is
broken.
Tamper seal cannot be broken or seal is
reusable (can be opened and resealed
without destroying the seal).
b. First Aid Kit
1) Kit box and condition: Buses built
since 1985 require a moisture and
dust-proof kit box with a clear lid.
Check for the presence of a
breakable, non-reusable tamper seal
for buses built since September 1995.
2) Mounting: Check accessibility and
mounting of kit. Kit should be mounted
in the driver’s area in such a manner
that it can be easily detached and
made portable.
Kit is not present; kit box is not moisture- proof
and dust-proof, will not stay latched, cannot
be opened or is not equipped with a clear lid.
Tamper seal is broken, missing or reusable
(can be opened and resealed without
destroying the seal).
NOTE: Must check kit contents if seal is
broken or missing (also see the NOTE on
page 3).
(Continued on Page 4)
2
Tamper seal cannot be broken.
Kit is not secured, not mounted in the driver's
compartment, not easily detached or mounted
in a lockable compartment not equipped with
an operational ignition-warning buzzer or
interlock.
CHART 1a: BODY FLUID CLEANUP KIT
CHART 1: FIRST AID KITS
BUSES MANUFACTURED FROM 1985 TO PRESENT
DESCRIPTION
QUANTITY
DESCRIPTION
1” bandage compress (e.g., Band-Aid)
40” triangular bandage with two safety pins
2 pkgs.
1 pkg.
6 pkgs.
of 2 each
1 pkg.
1 roll
2 pkgs.
An Environmental Protection Agency
(EPA)-registered germicide (tuberculocidal)
disinfectant
A fully disposable wiping cloth
A water-resistant spatula
Step-by-step directions
Odor-counteracting absorbent material
Latex gloves
Towelettes
A discard bag (non-labeled paper bag with
plastic liner and twist tie). This bag shall be
approximately 4” x 6” x 14” and be of a nonsafety color (i.e., not red, orange or yellow).
4” X 4” sterile gauze pads
2” rolled curlex bandages 6 yards in length
1” roll adhesive tape 2-1/2 yards in length
Eye dressing packet
QUANTITY
1
1
1
1
1
2 pairs
1 pkg.
1
Note: In addition to scheduled inspections, all first aid and body
fluid cleanup kits should be opened and inspected annually to
check the condition and presence of contents according to A 1.
b. & c.
3
A.
INSIDE BUS
1. Emergency Equipment
Inspection Procedures:
3) Contents: Check that all contents are
intact, have not deteriorated and are
sterile. (For contents list, see chart 1,
page 3)
Repair (or note) if:
Bandages are missing or incomplete.
c. Body Fluid Cleanup Kit
Out-of-Service if:
Contents are incomplete (except Bandages),
improper type or not usable due to
contamination, age or deterioration.
Kit is not present or not sealed, or box will not
stay latched or cannot be opened.
1) Kit box and condition: Buses
manufactured since 1992 require a
sealed kit.
Check for the presence of a breakable, Tamper seal is broken, missing or reusable
non-reusable tamper seal for all buses (can be opened and resealed without
manufactured since September 1995. destroying the seal).
2) Mounting: Check accessibility and
mounting of kit. Kit should be mounted
in the driver’s area in such a manner
that it can be easily detached and
made portable.
Tamper seal cannot be broken.
Kit is not secured, not mounted in the driver's
compartment, not easily detached without the
use of tools, or mounted in a lockable
compartment that is not equipped with an
operational
ignition-warning
buzzer
or
interlock.
3) Contents: Check that all contents are
intact, have not deteriorated and are
sealed. (For contents list, see chart 1a,
page 3.)
Contents are incomplete or not usable due to
age and deterioration.
Note: Must check kit contents if seal is
broken or missing (also see the note on
page 3).
(Continued on Next Page)
4
A.
INSIDE BUS
1. Emergency Equipment
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Reflectors
1) Check for proper quantity, type and
condition of emergency roadside
reflectors.
Not equipped with three self-standing, 17-inch
triangular reflectors or any of the reflectors, or
box is unusable due to age, damage or
deterioration.
2) Check accessibility, mounting and
condition of box. Must be securely
mounted in driver’s area.
Storage box is broken, will not remain latched,
is not easily accessible, is not securely
mounted forward of the passenger
compartment, or mounted in a lockable
compartment, or is not equipped with an
operational ignition warning buzzer or interlock.
3) Check for the presence of a breakable,
non-reusable tamper seal for buses
manufactured since September 1995.
Tamper seal is broken, missing or reusable
(can be opened and resealed without
destroying the seal).
5
Tamper seal cannot be broken.
A.
INSIDE BUS
2. Registration and Insurance Card
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Registration
Check for
certificate.
a
valid
Florida
registration
Registration certificate is expired, missing or
illegible.
b. Insurance Card
Check for a valid insurance card.
Insurance card is invalid, missing or illegible.
6
A. INSIDE BUS
3. Shifter, Noise Abatement Switch and
Neutral Safety Switch
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Shifter - Automatic Transmission
1) Check that shifter operates easily.
Transmission does not shift easily into all gear
ranges.
Shifter will not select all gear ranges.
2) Check that correct transmission gear
range is indicated.
Indicator is slightly misaligned, but correctly
indicates the gear range selected.
Indicator indicates the wrong gear range
selected.
3) Check that shifter has a functional
detent mechanism and handle (ball,
knob or “T” type).
Shifter handle is loose.
Detent or handle is nonfunctional or missing.
b. Shifter - With Shifter Park Brake Option
(if equipped). Same as above plus:
Rear spring brake does not apply when shifter
is in the “P” (park) position.
1) Check that parking brake applies
when shifter is placed in “P” (park)
position.
Rear spring brake applies automatically in any
gear range except the “P” (park) position.
(Continued on Next Page)
7
A. INSIDE BUS
3. Shifter, Noise Abatement Switch and
Neutral Safety Switch
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Switch is not clearly labeled or not of an
alternate color.
Switch/System does not work or does not
deactivate required items such as AM/FM
radio and CD player, heaters, defrosters, fans
and air conditioners.
c. Noise Abatement Switch (Required on
buses manufactured since 2002)
Inspect for proper operation. Switch must
deactivate all non-safety-essential noisemaking equipment.
Switch/System deactivates safety-essential
items such as windshield wipers and lighting
systems.
d. Neutral Safety Switch
Check to determine that automatic
transmission bus has a functional neutral
safety switch that will allow the starter to
operate only in park or neutral.
The starter will engage when automatic
transmission is in any gear other than park or
neutral.
8
A.
INSIDE BUS
4. Engine Controls
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Key/Ignition Switch
1) Check that ignition switch operates
with a key only.
Key sticks in the switch, switch can be
operated without a key or bus is equipped with
a push button or non-OEM starting device.
2) Must be mounted securely in the
Original Equipment Manufacturer
(OEM) location.
Switch is loose or not mounted in the OEM
location.
3) Must freely select all positions; i.e.,
start, run, off and accessory position.
Switch does not function properly in start, run,
off or accessory position; is intermittent in any
position; or sticks in or between any positions.
(Continued on Next Page)
9
A.
INSIDE BUS
4. Engine Controls
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Pedal cover worn but not causing a slippery
pedal condition.
Pedal cover is worn badly or missing. Pedal
assembly is modified or not mounted securely
in the OEM location.
b. Accelerator
1) Check condition of pedal assembly,
mounting and securement.
2) Inspect pedal assembly, wiring,
connectors and linkage for condition
and loose or missing hardware.
Mechanical linkage type must have
dual (two) return springs.
Pedal assembly is not operating properly;
wiring is loose, damaged or improperly
routed; hardware is loose or missing; or
mechanical type linkage is loose, damaged or
not equipped with dual return springs.
3) Check for smooth operation of pedal
assembly and linkage in the
accelerating and coast position.
Accelerator control and/or linkage sticks or
does not operate freely.
10
A. INSIDE BUS
5. Gauges, Indicators, Dash and Switch
Panel Lights, Engine Warning
Lights/Buzzers and ABS Warning Light
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
1) Speedometer and odometer
Odometer is unreadable, does not work or is
not working properly.
Speedometer is unreadable, damaged, does
not function or is confirmed to be inaccurate.
2) Engine oil pressure, temperature and
transmission temperature
Oil pressure or temperature
inaccurate or difficult to read.
Oil pressure or engine and transmission
temperature gauge is unreadable, damaged
or does not function.
3) Fuel
Fuel gauge is inaccurate or difficult to read.
Fuel gauge is unreadable, damaged or does
not function.
4) Voltmeter or ammeter
Voltmeter or ammeter is inaccurate, damaged
or difficult to read.
Voltmeter or ammeter does not work or does
not indicate that alternator is charging. Refer
to C-5, f. on page 106.
a. Gauges
From the driver’s position, check the visibility,
OEM
location,
readability,
operation,
accuracy and condition of the following
gauges:
11
gauge
is
A. INSIDE BUS
5. Gauges, Indicators, Dash and Switch
Panel Lights, Engine Warning
Lights/Buzzers and ABS Warning Light
Inspection Procedures:
Repair (or note) if:
5) Air pressure or vacuum.
6) Diesel exhaust fluid (DEF) level
gauge.
Out-of-Service if:
Air pressure or vacuum gauge(s) are
inaccurate, unreadable or not working. Air
pressure gauge must read within plus or
minus seven pounds per square inch (psi)
(single gauge) at 100 psi.
DEF gauge is inaccurate, damaged or difficult
to read.
DEF gauge does not work or is not present.
Any illuminated indicator, dash item or switch
does not light except for items listed to the
right in the “Out-of-Service” column.
Any one of the following fails to illuminate:
b. Indicators, Dash Lights and Switch
Panel Lighting
Check operation of indicators, dash lights and
switch panel lighting.
Dimmer control (if equipped) does not
function properly.
1) Air or vacuum gauge or associated
low warning lights
2) High beam headlight indicator
3) Left/right turn signal and
four-way hazard dash indicators
4) Speedometer
5) Shift Indicator
All dash or control panel lights are inoperative.
12
A. INSIDE BUS
5. Gauges, Indicators, Dash and Switch
Panel Lights, Engine Warning
Lights/Buzzers and ABS Warning Light
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Engine/Transmission Warning Lights
and Buzzer
Check for presence and operation of the
following warning lights and audible alarms:
1) High coolant temperature dash
warning light and alarm on diesel
buses
High coolant temperature dash warning light
and/or alarm is inoperative.
2) High transmission temperature dash
warning light and alarm
Transmission high temperature light and/or
alarm is inoperative.
3) Low oil pressure, dash warning light
and alarm on diesel buses
Low oil pressure, dash warning light and/or
alarm is inoperative.
d. ABS Warning Light
Any of the above lights are on, indicating a
critical mechanical condition.
Check condition of ABS warning lamp and
system (if equipped). Refer to applicable
vehicle technical publication for test
procedures and diagnostic information.
Lamp fails to turn on during initial startup
sequence.
Lamp fails to turn off.
System fails to operate per manufacturer's
specifications.
13
A.
INSIDE BUS
6. Air Brake System
Note: Chock bus wheels when inspection procedures require the service, parking and/or emergency brakes to be in the released
position.
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Gauge(s)
Check for presence of two air pressure
gauges or a single gauge with dual needles.
One gauge or needle should indicate air
pressure available to the front air brake
system, and the other should indicate air
pressure available to the rear air brake
system. Both gauges must be accurate to
within plus or minus seven psi.
Any gauge is missing or unreadable. Gauge
is not accurate to within plus or minus 7
percent. Any gauge is not in OEM location.
More than 15-psi difference in dual air brake
system (dual gauges) with system built up to
full pressure (100-125 psi).
b. Buildup
Drain air reservoir thoroughly before making
this check. Check the time required for air
pressure to build up from 85 to 100 psi with
engine at approximately 1,200 RPM.
Air pressure buildup time from 85 to 100 psi at
fast idle is greater than 40 seconds.
Note:
If air brake gauge(s) failed
inspection step a. of this section, make
necessary repairs prior to performing the
test in step b.
(Continued on Next Page)
14
A.
INSIDE BUS
6. Air Brake System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Governor
Check air brake system governor operation. Cut-out pressure is below 120 psi (for buses Cut-out pressure is too low (below 100 psi) or
While building up system air pressure, note equipped with air dryer).
too high (above 130 psi).
pressure at which governor cuts out
(compressor quits compressing). With engine
Difference between governor cut-out and cutstill running, pump brakes to lower air pressure
in pressure exceeds 30 psi.
until compressor cuts in (starts compressing
again). Note pressure.
Note: If gauge(s) failed previous check for
accuracy, do not perform this check until
gauge(s) are repaired.
d. Park/Emergency Brake
Check condition, mounting and location of Valve labeling is missing or unreadable.
park/emergency brake valve, proper release
and application of park/emergency brake and
interlock(s) operation (if equipped).
Valve not mounted securely in original
position; knob is missing, broken or cracked;
park/emergency brake does not release
and/or apply properly; or interlock(s) (if
equipped) do not function properly.
With parking/emergency brake applied and NOTE: If a bus is equipped with a rear Vehicle moves forward upon applying engine
service brake released, apply engine torque diesel engine and an Allison World torque with park/emergency brake applied and
by placing transmission selector in “Drive” (D) transmission, perform this test at 900 RPM. service brake released.
and briefly accelerate the engine to
approximately 1,200 revolutions per minute
(RPM); vehicle should not move forward.
(Continued on Next Page)
15
A.
INSIDE BUS
6. Air Brake System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
e. Adjustment
Drain water from air reservoir(s). With engine
off,
wheels
chocked,
service
and
park/emergency brakes released and system
air pressure at 100 psi or above:
System pressure drop upon service brake
application is greater than 15 psi.
Note: If pressure drop exceeds 15 psi,
mark item A. 6. "Out-of-Service" and follow
the inspection procedures in sections D. 2.,
"Front Brake," pages 118 through 127, and
D. 10, "Rear Brake," pages 145 through
153, in this manual.
1) Note air pressure.
2) Apply service brakes
release immediately.
firmly
and
2) Note air pressure drop resulting from
brake application.
Note: If gauge(s) failed previous check for
accuracy, do not perform this check until
after repairs.
Note: Pressure drop exceeding 15 psi
indicates brakes may be out of adjustment,
foundation brake hardware may be worn
out or damaged, and/or there is excessive
water in the air reservoir(s).
Note: Do NOT manually adjust automatic Note: Adjust Manual Slack Adjuster (MSA)slack adjuster (ASA) type brakes during equipped brakes at every required
inspections. See sections D. 2. "Front inspection.
Brake," pages 118 through 127, and D. 10.
"Rear Brake," pages 145 through 153, for
additional information.
16
A.
INSIDE BUS
6. Air Brake System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
f. Air Leaks
1) Build up air system to at least 100 psi.
2) Shut off engine, chock wheels and
release the parking brake.
3) With service and parking brakes in Pressure drops less than two psi per minute.
released position, check for air
pressure drop for one minute. Note
pressure drop, if any.
Pressure drops two or more psi per minute.
4) Firmly apply and hold service brake. Pressure drops less than three psi per minute. Pressure drops three or more psi per minute.
Check for air pressure drop for one
minute. Note pressure drop, if any.
5) During both checks, listen for any
audible air leaks.
There is any audible air leak in the air brake
system.
Note: If gauge(s) failed previous check for
accuracy, do not perform this test until
gauge(s) are repaired.
(Continued on Next Page)
17
A.
INSIDE BUS
6. Air Brake System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
g. Low Air Warning
Check operation of low-air warning buzzer and
light by building air pressure to 100-125 psi.
Shut down engine and perform the following
procedure:
Light or buzzer is inoperative.
1) Turn ignition to the on position and
pump brake pedal to drop air pressure.
The low-air warning buzzer and light
must not activate above 70 psi and
must activate by 50 psi.
While dropping the air pressure, light and/or
buzzer activates above 70 psi or fails to
activate by 50 psi.
2) Start engine and build up air pressure.
The low-air warning buzzer and light
must deactivate by 70 psi.
While building pressure, light and/or buzzer
continues to activate above 70 psi.
Note: If gauge(s) failed previous check for
accuracy, do not perform this check until
gauge(s) are repaired.
(Continued on Next Page)
18
A.
INSIDE BUS
6. Air Brake System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
h. Park/Emergency Brake Valve Pop-Out
Check
for
emergency
activation
of
park/emergency brake valve by dropping air
pressure (starting with at least 60 psi in air
system) and noting pressure at which valve
“pops out.”
i.
While
dropping
air
pressure,
valve
automatically “pops out” above 50 psi or fails
to “pop out” between 50 and 15 psi.
Service Brake Pedal
Check service brake pedal assembly for Rubber cover pad is worn, but not causing a Rubber cover pad is missing or badly worn.
adjustment, mounting, condition, operation slippery pedal condition.
and rubber cover pad. Check for presence of
Any part of pedal and assembly is damaged,
prohibited modifications and/or extender
loose, missing or modified.
block.
Pedal has any type of extender block.
19
A.
INSIDE BUS
7. Hydraulic Brakes
Note: Several inspection procedures outlined in this manual require the service, parking and/or emergency brakes in the released
position. When performing these checks, bus wheels must be chocked to prevent the bus from moving.
Inspection Procedures:
Note:
Repair (or note) if:
Out-of-Service if:
If bus is not equipped with
hydraulic brakes, proceed to page
33.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Since there are four distinct types of hydraulic brake systems in use on Florida school buses, this manual will cover each system individually. It
is imperative that you know the type of system you will be inspecting to ensure that the proper inspection procedure is used.
The four types of systems are:
a. Standard Vacuum Assisted Hydraulic Brakes. (See page 21)
b. Hydraulic Power Assisted Hydraulic Brake with Accumulator Backup. (See page 24)
c. Hydraulic Power Assisted Hydraulic Brakes with Electric Pump Backup and Driveshaft Parking Brake Systems. (See page 27)
d. Hydraulic Power Assisted Hydraulic Brakes with Spring Set (hydraulically released) Parking Brakes (Ford Maxi-brake(s)). (See page 29)
(Continued on Next Page)
20
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Standard Vacuum Assisted Hydraulic
Brakes. Inspect for:
1) Any visible seepage or leaks in the NOTE: See page 131 for definitions of fluid Any seepage or leaks are found.
“leaks” and “seepage.”
hydraulic brake system.
2) a) Brake pedal reserve (distance from
floor) upon firm brake application
(engine running).
Brake pedal (reserve) is less than one inch
from floor.
b) Brake pedal fade (pedal falls to
floor when held down with engine
running and with engine off)
indicating brake system leak.
Any brake pedal fade is felt.
3) a) Vacuum gauge operation (if
equipped) and low vacuum
indicator light and buzzer (if
equipped) with full vacuum below
eight inches of mercury (hg).
Vacuum gauge (if equipped) is inoperative,
inaccurate or not clearly visible.
Low vacuum indicator light and buzzer do not
come on below eight inches of mercury (hg).
(Continued on Next Page)
21
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b) Brake warning light illumination
with ignition key in start position.
Check to ensure brake failure
warning light is not on during
normal operation (with and without
brakes applied).
Brake failure warning light does not activate
when key is moved to the start position.
c) Vacuum drop while engine is off
and brakes are not applied.
Vacuum reserve drops while engine is off.
Brake failure warning light comes on (or stays
on) during normal operation (with or without
brakes applied).
4) Vacuum Assist Booster Operation
Vacuum assist system malfunctions (pedal
does not fall away slightly when engine is
started.)
With engine off, apply brakes several
times to exhaust vacuum. Depress and
hold the brake pedal down while
starting the engine. Pedal should fall
away slightly, indicating increased
pressure being applied by the assist
unit.
Vacuum reserve is insufficient to allow at least
one brake application.
5) Sufficient reserve in the vacuum
system to allow at least one powerassisted brake application. Check this
by turning the engine off and applying
the brakes.
(Continued on Next Page)
22
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
6) All brake hardware components inside
bus for secure mounting, routing and
condition, including:
Out-of-Service if:
Brake pedal assembly, push rod and clevis or
emergency brake control assembly is
insecurely mounted; poorly routed; has loose,
missing or worn hardware; or is damaged.
a) Brake pedal assembly and rubber Rubber cover is worn, but not causing a Rubber cover pad is missing or badly worn.
cover (if originally equipped).
slippery pedal condition.
Any part of pedal and assembly is damaged,
loose, missing or modified.
Pedal has any type of extender block.
b) Emergency brake control
assembly.
Emergency brake control is hard to operate or
does not latch and release properly.
7) Parking Brake Operation
With parking brake applied and service
brake released, apply engine torque by
placing transmission selector in “D”
and briefly accelerate the engine to
approximately 1,200 RPM. Vehicle
should not move forward.
Vehicle moves forward upon applying engine
torque with park brake applied and service
brake released.
23
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b. Hydraulic Power Assisted Hydraulic
Brakes with Accumulator Backup.
Inspect for:
1) Visible seepage or leaks in the
brake or hydraulic assist systems.
Note: See page 131 for definitions of fluid Any brake or hydraulic assist fluid is seeping
“leaks” and “seepage.”
or leaking.
2) a) Brake pedal reserve (distance from
floor) upon one firm brake
application
(engine
off,
accumulator depleted).
Brake pedal does not have at least a one and
a half inch of reserve distance from floor.
b) Brake pedal fade (test for at least
one and a half minutes with the
engine off). Firmly apply brake
pedal and hold.
Pedal falls to floor (fades) when held down
(engine off), indicating a brake system leak.
3) Brake warning light illumination with
ignition key in start position. Check to
ensure brake failure warning light is not
on during normal operation (with and
without brakes applied).
Brake failure warning light does not activate
when key is turned to the start position or stays
on during normal operation.
(Continued on Next Page)
24
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
4) Power assist check:
a) With engine off, apply the foot
brake several times, and then hold
the brake pedal down.
b) Start the engine.
c) The pedal should fall away, then
push back, against your foot.
Power assist unit is malfunctioning (pedal
does not fall away or push back).
d) Listen for engine drive belt squeal.
Engine drive belt is squealing.
e) Release brake pedal.
f) Turn engine off.
g) Depress brake pedal. Accumulator
should hold enough pressure to
allow
two
assisted
brake
applications.
Accumulator will not hold enough pressure for
two brake applications.
5) All brake hardware components inside
bus for secure mounting, routing and
condition, including:
Brake pedal assembly, push rod, clevis or
emergency brake control assembly is
insecurely mounted; poorly routed; has loose,
missing or worn hardware; or is damaged.
(Continued on Next Page)
25
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a) Brake pedal assembly and rubber Rubber cover pad is worn, but not causing a Rubber cover pad is missing or badly worn.
cover pad (if originally equipped).
slippery pedal condition.
Any part of pedal and assembly is damaged,
loose, missing or modified.
Pedal has any type of extender block.
b) Emergency brake control
assembly.
Emergency brake control is hard to operate or
does not latch and release properly.
6) Parking Brake Operation
With parking brake applied and service
brake released, apply engine torque by
placing transmission selector in “D”
and briefly accelerate the engine to
approximately 1,200 RPM. Vehicle
should not move forward.
Vehicle moves forward upon applying engine
torque with park brake applied and service
brake released.
(Continued on Next Page)
26
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Hydraulic Power Assisted Hydraulic
Brakes with electric pump backup and
driveshaft parking brake system.
Inspect for:
1) Visible seepage or leaks in the brake
or hydraulic assist system.
NOTE: See page 131 for definitions of fluid Any brake or hydraulic assist fluid is seeping
“leaks” and “seepage.”
or leaking.
2) Brake warning and backup systems
using
the
appropriate
chassis
manufacturer’s procedure in chart 2,
page 31.
The brake system does not pass all tests in
chart 2, page 31.
3) a) Brake pedal distance from floor
(reserve) upon one firm brake
application with engine off and
hydraulic boost depleted.
Brake pedal reserve is less than one inch from
floor.
b) Brake pedal fade (continues to fall
to floor after initial firm application)
with engine off.
Any brake pedal fade is felt.
6) All brake hardware components inside
bus for secure mounting, routing and
condition, including:
(Continued on Next Page)
27
Brake pedal assembly, push rod, clevis or
emergency brake control assembly is
insecurely mounted; poorly routed; has loose,
missing or worn hardware; or is damaged.
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a) Brake pedal assembly and rubber Rubber cover pad is worn, but not causing a Rubber cover pad is missing or badly worn.
cover pad (if originally equipped).
slippery pedal condition.
Any part of pedal and assembly is damaged,
loose, missing or modified.
Pedal has any type of extender block.
b) Emergency
assembly.
brake
control
Emergency brake control is hard to operate or
does not latch and release properly.
With parking brake applied and service
brake released, apply engine torque by
placing transmission selector in “D”
and briefly accelerate the engine to
approximately 1,200 RPM. Vehicle
should not move forward.
Vehicle moves forward upon applying engine
torque with park brake applied and service
brake released.
5) Parking Brake Operation
(Continued on Next Page)
28
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Hydraulic Power Assisted Hydraulic
Brakes with Spring Set (hydraulically
released) Parking Brakes (Ford Maxi
brake). Inspect for:
1) Visible seepage or leaks in the brake
or power assist system.
NOTE: See page 131 for definitions of fluid Any brake or hydraulic assist fluid is seeping
“leaks” and “seepage.”
or leaking.
2) Brake warning and backup system
using chart 3, page 32.
The brake systems do not pass all tests in
chart 3, page 32.
3) Brake pedal travel: Push brake pedal
down as far as possible.
Brake pedal travels more than halfway down.
4) Brake pedal fade (pedal falls away to
floor when held down with engine
running and with engine off, indicating
brake system leaks).
Any brake pedal fade is felt.
5) Parking Brake Operation
a) With engine running, release the
parking brake.
b) Check to be sure brakes are
released (bus will move).
c) Turn engine off.
(Continued on Next Page)
29
A.
INSIDE BUS
7. Hydraulic Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d) System must maintain pressure
(keep parking brake released) for
at least five minutes.
Parking brake system will not hold pressure
(i.e., release brakes) for at least five minutes.
e) With parking brake applied and
service brake released, apply
engine
torque
by
placing
transmission selector in “D” and
briefly accelerate the engine to
approximately 1,200 RPM. Vehicle
should not move forward.
Vehicle moves forward upon applying engine
torque with park brake applied and service
brake released.
6) Check all brake hardware and
components inside the bus for secure
mounting, routing and condition,
including:
Brake pedal assembly, push rod, clevis or
emergency brake control assembly is
insecurely mounted; poorly routed; has loose,
missing or worn hardware; or is damaged.
a) Brake pedal assembly and rubber Rubber cover pad is worn but not causing a Rubber cover pad is missing or badly worn.
cover pad (if originally equipped).
slippery pedal condition.
Any part of pedal and assembly is damaged,
loose, missing or modified.
Pedal has any type of extender block.
b) Emergency brake control
assembly
Emergency brake control is hard to operate or
does not latch and release properly.
30
CHART 2
WARNING LIGHTS/BUZZER
Normal Operation
Indicator
MODE
Brake Failure Warning System Checks
INTERNATIONAL/NAVISTAR
Brake
Lamp
Brake
Electric
Motor
Lamp
Buzzer
Off
Off
Off
Off
On
On
On
On
On
Off
Off
Off
FORD
1a. Engine Off/Ignition Off/no
brake applied
1b. Engine Off/Ignition Off/brake
applied
2. Engine Off/Ignition On or start
with or without brake applied
3. Engine On, with or without
brake applied
CONDITION
NORMAL OPERATION
PARK BRAKE LIGHT
Key switch in start position with
park brake released - (bulb
Light on
check).
Key switch on with park brake
Light on
applied.
BRAKE PRESSURE LIGHT
Key switch off.
Light off. Electric hydraulic pump
operates when service brakes
are applied.
Key switch in on position.
Light on and electric hydraulic
Engine not running (pump and pump
operation
(some
bulb check).
vehicles). See Navistar manual.
Light on and electric hydraulic
pump operates when service
brakes are applied.
Key switch in on position and
engine operating with service
Light off
brakes applied.
Key switch in start position.
Light on momentarily and
electric
hydraulic
pump
operates.
Key switch in on position and
engine operating with service
brakes applied.
Light off
Normal Operation
MODE
GMC
1. Engine off/ignition off
A. No brake applied
B. Brake applied
2. Engine off/ignition on,
with or without brake
applied (bulb check).
3. Engine off/ignition on,
start with or without brake
applied.
4. Engine on, with or without
brake applied.
Brake
Warning
Light
Brake Electric
Hydraulic
Boost
Warning Light
Tone
Alarm
Off
On
Off
Off
Off
Off
On
On
On
On
Off
On
Off
Off
Off
31
CHART 3
FORD HYDRAULIC, MAXI BRAKE SYSTEM
NORMAL BRAKE SYSTEM CONDITIONS
CONTROLS
ENGINE
OFF
ON
START
OFF
ON
X
X
X
RELEASED
APPLIED
X
X
FULLY
PARTIALLY
FULLY
X
or
X
X
X
or
X
X
X
or
X
X
X
X
X
X
or
X
X
X
X
or
X
X
X
X
or
X
X
X
X
or
X
X
X
X
or
X
*ELECTRIC PUMP
LIGHT
BUZZER
PARKING BRAKE
LIGHT
OFF ON OFF ON OFF ON OFF ON
X
X
LIGHT
OFF or ON
PARTIALLY
X
SERVICE
BRAKE
PARKING BRAKE
SERVICE
BRAKE
IGNITION
OFF ON
RESULTS
X
X
X
X
X
X
X
X
X
X
OFF
X
X
X
X
X
ON
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
* Whenever the ignition switch is in the start position, the Hydro-Max electric pump will cycle momentarily.
** Parking brake buzzer will sound momentarily during application of the parking brake in cold ambient conditions.
32
X
**BUZZER
X
X
X
A.
INSIDE BUS
8. Windshield Wipers and Washers
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Operation
Inspect both wipers for:
1) Swept area field of
effectiveness of wiping.
view
and
2) Proper operation on high and low
speeds, intermittent function (if
equipped) condition, and mounting of
switches and knobs.
Either wiper does not operate on low speed or Any wiper does not operate properly at high
intermittent function (if equipped) does not speed and switches or knobs are missing or
work properly or wiper goes past perimeter of loose.
glass.
3) Condition and mounting of wiper
motors and linkage.
Either wiper motor or linkage is visibly
damaged, loose or excessively worn.
4) Proper washer operation.
Washer is slightly misadjusted.
b. Park
Inspect for parked position of wipers when
turned off (electric) or when manually parked
(air).
Electric wipers do not automatically return to
parked position out of the driver’s line of sight
when turned off, or air wipers cannot be
manually parked out of the driver’s line of
sight.
c. Blades
Inspect blades for condition, mounting and Poor cleaning of windshield.
tension.
33
Either
blade
is
missing,
damaged,
deteriorated, loose, does not hold proper
tension against windshield or does not
effectively clear driver’s field of vision.
A. INSIDE BUS
9. Heaters, Defrosters, Auxiliary Dash or
Header Fan(s)
Inspection Procedures:
a. Heaters
Inspect heater system for
operation and condition.
Repair (or note) if:
Out-of-Service if:
NOTE: See page 131 for definitions of fluid
“leaks” and “seepage.”
performance, Coolant control valve is hard to operate.
System is not producing heat.
Any blower does not work on all speeds, is
noisy or vibrates, or switches are loose or Any blower is extremely noisy, indicating
improperly labeled.
imminent failure or system wiring and
connections are loose, damaged or chafed,
creating an electrical short or high resistance.
Heater hoses are cracked, swollen or badly
chafed, or there is any coolant leakage inside
the bus.
Hose and/or component shielding is missing
or
does
not
completely
cover
hoses/components in a manner that protects
passengers from contact with hot surfaces and
prevents spraying of coolant in the event of a
hose/component failure.
(Continued on Next Page)
34
Any portion of heating system within
passenger area creates sharp edges,
projections or other hazards to passengers.
A. INSIDE BUS
9. Heaters, Defrosters, Auxiliary Dash or
Header Fan(s)
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b. Defrosters
Inspect defroster system for performance, Any blower does not work on low speed, is Any blower is extremely noisy, indicating
operation and condition.
noisy or vibrates, or switches are loose or imminent failure or system wiring and
improperly labeled.
connections are loose, damaged or chafed,
creating an electrical short or high resistance.
Airflow is not present at all defroster outlets, or
system does not produce adequate heat.
Any defroster blower does not work on high
speed.
Any ductwork or diffusers are loose or Any ductwork or diffusers are damaged,
damaged, but can still effectively route airflow. rendering them ineffective.
Fresh air control (if equipped) does not
function.
(Continued on Next Page)
35
Any portion of defroster system within
passenger area creates sharp edges,
projections or other hazards to passengers.
A. INSIDE BUS
9. Heaters, Defrosters, Auxiliary Dash or
Header Fan(s)
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Auxiliary Dash Fan
Inspect fan for performance, operation and Fan does not work on low speed, is noisy or Fan is extremely noisy, indicating imminent
condition.
vibrates, or switches are loose or improperly failure or wiring, and connections are loose,
labeled.
damaged or chafed, creating an electrical
short or high resistance.
Fan is not present, is loose, or it will not stay
adjusted.
Note: Dash fan may be squirrel cage type
and header-mounted on some buses.
Protective cage is missing, loose or damaged.
Fan does not operate.
36
A.
INSIDE BUS
10. Dome and Step Well Lights
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Dome and Step Well Lights
Check passenger and driver dome lights for Any lens is cracked or dirty.
Any lens is broken or missing, exposing light
condition and operation. A driver dome light
bulb or fixture.
has been required since September 1995.
Any single passenger dome light is not Two or more passenger dome lights are not
working.
working.
Dome light switch is loosely mounted.
Check step well lights for condition and Step well light is on when door is closed.
operation.
Lens is cracked or dirty.
37
Any driver’s compartment dome light is not
working.
Step well light does not activate when
clearance lights are on and the service door is
open.
A.
INSIDE BUS
11. Service Door
Inspection Procedures:
Repair (or note) if:
a. Operation
Out-of-Service if:
Air or manual door binds, or will not open a
minimum of 24 inches or is unsecure in the
closed position.
Check service door assembly for operation,
adjustment, condition, mounting and fit.
Manual door control requires more than 25
pounds of effort to open or close.
Manual door control will not lock open over
center, or closed latching mechanism is
inoperative.
Air door emergency release does not function
properly.
Air door opens or closes at an excessive rate
and force or too slowly.
Air door system leaks air.
Glass is broken, cracked or has been replaced
with material other than laminated or tempered
safety glass.
Door glass is fogged more than one inch in
from edges, or visibility through the glass is
poor.
(Continued on Next Page)
38
Door is equipped with a locking system that is
not OEM factory approved.
A.
INSIDE BUS
11. Service Door
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Door assembly is damaged, not securely
mounted or has excessively worn hinges, pins,
bearings/bushings or other components.
Door does not seal properly or seals are Door seals are not present.
damaged, ripped or deteriorated.
b. Overhead Pad
Check bus for a padded safety cushion directly Pad is loose or cover has minor damage or Pad is missing or cover has excessive
above the inside of the service door. Pad is wear.
damage or wear, exposing foam.
required to be a minimum of three inches wide.
39
A.
INSIDE BUS
12. Horns
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Horns
Check for operation of both horns while
rotating steering wheel left and right and check
for location and condition of horn switch.
Either horn is inoperative or both horns sound
the same note.
Horns are not audible at 500 feet.
Horn button is not mounted in OEM location.
Horn button sticks or horn button operates
intermittently, such as when steering wheel is
rotated.
40
A.
INSIDE BUS
13. Mirror Adjustment and Condition
Inspection Procedures:
a. Rear-View
Mirrors)
Mirror
System
Repair (or note) if:
Out-of-Service if:
(Traffic
Check exterior (flat and convex) rear-view Electrically controlled mirror (if applicable) is Any required rear-view mirror is not present.
mirrors for specifications, condition and not operating properly and can still be adjusted
adjustment.
manually.
Rear-view mirrors cannot be adjusted.
Any mirror is cracked, broken or has reflective
surface deterioration; view is diminished; or
any damage is visible.
Any mirror does
specifications.
not
meet
applicable
Any rear-view mirror is out of adjustment. (If in
doubt, consult with operations supervisors
and/or driver trainers).
(Continued on Next Page)
41
A.
INSIDE BUS
13. Mirror Adjustment and Condition
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b. Cross/Side-View Mirror System (Crosswalk Mirrors)
Check cross-walk/side-view mirrors
specifications, condition and adjustment.
for
Any required cross-walk/side-view mirror is
not present.
Any mirror is cracked, broken or has reflective
surface deterioration; view is diminished; or
any damage is visible.
Note: “No blind-spot” mirror system
(meeting new performance specifications),
has been a requirement since November
1990. (i.e., single cross-walk/side-view
mirror at each front corner).
Any mirror does
specifications.
(Continued on Next Page)
42
not
meet
applicable
Any cross-walk/side-view mirror is out of
adjustment, i.e., mirrors do not provide driver
with an indirect view of the area at ground level
from the front bumper forward, the entire width
of the bus and around the left and right front
corners so that the driver can see by direct
vision, and/or does not provide driver with
indirect vision of the area at ground level, to
include the tires and service entrance on all
types of buses so that view overlaps with the
rear-view mirror system. (If in doubt, consult
with operations supervisors and/or driver
trainers).
A.
INSIDE BUS
13. Mirror Adjustment and Condition
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Interior Mirror
Check interior mirror for
condition and adjustment.
specifications,
Interior mirror is not present.
Mirror is cracked, broken or has reflective
surface deterioration; or view is diminished by
distortion, stickers or other items.
Interior rearview mirror is not at least six
inches x 30 inches (except Type A1, which
shall be a minimum of 50 square inches).
Mirror does not have rounded corners and
protected edges.
Mirror or mounting/adjusting system is loose
or cannot be adjusted by the driver.
43
A.
INSIDE BUS
14. Driver’s Seat and Seat Belt
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Driver’s Seat and Belt
Inspect driver’s seat
and belt for Seat adjustments are stiff but still operational.
specifications, condition, mounting and
operation. Air suspension seat required on all
air brake equipped buses since September
1995.
Driver’s seat will not adjust forward and back
and up and down and remain in position; back
will not tilt and lock into position; or adjustment
hardware is loose, missing or damaged.
Buses manufactured since 1989 require high Seat upholstery or foam is deteriorated or Seat assembly is unstable, cracked or
back seat with cloth insert and a three-point damaged.
damaged or loose at floor; mounting hardware
shoulder harness/lap belt assembly.
is missing or not OEM or equivalent.
Buses manufactured since 2009 require bright Driver’s seat belt webbing is incorrect color
orange or lime green seat belt webbing.
(not orange or lime green for new buses
manufactured since 2009).
Type A1 buses require manufacturer’s
standard driver seat and belt assembly.
Seat bottom or back is loose, or frame is
exposed due to deterioration of upholstery or
foam.
Seat suspension system is leaking air.
Wrong type of
seat,
not
specifications, has been installed.
meeting
Driver’s seat belt is missing; is wrong type (i.e.,
not manufacturer’s standard for year, make
and model of bus); belt guides or retractors are
insecure, damaged or not operating properly;
belt is loose or routed improperly or does not
extend or retract freely; or buckle-and-tongue
assembly does not latch or release properly.
(Continued on Next Page)
44
Seat belt is frayed or damaged.
A.
INSIDE BUS
15. Passenger Seats
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Frames
Inspect passenger seat frames for condition,
hardware and modifications.
Any seat frame tubing or welds are broken or
cracked; any frame has been repaired,
modified or reinforced using non-OEM
approved hardware or methods or projections;
or sharp edges exist.
Check for presence of non-OEM seat frames.
Any non-OEM seat frames have been
installed.
b. Mounting
Inspect condition of passenger seat mounting.
Mounting at floor or seat rail is loose;
components are cracked, broken or damaged;
or any fasteners are missing, damaged or not
OEM or equivalent.
(Continued on Next Page)
45
A.
INSIDE BUS
15. Passenger Seats
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Backs/Crash Barriers/Padding
Inspect seat back, crash barriers and padding
for specifications and condition.
Any bus manufactured since April 1977 does
not have a properly spaced and padded crash
barrier forward of any passenger seat without
another seat directly ahead (exception: Pre1990 Type A Bus).
Requirements:
Original thickness or density of any seat back
or crash barrier foam has been reduced due to
wear, damage, deterioration or other factors
so that there is no padding between any
portion of seat back frame and covering.
1) Up to early 2007 models: Standard
height
padded
seat
backs,
approximately
24
inches
high
measured from the seat bottom
cushion.
Any seat back or crash barrier foam is the
wrong type (i.e., not manufacturer standard for
year, make and model of bus).
2) Early 2007 to present year models:
High-back padded seat backs,
approximately
28
inches
high
measured from the seat bottom
cushion.
(Continued on Next Page)
46
A.
INSIDE BUS
15. Passenger Seats
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Bottoms
1) Inspect seat bottoms for securement
and condition.
Any seat bottom is not attached to its seat
frame; or tilt-up bottoms will not latch or stay
latched in the closed position.
2) Inspect automatic retracting seat
bottom at side emergency door for
proper operation, if equipped. Must
have clear access to emergency door,
with a minimum aisle width of 12
inches between seats.
Original thickness or density of any seat
bottom cushion is reduced due to wear,
damage, deterioration or other factors so that
there is no padding between any portion of
seat bottom frame and covering.
Any seat bottom has a protruding edge or its
plywood is broken.
Any automatically retracting seat bottom will
not fold down, automatically retract and stay in
position when not occupied, or there is less
than a 12-inch aisle width between the seat
and the side emergency door.
(Continued on Next Page)
47
A.
INSIDE BUS
15. Passenger Seats
Inspection Procedures:
Repair (or note) if:
e. Cuts and other upholstery damage
Out-of-Service if:
Any portion of seat bottom or back upholstery
is missing, cut, torn, ripped or improperly
repaired, exposing foam.
Inspect seat upholstery for condition and
specifications.
Note:
The use of fire-blocking seat
material is required since 1989.
Any upholstery is non-fire-blocking type for
buses built since 1989.
Note: Punctures where no material is
missing and no foam is exposed shall not
be cause for removing bus from service.
f.
Modesty Panels
Inspect modesty panels for presence,
condition and mounting.
Any modesty panel is missing, excessively
loose or damaged, causing sharp edges or
pinch points.
g. Optional Integrated Child Seating
If the integrated system does not function
properly according to the manufacturer’s
operational procedures or any of the same
out-of-service conditions exist as applicable to
regular passenger seats.
Check the condition and operation of the
seating system.
(Continued on Next Page)
48
A.
INSIDE BUS
15. Passenger Seats
Inspection Procedures:
h. Passenger
equipped).
Securement
Devices
Repair (or note) if:
Out-of-Service if:
(if
All buses equipped with two or three-point Each two-part belt assembly is not separately
passenger securement systems shall be color-coded.
equipped with FMVSS No. 210 compliant seat
frames and FMVSS No. 209 compliant belt
assemblies in all passenger-seating positions.
Check type, condition and operation of Belts are knotted or misrouted or retractor Belts will not latch, stay latched or unlatch
passenger securement devices.
covers are damaged or loose.
properly or are the wrong type, missing,
broken, mismatched, improperly installed or
excessively frayed.
Type A buses built since April 1, 1977, must
have a functional seat belt at each passenger
position. All buses ordered after January 1,
2001, must be equipped with seat belts at all
seating positions.
i. Webbing Cutter
Check for presence, type, condition and
mounting of the required webbing cutter. It
must be mounted in a location accessible to
the driver from a seated position and be easily
detachable.
Any required webbing cutter is missing,
broken, unusable, improperly mounted or
difficult to remove.
Note: Lift-equipped buses or buses using
other
assistive/restraining
devices Wrong type of webbing cutter.
containing webbing must have a second
webbing cutter properly mounted in a
location determined by the school district.
49
A.
INSIDE BUS
16. Emergency Doors, Windows, Hatches and Passenger Check System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Operation
Inspect for operation and condition of rear
emergency exit door and side emergency exit
door (if equipped), door hold-open feature
(buses built after November 1993), emergency
exit windows and emergency exit roof
hatches.
Any emergency exit does not operate
smoothly and easily to a fully open position
and back to closed, from the inside and
outside when unlatching, opening, closing and
latching (windows from inside only).
Door (or rear window on rear engine (RE)
buses) hold-open feature does not secure the
exit in the fully open position.
Any emergency exit handle, guard or latch Any emergency exit handle, guard, latch or
mounting hardware is slightly loose.
mounting hardware is missing, or latching
mechanism does not operate smoothly and
secure the exit in the closed position.
Powered roof hatch ventilator (if equipped) Roof hatch is insecure in the ventilation
does not work properly.
position.
Any emergency exit is equipped with any type
of a hasp, lock or any other locking device,
except for an OEM interlock system.
Bus will start with any emergency door (or rear
window on RE buses) locked.
Roof hatch seal is damaged or dislodged.
(Continued on Next Page)
50
Any emergency exit door does not seal off the
entire opening when latched closed.
A.
INSIDE BUS
16. Emergency Doors, Windows, Hatches and Passenger Check System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b. Buzzers
Check emergency exit door(s) and window
warning buzzers.
Buzzer warning system for emergency door
(or rear window on RE buses) or any exit
window does not function, gives false alarms
or is not audible in the driver’s compartment.
Buzzer operation is intermittent.
c. Labeling and Pad
1) Inspect for identification and operating Hold-open device operating instructions label All emergency exits are not clearly labeled
instruction labels and for emergency is missing or illegible.
“Emergency Door” or “Emergency Exit” on the
door, windows, roof hatches and holdinside and outside of the bus.
open device.
Any emergency door (or rear window on RE
buses), window or roof hatch does not have
clearly labeled instructions on the inside and
outside.
2) Inspect emergency door header pad.
Door pad is ripped or loose.
(Continued on Next Page)
51
Door pad is missing or has a protruding edge.
A.
INSIDE BUS
16. Emergency Doors, Windows, Hatches and Passenger Check System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Post-Trip Passenger Check System
(if applicable)
Check for proper operation of post-trip Post-trip passenger check system is Buses built since 2005 are not equipped with
passenger check system (required on inoperative or does not operate according to a post-trip passenger check system.
buses manufactured since 2005).
specifications.
52
A. INSIDE BUS
17. Windshield, Side and Rear
Windows
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Glass Cracks
Inspect windshield and all windows for cracks
and other damage.
Windshield has any cracks, chips or damage
that obstructs the driver’s view.
Note: Windshield must be laminated safety
glass. All other windows can be made from
laminated or tempered safety glass.
Any windshield or other laminated safety glass
window is cracked greater than two inches in
length or any laminated glass crack or splinter
creates a sharp surface that could cause injury
when touched.
Any tempered safety glass is cracked.
Any window rearward of the windshield is not
laminated, tempered or equivalent safety
glass.
Any glass is missing.
(Continued on Next Page)
53
A. INSIDE BUS
17. Windshield, Side and Rear
Windows
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b. Fogging, Tinting and Visibility
Check windshield and windows for fogging,
reduced visibility or improper level of tinting.
Any glass is fogged more than two inches in
from any outer edge.
Any windshield or window fogging or clouding
results in reduced visibility of a mirror.
Any tinting on the windshield or windows to
either side of the driver in the driver’s
compartment (including service door) is not 70
percent light transmitting or clearer.
Any tinted windows behind the driver’s
compartment are not 28 percent light
transmitting or clearer.
Visibility is reduced for any reason (except for
the allowed fogging from the repair or note
column).
(Continued on Next Page)
54
A. INSIDE BUS
17. Windshield, Side and Rear
Windows
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Latches and Window Operation
Check latches and windows for condition and Any window latch is difficult to operate, or any Any window will not move fully up and down or
operation.
window does not move up and down freely.
will not stay closed.
Any window has loose, damaged or protruding
hardware in the passenger compartment.
d. Visor
Sun visor is cracked or damaged, cannot be
adjusted or will not stay in position.
Check sun visors for condition and operation.
Visibility is reduced for any reason (clouded,
dirty or has foreign objects or decals affixed).
Sun visor is missing.
55
A.
INSIDE BUS
18. Wheelchair Lift, Door and Securement System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Wheelchair Lift, Door and Securement
System
1) Operate lift through complete cycle
and inspect for proper operation,
condition, safety features, manual
backup
system,
fluid
leakage/seepage, mounting, roll stop
operation, warning light, buzzer
operation and overall mechanical
condition.
Dome light at inside lift area is inoperative.
Lift door or latch does not operate smoothly.
White light at exterior lift area (if originally
equipped) is inoperative.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Lift door warning buzzer or light does not
operate.
Lift door latches, weather stripping
securement system is damaged or loose.
or
Door switch (to prevent lift operation when the
lift door is closed) or other safety override
features do not function.
Lift does not properly deploy, lower, raise or
retract; jerks; binds; or jacks the vehicle when
fully lowered.
Inboard and outboard roll stops, or handrails
do not deploy and retract reliably to the proper
positions.
Lift will not stay in the fully retracted position
(falls against door).
(Continued on Next Page)
56
Lift safety chain or belt (if originally equipped)
is damaged or missing, or lift safety interlock
system is not operating according to
manufacturer’s specifications.
A.
INSIDE BUS
18. Wheelchair Lift, Door and Securement System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
There is side play in excess of two inches in
the lift mechanism when the platform is
extended.
Hydraulic fluid is seeping (note).
Hydraulic fluid is leaking.
Lift is not securely mounted to the vehicle.
Lift on 1989 or later buses is not equipped with
frame padding.
Any part of the lift mechanism or hardware is
damaged, missing or unsecure, including
cams, clips, pins, rollers, platform fasteners
and control head, cables and wiring.
Manual backup system does not function
properly.
(Continued on Next Page)
57
A.
INSIDE BUS
18. Wheelchair Lift, Door and Securement System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Track contains dirt/debris, but occupant
securement straps and wheel chair tie-down
straps can still be easily attached to or
detached from the track.
Track contains excessive dirt or debris.
Wheelchair tie-down track or fasteners are
loose, broken, corroded or improper type (i.e.,
lag bolts, sheet metal screws, etc.).
Note:
Starting in 1989, each 50-inch Optional below-chair rail lighting for
section of tie-down track may consist of wheelchair securement area (if equipped) is
two pieces of track, with neither piece less inoperative.
than 16 inches long, and must extend the
full length of the wheelchair position, with
no gaps.
Any 50-inch wheelchair position has more
than two pieces of track, or any piece of track
is shorter than 16 inches. Pre-1989, any
wheelchair position does not have continuous
one-piece, 50-inch tracks.
2) Inspect wheelchair and occupant
securement (tie-down) system for
proper operation, condition, mounting,
type and location.
3) Check for presence, proper type,
proper mounting and condition of a
second durable webbing cutter.
Wheelchair or occupant securement straps
are broken or frayed, cannot be easily
attached to or detached from track, or will not
operate.
Securement system for buses built between
October 1983 and November 1989 is not a
side-facing, track-and-belt system meeting
Florida specifications.
Note: Buses equipped with lifts and other
assistive/restraining devices containing
webbing must have a second webbing
cutter properly mounted in a location
determined by the school district.
Securement system (for buses built after
November 1989) is not a forward-facing
wheelchair and occupant securement system
meeting Florida specifications.
Any required webbing cutter is missing,
broken, unusable, improperly mounted or
difficult to remove.
Wrong type of webbing cutter.
58
A.
INSIDE BUS
19. Two-Way Radio Operation
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Two-Way Radio Operation (if equipped)
Inspect radio and antenna for condition, Radio will not transmit or receive.
mounting, location and routing of wiring, and
perform function check.
Mounting is loose.
Driver has to move out of the normal driving
position to operate radio.
Wiring or connectors are routed or installed
incorrectly, or there is the possibility of an
electrical short circuit due to unsecured or
damaged wiring.
Any part of radio, external speaker,
microphone or wiring interferes with driver’s
controls or blocks any of the driver’s view
through any portion of windshield or other
window.
59
A.
INSIDE BUS
20. Interior Wiring, Cab Hoses and Fire Wall Seals
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Interior Wiring
Inspect visible wiring and connectors for
mounting, condition, chafing, abrasion,
corrosion, loose connections and improper
repairs.
Any wire or connector is cut, chafed, missing
insulation, routed against sharp edges or
interferes with driver's controls.
Any wiring is exposed within the passenger
compartment.
b. Cab Hoses
Inspect all hoses for leaks, condition, routing, Any hose inside the bus is seeping lubricant or Any hose is leaking, cut, chafed, routed
abrasion and presence of heater hose coolant.
against sharp edges or interferes with driver's
shielding. (See page 131 for definitions of fluid
controls.
“leaks” and “seepage.”
Any heater hose inside the bus is not shielded
in a manner to prevent spraying of coolant in
c. Firewall Seals
the event of a hose failure.
Inspect firewall for any holes, cracks, unsealed Sound deadening/insulation material
openings and deteriorated or missing sound missing, unsecured or deteriorated.
deadening/insulation material.
60
is There is any open hole or unsealed area in the
firewall.
A.
INSIDE BUS
21. General Condition of Bus Interior
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Floor
Inspect floor covering, plywood sub-floor (if Floor covering material is loose, deteriorated There are any unsealed holes or cracks
installed), aisle and cove molding strips, and or cracked.
through the floor to underside of bus.
ribbed rubber in aisle for condition, adhesion,
loose or missing fasteners, and/or holes and Plywood is soft.
Aisle is not equipped with 12-inch wide ribbed
cracks.
rubber.
Any aisle or front-area-molding strip is not
securely fastened to floor, or any aisle or cove
molding presents a sharp edge or protrusion.
Any damage, wear or condition of the floor
covering material and moldings presents a
tripping hazard.
b. Stepwell
Check specifications and condition of step well Step tread is not sealed at inside edge where Step well tread and jointing edge at aisle are
and tread.
it meets next step.
not flush and securely adhered.
Step well tread ribs/nubs on top surface at
leading edge are worn smooth more than four
inches in width.
Step well support structure is not secure,
broken, or step well is rusted through.
(Continued on Next Page)
61
A.
INSIDE BUS
21. General Condition of Bus Interior
Inspection Procedures:
Repair (or note) if:
Check stepwell area for added (non-OEM)
items/equipment or any other condition that
could create snagging points. If anything is
suspect, perform the National Highway Traffic
Safety Administration (NHTSA) string-and-nut
test as described in the National School
Transportation
Specifications
and
Procedures. See page 65.
Out-of-Service if:
Any Type C or D bus manufactured since
December 1990 is not equipped with a threestep riser with full-width steps.
Step warning decals are missing or
unreadable (flat floor-equipped buses only).
Any non-OEM items have been added or other
condition exists that could cause snagging.
c. Grab Rail(s)
Grab rails are missing or not securely
mounted.
Check for presence and secure mounting of
entrance grab rail(s).
Lift-equipped buses do not have a left and
right side grab rail at the entrance step well.
Check grab rails for any condition that could
create snagging points. If anything is suspect,
perform the NHTSA string-and-nut test as
described
in
the
National
School
Transportation Specifications and Procedures
See page 65.
Grab rails fail NHTSA string-and-nut test.
(Continued on Next Page)
62
A.
INSIDE BUS
21. General Condition of Bus Interior
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Paneling and Trim
Check front, sides, rear, ceiling and driver’s There are loose or missing fasteners on any Sharp edges, pinch points, excessive rust,
area paneling and trim pieces for secure maintenance access panel.
loose fasteners or projections from paneling
fastening, projections, sharp edges, pinch
exist that could cause injury to passengers or
points and condition.
driver.
There are any non-flush mounted speakers
(except trim rings) or any other unauthorized
items affixed to the interior paneling of the bus
in the passenger area.
There is graffiti, unauthorized stickers, missing There is excessive graffiti or mildew inside the
paint or mildew on interior panels.
bus.
e. Broom Mounting
Check securement and location of broom.
Broom is not securely mounted in the driver’s
compartment.
(Continued on Next Page)
63
A.
INSIDE BUS
21. General Condition of Bus Interior
Inspection Procedures:
f.
Repair (or note) if:
Out-of-Service if:
Loose Objects and Cleanliness
Check to see that all objects within the bus are
secured.
Loose objects such as trashcans, clothing,
cleaning supplies are present that are not
located in a secured compartment or
container.
Check cleanliness of bus.
There is excessive dirt or trash on the floor,
causing it to be slippery.
Check for the presence of aerosol containers Trash not emptied from trash can or floor not Any aerosol cans or other containers with
and non-aerosol liquid containers.
swept.
flammable or volatile contents are present.
Any unlabeled liquid container is present.
g. Dog House/Engine Cover
Inspect dog house/engine cover seals, Soundproofing is not present or is loose or Seals or weather stripping are leaking and
soundproofing, weather stripping, prop-rod deteriorated.
allowing air/fumes into driver’s compartment.
and latch operation.
Prop-rod does not safely support the dog
house/engine cover.
Latches are hard to operate or do not secure
the dog house/engine cover properly.
64
CHART 4
NUT-AND-STRING TEST
The Handrail Inspection Tool and Procedure
The inspection tool is inexpensive, and the procedure for detecting potentially fatal handrail designs is quite simple. The inspection tool is a
standard one half inch hex nut, measuring three-quarters of an inch across the flats. This nut is tied to a one-eighth inch thick cotton cord
measuring 36 inches in length with overhand knots. The drawstring should have a minimum length of 30 inches when tied to the nut and attached
so that a pull of at least 10 pounds does not separate the nut from, or break the drawstring.
Steps to conduct a handrail inspection are:
 Stand on the ground outside of the bus;
 Drop the inspection tool between the handrail and step well wall, simulating the typical way students exit the bus;
 Draw the inspection tool through the handrail in a smooth, continuous slow motion; and
 Repeat this procedure a minimum of three times.
Note: It is important to drop the inspection tool over the handrail in such a way as to simulate a child exiting the bus. This is a drop-and-drag
test. Do not create a snagging situation by placing the nut in an area that would not be exposed to a drawstring or other articles.
Inspection Results
Take the bus out-of-service and repair it if the inspection tool catches or snags anywhere on the handrail. If the nut separates from the drawstring
or the drawstring breaks, reassemble the tool and retest. If the inspection tool pulls freely without catching or snagging, the bus should not be
rejected.
65
(This Page Intentionally Left Blank) 66
B. OUTSIDE BUS
1. Headlights, Turn Signals, Hazard, Brake, Tail, Backup Lights, Backup Alarm and
Park Lights
Inspection Procedures:
Repair (or note) if:
NOTE: When checking LED lights, If 75
percent or more of the LED elements
illuminate, the light is considered good. If
less than 75 percent of the LED elements
illuminate, the light must be replaced.
Out-of-Service if:
Less than 75 percent of the LED elements
illuminate.
a. Headlights
Check both headlights for brightness,
operation, condition and visible misaiming.
Check high-beam indicator operation and
headlight switch.
Left and right headlights are of different types
(conventional, halogen or LED).
Check Daytime Running Lamps (DRL) (if
equipped) for proper operation.
DRL system does not work according to
specifications.
Either headlight fails to function on low and
high beam, any lens or sealed beam is fogged
or cracked, or light is dim.
High beam indicator is inoperative.
Dimmer switch sticks, is hard to operate or
fails to function.
Headlight switch is damaged or not securely
mounted, or the knob is missing.
Headlight operation is intermittent.
Upon visible inspection, there is any obvious
misaiming of headlights.
(Continued on Next Page)
67
B. OUTSIDE BUS
1. Headlights, Turn Signals, Hazard, Brake, Tail, Backup Lights, Backup Alarm
and Park Lights
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b. Turn Signals
Check turn signals for operation, condition
and specifications (see charts 6 and 7 on
pages 83 and 84).
Any turn signal lens is cracked.
Any turn signal fails to function, does not flash
or is dim.
Turn signals do not flash 60 to 120 times per
minute.
Any bus manufactured since December 1990,
is not equipped with side-mounted turn
signals, and buses over 30 feet in length do
not have two signals on each side.
Any turn signal is not amber in color.
Any turn signal lens is damaged, darkened,
faded or dirty, affecting visibility or color of the
light, or white light is visible.
Turn signal switch does not function properly,
will not maintain selected position, or does not
cancel and return to neutral position.
Turn signal dash indicators fail to function or
do not properly indicate position of turn signal
switch and operation of signal.
(Continued on Next Page)
68
B. OUTSIDE BUS
1. Headlights, Turn Signals, Hazard, Brake, Tail, Backup Lights, Backup Alarm
and Park Lights
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Hazard Lights
Check four-way hazard lights for operation
and condition.
Any lens is cracked or dirty.
Any four-way hazard light fails to function.
Hazard lights do not flash 60 to 120 times per
minute.
Switch does not function or will not maintain
the “on” position.
d. Brake Lights
Check brake lights for operation, condition
and specifications (see chart 7, page 84).
One brake light fails to function on buses with
four brake light systems.
More than one brake light fails to function on
buses with four brake light systems.
Either brake light fails to function on buses with
two brake light systems.
Brake lights stay on after brake pedal is
released.
(Continued on Next Page)
69
B. OUTSIDE BUS
1. Headlights, Turn Signals, Hazard, Brake, Tail, Backup Lights, Backup Alarm
and Park Lights
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Any 19 capacity or larger bus built since
November 1980 is not equipped with two
seven-inch and two four-inch brake lights.
Any brake light is not red in color.
Any brake light lens is cracked.
Any brake light lens is damaged, darkened,
faded or dirty; affecting visibility or color of the
light, or white light is visible.
One tail light fails to function on buses with
four tail light systems.
More than one tail light fails to function on
buses with four brake light system.
e. Tail Lights
Check tail lights for operation, condition and
specifications (see chart 7, page 84).
Either tail light fails to function on buses with
two brake light system.
Tail light operation is intermittent.
Any 19 capacity or larger bus built since
November 1980 is not equipped with two
seven-inch and two four-inch taillights.
Any tail light is not red in color.
Any tail light lens is cracked.
(Continued on Next Page)
70
Any tail light lens is damaged, darkened, faded
or dirty, affecting visibility or color of the light,
or white light is visible.
B. OUTSIDE BUS
1. Headlights, Turn Signals, Hazard, Brake, Tail, Backup Lights, Backup Alarm
and Park Lights
Inspection Procedures:
f.
Repair (or note) if:
Out-of-Service if:
Backup Lights
Check backup lights for proper operation and
condition (see chart 7, page 84).
One of two backup lights does not function.
Any backup lens is cracked.
Any bus is not equipped with at least one
functional white backup light.
Backup light(s) stays on all the time or stays
on in any gear position other than reverse.
g. Backup Alarm
Check for presence of backup alarm (buses
manufactured since November 1990) and
dash sticker (buses manufactured since
November 1993). Check proper operation of
alarm (or variable volume alarm if equipped)
by placing transmission in reverse (engine
running) and listening for alarm sound.
Dash sticker is not visible in driver
compartment in plain view of the driver.
Dash sticker is not present (for buses
manufactured since November 1993).
Variable volume backup alarm (if equipped) is
not variable.
(Continued on Next Page)
71
Backup alarm does not sound.
B. OUTSIDE BUS
1. Headlights, Turn Signals, Hazard, Brake, Tail, Backup Lights, Backup Alarm
and Park Lights
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
One front or rear parking light fails to function
on buses with four front and four rear parking
light systems.
More than one front or rear parking light fails
to function on buses with four front and four
rear parking light systems.
h. Parking Lights
Check parking lights for proper operation and
condition (see charts 6 and 7, pages 83 and
84).
Any parking light lens is cracked or damaged.
One front or rear parking light fails to function
on buses with a two parking light system.
Any parking light lens is damaged, darkened,
faded or dirty, affecting visibility or color of the
light, or white light is visible.
72
B.
OUTSIDE BUS
2. Clearance, Side Marker, ID Lights, Reflectors and Strobe Light
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Check lights for operation, condition and
location. Also check license plate light (see
charts 6 and 7 on pages 83 and 84).
Any intermediate (center) side marker light
fails to function.
Any front or rear top corner-mounted
clearance, side marker or clearance/side
marker combination light fails to function.
Note: When there are two lights factorymounted at the top corners, the front is a
clearance and the side is a side marker.
When there is one light factory-mounted at
the top corners, it is a clearance/side
marker combination, meeting both
requirements.
Any clearance or ID light lens is cracked.
Any bus over 30 feet in length is not equipped
with intermediate amber side marker lights on
both sides.
a. Clearance, Side Marker and ID lights
One or two ID lights (but not all ID lights) on
the front or rear of the bus fail to function.
License plate light is inoperative.
Any intermediate or front clearance, side
marker, clearance/side marker combination
light or ID light lens is not amber.
Any
rear
clearance,
side
marker,
clearance/side marker combination light or ID
lens is not red.
Any clearance, side marker, clearance/side
marker combination light or ID light lens is
damaged, darkened, faded or dirty, affecting
visibility or color of the light, or white light is
visible.
(Continued on Next Page)
73
All ID lights on either the front or the rear of the
bus are inoperative.
B.
OUTSIDE BUS
2. Clearance, Side Marker, ID Lights, Reflectors and Strobe Light
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b. Reflectors
Check reflectors for condition and location
(see charts 6 and 7 on pages 83 and 84).
Any reflector is damaged or cracked.
Any required reflectors are missing.
Any required reflector is faded, significantly
affecting its original color.
Note: Reflectors are required as follows:
1) Buses over 30 feet in length: two red on
rear, one red on each side at rear, one
intermediate amber on each side, one
amber at front and one amber front of
cowl on each side.
2) Buses under 30 feet in length: same,
except intermediate amber reflectors are
not required.
c. Strobe Light
Check roof-mounted white flashing strobe
light for operation, location and condition.
Any bus manufactured since December 1990
is not equipped with a roof-mounted white
flashing strobe light mounted in the center of
the roof approximately 48 inches from the rear
of the bus.
The strobe light on any bus built prior to
December 1990 is not mounted in the center
of the rear part of the roof.
Strobe light does not function.
(Continued on Next Page)
74
B.
OUTSIDE BUS
3. Pupil Warning Lights
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Either of the two pupil warning lights or interior
pilot lights fail to function.
Any pupil warning light fails to function or is
dim.
Pupil Warning Lights
Check pupil warning lights for operation and
condition (see charts 6 and 7 on pages 83 and
84).
Front and rear amber and red lights do not
alternately flash (side to side).
Note: See chart 5, page 76, for function
checks.
Any outer pupil warning light is not red, inner
pupil warning light is not amber, or any pupil
warning light is not OEM or equivalent.
Note: Pupil warning light hoods in the
front and rear of the bus are not required
since September 1993.
Any pupil warning light lens is damaged and
white light is visible.
Any pupil warning light lens is obstructed,
misaimed, dirty, darkened or faded, affecting
the color of the light or reducing the visibility
to less than 500 feet in bright sunlight.
Pupil warning lights fail to function according
to all conditions in chart 5, page 76.
75
CHART 5
EIGHT-LIGHT WARNING SYSTEM
NOTE:
System may not be designed in such a way that the operator is required to actuate controls in a
particular sequence to achieve the desired combination of conditions.
EXAMPLE:
If the driver places the three-position switch in the amber position with the master switch on, he should not
have to move the three-position switch to red or open the service door to deactivate the amber warning lights.
The driver must be able to deactivate the amber warning lights by going directly from the amber to the off
position.
WITH MASTER SWITCH, CONTROL SWITCH and SERVICE DOOR
IN THE FOLLOWING POSITIONS:
MASTER
CONTROL
SWITCH
SWITCH
SERVICE
POSITION
POSITION
DOOR
(ON or OFF)
(three-positions: OFF,
POSITION
AMBER or RED)
1)
ON
OFF
CLOSED
2)
ON
OFF
OPEN
3)
ON
AMBER
CLOSED
4)
ON
AMBER
OPEN
5)
ON
RED
CLOSED
6)
ON
RED
OPEN
7)
OFF
ANY POSITION
ANY POSITION
CONDITION OF STOP ARM(S), STOP ARM LIGHTS, AMBER
WARNING LIGHTS AND RED WARNING LIGHTS MUST BE:
AMBER
STOP ARMS,
WARNING
RED WARNING
*AUDIBLE
STOP ARM
and
and
ALARM
LIGHTS
PILOT LIGHTS
PILOT LIGHTS
RETRACTED,
OFF
RETRACTED,
OFF**
RETRACTED,
OFF
RETRACTED,
OFF**
EXTENDED,
ON
EXTENDED,
ON
RETRACTED,
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
ON
OFF
OFF
OFF
OFF
* Note: Effective September 1, 1992.
**Note: The stop arm lights may flash in the retracted position on buses built prior to November 1983.
76
B.
OUTSIDE BUS
4. Stop Arm(s) and Student Crossing Arm
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Stop Arm(s)
Check stop arm(s) for specifications,
operation and condition. (See chart 6, page
83).
Any wiring is not properly routed and secured.
Any wires or ground strap(s) are broken.
Hinges or bushings are not adequately
lubricated.
Any stop arm light fails to function or lights do
not flash 60 to 120 times per minute in an
alternating pattern.
Stop arm extends more than 90 degrees (plus
or minus five degrees).
Stop arm extends less than 90 degrees (plus
or minus five degrees).
Stop arm does not extend or retract, or is slow
to extend or retract.
Any stop arm has an air or vacuum leak or is
loosely mounted, or components are badly
worn.
Any stop arm paint or decal is significantly
faded or discolored.
Stop arm does not operate according to all the
conditions in chart 5, page 76.
Stop arm(s) not
specifications:
of
proper
type
and
1) Octagonal (since September 1, 1985).
2) Alternately flashing red lights.
(Continued on Next Page)
77
B.
OUTSIDE BUS
4. Stop Arm(s) and Student Crossing Arm
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
3) High intensity reflectivity (since
December 1990).
4) Dual stop arms required on all
modified Type B and Type C 47passenger capacity and up and all
Type D since December 1990.
Check that rear stop-arm decal is not present
on forward side of arm on buses built after
September 1, 1993.
A stop arm decal has been installed on the
forward side of the rear stop arm for buses
built after September 1, 1993.
b. Student Crossing Arm (if equipped)
Check front bumper-mounted student
crossing arm for specifications, operation and
condition.
Note: For crossing arm and stop arm
requirements, see Federal Motor Vehicle
Safety Standard (FMVSS) 131.
Crossing arm extends more than 90 degrees
(plus or minus five degrees).
Not equipped with student crossing arm, since
December 1992.
Crossing arm extends less than 90 degrees
(plus or minus five degrees).
Crossing arm does not extend or retract, or is
slow to extend or retract.
Hinges or bushings are not adequately
lubricated.
Any crossing arm has an air or vacuum leak,
is loosely mounted or has badly worn
components.
78
B.
OUTSIDE BUS
5. General Condition of Bus Exterior
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Mirrors
Check all exterior mirrors, mounts and
brackets for tightness and condition.
Mirror mounts or bracket(s) are bent, broken,
not secure, or have loose or missing
fasteners.
Any exterior mirror is broken, cracked or loose
in the frame, or reflective surface is faded or
deteriorated.
b. Bumpers
Check bumpers for mounting, condition, color
and body seal on rear bumper.
Bumper is not black.
Bumper is significantly bent or has protruding
metal.
Bumper is equipped with any unauthorized
stickers or decals.
Bumper, mounts or braces are bent, broken,
not secure, or have loose or missing
fasteners.
Diagonal reflective striping (if equipped) is
missing, significantly damaged or not
reflective.
Front bumper on buses built since October
1982 permanently deforms or is not of
sufficient strength to allow the front of the bus
to be lifted without permanent deformation.
(Continued on Next Page)
79
Rear bumper to body seal is damaged or
missing.
B.
OUTSIDE BUS
5. General Condition of Bus Exterior
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Body Damage
Check body exterior for damage, scratches,
dents, etc.
Body has small dents, scratches, etc.
Any body part is damaged or dislocated,
creating a protrusion or sharp edge.
Body has small rust spots or water leaks.
Body panels, rivets or other components are
damaged or corroded so that joint strength or
body structural integrity is compromised.
Paint is faded, discolored or damaged.
Paint is not National School Bus Yellow
(except white roof). Trim, rub rails, warning
light, hoods or background are not black.
Stud-piloted disk wheels and spoke hubmounted wheels are not black, or hub-piloted
wheels are not National School Bus Yellow.
Reflective markings other than those around
any emergency exit as required by FMVSS
No. 217 are faded, discolored, damaged or
peeling.
Any required reflective markings are missing,
significantly faded or discolored around any
emergency exit door, window or roof hatch.
d. Paint
Check paint on body, trim and wheels for
required coloration and condition.
e. Reflective Markings (if equipped)
Check reflective markings for coloration,
reflectivity and condition. Reflective markings
required since September 1995.
Check for presence of reflective markings
around any emergency exit door, window or
roof hatch as required by FMVSS No. 217
(buses purchased after November 1993).
(Continued on Next Page)
80
B.
OUTSIDE BUS
5. General Condition of Bus Exterior
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
f. Lettering
Check all lettering for required type, size,
location and color (see charts 6 and 7 on
pages 83 and 84).
Note: See Florida school bus specifications
for additional lettering requirements.
Bus is not equipped with following lettering:
1) Eight-inch “SCHOOL BUS” front and
rear.
2) “Name District Schools” on left and
right sides of body in four-inch letters
since November 1978 and six-inch
letters since 1993.
3) Local bus number on rear, both sides
and front. Six-inch minimum lettering
since 1998.
Any required lettering is not clearly readable.
Exterior
emergency
hatch
operating
instructions are not clearly readable.
(Continued on Next Page)
81
Bus is not equipped with following lettering:
1) Handicapped symbol on front and rear
of wheelchair lift-equipped buses built
starting September 1984.
2) Minimum
two-inch
lettering
“Emergency Door” at top or above
emergency exit door.
3) Emergency exit windows and roof
hatches labeled “Emergency Exit” on
buses built since December 1990.
4) Fuel type lettering is not present on
buses built since September 1985.
There is not at least one local bus number and
district name present on the exterior.
Any required handicapped symbol is not
reflective, white on blue background and a
minimum of six inches by six inches.
B.
OUTSIDE BUS
5. General Condition of Bus Exterior
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
g. Emergency Door Operation
Check emergency door for operation and
condition from exterior of bus.
Emergency door is hard to open fully from
outside of bus.
Emergency door latch mechanism requires
more than 40 pounds to release.
Emergency door handle is mounted to allow
“hitching” onto the bus.
h. Engine Hood
Check engine hood for operation, condition
and safety latch.
i.
Hood is misaligned.
Hood cannot be opened as designed.
Hood hinges are stiff or damaged, but remain
operational.
Safety latch is damaged or stiff, or does not
secure the hood.
Hood prop rod(s) or hold-open feature does
not function properly.
Cleanliness
Check exterior of bus for cleanliness.
Exterior of bus is dirty.
82
Bus is dirty to the point that visibility through
any window or mirror, or brightness of any
light, is significantly reduced.
CHART 6 MINIMUM LETTERING AND LIGHTING REQUIREMENTS
A.
Clearance and Side Marker Lights (one intermediate
on buses 30 feet or longer).
BB. Stop Arm(s)
C.
Front Turn Signals and Parking Lamps
F.
Pupil Warning Lights--Dual (side by side, amber and red)
G.
Reflectors, one at rear body side panel, one
near front of body and one intermediate
(only on buses 30 feet or longer) on both sides
I.
Emergency Exit Lettering
J.
Double-Faced Flashing Red Lights
K.
“School Bus” Lettering (front and rear)
(see specifications)
83
L.
(Name of District) District Schools (both sides)
M.
Local Bus Number (both sides and front and back)
N.
Universal Handicapped Symbol (lift buses)
O.
Identification Lamps
S.
Battery Box
U.
Pupil Crossing Arm
Y. Rear-View Mirror System (see specifications)
Z. Cross/Side View Mirror System (see specifications)
CHART 7 MINIMUM LETTERING AND LIGHTING REQUIREMENTS
A.
Clearance and Side Marker Lights
I.
Emergency Door and Exit Lettering
P.
Backup Lights
B.
Seven-Inch Brake/Tail/Parking Lights
K.
R.
Fuel Door and Fuel Type Lettering
C.
Seven-Inch Turn Signals (amber)
“School Bus” Lettering (front and rear)
(see specifications)
Wheelchair Lift Landing Light
Four-Inch Brake/Tail/Parking Lights
(Name of District) District Schools
T.
E.
L.
F.
Pupil Warning Lights--Dual (side-by-side
amber and red)
G.
Reflectors
H.
License Plate Lamp (one minimum)
M.
N.
O.
Y.
Local Bus Number (both sides and front
and back)
Z.
Rear View Mirror System
Cross/Side View Mirror System
Universal Handicapped Symbol (lift- AA. Roof-Mounted White Strobe Light
equipped buses)
CC. Rear Door Lettering (see specifications)
Identification Lamps
84
C.
ENGINE COMPARTMENT
1. Steering
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Steering wheel OEM covering has minor
wear, cracks or looseness not exposing metal
reinforcement.
Any portion of the OEM covering is loose,
deteriorated, cracked or missing, exposing
metal steering wheel reinforcement or
interfering with usage.
a. Steering Wheel, Play and Assist
Check condition of the steering wheel.
Check for play in the steering system at the
steering
wheel
using
the
following
procedures:
Steering wheel is loose on column.
Steering wheel or covering is non-OEM
design.
1) Visual check: From inside bus with
engine running, rotate steering wheel
lightly from side to side until motion
can be observed at tires. Measure the
free play (lash) at steering wheel outer
diameter. This procedure must be
performed with the vehicle on the
ground.
Free play (lash) exceeds amounts specified in
chart 8, page 86.
Power assist is inadequate, or there is
binding, jamming or belt slippage.
2) To check power assist operation, run
engine at fast idle, turn steering wheel
a full right and left turn, and feel for
binding, jamming or belt slippage.
(Continued on Page 87)
85
CHART 8
STEERING WHEEL PLAY (LASH) MEASUREMENTS
Figure 1
Figure 2
Steering Wheel Size
15 inches – 1-3/4” (4.4 cm)
16 inches - 2” (5.1 cm)
18 inches – 2-1/4” (5.7 cm)
20 inches – 2-1/2” (6.4 cm)
22 inches – 2-3/4” (7.0 cm)
Wheel (rim) Size:
16 inches or less - 1/4” (6.5 mm)
17 to 18 inches - 3/8” (9.5 mm)
Over 18 inches - 1/2” (13 mm)
86
C.
ENGINE COMPARTMENT
1. Steering
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b. Column
Check steering column inside bus for up-anddown play (parallel to shaft), side-to-side play
(perpendicular to shaft) and proper mounting.
Any column shaft yoke, coupler or joint dust
boot is torn.
Column side-to-side play exceeds one-fourth
inch or up-and-down play exceeds one inch.
Column assembly mounting (including floor
mounting plate) or fasteners are loose.
Tilt/telescopic assembly (if equipped) will not
stay locked in position.
Steering column shaft U-joint inside the bus (if
equipped) is loose, damaged or noisy after
lubrication.
Firewall or floor rubber boot is torn, ripped or
missing.
Steering column shaft u-joints, couplers, slide
yokes, pinch bolts, etc., are loose, worn,
damaged, have excessive play, or have loose
or missing fasteners.
Any column shaft yoke, coupler or joint dust
boot is missing.
c. Steering Gear Box and other external
components
Check condition of the steering system using
the following procedures with the vehicle on
the ground (not suspended):
Steering gear box is loose on frame or any
fasteners are loose or missing.
(Continued on Next Page)
87
C.
ENGINE COMPARTMENT
1. Steering
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
1) With engine running, have assistant
move steering wheel back and forth
repeatedly
to
load
steering
components.
There is any binding in steering gear box.
2) Observe the following external
steering and related suspension and
frame components for looseness
while assistant works the steering
(also see specific procedures under
each component):
Any axle or suspension/steering component
is loose or worn beyond specifications
prescribed elsewhere in this manual.
Frame braces or cross-members are cracked,
loose or missing fasteners.
a) Column shaft and hardware
b) Column U-joints, couplers, slide
yokes (as equipped)
c) Coupling at gear box
d) Gear box
e) Pitman arm
f) Drag link
g) Steering knuckle or arms
h) Tie rod ends
i) Idler arm (as equipped)
j) Vehicle frame cross-members and
frame braces, including associated
rivets and fasteners for looseness
and condition.
(Continued on Next Page)
88
C.
ENGINE COMPARTMENT
1. Steering
Inspection Procedures:
Repair (or note) if:
3) Have an assistant carefully rotate the
steering wheel all the way to the left,
then all the way to the right, to check
the steering stops, and to check the
power steering pressure relief valve.
Out-of-Service if:
Tire contacts any part of the bus frame,
suspension, steering or other components.
d. Pitman Arm
Check the Pitman arm for looseness or
misalignment at sector shaft splines and
looseness at all joints. Check looseness of
pinch bolt and fasteners and condition of
Pitman arm.
Pitman arm grease fitting (if equipped) is
loose or missing.
Any play is observed between Pitman arm
and sector shaft.
Pinch bolt at sector shaft is loose or missing.
Pitman arm to steering sector shaft marks are
misaligned.
Pitman arm ball joint (if equipped) has more
than one-sixteenth inch axial play (i.e., in-andout play between the ball stud and socket; see
figure 6, page 93).
Pitman arm ball joint nut or cotter pin is loose
or missing.
Pitman arm is cracked or damaged.
(Continued on Page 91)
89
TIGHTENING STEERING COLUMN JOINT BOLTS
WARNING: FAILURE TO MAINTAIN THE STEERING
SYSTEM IN PROPER CONDITION CAN CAUSE
REDUCED STEERING FUNCTION, RESULTING IN
PERSONAL INJURY AND PROPERTY DAMAGE.
It is recommended that steering column joint bolts be
checked for tightness every 50,000 miles or annually,
whichever occurs first. DO NOT OVERTIGHTEN
90
C.
ENGINE COMPARTMENT
1. Steering
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Any grease fitting is loose, missing or will not
take grease.
Drag link ball stud is loose in Pitman arm or
upper steering arm.
Drag link needs lubrication.
Any nut or cotter pin is loose or missing.
Drag link dust boots are cut, damaged or
missing.
Drag link shaft is damaged or bent.
e. Drag Link
Check the drag link ends, shaft and fasteners
for looseness and condition.
Drag link ends axial or horizontal play
exceeds one-sixteenth inch (See figure 6,
page 93).
Horizontal socket type (adjustable) drag link
end has more than one-sixteenth inch axial or
lateral play.
f.
Steering Arm
Check upper steering arm (Ackerman arm)
and left and right side lower steering arms for
securement and condition.
Any steering arm is bent, cracked or
damaged.
Any steering arm attachment point is loose, or
any fasteners or cotter pins are missing.
Check condition and securement of steering
stops and lock nuts.
Either steering stop or lock is loose, damaged
or missing.
(Continued on Next Page)
91
C.
ENGINE COMPARTMENT
1. Steering
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Tie rod end dust boots are cut, damaged or
missing.
Tie rod to end clamps or fasteners are
stripped, missing, loose or improperly
positioned for proper clearance.
g. Tie Rod and Ends
Check tie rod, tie rod ends, dust boots, clamps
and fasteners for looseness, damage and
condition.
Tie rod end needs lubrication.
Any tie rod end grease fitting is loose, missing
or will not take grease.
Any tie rod or end is bent, cracked or
damaged.
Tie rod ends axial or horizontal play exceeds
one-sixteenth inch. (See figure 6, page 93).
Tie rod end ball stud is loose in steering arm
or idler arm, has missing or loose fasteners,
or has missing cotter pins.
h. Idler Arm
Check idler arm assembly (as equipped) for
looseness, damage and condition.
Idler arm needs lubrication.
Idler arm grease fitting is loose, missing or will
not take grease.
92
Idler arm is cracked or damaged, or cotter pin
is missing.
Idler arm up-and-down play is greater than
one-fourth inch total (one-eighth inch either
direction). (See figure 7, page 93.)
Figure 6 - Checking the Rod and Drag
Link End Movement
Figure 7 - Checking Idler Movement, Typical
A. Movement in the axial direction
must be less than one-sixteenth inch.
B. Tie rod/drag link free to rotate
within steering arm socket.
1. Tie rod/drag link end
2. Steering arm
93
C.
ENGINE COMPARTMENT
2. Batteries
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Battery slide tray is corroded, dirty or hard to
slide in and out.
Battery slide tray or box is loose, corroded or
damaged, reducing securement of the
batteries, or door does not open or will not
stay latched.
a. Battery Box, Door and Tray
Check battery box, door and tray for
operation, condition and securement.
Battery slide tray does not slide in and out or
tray lock, or stop is missing or nonfunctional.
b. Hold-down
Check for tightness, condition and type of
battery hold-down.
Hold-down assembly is not OEM design,
missing, loose, corroded or damaged,
reducing securement of the batteries.
c. Battery Terminals
Check terminals for cleanliness, tightness and
condition.
Any terminal is loose, damaged, corroded or
has missing hardware or insulation.
d. Battery Cables
Check cable assemblies for
securement, condition and size.
routing,
Cable or insulation is cracked, damaged or
corroded.
Cable is misrouted, unsecured or missing
protective grommets, loom or other means of
protection from chafing against any metal,
sharp edge or hot surface.
Cable is smaller than original equipment size.
(Continued on Next Page)
94
C.
ENGINE COMPARTMENT
2. Batteries
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Cable appears to be too small in diameter or
of excessive length (see chart 9, page 96).
Flat braided engine ground cable is frayed or
corroded, or ends are not secure.
e. Cleanliness
Check cleanliness of battery or batteries.
f.
Battery top or sides are corroded, greasy,
dirty or wet with electrolyte.
Batteries and compartment are excessively
dirty or corroded.
Electrolyte is low (not exposing plates).
Electrolyte is low (exposing plates).
Electrolyte Level
Check electrolyte in battery or batteries for
proper level (if applicable).
(Continued on Page 97)
95
CHART 9
CHARGING SYSTEMS CABLE SIZE CHART SYSTEM
VOLTAGE
12 VOLT
RATED
OUTPUT
IN
AMPERES
RECOMMENDED MINIMUM CHARGING CABLE GAUGE SIZE
4 FT. or
Less
4 -7 FT.
7 -10 FT.
10 -13 FT.
13 -16 FT.
16 -19 FT.
19 -22 FT.
22 -28 FT.
0 - 20
14
12
12
10
10
8
8
8
20 - 35
12
10
8
8
6
6
6
4
35 - 50
10
8
8
6
6
4
4
4
50 - 65
8
8
6
4
4
4
4
2
65 - 85
6
6
4
4
2
2
2
0
85 - 105
6
6
4
2
2
2
2
0
105 - 125
4
4
4
2
2
0
0
0
125 - 150
2
2
2
2
0
0
0
00
Maximum difference between battery voltage and alternator voltage is 0.5 volt for 12-volt systems at full-rated output.
Maximum voltage drop in the sensing (#2-terminal) lead must not exceed 0.2 volt for 12-volt three-wire systems.
Cable gauge size calculation above takes into account terminal-connection resistance.
Note: When an insulated (no frame ground) charging system is installed, the length of the return circuit must be included to obtain
total circuit length and determine the proper wire size.
96
C.
ENGINE COMPARTMENT
2. Batteries
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Battery cable length or battery mounting
restricts access to battery or batteries for
servicing.
Battery or batteries are of insufficient cold
cranking amp (CCA) rating.
g. Load Test (Optional)
Perform battery load test on battery or
batteries to check condition. Check battery or
batteries for proper type and load rating.
CHART 10
BATTERY TEST
REMOVE SURFACE-CHARGE:
Discharge at 300 amps for 15 seconds.
Check for blue haze or smoke.
TEST
Measure electrolyte temperature. Discharge at
one-half the CCA rating of the battery for 15
seconds.
Battery voltage must not drop below the listed
values during the 15-second test.
Degrees in F
Min. Voltage
70 or over------------------------- 9.6
60------------------------------- 9.5
50------------------------------- 9.4
40------------------------------- 9.3
30------------------------------- 9.1
20------------------------------- 8.9
10------------------------------- 8.7
0-------------------------------- 8.5
97
Battery fails load test (see chart 10, page 97).
C.
ENGINE COMPARTMENT
3. Fluid Levels and Condition
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Brake Fluid
Check brake fluid and brake power-assist
hydraulic fluid (if equipped) for level and
condition.
Level of brake fluid in either side of master
cylinder reservoir is lower than one-fourth inch
from top or below “add” mark.
Brake fluid or power-assist fluid shows
evidence of excessive water, oil or dirt
contamination.
Brake power-assist hydraulic fluid is below
cold “add” mark.
b. Power Steering Fluid
Check power
condition.
steering
fluid
level
and
Power steering fluid shows evidence of
excessive water, oil or dirt contamination.
Power steering fluid is below cold “add” mark.
No oil is observed on dipstick.
c. Oil
Check engine oil level and condition.
Engine oil level is below the “full” mark.
Dipstick is missing.
Engine oil level is below the “add” mark or
above “full” mark.
(Continued on Next Page)
98
There is evidence of
contamination in the oil.
fuel
or
water
C.
ENGINE COMPARTMENT
3. Fluid Levels and Condition
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Transmission fluid level is below the “full”
mark.
Dipstick is missing, broken or the incorrect
type.
Transmission fluid shows need of servicing
(discoloration or smell).
Transmission fluid is below the “add” mark or
above the “full” mark.
d. Transmission Fluid
Check transmission fluid level and condition.
Transmission fluid shows
excessive
dirt,
metal
contamination.
e. Windshield Washer Fluid
Check windshield washer fluid level.
Reservoir level is low or cap is missing.
(Continued on Next Page)
99
Reservoir is empty.
evidence of
or
coolant
C.
ENGINE COMPARTMENT
3. Fluid Levels and Condition
Inspection Procedures:
f.
Repair (or note) if:
Out-of-Service if:
Coolant
Check engine coolant level, condition and
freeze protection.
Coolant level is below the “full” mark.
Note: Follow manufacturer’s
recommendations for checking coolant
condition, PH and additive package.
Coolant shows evidence of excessive oil, dirt
contamination, or rust and corrosion.
Note: Use caution when opening a hot
cooling system.
Coolant freeze protection is minus 20 degrees
Fahrenheit or lower (see chart 11, page 101).
Coolant pH level is too high or too low, or
coolant additive package has depleted to an
unacceptable level.
100
Coolant level is below the “add” mark or
cannot be seen in the reservoir or radiator
with cap removed.
CHART 11
Freezing-Points of Antifreeze Solutions
Boiling Points of Antifreeze Solutions at Various
Pressures
SOLUTION
PROTECTION
Percentage Percentage
of
of
Antifreeze
Water
Celsius Fahrenheit
0%
0%
0
32
10%
90%
-3
27
12%
88%
-4
25
14%
86%
-5
23
16%
84%
-6
21
18%
82%
-7
19
20%
80%
-8
18
24%
76%
-10
14
28%
72%
-13
9
30%
70%
-15
5
32%
68%
-16
3
36%
64%
-20
-4
40%
60%
-24
-11
44%
56%
-28
-18
48%
52%
-33
-27
50%
50%
-37
-35
52%
48%
-39
-38
56%
44%
-45
-49
60%
40%
-51
-60
Pressure in Pounds per Square Inch (PSI)
Percentage
of
Antifreeze
Solution
0 PSI
8 PSI
12 PSI
16 PSI
20 PSI
0%
212
233
242
252
260
33%
220
240
253
260
268
44%
224
245
257
265
272
50%
226
248
259
267
275
60%
231
253
264
273
280
Boiling Points in Degrees Fahrenheit (°F)
Note: Technicians should test engine coolant properties during
every inspection using a coolant-test-strip kit. Consult the Original
Equipment Manufacturer (OEM) for recommended test kits and
procedures.
101
C.
ENGINE COMPARTMENT
4. Belts and All Hoses
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Belt(s)
1) Tightness
Visually and physically check all drive
belts for proper tension. If available,
use a tension gauge (see figure 9,
page 103). If a gauge is not available,
use a ruler to measure the deflection
of the belt(s) up and down at the
widest point between the drive and
driven pulley(s) (see figure 10, page
103).
Any
belt
exceeds
tension
recommended by manufacturer.
reading
Any belt tensioner (automatic or manual) does
not apply proper tension to belt.
Tension on any belt is too loose (based on
specifications of type tension gauge used).
Using ruler method, any belt has less than half
an inch deflection (too tight) when firm
pressure is applied (See figure 10, page 103).
Tension of any belt (using ruler method) is too
loose when firm pressure is applied (greater
than three-fourth inch deflection).
Any belt is glazed.
Any belt is missing, oil saturated, dry-rotted or
cut, or plies of belt(s) are separated.
2) Condition
Inspect belt(s) for presence, glazing,
oil contamination, dry rotting, cuts and
separation of plies. Check belts for
twisting or distortion.
Any belt is twisted or distorted.
3) Routing and Alignment
Inspect belt(s) for correct routing,
alignment and contact with objects
other than pulleys.
Any belt is slightly misaligned.
Belt misalignment is excessive and could
result in failure.
Any belt is making contact with objects other
than pulley(s).
(Continued on Next Page)
102
Any belt is routed incorrectly.
CHECKING BELT TENSION AFTER TIGHTENING
Figure 9 - Checking Belt Tension
(Gauge Method)
Figure 10 - Measuring Belt Tension
(Ruler Method)
103
C.
ENGINE COMPARTMENT
4. Belts and All Hoses
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Visually and physically check that
hose connections or clamp(s) are
tight.
Any hose connection or clamp is loose or
overtightened.
Any hose connection or clamp is stripped,
damaged or overtightened, causing hose
damage beyond the outer cover.
Note: References to hoses include
all types of hoses located in the
engine compartment and related
components,
including
power
steering, coolant, air compressor
intake, vacuum, brake hydraulic
assist, engine oil and transmission
hoses.
Any hose connection (other than brake) is
seeping.
Any brake hose is seeping or leaking.
b. Hose(s)
1) Clamps and Connections
2) Condition
Inspect all hoses for cuts, abrasions
and wear, oil saturation, dry rotting
and ballooning.
Any hose is cut, abraded, worn, oil-saturated,
dry-rotted or ballooned to the point that failure
is likely.
3) Routing
Inspect routing and securement of all
hoses.
Any hose is misrouted or unsecured so that
heat, abrasion or other damage is possible.
104
Any hose is misrouted or unsecured so that
heat, abrasion or other damage is likely.
C.
ENGINE COMPARTMENT
5. Accessory Mounting and Condition
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Check air intake system, housing, lid, piping,
gaskets, seals and clamps for leaks,
securement and condition. Record air filter
restriction gauge measurement.
Any portion of air intake system has minor
dents or damage that is not causing air leaks.
There are intake system leaks; loose, missing
or damaged components; or other conditions
that could allow dust or dirt damage to internal
engine parts.
Note: If air leaks are suspect, inspect for
dirt/dust tracking through air cleaner
assembly and intake piping.
Air filter restriction gauge is not working
properly.
Air filter restriction exceeds manufacturer’s
specifications.
a. Air Cleaner
b. Power Steering Pump
Check securement and condition of power
steering pump.
Any portion of the power steering pump,
mounting brackets or fasteners is cracked,
damaged, loose or missing.
c. Air Compressor and Filter
Check securement and condition of air
compressor and filter assembly.
Air compressor external air filter (if equipped)
is dirty.
(Continued on Next Page)
105
Any portion of the air compressor, mounting
brackets, fasteners or compressor air-filter
system is cracked, damaged, loose or
missing.
C.
ENGINE COMPARTMENT
5. Accessory Mounting and Condition
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
There is evidence of coolant seepage from
water pump, seal, gasket surface or weep
hole.
Water pump is noisy, bearing is damaged or
coolant is leaking.
d. Water Pump
Check condition of water pump and pulley.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Water pump and/or fan fasteners are loose,
damaged or missing to the point that failure or
leaks could occur.
e. Fan
Check fan blades, hub and fan clutch
assembly for securement and condition.
Fan has any cracked, bent or broken blades.
Any portion of fan mounting is loose.
Fan clutch is seized or loose.
f.
Alternator
Check securement and condition of alternator
assembly.
Alternator is noisy.
Any of the alternator, mounting brackets or
fasteners are cracked, loose or missing.
Alternator is not charging.
106
C.
ENGINE COMPARTMENT
6. Wiring
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
There is any slightly loose, damaged or
corroded wiring connector or terminal end.
Any wiring is misrouted, unsecured or missing
protective grommets, loom or other means of
protection from chafing against any metal,
sharp edge or hot surfaces.
Routing and Condition
Check routing, securement and condition of
all wiring and any electrical cable in the
engine compartment and related areas.
Any repair has been made using improper
gauge wiring.
107
There are any burnt wires, or any wires are
missing insulation (other than ground straps).
C.
ENGINE COMPARTMENT
7. Fuel System and Lines
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
There is evidence of dirt, algae or water in a
fuel water separator.
There is any unsecured, poorly routed or
loose fuel line or hose that could cause fire
due to abrasion or heat damage.
Fuel System and Lines
Visually check the condition, operation and
securement of all fuel system components,
including fuel lines and routing in the engine
compartment.
Any fuel system connection is stripped, loose,
cracked or leaking.
Any fuel system component is damaged or
not mounted securely.
108
C.
ENGINE COMPARTMENT
8. Radiator
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Any portion of the radiator, reservoir or
mounting system is cracked or damaged, or
has loose or missing fasteners not causing
leaks or failure.
Any portion of the radiator, reservoir or
mounting system is cracked, damaged or has
loose or missing fasteners, causing leaks or
failure.
Check condition of radiator cap and perform
pressure test.
Radiator cap is hard to open or close.
Radiator cap is missing.
WARNING: ALWAYS
PROCEDURES WHEN
RADIATOR CAP.
Radiator cap leaks down slowly at rated
pressure.
Radiator cap is the incorrect type or pressure
rating, or fails pressure test.
a. Radiator and Reservoir
Check radiator and reservoir assemblies for
mounting, securement and condition.
b. Cap
USE PROPER
REMOVING A
d. Fan Shroud
Check fan shroud for mounting and condition.
Fan shroud is missing, loose or has excessive
damage that may interfere with the cooling fan.
109
(This Page Intentionally Left Blank)
110
D.
UNDERNEATH BUS
1. Front Suspension
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Oil or grease is seeping from hub bearing
caps.
Oil or grease is leaking from hub bearing
caps.
a. Front Wheel Bearings
Inspect front wheel bearings and related
components for condition and proper
adjustment of bearings. With front wheels
raised, grasp tire and attempt to rock wheel
and move In-and-Out to check for play. Spin
tire to check for noise and condition of
bearings.
Note: See page 131 for definitions of fluid Wheel
bearing
endplay
exceeds
“leaks” and “seepage.”
manufacturer’s specifications of .010-inch
maximum, measured at the hub.
Any noise, binding or roughness is discovered
in bearings.
Note: To correctly identify the source of
any play or to determine if the play is in
wheel bearings, have an assistant press
and hold the foot brake pedal (ensuring
the front brakes are engaged) while
rechecking play. If movement disappears
with brakes applied, then the play was in
the wheel bearings.
b. I-Beam
Inspect I-beam axle assembly.
I-beam has been heated, cut or modified, or is
cracked or damaged.
(Continued on Next Page)
111
D.
UNDERNEATH BUS
1. Front Suspension
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Kingpins
Inspect kingpin assemblies for condition and
play as follows:
End cap O-rings or bolts are loose or missing.
Locking pin is backing out or missing.
Note: Wheel bearings must be adjusted
properly (or wheel bearing play
must be eliminated by locking
brakes) before checking kingpins.
Do not tighten kingpin lock (if
equipped) or grease kingpins
before inspecting.
1) With front wheels raised, use a pry bar
for leverage, and attempt to move the
wheel In-and-Out at the top and
bottom. (See figure 11, page 117.)
Kingpin movement is more than one-fourth
inch measured at outside edge of tire (see
figure 11, page 117).
2) Place a pry bar under wheel and lift
tire straight up and down to determine
condition of thrust bearing.
Vertical (up and down) play in kingpin
assembly is greater than 0.06 inch (see figure
12, page 117), and/or thrust bearing is
damaged or missing.
Note: If play is beyond specifications, wear
may be in the kingpin, axle eye, thrust
bearing and/or kingpin bushings.
(Continued on Next Page)
112
D.
UNDERNEATH BUS
1. Front Suspension
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Shackles
Inspect condition of shackles, spring hangers
and pinch bolts.
Any front spring shackle or hanger is cracked,
broken or has significant side wear at spring
eye.
Any front spring shackle or hanger is worn or
pinch bolt is stripped or missing so that spring
pin cannot be clamped tightly.
e. Spring Mounts
Inspect spring mount bracket(s) for condition
and securement.
Any front spring mount is cracked or broken.
Any front spring mount-to-frame fastener is
loose or missing.
Frame is cracked at any spring mounting
location.
(Continued on Next Page)
113
D.
UNDERNEATH BUS
1. Front Suspension
Inspection Procedures:
f.
Repair (or note) if:
Out-of-Service if:
Any spring pin assembly will not accept
lubrication or zerk (grease) fitting is damaged
or missing.
Total free play (up and down) of pins and
bushings exceeds one-fourth inch (two-pin
type) or one-eighth inch (one-pin type). (See
figure 13, page 117.)
Pins and Bushings
Inspect pins and bushings as follows:
Note: Do not grease pins and bushings
before inspecting.
Inspect front spring pins and bushings for
wear and lubrication. Check for wear with
front axle loaded. Insert pry bar between
spring eye and fixed point at frame and
pull down. Measure total free play in pins
and bushings (see figure 13, page 117).
Inner sleeve or rubber bushing type spring pin
assembly or assemblies are worn through, or
rubber bushing is excessively worn (rubber is
compacted or deteriorated, resulting in free
play between rubber and spring eye or inner
sleeve).
g. A-Frames and Bushings
Inspect A-frames and bushings for condition
and securement.
Rubber bushing(s) are split, deteriorated or
extruded from suspension joints.
Rubber bushing(s) are worn excessively or
missing.
Any A-frame assembly is bent, damaged or
broken, or any fasteners or brackets are loose
or missing.
Any A-frame, bushing or pivot arm has more
than 0.05 inch free play at pivot point.
(Continued on Next Page)
114
D.
UNDERNEATH BUS
1. Front Suspension
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Zerk (grease) fitting is missing or damaged or
ball joint will not take lubrication.
Any ball joint has more than 3/32-inch axial
play.
h. Ball Joints
Inspect ball joint(s) for condition, securement
and lubrication.
Any ball joint nut is loose or missing, or cotter
pin is missing.
Ball joint to A-frame mounting is cracked,
loose or has been welded.
i.
U-Bolts
Inspect spring U-bolts for condition and
securement.
Any U-bolt(s) is misaligned.
There is rust underneath U-bolt
indicating possibility of looseness.
nuts,
Any U-bolt, seating plate, shock mount
bracket or fastener is loose, missing, cracked
or stripped.
j.
Shock Absorbers
Inspect shocks for condition and securement.
Any shock is leaking fluid.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any shock mounting or fastener is loose,
missing, cracked or broken.
Any shock is broken.
(Continued on Next Page)
115
Any shock fails to function.
D.
UNDERNEATH BUS
1. Front Suspension
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
There are any loose, missing, broken or worn
spring clips.
Any spring leaf is broken, cracked or missing.
k. Springs
Inspect
front
springs
for
securement and alignment.
condition,
Any leaf spring or air-suspension ride height
is less than manufacturer’s specifications.
Either front spring saddle (if equipped) is worn
or missing.
Rubber bumper is missing.
Spring eye is worn or spread such that
bushings are loose in spring eye.
Any coil spring(s) is non-OEM, broken or
insecurely mounted, or non-OEM blocks or
spacers are installed.
There is any misalignment of spring leaves or
other evidence that center pin is loose or
broken.
Either front coil or leaf spring is worn so that
rubber frame bumper is damaged or worn due
to frequent bottoming of front suspension.
Any alignment wedge is loose or damaged.
On any air bag type spring assembly, air bag
is damaged or leaking.
l.
Wheel Seals
Check for condition and leakage.
Either front wheel seal is seeping.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
116
Either front wheel seal is damaged or leaking.
117
D.
UNDERNEATH BUS
2. Front Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Brake Hoses
Inspect air and hydraulic front brake flexible
hoses for condition, securement and routing.
Any front hydraulic brake flex hose or
connection is seeping or leaking fluid, or any
air brake hose is leaking air pressure.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any front brake flex hose is kinked, collapsed,
bulging, has damaged plies/cord or is
damaged below outer covering.
Any front brake flex hose supporting brackets
are damaged or have loose fasteners.
Any front brake flex hose is rubbing against
other components or is improperly routed.
b. Lines
Any brake line is bent, crimped or damaged
significantly, restricting air pressure or
hydraulic fluid.
Inspect air and hydraulic brakes lines for
routing, securement and condition.
Any hydraulic brake line or connection is
seeping or leaking fluid, or any air brake line
is leaking air pressure.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any brake line is rubbing against other
components or is improperly routed.
(Continued on Next Page)
118
D.
UNDERNEATH BUS
2. Front Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Any brake line is not of OEM material, size or
type.
c. Chambers
Inspect front brake chamber assemblies for
securement, condition and proper size.
Any front brake chamber, mounting bracket or
hardware is cracked, bent, broken or missing.
Any front brake chamber or mounting fastener
is damaged, loose, missing or of the wrong
type.
Either front chamber is not OEM size and
stroke length.
d. Slack Adjusters
Inspect slack adjusters and S-cam
assemblies for wear, condition, operation and
securement.
Note: See section D.2.k., pages 124-125,
(brake adjustment) for procedure to check
operation of Automatic Slack Adjusters
(ASA).
Any portion of slack adjuster or S-cam is
missing, broken, cracked or worn beyond
limits (see figure 14 on page 125 and figure
15 on page 126).
(Continued on Next Page)
119
D.
UNDERNEATH BUS
2. Front Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
S-cam snap ring is missing.
Slack adjuster has frozen or stripped worm
gear or ratchet assembly.
e. Push Rods
Inspect push rod assemblies for condition,
securement and alignment.
Any portion of push rod assembly (locknut,
push rod, clevis, pin or cotter pin) is loose,
missing or damaged.
Push rod is rubbing against body of chamber,
or chamber is misaligned.
Push rods on left and right sides are not
mounted in identical (same) slack adjuster
location hole (resulting in same effective slack
adjuster length).
f.
Linings
Inspect linings and foundation brake
hardware for contamination, wear, damage
and securement.
There is a significant difference in lining
thickness between the left and right sides.
Any foundation brake assembly does not
have at least one lining inspection hole.
For riveted type shoes, front brake lining is
less than 3/16 inch thick (Q-type) or onefourth inch (Q-plus-type) above shoe table at
the center of the shoe.
(Continued on Next Page)
120
For bonded type shoes, front brake lining is
worn to within one-sixteenth inch of shoe table
at the center of the shoe.
D.
UNDERNEATH BUS
2. Front Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Front brake lining is worn to within one-
sixteenth inch of any rivet.
Lining is broken, cracked or loose on shoe.
Lining is not proper size.
Friction surface is contaminated with oil,
grease or brake fluid.
There is any shimming material between
lining and shoe.
Shoe table or webbing is cracked or
damaged.
There is any loose, damaged or missing
foundation brake hardware within the drum.
g.
Disc Brake Pads
Inspect disc brake pads for contamination,
wear, damage and securement.
There is significant difference in pad thickness
between the left and right sides of the bus.
Pad surface is contaminated, cracked,
broken or missing.
Thickness of friction material is less than
one-eighth inch.
Pad wear is uneven end-to-end exceeding
3/32 inch.
(Continued on Next Page)
121
Difference between the inboard and
outboard pads on one side is greater than
one-eighth inch.
D.
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2. Front Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
h. Drums
Inspect front brake drum(s) for condition and
size.
There is any crack (other than heat checks) in
any drum.
There is more than 0.06-inch wear in drum
friction surface (inside diameter is more than
0.12 inch over original).
There is any grease, oil or brake fluid on
inside of drum.
Drum is not mounted securely to hub or
fasteners are loose.
i.
Drum is not centered on hub, causing more
than 0.01 inch out of round.
Rotors
Inspect brake rotor(s) for mounting, thickness
and condition.
Rotor mounting is not secure or has run out
beyond
manufacturer’s
specifications,
causing a pulsating brake pedal.
Rotor has cracks (other than heat checks) or
other mechanical defects, or is contaminated
with oil, grease or brake fluid.
(Continued on Next Page)
122
Rotor thickness is less than manufacturer’s
specifications stamped on rotor.
Any rotor friction surface is significantly
grooved or damaged.
D. UNDERNEATH BUS
2. Front Brakes
Inspection Procedures:
j.
Repair (or note) if:
Out-of-Service if:
Wheel Cylinders or Calipers
Inspect wheel cylinders or calipers for Any wheel cylinder or caliper dust boot is
seepage, leaks, mounting and condition.
damaged or missing.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any wheel cylinder or caliper is seeping,
leaking, not securely mounted, or has loose or
missing fasteners.
There is uneven lining or pad wear, rotor or
drum damage, evidence of dragging or other
evidence that any wheel cylinder or caliper
may be sticking.
(Continued on Next Page)
123
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UNDERNEATH BUS
2. Front Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
k. Adjust Brakes
1) Any brakes (air or hydraulic) without
automatic adjusting capabilities must
be adjusted at each inspection using
the following procedure:
Any condition prevents proper adjustment of
manual adjusting brakes.
a) Tighten brake adjuster until wheel
locks up.
b) Back off brake adjuster until there
is a very slight drag on friction
surfaces.
2) For all Manual Slack Adjuster (MSA)
equipped S-cam brakes, each brake
chamber push rod travel must be
measured and brakes must be
adjusted at every required inspection
at all wheel positions (see figure 15,
page 126). Push rod travel must not
exceed limits shown in chart 13 on
page 127.
Any MSA-equipped S-cam cannot be
adjusted to bring push rod travel within limits
shown in chart 13 on page 127 of this manual.
(Continued on Next Page)
124
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2. Front Brakes
Inspection Procedures:
Repair (or note) if:
3) Do not adjust ASA-equipped brakes.
Push-rod travel must be measured
and must not exceed limits shown in
chart 13 on page 127. If the push rod
travel measurement exceeds the
limits, the foundation brakes, slack
adjusters, push rods and chambers
must all be inspected and repaired or
replaced, if found defective. Correctly
installed and properly working ASAs
should keep the brakes in adjustment
throughout the life of the linings.
Out-of-Service if:
Any ASA is damaged or malfunctioning, or
push rod travel exceeds the limits shown in
chart 13, page 127.
Figure 14
S-cam Bushing Up-and-Down Play
S-cam In-and-Out Play
125
Figure 15
PROCEDURE FOR MEASURING PUSH ROD TRAVEL
Brake chamber push rod travel shall not exceed maximum stroke specifications. Performance of the brake pushrod travel inspection requires full application of the brake, with a minimum of 80 to 90 psi of application air pressure.
CAUTION: Chock wheels before commencing this inspection,
as vehicle emergency brake(s) must be off.
With brakes off,
mark push rod at
chamber.
Apply brakes and
measure distance of
mark from chamber.
Note: When brakes are properly
adjusted and fully applied, the
slack adjuster should be at an
angle of 90° measured from
centerline of adjuster to push
rod.
Note: Refer to chart 13, page 127 for maximum push rod travel (stroke) at which brake adjustment is required.
126
CHART 13
Dimensions in inches
CLAMP TYPE BRAKE CHAMBER
"LONG STROKE" CLAMP-TYPE
BRAKE CHAMBER
ROTOCHAMBER
AIR DISC BRAKES
Type
Maximum
Stroke
6
1-5/8
1-1/4
9
1-3/4
1-3/8
12
1-3/4
16
2-1/4
20
2-1/4
24
2-1/4
30
2-1/2
2
36
3
2-1/4
16
2-1/2
2
20
2-1/2
24
2-1/2
24
3
30
3-3/8
2-1/2
9
2
1-5/8
12
2
1-5/8
16
2-1/2
20
2-1/2
24
2-1/2
30
3
36
3-1/2
2-3/4
50
4
3-1/4
12
1-3/8
1-3/8
16
1-1/2
20
1-5/8
24
1-3/4
30
1-7/8
127
Maximum stroke with
brakes adjusted
Should be as short as
possible without brakes
dragging
Should be as short as
possible without brakes
dragging
Should be as short as
possible without brakes
dragging
Should be as short as
possible without brakes
dragging
Maximum stroke at which
brakes should be
adjusted
1-3/8
1-3/4
1-3/4
1-3/4
2
2
2-1/2
2
2
2
2-1/2
1-3/4
1-3/4
1-3/4
2
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UNDERNEATH BUS
3. Engine Mounts, Transmission Mounts and Starter Mounting
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Engine/Transmission Mounts
Inspect engine and transmission mounts for
condition and securement.
Any mounting fasteners are loose, missing or
broken.
Any mount is cracked or has deteriorated
rubber.
b. Starter Mounting
Inspect starter for securement and condition.
Any starter-mounting bolt, stud or nut is loose,
damaged, broken or missing.
Starter is damaged or loose.
Any starter cables are loose or bare, or any
positive cable could short to ground.
128
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UNDERNEATH BUS
4. Transmission
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Any transmission assembly fastener is loose,
missing or damaged.
Transmission is not mounted securely to
flywheel housing.
a. Transmission Bolts
Inspect transmission assembly and mounting
fasteners for condition and securement.
There is any indication that any torque
converter bolt is loose or missing.
b. Linkage
Inspect transmission linkage for routing,
condition and securement.
c. Lines
Inspect transmission lines for securement,
routing and condition.
Modulator, Throttle Valve (TV) cable or
vacuum hose is routed where it is subject to
excessive heat or abrasion.
Linkage is bent, damaged, binding or severely
misadjusted.
Any linkage hardware or fasteners are loose.
Any linkage hardware or fasteners are
missing, or linkage is damaged, causing a
sticking or binding condition.
Modulator or TV cable is exposed or casing is
damaged.
Vacuum-modulator hose is leaking or not
connected.
Vacuum modulator hose is deteriorated or
loose.
Any transmission line is unsecured.
(Continued on Next Page)
129
Any transmission line is improper type,
crimped, improperly routed, damaged or
leaking.
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UNDERNEATH BUS
4. Transmission
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Filter
Inspect transmission external filter assembly
(if equipped) for securement and condition.
External filter or base is loose or leaking.
e. Cooler
Inspect transmission cooler (as equipped) for
securement and condition.
Mounting of separate transmission cooler (if
equipped) is not secure or has loose or
missing fasteners.
(Continued on Next Page)
130
Transmission cooler is cracked or damaged,
or hoses and connections are leaking.
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5. Fluid Leaks
Note: Leaks and Seepage are types of fluid loss defined as:
Leak: Enough fluid loss to cause dripping fluid. Leaking fluid can also be slung from rotating assemblies.
Seepage: Fluid loss that may cause dampness or staining, but not dripping or slung fluid.
Inspection Procedures:
Repair (or note) if:
Inspect for engine oil leaks at all locations and
determine severity.
Engine oil is seeping or slightly leaking onto
any location except exhaust system.
Out-of-Service if:
a. Oil
Engine oil leakage is causing deterioration of
any rubber parts, such as steering linkage
boots, hoses, etc.
Engine oil leakage is excessive.
Engine oil is dripping, slinging or being blown
on to any portion of exhaust system.
There is a drip shield installed to divert leaking
oil from the exhaust system.
b. Coolant
Inspect all locations for coolant leaks.
There is coolant seeping at radiator, hoses,
engine oil cooler, thermostat housing, head
gaskets, freeze plugs, reservoir, water pump
or other locations.
(Continued on Next Page)
131
Coolant leakage is excessive.
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UNDERNEATH BUS
5. Fluid Leaks
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Transmission
Inspect for transmission fluid leaks at all
locations and determine severity.
Transmission fluid is seeping or slightly
leaking on to any location except exhaust
system.
Note: See page 131 for definitions of fluid Transmission fluid is causing deterioration of
“leaks” and “seepage.”
any rubber parts, such as steering linkage
boots, hoses, etc.
Transmission fluid leakage is excessive.
Transmission fluid is dripping on any portion
of exhaust system.
d. Power Steering
Inspect for power steering fluid leaks at all
locations and determine severity.
Power steering fluid is seeping.
Power steering fluid is leaking.
Power steering fluid is causing deterioration of
any rubber parts, such as steering linkage
boots, hoses, etc.
Power steering reservoir cap or dipstick is
missing.
132
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6. Fuel and DEF Tank
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Leaks
Inspect fuel and DEF tank assembly for leaks.
There is any fuel or DEF leakage from the
tank, sending unit, connections, vent or cap,
or cap is missing.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any tank is cracked.
Any hose connection is loose at the tank.
b. Mounting
Inspect fuel and DEF tank mounting system
and barrier (if equipped) for securement and
condition.
Any portion of tank mounting system
(including support brackets, retaining straps
and chassis frame) is missing, loose, cracked
or broken.
Any tank mounting fasteners are loose or
missing.
Barrier assembly (if required) is damaged,
insecurely mounted or missing.
(Continued on Next Page)
133
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6. Fuel and DEF Tank
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Hoses
Inspect all fuel and DEF system lines, hoses
and under-bus components for routing,
secure mounting and condition.
Any line or hose is unsecured or improperly
routed, or subject to excessive heat or
abrasion.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any line or hose is deteriorated or damaged
(including cracks or any damage that may
cause seepage or leaks), or clamps are loose
or missing.
Any fuel or DEF system filter, water separator
or other component is insecurely mounted,
cracked or damaged.
d. Wiring
Inspect fuel tank and DEF sending unit wiring
for securement, routing and condition.
Any portion of sending unit wiring (including
ground) or connections is unsecured, missing
insulation or routed, subject to excessive heat
or abrasion.
134
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7. Brake Equipment
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Brake Lines
Inspect all brake hoses, lines and connections
for routing, securement and condition.
Any brake hose or line is unsecured.
Any brake line or hose is improperly routed, or
subject to excessive heat or abrasion.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any brake line or hose is deteriorated or
damaged to the point that failure could occur
(frayed, thin wall; rubber contaminated with
oil; crimped; etc.).
Note: External layer weather cracking
only shall not be cause for rejection.
Any brake line or hose connection is loose.
b. Brake Valves
Inspect all brake system
securement and condition.
There is any audible air leak or visible
hydraulic brake fluid seepage or leak.
valves
for
There are any audible air leaks or visible
hydraulic fluid leaks or seepage from any
brake valve.
Any brake valve is not mounted securely, is
cracked or is damaged.
c. Reservoir Mounting
Inspect reservoirs (air and vacuum tanks) for
securement and condition.
Any reservoir mounting, brackets, straps or
fasteners are cracked, loose or missing.
(Continued on Next Page)
135
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UNDERNEATH BUS
7. Brake Equipment
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Bleed Reservoirs
1) With air system fully charged, check
manual operation of safety pressure
relief valve.
Safety relief valve leaks or does not release
pressure.
2) Partially open manual petcock valve
on the first (wet) tank.
3) Allow draining of any moisture (water)
or contamination.
There is moisture in reservoir (desiccant-type
dryer only).
There is excessive sludge or oil contamination
in the reservoir (more than eight fluid ounces).
Reservoir leaks due to corrosion or is
cracked.
e. Anti-lock Brake System (ABS)
Visual inspection reveals that ABS
components are loose, damaged, missing,
improperly routed or non-operational.
Perform a visual inspection of all ABS
components, including wiring, connectors and
controllers.
Note: Wiring from ABS controller(s) to
wheel speed sensor(s) that has been
abraded or otherwise damaged, exposing
any wire conductor or grounding sheath,
may cause failure of the antilock brake
system. This damage is considered
severe.
136
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8. Driveline
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Drive shafts
Inspect drive shafts for condition.
Any driveshaft balancing weight (if originally
equipped) is missing.
Any driveshaft is bent or seriously dented.
Driveshaft is assembled out of phase.
There are cracks or other damage that could
cause structural failure.
U-joints or CV joints are insufficiently
lubricated or grease fitting is missing, clogged
or not accessible.
There is any missing hardware or fasteners in
any U-joint or CV joint assembly.
b. U-Joints
Prior to lubrication, inspect U-joints or
constant velocity (CV) joints (if equipped) for
condition, phasing (alignment of joints),
lubrication and presence of all hardware.
Any U-joint has significant cross-shaft-tobearing cup play, or CV joint has significant
play.
Any U-joint or CV joint shows evidence of
significant rusting of bearings.
Any bearing cup is loose in yoke.
Any U-joint is cracked or broken.
(Continued on Next Page)
137
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UNDERNEATH BUS
8. Driveline
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Yokes
Inspect driveshaft yokes for condition and
lubrication.
Driveshaft splines are not lubricated.
Any yoke has significant play in splines.
Dust cap on yoke is missing.
Any yoke is cracked or damaged.
Grease fitting is missing or clogged.
Cork washer in dust cap is missing.
d. Hanger Bearings
Inspect hanger bearings and rubber
insulators for condition and securement.
Hanger
bearing
rubber
insulator
deteriorated, damaged or oil-soaked.
Hanger bearing support is misaligned.
is
Bearing outer race is loose in insulator or
inner race is loose on shaft.
There is significant play in hanger bearing.
There is any missing or damaged hardware or
fasteners in hanger bearing or support
assembly.
e. Guards
Inspect for presence and condition
driveshaft guards.
of
Any driveshaft guard is bent or damaged.
(Continued on Next Page)
138
Any driveshaft guard is missing or has loose
or damaged mounting fasteners.
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UNDERNEATH BUS
8. Driveline
Inspection Procedures:
f.
Repair (or note) if:
Out-of-Service if:
Driveshaft Parking Brake
Inspect driveshaft parking brake assembly for
condition, mounting, securement and
adjustment of linings, drum, linkage and all
other related hardware.
Lining is worn down to 2/32 inch from top of
rivet head.
Lining is contaminated with grease or oil.
Lining is broken, cracked or loose.
Drum is cracked or has excessive heat damage or scoring of friction surface.
Any actuating or mounting hardware or
fastener is damaged, loose or missing.
Parking brake is not adjusted
manufacturer’s specifications.
139
per
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9. Rear Suspension
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Axle Housing
Inspect axle housing for condition and
leakage.
Axle housing is seeping lubricant.
Any portion of axle housing is cracked or bent.
Any portion of axle housing is leaking
lubricant due to cracks, porous metal or
defective welds.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
There is any leakage at or around axle
housing ends.
b. Vent
Inspect condition of axle housing vent.
Vent cap is clogged.
Axle vent is not functional or is missing.
Vent hose (if originally equipped) is cracked
or missing.
c. Differential
Inspect differential assembly for condition,
lubricant level and leakage.
Lubricant level is low.
Note: See page 131 for definitions of fluid Differential gaskets or seals are seeping.
“leaks” and “seepage.”
(Continued on Next Page)
140
Differential gaskets or seals are leaking.
There is no lubricant in the differential.
Any external differential hardware
fasteners are loose or missing.
or
Differential pinion yoke nut is loose or has
endplay
or
side
play
exceeding
manufacturer’s specifications.
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UNDERNEATH BUS
9. Rear Suspension
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Springs
Inspect rear springs for condition, securement
and alignment.
There are any loose, missing, broken or worn
spring clips.
Any leaf spring is broken or missing.
Any leaf spring or air-suspension ride height
is less than manufacturer’s specifications.
On any type spring assembly, airbag is
damaged or leaking, or airlines and valving
are damaged or leaking.
Rubber frame bumper is missing.
Air ride pivot pins and bushings are loose.
There is any misalignment of spring leaves or
other evidence that centering pin is loose or
broken.
Either rear leaf spring is worn to the point that
suspension bottoming has damaged rubber
frame bumper.
e. U-Bolts
Inspect spring U-bolts for condition and
securement.
Any U-bolt is misaligned.
(Continued on Next Page)
141
There is rust underneath U-bolt
indicating possibility of looseness.
nuts,
Any U-bolt, U-bolt seating plate, shock mount
bracket or nut is loose, missing, cracked or
stripped.
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UNDERNEATH BUS
9. Rear Suspension
Inspection Procedures:
f.
Repair (or note) if:
Out-of-Service if:
Shock Absorbers
Inspect rear
securement.
shocks for
condition
and
Any shock is broken.
Any shock fails to function.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any shock mounting or fastener is loose,
missing, cracked or broken.
Any shock is leaking fluid.
Note: A very small amount of fluid staining
at the shock-piston shaft seal area is
normal due to the wiping function of the
shaft seal. This does not indicate a leaking
shock.
g. Shackles
Inspect rear suspension shackles, spring
hangers and hanger pinch bolts for condition
and securement.
Any rear spring shackle or hanger is cracked
or broken.
Any rear spring shackle/hanger is worn or any
pinch bolt is stripped/missing, preventing the
spring pin from being clamped tightly.
(Continued on Next Page)
142
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UNDERNEATH BUS
9. Rear Suspension
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Any spring pin assembly will not accept
lubrication, or grease fitting is damaged or
missing.
Inner sleeve on rubber type spring pin
assemblies is worn through or rubber bushing
is excessively worn (rubber is compacted or
deteriorated, resulting in free play between
rubber and spring eye or inner sleeve).
h. Pins and Bushings
Inspect rear spring pins and bushings for wear
and lubrication. See figure 13, page 117, for
shackle type system on checking play in pins
and bushings. For other types of pin and
bushing configurations, see manufacturer’s
service manual.
Rear spring pin bushing (metal type bushing)
is worn through.
Total free play (up and down) of pin and
bushing exceeds one-eighth inch for single
pin type.
On system using two pins and bushings,
combined free play exceeds one-fourth inch.
(Continued on Next Page)
143
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UNDERNEATH BUS
9. Rear Suspension
Inspection Procedures:
i.
Repair (or Note) if:
Hangers
Inspect hangers for mounting and condition.
j.
Out-of-Service if:
Any spring hanger or bracket is cracked or
broken, or any mounting fastener is loose or
missing.
Seals
Inspect rear wheel seals for condition and
leakage.
There is seepage of oil or grease around axle
flange or wheel seal.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any axle flange stud or nut is loose or missing.
k. Wheel Bearings
Inspect rear wheel bearings for condition and
proper adjustment of bearings.
Either rear wheel seal or axle flange is
damaged or leaking.
Note: Rear wheel bearing in-out play
should be 0.000 inches.
1) Raise rear wheels (wheels unloaded)
and release parking brake.
2) Grasp tire and attempt to rock wheel
assembly to check for movement.
144
There is any detectable looseness
roughness in rear wheel bearings.
or
D.
UNDERNEATH BUS
10. Rear Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Hoses
Inspect rear brake flexible hoses for condition,
securement and routing.
Any rear brake flex hose or connection is
seeping, leaking fluid or leaking air pressure.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any rear brake flex hose is kinked, collapsed,
bulging, has damaged plies or is damaged
below outer covering.
Any rear brake flex hose supporting brackets
are damaged or have loose fasteners.
Any rear brake flex hose is rubbing on or
routed against other components.
b. Lines
Inspect air and hydraulic brake lines for
routing, securement and condition.
Brake line bracket(s) or securement system is
loose or missing.
Any brake line is bent, crimped or damaged,
restricting air pressure or hydraulic fluid.
Any brake line or connection is seeping or
leaking hydraulic fluid or leaking air pressure.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any brake line is rubbing
components or is abraded.
on
other
Any brake line is not of OEM material, size or
type.
(Continued on Next Page)
145
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UNDERNEATH BUS
10. Rear Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Chambers
Inspect rear brake chamber assemblies for
securement, condition and proper size.
Any rear chamber-mounting bracket or
hardware is cracked, bent, broken or missing.
Any rear brake chamber or mounting fastener
is damaged, loose, missing or of the wrong
type.
Either rear chamber is not OEM size and
stroke length.
d. Slacks
Inspect slack adjusters and S-cam
assemblies for wear, condition, operation and
securement.
Slack adjuster is mounted so that adjuster bolt
is facing chamber.
Note: See section D.10.k, page 152-153, on
brake adjustment for procedure to check
operation of ASA.
Any portion of slack adjuster or S-cam is
missing, broken, cracked, worn beyond limits
or improperly installed.
S-cam shaft and/or S-cam bushing total wear
(up and down) is greater than 0.04 inch (see
figure 14, page 125).
S-cam In-and-Out endplay is more than 0.06
inch (see figure 14, page 125).
S-cam snap ring is missing.
Slack adjuster has frozen or stripped worm
gear or ratchet assembly.
(Continued on Next Page)
146
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UNDERNEATH BUS
10. Rear Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
e. Push Rods
Inspect push rod assemblies for condition,
securement and alignment.
Any portion of push rod assembly (locknut,
push rod, clevis, pin or cotter pin) is loose,
missing or damaged.
Push rod is rubbing against body of chamber,
or chamber is misaligned.
Push rods on left and right sides are not
mounted in identical (same) slack adjuster
location hole (resulting in same effective slack
adjuster length).
(Continued on Next Page)
147
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UNDERNEATH BUS
10. Rear Brakes
Inspection Procedures:
f.
Repair (or note) if:
Out-of-Service if:
There is a significant difference in lining
thickness between the left and right sides.
Any foundation brake assembly does not
have at least one lining inspection hole.
Rear brake lining is less than five-sixteenths
inch thick at center of shoe (on brake blocks
with original three-fourths inch thickness).
For riveted type shoes, rear brake lining is
less than one-fourth inch thick at center of
shoe (on brake blocks with original threefourths inch thickness).
Linings
Inspect linings and foundation brake
hardware for contamination, wear, damage
and securement.
Rear brake lining is worn to within onesixteenth inch of any rivet.
For bonded type shoes, rear brake lining is
worn to within one-sixteenth inch of shoe table
(at center of shoe).
Lining is broken, cracked or loose on shoe.
Lining is not proper size.
Friction surface is contaminated with oil,
grease or brake fluid.
There is any shimming material between
lining and shoe.
(Continued on Next Page)
148
Shoe table or webbing is cracked or
damaged.
There is any loose, damaged or missing
foundation brake hardware within the drum.
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UNDERNEATH BUS
10. Rear Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
There is a significant difference in pad
thickness between the left and right sides of
the bus.
Pad surface is contaminated, cracked, broken
or missing.
g. Disc Brake Pads
Inspect disc brake pads for contamination,
wear, damage and securement
Thickness of friction material is less than oneeighth inch.
Pad wear is uneven end-to-end exceeding
3/32 inch.
Difference between the inboard and outboard
pads is greater than one-eighth inch.
(Continued on Next Page)
149
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10. Rear Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
h. Drums
Inspect rear brake drum(s) for condition and
oversize.
There is any crack (other than heat checks) in
drum.
There is more than 0.060-inch wear in drum
friction surface (inside diameter is more than
0.120 inch over original).
There is any grease, oil or brake fluid on
inside of drum.
Drum is not mounted securely to hub or
fasteners are loose.
Drum is not centered on hub, causing more
than 0.010 inch out of round.
(Continued on Next Page)
150
D.
UNDERNEATH BUS
10. Rear Brakes
Inspection Procedures:
i.
Repair (or note) if:
Out-of-Service if:
Rotors
Inspect rear brake rotor(s) for mounting,
thickness and condition.
Rotor is not secure or has run-out beyond
manufacturer’s specifications, causing a
pulsating brake pedal.
Rotor has cracks (other than heat checks) or
other mechanical defects or is contaminated
with oil, grease or brake fluid.
Rotor thickness is less than manufacturer’s
specifications stamped on rotor.
Any rotor friction surface is significantly
grooved or damaged.
j.
Wheel Cylinders or Calipers
Inspect wheel cylinder(s) or caliper(s) for
seepage, leaks, mounting and condition.
Any wheel cylinder or caliper dust boot is
damaged or missing.
Note: See page 131 for definitions of fluid
“leaks” and “seepage.”
Any wheel cylinder or caliper is seeping,
leaking, not securely mounted or has loose or
missing fasteners.
There is uneven lining or pad wear, rotor or
drum damage, evidence of dragging or other
evidence that any wheel cylinder or caliper
may be sticking.
(Continued on Next Page)
151
D.
UNDERNEATH BUS
10. Rear Brakes
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
k. Adjust Brakes
1) Any brakes (air or hydraulic) without
automatic adjusting capabilities must
be adjusted at each inspection using
the following procedure:
Any damage or condition prevents proper
adjustment of manual adjusting brakes.
a) Tighten brake adjuster until wheel
locks up.
b) Back off brake adjuster until there
is very slight drag on friction
surfaces.
2) MSA equipped brakes must be
adjusted at every required inspection
at all wheel positions (see f
igure 15, page 126). Push rod travel must not
exceed limits shown in chart 13 on
page 127.
Any MSA-equipped brakes cannot be
adjusted to bring push rod travel within limits
shown in chart 13 on page 127 of this manual.
(Continued on Next Page)
152
D.
UNDERNEATH BUS
10. Rear Brakes
Inspection Procedures:
Repair (or note) if:
3) Do not adjust brakes equipped with
ASAs. Push rod travel must be
measured and must not exceed limits
shown in chart 13 on page 127. If the
push rod travel measurement exceeds
the limits, the foundation brakes, slack
adjusters, push rods and chambers
must all be inspected and repaired or
replaced, if found defective. Correctly
installed and properly working ASAs
should keep the brakes in adjustment
throughout the life of the linings.
Out-of-Service if:
Any ASA is damaged or malfunctioning or
push rod travel exceeds the limits shown in
chart 13, page 127.
153
D.
UNDERNEATH BUS
11. Body Securement and Structure
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
One or two body hold-downs are loose or
misaligned, or there are any cracks or
stripped fasteners at floor securement points.
Any OEM installed body hold-down or cowl
mount is missing.
a. Body Hold-downs
Inspect for securement and condition of all
body hold-downs, chassis cowl mounts and
frame pads. Body hold-downs include any Jbolt, U-bolt or clamp type hold-down used to
secure body to chassis frame.
Padding between frame rails and floor sills is
misaligned.
Three or more body hold-downs are loose,
cracked, stripped, misaligned or have missing
hardware.
b. Floor
Inspect condition of floor structure, sills and
braces.
There are any minor cracks in floor sills,
braces or welds.
There are any holes or cracks in floor sheet
metal, creating an opening to the passenger
compartment.
Entire cross-section of any floor sill or brace is
broken.
There is any broken weld or mounting of a
floor sill or brace, resulting in complete
separation of more than one foot in length.
(Continued on Next Page)
154
There is any broken weld or loose mounting
of the floor bracing, K-member, etc., at the
front under the driver, center and step well
areas (or “cab” area).
D.
UNDERNEATH BUS
11. Body Securement and Structure
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
c. Outriggers
Inspect body outriggers and hardware for
condition and securement.
Any OEM-installed outrigger is missing, or
body outrigger is cracked or has loose or
missing hardware.
d. Braces
Inspect for condition and securement of all
chassis and body braces.
There are any minor cracks in bracing
underneath the body.
Any bumper brace is broken, cracked or
missing.
Body skirt, skirt brace or luggage
compartment has minor cracks, broken sheet
metal or mounting points.
Luggage compartment door-latch, hinge or
lock is sticking, damaged or malfunctioning.
Any mud flap is missing.
Any mud flap is loose or damaged and may
detach while bus is in route.
e. Skirts
Inspect
body
skirts
(and
luggage
compartments, if equipped) for securement
and condition.
f.
Mud Flaps
Inspect for required mud flaps and splash
shielding on buses with skirt-mounted A/C
condensers.
g. Frame Rails
There is any crack in either frame rail or any
cross-member.
Inspect condition of chassis frame rails, cross
members and all hardware attachment points.
There is any loose or missing rivet or other
fastener securing a cross-member to the
frame.
155
D.
UNDERNEATH BUS
12. Exhaust System
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
There is any physical damage to exhaust
system, not restricting flow or causing leaks.
Any leakage is audible or can be felt around
any portion of the exhaust system including
manifold, pipe sections or any junction.
Any exhaust system hanger is not securely
mounted.
Any exhaust hanger is missing, broken or
detached from exhaust system or frame
mounting point.
a. Exhaust Leaks
Inspect for condition and securement. With
engine running at operating temperature,
inspect exhaust system for leaks.
b. Mounting
Inspect mounting of the exhaust system.
c. Mufflers and DPF
Any exhaust pipe or clamp is loose.
Inspect condition of the muffler and DPF.
The muffler or DPF is leaking, restricted or
damaged.
d. DEF Components
Inspect DEF components.
DEF tank lines or injector is loose, damaged
or leaking fluid.
e. Tailpipe
Inspect condition of tailpipe and ensure that it
extends beyond the rear bumper and exits to
the left of the left frame rail (since 1998). If
equipped with regenerative type exhaust
system or for type D rear engine buses, see
2008 specifications for tailpipe exceptions.
The tailpipe is cracked.
There is other significant physical damage to
the tailpipe.
156
The tailpipe is leaking, or does not extend to
at least the rear outer surface of the rear
bumper, or the tailpipe extends more than two
inches beyond the rear outer surface of the
rear bumper (see figure 16 on page 157), or
the tailpipe does not exit to the left of the left
frame rail.
Figure 16
Tailpipe Length
Two inches
maximum
Note: The end of the tailpipe (see vertical line touching
rearmost point of tailpipe in illustration at left) must
extend beyond the rear outer surface of the
bumper for a distance no more than two inches.
157
D.
UNDERNEATH BUS
13. Wheels and Tires
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Tread Depth
Inspect and measure all tires for tread depth
and record measurements on inspection
form.
Tread depth of any tire is less than:
 Front: 4/32 inch
 Rear: 2/32 inch
measured at three points spaced equally
around the circumference of the tire in the
same major tread groove. Do not measure at
wear bars. Measurements for all three points
must fall below the limits above before tire is
required to be out-of-service. Measurements
shall be taken at the most worn major tread
groove of the tire.
Any single point of the most worn major tread
groove of any tire measures less than:
 Front: 2/32 inch
 Rear: 1/32 inch
There is evidence of any regrooved tire.
Any front tire is recapped or regrooved.
There is evidence that any tire has been
regrooved using a procedure not approved by
tire manufacturer or dealer.
(Continued on Next Page)
158
D.
UNDERNEATH BUS
13. Wheels and Tires
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
b. Pressure
With tires cold, check pressures of all tires
and record measurements on the inspection
form.
Pressure in any tire is lower than 20 percent
below the maximum cold inflation pressure
stated on sidewall of the tire.
Pressure in any tire is higher than 5 percent
above the maximum cold inflation pressure
stated on sidewall of the tire.
There is greater than 20 percent difference in
pressure between any tires on a particular
axle.
c. Damage
Inspect for damage to wheels and tires.
There is foreign material in the tire tread that
could cause damage or loss of air pressure.
There are any cuts, abrasions or other
damage to tire sidewall, resulting in exposed
or damaged cord.
There is any evidence of separation, bulges
(other than normal manufacturer bulge) or
other damage within the carcass of the tire.
Note: Weather cracking only shall not be
cause for rejection.
Any cracks run around the bead or sidewall of
the tire.
(Continued on Next Page)
159
D.
UNDERNEATH BUS
13. Wheels and Tires
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Retreaded tires have any separation of the
tire tread from the tire carcass that could
result in tire or tread failure.
Any valve cap is missing.
Any valve stem is damaged or misaligned so
that tire cannot be filled with air.
Any damage to the lock ring assembly or
groove of a multi-piece rim that could cause
the lock ring not to seat fully.
There are any cracks or breaks at the
lugholes or any other part of a rim or cast
spokes.
There are minor dents or bends in a rim.
There are any dents, bends or non-OEM
welds to a rim.
d. Matching
Inspect for matching of tire construction,
design, size and load rating on each axle.
There is mismatching of inner and outer dual
tire diameters greater than three-eighths inch.
There is any tire marked for use other than
highway use.
(Continued on Next Page)
160
Any tire is not of proper type, size and
minimum load rating according to Florida
Specifications.
D.
UNDERNEATH BUS
13. Wheels and Tires
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Not all tires on an axle are of same type (i.e.,
lug or rib) and size.
Radial and bias ply tires are intermixed on the
same axle.
e. Alignment
Inspect tires for evidence of proper alignment.
f.
Wheel Hardware
Any tire is feather-edged, cupped or has
uneven tread wear.
Tires/wheels are grossly misaligned, affecting
steering control.
Lateral run-out of any tire/rim assembly
exceeds one-fourth inch.
1) Inspect for presence, type, condition
and securement of all wheel
hardware.
There is improper matching of rims and lock
rings.
2) Check for proper spacing of rear dual
wheels and tires (proper spacer
width).
There is evidence of slippage of wheel
assembly on cast spoke hub.
Stud holes are elongated.
Any wheel nut, stud or clamp is loose, or there
is rust or corrosion, indicating possible
looseness.
(Continued on Next Page)
161
D.
UNDERNEATH BUS
13. Wheels and Tires
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
Any wheel, nut, stud or clamp is broken,
stripped or missing.
Any improper spacer is installed between dual
wheels.
Any bus built since October 1987 is not
equipped with disc type (Budd) wheels.
3) Inspect for correct wheel color. Studpiloted and spoke wheels are to be
painted black. Hub-piloted wheels are
to be painted National School Bus
Yellow.
Wheel(s) not painted the correct color.
4) Inspect for correct wheel type.
Incorrect wheel is installed on any axle or hub,
i.e., hub and stud piloted wheels are not
interchangeable.
162
E.
LUBRICATION AND MAINTENANCE
(OPTIONAL)
Inspection Procedures:
Repair (or note) if:
This section of the form is for the convenience
of school districts. School districts should
implement their own lubrication and
maintenance policies and procedures.
(Continued on Next Page)
163
Out-of-Service if:
E.
LUBRICATION AND MAINTENANCE
(OPTIONAL)
Inspection Procedures:
Repair (or note) if:
164
Out-of-Service if:
F.
ROAD TEST
1. Brake Performance
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Parking Brake
Check for proper operation of parking brake
as follows:
Apply parking brake. Place automatic
transmission gear selector in drive and
speed up the engine to a fast idle
(approximately 1,200 RPM). Vehicle
should not move forward.
Note: Buses equipped with Rear Diesel Vehicle moves forward.
Engine and Allison World Transmission
should be checked at 900 RPM.
b. Stopping Distance and Equalization
1) Stopping distance
The following stopping distance
requirements should be met when
stopping the vehicle on a level, dry,
smooth, hard surface that is free from
loose material from a speed of 20
mph:
a) Decelerometer reading (feet per
second per second) minimum of
14.
F.
Decelerometer reading is close to 14, but
within acceptable limits.
(Continued on Next Page)
ROAD TEST
1. Brake Performance
165
Decelerometer reading is less than 14.
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
OR
b) Stopping distance (at 20 mph from
point of brake pedal application)
maximum of 30 feet.
Stopping distance is close to, but within,
acceptable limit.
Distance to stop is greater than 30 feet.
c) Check for tire flat spotting before
and after conducting this test.
Flat spotting but will not cause tires to be
rejected when following procedures on page
158 of this manual.
Flat spotting causes any tire to fail inspection
(follow measuring procedures beginning on
page 158 of this manual).
Bus pulls, but stops, within a lane 12 feet
wide.
Bus pulls sharply and will not stop within a
lane 12 feet wide.
Note: Use of either decelerometer or
stopping distance measurement is
acceptable.
Lockup of
brakes is
discouraged, as it may cause extended
stopping distances and tire damage (flat
spotting).
2) Equalization
Check for excessive brake pulling
during the stopping distance test.
(Note: Pull is excessive if steering
pulls sharply and/or bus will not stop
within a lane 12 feet wide).
Note: Remove hands from steering wheel
while conducting the brake equalization
test.
F.
ROAD TEST
2. Engine, Transmission and Driveline
166
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Engine Performance & Governor
Check for starting, color and quantity of
exhaust smoke, proper idle, stalling,
missing/skipping or hesitation, performance
when accelerating and shutdown of engine.
Engine will not start, is difficult to start or will
not shut down.
Engine hesitates upon acceleration, stalls,
misfires or performs poorly.
Any engine/emissions system warning lights
or alarms are on, indicating a mechanical
safety condition.
b. Automatic Transmission
Check operation of shifter and transmission.
Up and down shifting is excessive, or shifts
are hard.
Transmission will not shift up and down
through all gears.
Transmission is slipping or noisy.
Shift points are not within manufacturer’s
specifications.
F.
ROAD TEST
3. Steering and Handling
167
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
a. Free Play
Check for free play in steering.
There is excessive wandering or shimmy due
to free play in steering.
Bus wanders and requires excessive steering
correction or effort to maintain straight-ahead
driving.
b. Power Assist
Check power steering assist effort when
turning to the left or right.
There is no power assist.
Bus is hard to turn to the left or right.
There is jerking in the steering wheel when
turning to the left or right.
c. Turning Radius
Check and compare the left turning radius to
the right turning radius.
F.
ROAD TEST
3. Steering and Handling
There is a minor difference between the left
turning radius and the right turning radius.
(Continued on Next Page)
168
There is a significant difference between the
left turning radius and the right turning radius.
Inspection Procedures:
Repair (or note) if:
Out-of-Service if:
d. Steering Column
Check up-and-down movement of steering
column.
Up-and-down movement is greater than one
inch.
e. Tracking
Check vehicle steering recovery from left and
right turns, wandering on rough or crowned
roads, and tracking and pulling when driving
straight ahead (not when stopping).
There is poor recovery on turns.
There is no recovery on turns.
Bus does not track properly (front and rear
wheels are not in line).
There is minor pulling in the steering.
169
Bus wanders and requires excessive steering
correction or effort to maintain straight-ahead
driving.
(Intentionally Left This Page Blank)
170
CHART AND FIGURE CONTENTS
CHART NUMBER
DESCRIPTION
PAGE NUMBER
1
First Aid Kit Contents
3
1a.
Body Fluid Cleanup Kit
3
2
Brake Failure Warning
31
3
Ford Hydraulic Brake-Maxi System
32
4
Nut and String Test
65
5
Pupil Eight-Light Warning System
76
6
Lettering & Lights-Front of Bus
84
7
Lettering & Lights-Rear of Bus
84
8
Steering Wheel Lash Play
86
9
Charging System Cable Size Chart
96
10
Battery Load Test
97
11
Antifreeze Tables
101
12
For Future Use
13
Air Brake Push Rod Travel
127
FIGURE NUMBER
DESCRIPTION
PAGE NUMBER
1
Steering Wheel Size
86
2
Wheel Size
86
3
Column Yoke/Joint
90
4
Rag Joint
90
5
Column Shell Coupling
90
6
Checking Tie Rod Ends
93
7
Checking Idler Arm
93
8
Not used
9
Belt Tension-Gauge Method
103
10
Belt Tension-Ruler Method
103
11
Checking Kingpins
117
12
Checking Front Axle Thrust Bearing
117
13
Checking Spring Pin and Bushing
117
14
S-cam Bushing Wear
125
15
Measuring Air Brake Push Rod Travel
126
16
Tailpipe Length
157
171
STATUTORY REQUIREMENT FOR SAFE TRANSPORTATION OF STUDENTS
1006.22 Safety and health of students being transported - Maximum regard for safety and adequate
protection of health are primary requirements that must be observed by school boards in routing buses,
appointing drivers, providing and operating equipment, in accordance with all requirements of law and
rules of the State Board of Education in providing transportation pursuant to s. 1006.21:
(10) Each district school board shall designate and adopt a specific plan for adequate examination,
maintenance and repair of transportation equipment. Examination of the mechanical and safety
condition of each school bus must be made as required pursuant to rule of the State Board of Education.
The State Board of Education shall base the rule on student safety considerations.
(11) The district school superintendent shall notify the district school board of any school bus that
does not meet all requirements of law and rule of the State Board of Education and the district school
board shall, if such school bus is in an unsafe condition, withdraw it from use as a school bus until the
bus meets the requirements. The department may inspect or have inspected any school bus to
determine whether the bus meets requirements of law and rules of the State Board of Education. The
department may, after due notice to a district school board that any school bus does not meet certain
requirements of law and rules of the State Board of Education, rule that the bus must be withdrawn from
use as a school bus, this ruling to be effective immediately or upon a date specified in the ruling,
whereupon the district school board shall withdraw same from use as a school bus until it meets
requirements of law and rules of the State Board of Education and until the department has officially
revoked the pertinent ruling. Notwithstanding any other provisions of this chapter, general-purpose
urban transit systems are declared qualified to transport children to and from school.
STATE BOARD OF EDUCATION RULE ON SCHOOL DISTRICT RESPONSIBILITIES FOR THE
SAFE TRANSPORTATION OF STUDENTS
6A-3.0171 Responsibilities of School Districts for Student Transportation.
Each school board shall exercise specific powers and responsibilities, as follows:
(8) Inspection and maintenance of school buses:
(a) To provide, after considering recommendations of the superintendent, adequate storage,
maintenance and inspection procedures for all buses owned by the school board and to assure that all
contract buses in use in the district are properly inspected and maintained in accordance with law and
rules of the State Board of Education.
(b) The inspection shall be conducted in accordance with procedures and include all items listed in the
State of Florida School Bus Safety Inspection Manual, 2017 Edition and documented on the Florida
School Bus Safety Inspection Form (2017-IF) effective March 2017. The manual and form 2017-IF are
hereby incorporated by reference and made a part of this rule. These documents may be obtained from
the
Department’s
website
at:
http://fldoe.org/core/fileparse.php/7585/urlt/0085485floridaschoolbussafetyinspectionmanual-1.pdf and may also be obtained from the School
Transportation Management Section, Department of Education, 325 West Gaines Street, Tallahassee,
Florida 32399, at a cost not to exceed actual production and distribution cost.
(c) Inspection of buses shall be scheduled and performed at a maximum interval of thirty school days.
Any bus removed from service to disrupt the safety inspection schedule shall be inspected prior to being
returned to service. All deficiencies discovered during the safety inspection shall be noted on the
inspection form. Follow-up repairs of all safety related items shall be made before the bus is returned
to service and shall be documented.
(d) School bus inspections shall be conducted by technicians certified as school bus safety inspectors
in accordance with the State of Florida School Bus Safety Inspection Manual, 2017 Edition. The
requirement that inspections be performed by a certified Florida School Bus Safety Inspector may be
waived for a period not to exceed six (6) months when an emergency condition exists, upon written
notification to the Commissioner of Education by the district superintendent.
(e) No person shall knowingly render inoperative or reduce compliance of any school bus equipment
required to meet Federal Motor Vehicle Safety Standards applicable at the time of manufacture.
172
FLORIDA SCHOOL BUS SAFETY INSPECTION FORM
FLORIDA SCHOOL BUS SAFETY INSPECTION FORM
District School Board
Status Code
  Item OK
X = Needs Repair
(or as noted)
O = Out of Service
N/A Not Applicable
_____________________________________________________________District School Board___
Bus #
Mileage
RO #
Date
Capacity
Model Year
Bus#______________Mileage________________RO#_________________Date________________
Chassis/Body
Chassis/Body_____________________________ Capacity______________Model Year__________
Shop Location
Shop Location_____________________________________________________________________
Status
Code
COMMENTS
(Note Specific Deficiencies)
INSPECTION ITEMS
Tech.
Initials
A. INSIDE BUS
1. Emergency Equipment - Fire Ext. (pressure/tag/mount), First Aid Kit,
Body Fluid Cleanup Kit and Reflectors
2. Registration and Insurance Card
3. Neutral Safety Switch, Shifter and Noise Abatement Switch
4. Engine Controls - Key Switch, Accelerator and Engine Shutdown
5. Gauges, Indicators, Dash and Switch Panel Lights, Engine Warning
Lights/ Buzzers and ABS Warning Light
6. Air Brake System - Gauge(s), Build-Up, Governor, Park Brake,
Adjustment, Air Leaks, Low Air Warning, PP-1 Pop-Off and Pedal
7. Hydraulic Brakes - Warning Light, Gauge, Pedal Travel and
Fade, Power Assist and Park Brake
8. Windshield Wipers and Washers - Operation, Park and Blades
9. Heaters, Defrosters, Auxiliary Dash or Header Fan(s)
10. Dome and Step Well Lights
11. Service Door - Operation, Control and Overhead Pad
12. Horns
13. Mirror Adjustment and Condition - Rear vision, Cross-view, Side-view and Interior
14. Driver’s Seat and Seat Belt
15. Passenger Seats - Frames, Mounting, Pads, Cuts, Bottoms, Modesty
Panels, Stanchions, Passenger Securement Devices and Webbing Cutter
16. Emergency Doors, Windows, Hatches and Passenger Check System
Operation, Buzzers, Labeling and Overhead Pad
17. Windshield, Side and Rear Windows - Cracks, Fogging, Latches and Visor
18. Wheelchair Lift, Door and Securement System - (if equipped)
19. Two-Way Radio Operation - (if equipped)
20. Interior Wiring, Cab Hoses and Fire Wall Seals
21. General Condition of Bus Interior - Floor, Step well, Grab Rail(s),
Paneling, Broom Mounting, Loose Objects Secured and Engine Cover
B. OUTSIDE BUS
1. Headlights, Turn Signals, Hazard, Brake, Tail, Backup
Lights, Backup Alarm and Park Lights
2. Clearance, Side Marker, ID Lights, Reflectors and Strobe Light
3. Pupil Warning Lights
4. Stop Arm(s) and Student Crossing Arm - Wiring, Air or Vacuum Leak and Decal
5. General Condition of Bus Exterior - Mirrors, Bumpers, Body Damage, Paint
Reflective Marking, Lettering, Emergency Door, Engine Hood and Cleanliness
C. ENGINE COMPARTMENT
1. Steering - Play, Column, Steering Gear Box Mounting, Pitman Arm,
Drag Link, Steering Arm, Tie Rod & Ends and Idler Arm
2. Batteries - Hold Down, Terminals, Cables, Cleanliness, Slide Tray and Load Test
3. Fluid Levels and Condition - Brake, Power Steering,
Oil, Transmission, Windshield Washer, Coolant (Antifreeze __________°F) and DEF
4. Belts and All Hoses - Tightness, Condition, Routing and Belt Alignment
5. Accessory Mounting and Condition – Power Steering Pump,
Air Compressor and Filter,
Water Pump, Fan, Alternator and Air Cleaner (Restriction) ________________(H2O)
6. Wiring - Routing and Condition

173
Form 2017-IF (effective March 2017)
Status
Code
COMMENTS
INSPECTION ITEMS
(Note Specific Deficiencies)
Tech.
Initials
7. Fuel System and Lines
8. Radiator - Mounting, Cap, Reservoir and Fan Shroud
D. UNDERNEATH BUS
1. Front Suspension - I-Beam, U-Bolts, Springs, Spring Mounts, Shackles, Pins and
Bushings, Shocks, Kingpins, Wheel Bearings, Seals, A-Frames, Bushings and Ball
Joints
2. Front Brakes - Hoses, Lines, Chambers, Slack Adjusters, Push rods, Linings, Drums,
Rotors and Wheel Cylinders or Calipers. Check and Adjust MSA-Equipped Brakes.
Do Not Adjust ASA-Equipped Brakes
3. Engine Mounts, Transmission Mounts and Starter Mounting
4. Transmission - Bolts, Linkage, Lines, Filter and Cooler
5. Fluid Leaks - Oil, Coolant, Transmission, Power Steering and DEF
6. Fuel and DEF Tank - Leaks, Mounting, Hoses and Wiring
7. Brake Equipment – ABS, Lines, Valves, Reservoir Mounting and Bleed Reservoirs
8. Driveline - Shafts, U-Joints, Yokes, Hanger Bearings, Guards Driveshaft and Park brake
9. Rear Suspension - Axle Housing, Vent, Differential, Springs, U-Bolts, Shocks, Spring
Shackles, Pins and Bushings, Hangers, Seals and Wheel Bearings
10.Rear Brakes - Hoses, Lines, Chambers, Slack Adjusters, Push rods, Linings, Drums,
Rotors and Wheel Cylinders or Calipers. Check and Adjust MSA-Equipped Brakes.
Do Not Adjust ASA-Equipped Brakes
11.Body Securement and Structure - Hold Downs, Floor, Outriggers, Braces,
Skirts and Chassis Frame Rails
12.Exhaust System - Leaks, Mounting, Muffler, Tailpipe and DEF System
13.Wheels and Tires - Tread Depth, Pressure, Damage, Matching, Alignment
and Wheel Hardware
E. LUBRICATION & MAINTENANCE (OPTIONAL)
1. Change Oil and Replace Oil Filter(s)
Qts. _______________
2. Replace Fuel Filter(s) Primary/Secondary and Drain Separator
3. Replace Transmission Filter(s)
Qts. _______________
4. Replace Air Compressor Filter (if applicable)
5. Replace Power Steering Filter
Pts. ______________
6. Replace Engine Air Cleaner Filter
7. Replace Coolant Filter (if applicable)
8. Test Starting and Charging System
Amps _________ Volts __________
9. Lubricate Chassis and Body
Lbs. ______________
10.Air Conditioning If equipped, perform A/C system preventive maintenance
according to manufacturer recommendations and district procedure.
F. ROAD TEST
1. Brake Performance - Park Brake, Stopping Distance and Equalization
2. Engine, Transmission and Driveline - Engine Performance, Governor and Shifting
3. Steering and Handling - Free Play, Power Assist, Column and Tracking
174
Form 2017-IF (effective March 2017)
FLORIDA SCHOOL BUS SAFETY INSPECTION FORM
FLORIDA SCHOOL BUS SAFETY INSPECTION FORM
District School Board
Status Code
  Item OK
X = Needs Repair
(or as noted)
O = Out of Service
N/A Not Applicable
__________________________________Sunshine___________________District School Board___
Bus #
Mileage
RO #
Date
Capacity
Model Year
Bus#_04-1234______Mileage__96,000________RO#____Y43219-R_____Date______8/20/2015__
Chassis/Body
Chassis/Body____IC/Thomas/BB_____________ Capacity_______77_____Model Year___2004___
Shop Location
Shop Location__________Busville__________________________________________________
Status
Code
COMMENTS
INSPECTION ITEMS
(Note Specific Deficiencies)
_
Tech.
Initials
A. INSIDE BUS






N/A

1. Emergency Equipment - Fire Ext. (pressure/tag/mount), First Aid Kit,
Body Fluid Cleanup Kit and Reflectors
2. Registration and Insurance Card
3. Neutral Safety Switch, Shifter and Noise Abatement Switch
4. Engine Controls - Key Switch, Accelerator and Engine Shutdown
5. Gauges, Indicators & Dash and Switch Panel Lights, Engine Warning
Lights/ Buzzers and ABS Warning Light
6. Air Brake System - Gauge(s), Build-Up, Governor, Park Brake,
Adjustment, Air Leaks, Low Air Warning, PP-1 Pop-Off and Pedal
7. Hydraulic Brakes - Warning Light, Gauge, Pedal, Travel &
Fade, Power Assist and Park Brake
8. Windshield Wipers & Washers - Operation, Park and Blades





9. Heaters, Defrosters, Auxiliary Dash or Header Fan(s)

14. Driver’s Seat and Seat Belt



10. Dome and Step Well Lights
11. Service Door - Operation, Control and Overhead Pad
12. Horn(s)
13. Mirror Adjustment and Condition - Rear vision, Cross/Side-View and Interior
15. Passenger Seats - Frames, Mounting, Pads, Cuts, Bottoms, Modesty
Panels, Stanchions, Passenger Securement Devices and Webbing Cutter
16. Emergency Doors, Windows, Hatches and Passenger Check System –
Operation, Buzzers, Labeling and Overhead Pad
17. Windshield, Side and Rear Windows -Cracks, Fogging, Latches and Visor
N/A
18. Wheelchair Lift, Door and Securement System - (if equipped)
N/A
19. Two-Way Radio Operation - (if equipped)

20. Interior Wiring, Cab Hoses and Fire Wall Seals

21. General Condition of Bus Interior - (Including floor, step well, grab rail(s),
paneling, trim, broom mounting, loose objects secured and engine cover
B. OUTSIDE BUS
X
1. Headlights, Turn Signals, Hazard, Brake, Tail, Backup
Lights, Backup Alarm and Park Lights
2. Clearance, Side Markers, ID Lights, Reflectors and Strobe Light

3. Pupil Warning Lights - (see eight light warning system chart)

4. Stop Arm(s) and Student Crossing Arm - Wiring, Air or Vacuum Leak and Decal

5. General Condition of Bus Exterior - Mirrors, Bumpers, Body Damage, Paint,
Reflective Marking, Lettering, Emergency Door, Engine Hood and Cleanliness

LF Corner Not Working
RM
C. ENGINE COMPARTMENT



X/O

1. Steering - Play, Column, Steering Gear Box Mounting, Pitman Arm,
Drag Link, Steering Arm, Tie Rod & Ends and Idler Arm
2. Batteries - Hold Down, Terminals, Cables, Cleanliness, Slide Tray and Load
Test
3. Fluid Levels and Condition - Brake, Power Steering,
Oil, Transmission, Windshield Washer, Coolant (Antifreeze ___________°F) and DEF
4. Belts and All Hoses - Tightness, Condition, Routing and Belt Alignment.
5. Accessory Mounting and Condition - P.S. Pump, Air Compressor
and Filter, Water Pump, Fan, Alternator and Air Cleaner (Restriction)__________(H2O)
6. Wiring - Routing and Condition.
X - Main Drive Belt Glazed
O- A/C Belt Twisted in Pulleys
175
Form 2017-IF (effective March 2017)
Status
Code
COMMENTS
INSPECTION ITEMS

7. Fuel System and Lines

8. Radiator - Mounting, Cap, Reservoir and Fan Shroud.
(Note Specific Deficiencies)
D. UNDERNEATH BUS
1. Front Suspension - I-Beam, U-Bolts, Springs, Spring Mounts, Shackles, Pins &

Bushings, Shocks, Kingpins, Wheel Bearings, Seals, A-Frames, Bushings; Ball Joints
2. Front Brakes - Hoses, Lines, Chambers, Slack Adjusters, Push rods, Linings,
O
Drums, Rotors, Wheel Cylinders or Calipers, Check and Adjust MSA Equipped Brakes.
Do Not Adjust ASA Equipped Brakes
3. Engine Mounts, Transmission Mounts and Starter Mounting


4. Transmission - Bolts, Linkage, Lines, Filter and Cooler

5. Fluid Leaks - Oil, Coolant, Transmission, P.S., DEF, etc.

6. Fuel and DEF Tank - Leaks, Mounting, Hoses and Wiring
X
7. Brake Equipment - ABS, Lines, Valves, Reservoir Mounting and Bleed Reservoirs





Less than ¼ inch (Q-Plus)
Bleed Tanks
RM
8. Driveline - Shafts, U-Joints, Yokes, Hanger Bearings, Guards and Driveshaft Park
Brake
9. Rear Suspension - Axle Housing, Vent, Differential, Springs, U-Bolts, Shocks,
Spring Shackles, Pins and Bushings, Hangers, Wheel Bearings and Seals
10. Rear Brakes - Hoses, Lines, Chambers, Slack Adjusters, Push rods, Linings,
Drums, Rotors and Wheel Cylinders or Calipers - Check and Adjust MSA Equipped
Brakes - Do Not Adjust ASA Equipped Brakes
11. Body Securement and Structure - Hold Downs, Floor, Outriggers, Braces,
Skirts and Chassis Frame Rails
12. Exhaust System - Leaks, Mounting, Muffler, Tailpipe and DEF System
13. Wheels and Tires - Tread Depth, Pressure, Damage, Matching, Alignment and
Wheel Hardware
E. LUBRICATION & MAINTENANCE (OPTIONAL)
1. Change Oil and Replace Oil Filter(s)
Qts. ____28_________
X
O
X
Tech
Initials
2. Replace Fuel Filter(s) Primary/Secondary and Drain Separator
N/A
3. Replace Transmission Filter(s)
N/A
4. Replace Air Compressor Filter (if applicable)
N/A
5. Replace Power Steering Filter
N/A
6. Replace Engine Air Cleaner Filter
N/A
7. Replace Coolant Filter (if applicable)
X
8. Test Starting and Charging System
X
9. Lubricate Chassis and Body
RF 1/32 inch, and Low Air
Pressure
RM
RM
Qts. _______________
Pts. ______________
Amps 105_____Volts 15.2
Lbs. ____1/2_______
10. Air Conditioning - Perform A/C System Preventive Maintenance
X
(if equipped) according to district procedure
F. ROAD TEST

1. Brake Performance - Park Brake, Stopping Distance and Equalization

2. Engine, Transmission and Driveline - Engine Performance, Governor and Shifting

3. Steering and Handling - Free Play, Power Assist, Column and Tracking
RM
RM
RM
176
Form 2017-IF (effective March 2017)
Repair Order
Vehicle Number
Mileage
Date:
Description of Vehicle
Year
Reg.
Make
Lift
A/C
Organization Name:
________________________ School District
Route/Driver:
Repairs Needed:
Repair Order #
Safety Inspection
Yes ( ) No ( )
Inspected By:
Out-of-service Date:
In Service Date:
Quantity
Parts
Est. Cost
Tech.
Init.
Repairs
Cost Subtotal
Quantity
Tires and Batteries
Time
1/10
Hrs.
Total Man-Hours
Filters
Mileage
Yes
Fuel/Oil
Air
Coolant
Trans
No
Tune/Up-Front/Wheels-Oil
Tune-Up
Frt Wheels
Oil Change
Total
177
Mileage
Yes
No
Repair Order, Example
Vehicle Number
Mileage
04-1234
96,000
Date:
Route/Driver:
Description of Vehicle
Year
Reg.
Make
IC/Thomas/ BB
Organization Name:
08/20/2015
Quantity
1
Lift
A/C
X
Parts
1157 Bulb
187439CI oil filter
LF 3949 oil filter
1872526CI fuel filter
PH79 fuel filter
1875921CI fuel filter
Quarts of Oil
Pounds of grease
Labor, Mechanic
1.3
1.0
Labor, Helper (@8.5/hr.)
Tire (see cost below)
(@12/hr.)
Cost Subtotal
Tires and Batteries
11Rx22.5 new tire
Cost Total
Est. Cost
Safety Inspection
Yes ( X ) No ( )
Inspected By:
Bill Smith
08/20/2015
In Service Date:
Repairs
08/21/2015
Time
1/10
Hrs.
RM
RM
RM
RM
RM
RM
RM
RM
BS
Replaced Bulb
Replaced Filter
Replaced Filter
Replaced Filter
Replaced Filter
Replaced Filter
Changed Oil
Lubricated Chassis
Inspection Adjustments and Repairs
0
0
0
0
0
0
0
0
1
11 05 RM
RM
77 66
Inspection Adjustments and Repairs
Change R/F Tire
0 1
0 3
2 3
8
14
7
5
4
11
1
12
67
50
50
82
32
90
40
50
00
Tech.
Init.
Y43219-I-R
Out-of-service Date:
See inspection form dated 08/20/2015
1
1
1
1
1
1
14
1/2
1.0
Quantity
X
Sunshine School District
15/Betty Bus Driver
Repairs Needed:
2004
Repair Order #
197 00
274 66
Filters
Fuel/Oil
Air
H20
Trans
Mileage
96,000
178
Yes
X
No
Tune/Up-Front/Wheels-Oil
X
X
Tune-Up
Frt Wheels
Oil Change
Total Man-Hours
Mileage
Yes
96,000
X
1
1
1
1
1
1
2
1
0
No
X
X
School Bus Safety Inspection Certification Program
This program shall meet the requirements of rule 6A-3.0171, F.A.C. Technicians performing
school bus inspections shall certify as School Bus Safety Inspectors. The certification shall be in
effect until the end of the fifth fiscal year (June 30) from the certification date stated on the
certificate. For example, a certificate issued on June 29, 2017, is valid through June 30, 2022.
Certifications renewed during the fifth fiscal year, shall be in effect for an additional five fiscal
years. The qualifications, training and testing requirements for certification are as follows:
A. Level 1 Certified School Bus Safety Inspector
1) Qualifications Requirements:
a) Candidates must document at least two years of journeyman-level mechanical
experience in the repair and maintenance of motor vehicles in the areas of automotive,
truck, heavy equipment or bus or successful course completion in vehicle maintenance
and repair from an accredited school with a minimum two-year curriculum. The
required mechanical experience is defined as “hands-on” or “wrench-turning”
experience.
b) Candidates must submit a State of Florida, School Bus Safety Inspector Application
(form 2017-SI) to the inspector-trainer for the two-day class; to the district test
administrator prior to the online test; and to the FDOE test administrator prior to the
hands-on test.
c) Candidates’ current employers shall classify them as journeyman-level
mechanics/technicians. This classification must be in the form of an official job
description. In cases where candidates are working as journeyman-level
mechanics/technicians without the proper classification, they may have their employer
submit a letter to the School Transportation Management Section (STMS) of the FDOE
requesting a waiver of the job description requirement. Acceptable job descriptions
cannot contain language indicating candidate’s primary responsibility is to perform
mechanic’s assistant or equivalent duties.
2) Training Requirements:
a) School bus safety inspector candidates shall attend a minimum two-day training
program conducted by a certified school bus safety inspector-trainer.
b) Candidates should be thoroughly familiar with the current edition of the State of Florida
School Bus Safety Inspection Manual prior to attending a training class.
c) Candidates shall train/practice performing school bus inspections on several school
buses prior to hands-on testing, using the procedures and information learned in the
training class.
3) Testing Requirements:
a) Testing consists of two parts, a 100-question online knowledge test and a hands-on
application test.
b) FDOE-approved test administrators will conduct online testing.
c) The STMS will administer the hands-on testing in the field.
d) Candidates shall pass both tests to certify as a State of Florida School Bus Safety
Inspector.
179
4)
Written (online) Test:
a) All written test questions correspond to material in the inspection manual.
b) Candidates have 90 minutes to take the test.
c) The minimum passing score is 80 percent.
d) This test is an open-book test. Candidates may use the State of Florida School Bus Safety Inspection Manual during the 100-question online test. e) Prior to hands-on testing, a candidate should pass the online test.
5)
Hands-on Test:
a) The FDOE will provide the time, date and location of each regionally scheduled handson testing class to school district transportation departments.
b) Candidates will be required to perform actual physical inspections of school buses and
should dress accordingly. All needed equipment will be provided at the test site.
c) Candidates must bring a current State of Florida School Bus Safety Inspection Manual
and a valid driver’s license to the test site.
d) Candidates should use the information learned in their training class, the inspection
manual and their professional knowledge while taking the hands-on inspection test.
e) Candidates have 90 minutes to take the test.
f) The test bus will have a minimum of nine specific and pre-determined deficiencies that
the candidate must identify and properly describe on the inspection form. The specific
deficiencies may be either existing or ones created by the test administrator.
g) Each of the nine deficiencies counts as 10 points.
h) A properly completed inspection form counts as 10 points. The candidate can make a
maximum of three mistakes on the form. Examples of some common mistakes are:
1) Odometer reading not recorded
2) A blank in the Status Code column.
3) Failure to clearly identify or describe any of the nine specific deficiencies
i) The minimum passing score is 90 percent.
j) The employer listed on the State of Florida School Bus Safety Inspector Application
(form 2017-SI) will receive certification status of each candidate.
180
B. Level 2 Certified School Bus Safety Inspector/Trainer
1) Qualifications Requirements
All the requirements listed in Section A. Level 1. Certified School Safety Bus Inspector,
plus the following additional items:
a) Candidates should be thoroughly knowledgeable of the contents of the current edition
of the State of Florida School Bus Safety Inspection Manual.
b) Candidates must possess skills and abilities required to present school bus inspection
training material in a manner that facilitates learning and must exhibit leadership
qualities and above-average professionalism in the performance of their duties.
c) Candidates must submit a copy of their completed State of Florida School Bus Safety
Inspector Application (form 2017-SI) to the FDOE trainer at the time of the train-thetrainer class.
2) Training Requirements
a) Trainer candidates must attend a two-day, FDOE-sponsored train-the-trainer class,
testing session and periodic update training sessions.
b) Candidates will receive intense training and detailed inspection program information
from the FDOE trainer in the following specific areas:
1) Training techniques
2) Purpose of the program and applicable laws and State Board of Education rules
3) How to use the inspection manual and the inspection form
4) Recertification program
5) Inspection, repair-or-note, and out-of-service criteria
3) Testing Requirements
a) See “Section A.” Trainers must meet the same testing requirements as an inspector.
b) Additional testing requirements include performance-based scoring at the two-day
train-the-trainer class in which trainer candidates will be required to conduct simulated
training classes.
c) The FDOE will schedule periodic train-the-trainer update classes. Trainers are strongly
encouraged to attend.
4) Duties
a) Trainers must ensure that inspector-testing candidates meet all requirements.
b) Trainers must sign the State of Florida School Bus Safety Inspector Application (form
2017-SI) to verify that inspector candidates have received appropriate training.
c) Trainers will occasionally conduct inspection training for school districts, charter
schools and private transportation providers that do not otherwise have trainers
available to them.
181
C. Level 3 Supervisor
The Supervisor 1 classification has the same requirements as the Level 1 Certified School Bus
Safety Inspector. This classification is for a supervisor who manages the school bus inspection
process and may perform inspections.
Inspector Classification Requirements
Classification
Levels
Min. 2 years
Technical
Experience
Classified as
Journeyman
Written
Test Passed
Hands-on
Test
Passed
Update
Course
Attended
1. Inspector
X
X (1)
X (3)
X
(5)
2. Trainer
X
X (1)
X (3), (4)
X
(5)
3. Supervisor
X
X (2)
X (3)
X
(5)
1) Requirements specified in Section A.
2) Supervisors with two years of journeyman-level experience are not required to have job
descriptions containing mechanic and/or technician classification language.
3) 100-question online test.
4) There is no written test for trainer candidates. Trainer candidates will receive a score
during the two-day train-the-trainer class.
5) 30-question online recertification test.
Note: A trainer must provide the candidate with inspection manual revision information
and sign the State of Florida School Bus Safety Inspector Application (form 2017-SI) prior
to testing.
182
School Bus Safety Inspection Recertification Program
School bus safety inspectors, inspector-trainers and supervisor-inspectors must recertify during
the fifth fiscal year of certification. Following are the qualifications, eligibility and testing
requirements for recertification:
1. Qualifications Requirements:
a) Recertification must take place between July 1 and June 30 of the fifth full fiscal year
following the date of original certification or subsequent recertification. For example, if an
inspector certified in January 2014, he/she would need to recertify anytime between July
1, 2018, and June 30, 2019. If an inspector certified in August 2014, recertification would
be required before June 30, 2020. Note: Recertification candidates are encouraged to
begin recertification study and testing early in the fiscal year during which
recertification is required.
b) Inspector-trainers must ensure that recertification candidates obtain manual revision
information and that candidates have thoroughly studied this information prior to testing.
Trainers must sign the State of Florida School Bus Safety Inspector Application (form
2017-SI) to file with the school district transportation department.
2. Eligibility Requirements:
Inspectors who fail to recertify by the expiration date on their certificate must not inspect
buses until recertified (see items (g) and (h) below).
3. Testing Requirements:
a) Testing consists of a 30-question online test.
b) The test consists of questions based on revised and non-revised inspection criteria from
the Florida School Bus Safety Inspection Manual.
c) District test administrators will conduct online testing.
d) This test is an open-book test. Candidates may use the State of Florida School Bus Safety
Inspection Manual during the 30-question online test.
e) The candidate must provide the test administrator with a valid driver license and a
completed State of Florida School Bus Safety Inspector Application (form 2017-SI) with
an email address, if available.
f) Recertification candidates will have 30 minutes to take the test.
g) Recertification candidates can take the test as many times as necessary to achieve a
passing score.
h) If an inspector fails to recertify before his/her current certification expires, he/she MUST
NOT inspect buses. If an inspector fails to recertify prior to the expiration date of his/her
last certification, he/she will be required to take the 100-question online test and pass a
hands-on test to recertify.
i) The minimum passing score for the online recertification test is 80 percent.
j) The online test program will provide the candidate with a score immediately. The current
employer listed on the State of Florida School Bus Safety Inspector Application (form
2017-SI) will receive the certificate by mail.
183
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184
District Online Test Administrator Guidelines and Requirements
1. District Online Test Administrator Guidelines
a) The candidate must present a photo ID and a copy of the State of Florida School Bus
Safety Inspector Application (form 2017-SI).
b) The candidate may not bring in cell phones, cameras or other electronic devices.
c) This is an open-book test and the candidate may only use the Florida School Bus Safety
Inspection Manual.
d) The candidate may not attempt to access a web browser, text messaging, email, or any
other communication or stored information from the testing computer.
e) There will be no talking during the test session or leaving seats without permission. This
is to prevent distractions to candidates.
f) The test administrator must maintain visual contact with the candidate at all times.
g) The test administrator should offer a restroom break to the candidate prior to beginning
the online test and emphasize that the clock will not stop during the test.
h) The candidate has up to 90 minutes to complete the certification test.
i) The candidate has up to 30 minutes to complete the recertification test.
j) The candidate can have a drink such as bottled water if permitted in the test facility.
2. District Online Test Administrator Requirements
a) The district test administrator shall be a qualified school district driver trainer or other
person in leadership.
b) The test administrator can be an employee of the school district, but ideally not in the
transportation fleet maintenance department.
c) Private or non-school district government entities may also have online test administrators
following the same criteria as school districts.
d) Test administrators must complete and submit a form, 2017-TA, District Online Test
Administrator Application to the FDOE for approval.
185
DISTRICT ONLINE TEST ADMINISTRATOR APPLICATION
To submit a request for qualification, this application must be completed by the school district or organization. Under
provisions of rule 6A-3.0171, Florida Administrative Code (F.A.C.), successful applicants will be qualified to administer the
State of Florida School Bus Safety Inspector online test. Test administrators will be in direct contact with Florida Department
of Education (FDOE) to coordinate all certification testing for the school district or organization. Test administrators may
assist other school districts or organizations that do not have a test administrator. Applicants must submit this application
to the FDOE, School Transportation Management Section. The superintendent of schools or an executive manager for any
other type of organization must sign this application.
PLEASE PRINT OR TYPE
Employer: ________________________________________________________________________________________
Name: _______________________________________________________________Date:________________________
Job Title: _________________________________________________________________________________________
Address: _________________________________________________________________________________________
Telephone Number: ___________________________Other Telephone Number: ________________________________
Email address: ____________________________________________________________________________________
Applicant’s Signature: ___________________________________________________Date:_______________________
I certify that the person listed above meets the requirements to be a School Bus Safety Inspector Test Administrator for
_______________________________________________________________________ (organization or school district).
I agree to work cooperatively to provide testing opportunities requested by other organizations or school districts that do not
have a test administrator or to fulfill testing requests made by the School Transportation Management Section of the FDOE.
Superintendent or Authorized Signature: _________________________________Date:__________________
Please send completed application to:
Florida Department of Education
School Transportation Management Section
325 West Gaines Street, Room 834
Tallahassee, Florida 32399-0400
850-245-9935 FAX
850-245-9795 Phone
schtrans@fldoe.org
Form 2017-TA
Effective March 2017
186
STATE OF FLO RID A, SCHOOL BUS S AF ETY INSPECTO R APPLI C ATION
(Please Type or Print)
_________________________________________________________________________________________________________________________
First Name
M.I.
Last Name
________________________________________________________________________________________
Email Address
_________________________________________________________________________________________________________________________
Home Street Address, Apt. #
City
State
Zip
____________________
____ / ____ / ____
Birth Date
Driver License Number (Last 6 Digits)
Education: (Check Highest Level achieved)
__ High School or GED __ Two-year College
__________________________________________________________
The School District or Employer You Work For
___ (CERTIFICATION)
__ Post graduate
__ Four-year College
___ (RECERTIFICATION): CHECK ONE
APPLICATION LEVEL - CHECK ONE:
___ 1. INSPECTOR
___ 2. TRAINER
___ 3. SUPERVISOR
WORK EXPERIENCE
For certification levels, 1, 2 and 3, the applicant must be able to document a minimum of two years journeyman-level mechanical experience or a twoyear Vocational/Technical (Vo-Tech) degree in any of the following areas: a) Automotive; b) Truck; c) Heavy Equipment or, d) Buses (transit or school).
List employers where you gained applicable experience:
1. Employer (Current or most recent):
____________________________________________________________________
________________________________________________________________________________________
Street Address
City
State
Zip
Your Position or Job Title: ___________________________________________________________________
Supervisor’s Name: _________________________________ Title: __________________________________
Tel. #: (______) _____ - ________
Employed From: _____/_____/_____
To: ____/_____/______
________________________________________________________________________________________
2. Employer (Previous):
_____________________________________________________________________________
________________________________________________________________________________________
Street Address
City
State
Zip
Your Position or Job Title: ___________________________________________________________________
Supervisor’s Name: _________________________________ Title: __________________________________
Tel. #: (______) _____ - ________
Employed From: _____/_____/_____
To: ____/_____/_____
Note: If needed to demonstrate compliance with requirements, list additional employers, mechanical
experience or degree information on a separate piece of paper and attach it to this application.
Form 2017-SI
Effective March 2017
187
CERTIFICATION INFORMATION
_____________________________________________________________________________
Name of Employer or School District
________________________________________________________, Florida _______________
Work or Mailing Address
City
Zip
Supervisor’s Name: _____________________________ Title:
___________________________
Note: Send the completed application to Florida Department of Education, School Transportation Management Section at 325 West Gaines Street, suite
834, Tallahassee, Florida 32399-0400. All signatures are required and the test candidate must bring a valid driver’s license to the hands-on test site.
Applicant’s Signature: ______________________________________________ Date:
____/____/______
The applicant meets all training requirements:
Trainer’s Signature: _________________________ Trainer’s Cert. # ______________ Date: ____/____/____
The applicant meets all applicable qualifications and requirements:
Transportation Director’s Signature: ___________________________________ Date:______/______/______
THIS SECTION FOR FDOE USE ONLY
Inspector: ________ Trainer: ________ Certification________ Recertification________
Applicant denied certification due to:
Insufficient Data ____ Does Not Qualify ____
Insufficient Experience _____ Classified Mechanic’s Helper ____ Training Not Received ____
Written (online) Test Date: ______/_____/______
Passed_________Failed________
* Retest Date: 1. ______/_____/______
* Retest Date: 2. ______/_____/______
* Retest Date: 3. ______/_____/______
Passed_________Failed________
Passed_________Failed________
Passed_________Failed________
Hands-On Test Date: ______/_____/______
* Retest Date: 1. ______/_____/______
* Retest Date: 2. ______/_____/______
* Retest Date: 3. ______/_____/______
* If Applicable
Passed_________Failed________
Passed_________Failed________
Passed_________Failed________
Passed_________Failed________
Certified By:_________________________________ Date______/______/_________
Name of FDOE Official
Form 2017-SI
Effective March 2017
188
2017 TABLE OF CHANGES
(Changes to Manual from 2008 to 2017)
ITEMS
Table of contents repaginated
Figures 1, 2 and 16 added; figures 6 and 7 revised
State Board of Education rule language revised to include
latest version of rule 6A-3.0171, F.A.C.
Specifications Notes (revised)
Inspection Form instructions (revised)
Inspection Form and Example Form (revised)
Certification expiration date changed from calendar to
fiscal year
Application now requires only the last six digits of driver’s
license number
Criteria for emergency equipment tamper-proof seal
revised
1969 to 1984 first aid kit contents chart deleted
Note concerning annual inspection of first aid and body
fluid cleanup kits revised
Mounting criteria for body fluid kit added
Out-of-service criteria for reflectors storage box revised
Noise abatement switch criteria revised
Engine choke deleted
Accelerator pedal and linkage revised
Pull cable engine shutdown deleted
Gauges criteria revised and DEF level gauge added
Out-of-service criteria for warning lights indicating
mechanical safety condition added
Pop-off changed to Park/Emergency brake pop-out
Service brake added to pedal and rubber cover pad
Brake system components not routed properly moved to
Out-of-service and pedal rubber cover pad
Windshield washer repair or note and out-of-service
criteria revised
Service door operation out-of-service criteria revised
Service door control repair or note and out-of-service
criteria revised
Air/Vacuum door out-of-service language revised
Criteria for horns revised
Criteria for mirrors revised
189
SECTIONS
TOC
Chart and Figure
Contents
Florida Statute
and
State Board
Rule
Specifications
Notes
Instructions
Inspection Form
School Bus
Safety
Inspection
Certification
Program
PAGES
VI - VIII
Application
187
A. 1. a. b. c. d.
1, 2, 3, 4, 5
A. 1
3
A. 1.
3
A. 1. c.
A. 1. d. 3)
A. 3. d
A. 4. b.
A. 4. b. 2)
A. 4. d. 2)
A. 5. a.
4
5
8
A. 5. c.
13
A. 6. h.
A. 6.i.
19
19
A. 7. 6) a.
23, 26, 28, 30
A. 8. a.
33
A. 11. a.
38, 39
A. 11. b.
38
A. 11. b. 2)
A. 12.
A. 13. a. b. & c.
38
40
41- 43
171
172
II
III
173, 175
179
10
11, 12
ITEMS
Criteria for driver’s seat and belt revised
Out-of-service criteria for passenger seat mounting
fasteners revised
Criteria for seats revised and seat height diagram added
Criteria for seat upholstery revised
Webbing cutter check and out-of-service criteria revised
Criteria for emergency door revised
Criteria for emergency hatch labeling revised
Post-Trip Passenger Check criteria revised
Criteria for glass cracks and fogging revised
Window will not stay closed moved to out-of-service
revised
Inspection procedures revised
Out-of-service criteria for radio added
Criteria for interior wiring and hoses revised
Criteria for step well revised
NHTSA references to hand rails deleted
Criteria for loose objects revised
NHTSA nut and string test from National Standards
(Chart 4) added
LED type lights criteria revised
Side Marker lights moved from B. 1. To B. 2.
Repair and out-of-service criteria for parking lights revised
Repair and out-of-service criteria for B. 2. revised
Criteria for switch on pre-1985 buses deleted
Criteria for out-of-service dates changed to OEM or
equivalent
Loose components moved from repair to out-of-service
Alternating pattern added to out-of-service
Old dates deleted from out-of-service
Criteria for mirror surfaces and fasteners revised
Bumper/body seal repair moved to out-of-service
Mirror and brightness of lights added to out-of-service
Repair and out-of-service criteria revised
Order of procedures and criteria revised
Box and door added to battery slide tray
Fluid levels criteria revised
Criteria for wrong dipstick moved to out-of-service
Procedures and criteria revised
Engine air cleaner loose components moved to out-ofservice
Water pump fasteners repair criteria deleted
Wiring procedures and out-of-service criteria revised
Reservoir added to radiator procedure and criteria
Radiator cap incorrect type moved to out-of-service
Fan shroud repair moved to out-of-service
Chart 12 proper wiring gauge usage deleted
190
SECTIONS
A. 14.
PAGES
44
A. 15. b.
45
A. 15. c.
A. 15. e.
A. 15. i.
A. 16. a.
A. 16. c. 1)
A. 16. d.
A. 17. a. & b.
46
48
49
50
51
52
53, 54
A. 17. c.
55
A. 18. 1)
A. 19.
A. 20.
A. 21. b.
A. 21. c.
A. 21. f.
56- 58
59
60
61, 62
64
65
B. 1.
B. 1.
B. 1. h.
B. 2.
B. 2. a.
67
73
72
73, 74
B. 3.
75
B. 4. a. & b.
B. 4. a.
B. 4. a.
B. 5. a.
B. 5. b.
B. 5. i.
C. 1. a.
C. 2.
C. 2. a.
C. 3. c., d. & f.
C. 3. d.
C. 4.
77, 78
77
77
79
79
82
85
94- 97
94
98- 100
99
102-104
C. 5. a.
105
C. 5. d.
C. 6.
C. 8. a.
C. 8. b.
C. 8. d.
107
109
109
109
ITEMS
Locking pin repair deleted
Note about greasing added to procedures
Repair criteria revised to include ride height and air spring
assembly
Brake lines routing out-of-service criteria added
Figure 12 specification change from 0.03 inch to 0.06 inch
Disc brake pads procedure and criteria added
Air wedge brakes deleted
Starter heat shield procedure and criteria deleted
Leakage out-of-service criteria revised
Leakage criteria revised
DEF procedure and criteria added to fuel tank
Wiring repair moved to out-of-service
Anti-lock brake systems repair criteria deleted
Drive-shaft foreign matter deleted
Guards out-of-service criteria revised
Differential leaking moved to out-of-service
Slack adjuster repair deleted, and out-of-service criteria
revised
Air wedge brake deleted
Frame rail padding missing repair deleted
Luggage compartment door latch repair moved to out-ofservice
Mud flap procedure and criteria added
Exhaust leak and muffler repair items moved to out-ofservice and DEF procedure and criteria added
Warning light indicating a mechanical safety condition
added to out-of-service
SECTIONS
D. 1. c.
D. 1. f.
PAGES
D. 1. k.
116
D. 2. b.
118
117
121
Manual transmission deleted
Supervisor II classification deleted
Application for school bus safety inspector certification
and application for school bus safety inspector
recertification have been combined into one application
F. 2. b. 2)
191
D. 2. g.
D. 2. j.
D. 3. b.
D. 5. a.
D. 5. c.
D. 6.
D. 6. d.
D. 7. e.
D. 8. a.
D. 8. e.
D. 9. c.
D. 10. d.
114
131
132
133, 134
134
138
140
146
D. 10. j.
D. 11. a.
D. 11. e.
155
D. 11.
155
D. 12.
156
F. 2. a.
167
187
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192