2017 D4500 Operator`s Manual

2017 D4500 Operator`s Manual
D SERIES OPERATORS MANUAL
TABLE OF CONTENTS
SUBJECT
PAGE
1 - INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 - PRE-SERVICE PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 - SWITCHES, WARNING LIGHTS AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 - STEERING COLUMN AND FLOOR MOUNTED CONTROLS . . . . . . . . . . . . . . . 27
5 - MISCELLANEOUS COMPONENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . 31
6 - ENGINE OPERATION, REGENERATION, FUEL AND EXHAUST . . . . . . . . . . . 35
7 - TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 - EMERGENCY CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9 - HEATING AND AIR CONDITIONING / HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10 - SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11 - WHEELCHAIR LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
12 - BASIC SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
13 - DIAGNOSTIC TROUBLE CODES / DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
14 - INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
15 - FIGURE INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
MCI D4000 / D4005 / D4500 / D4505 SERIES COACH
1 - INTRODUCTION
Typical illustrations may be used, therefore minor illustration differences may exist when compared to
actual parts or other publications.
To The Driver
Certification Plate
This manual provides information on how to operate the
basic, option and special equipment systems and
components used on this MCI Model D4000 / D4005 / D4500
/ D4505 Series Intercity Coach.
The MCI D4000 / D4005 / D4500 / D4505 series coach
certification plate is mounted on the rear stepwell panel. This
plate certifies compliance with all applicable Federal Motor
Vehicle Safety Standards in effect on the date of
manufacture. This plate also lists the date the coach was
built, the GVWR, GAWR's, rim size, tire pressures, coach
model and coach serial (V.I.N.) number (Figure 1.).
Complete knowledge of this coach and correct operating
practices are necessary in order to obtain the most
satisfactory and economical coach performance and also
ensure maximum passenger safety and comfort.
This manual is not intended to instruct operators how to drive
or operate an intercity coach safely and courteously on public
streets, roads and highways. A qualified coach driver should
already possess these required skills before attempting to
operate this coach.
Emission Control Decal
The emission control decal is affixed to the stepwell panel
beside the certification plate shown in Figure 1.
Positions “Left”, “Right”, “Front” and “Rear” are determined
from sitting in the driver's seat facing the coach forward travel
direction. To clarify this, sometimes “Curbside” and
“Roadside” are also used.
The specifications and information within this manual are up
to date at the time of publication, but are subject to change
without notice.
Report any malfunctions interfering with
satisfactory operation of the coach to service
personnel for immediate attention, especially if
safety is affected.
The terms “Optional” or “If Applicable” in this manual,
pertains to all equipment and features other than basic.
PUBLICATION DATE:
PART NUMBER:
August 2016
Figure 1. Coach Certification Plate
03-26-1422
Consider this manual a permanent part of this coach. If the
coach is sold or traded, also include this manual to provide
the next owner with important operating, safety and
maintenance information. Please inform MCI Service/
Warranty Department(s) if this coach is resold or traded.
August 2016
1
Vehicle Identification Number Explanation
Coach Nameplate
The nameplate in the engine cooling compartment and the
certification plate at the rear of the stepwell each contain the
seventeen-digit Vehicle Identification Number (VIN)
(Figure 2.). Coach-specific information is indicated by the
digits or letters in the vehicle identification number.
The alphabetical references shown correspond to each V.I.N.
character or character set. Each is explained in the following
list.
The MCI D4000 / D4005 / D4500 / D4505 series coach
nameplate is located in the engine cooling compartment at
the rear of the coach. The Vehicle Identification Number
(VIN), model year and date of manufacture are shown on this
plate ( Figure 3 ).
Figure 2. VIN Decoder, Example
Figure 3. Coach Nameplate
a. The first three digits and letters identify the
manufacturing company:
1M8 = MCI
b. The fourth digit identifies the coach model:
S = D4000
P = D4500
c.
The fifth digit identifies the series:
D = MCI
d. The sixth digit identifies the type of coach:
M = Passenger
e. The seventh digit identifies the type of
engine:
B = Cummins ISX, 425 HP
f.
The eighth digit identifies the type of
brakes:
A = Air Brake Intercity
g. The ninth digit is a check number.
h. The tenth digit identifies the year:
G = 2016
i.
The eleventh digit identifies the
manufacturing location:
P = Pembina, North Dakota
j.
2
The twelfth through seventeenth digits
define the actual unit number of the coach.
(*Sample of Unit No. shown in Figure 2.)
August 2016
Anti-Theft Precautions
a.
Do not leave coach unattended with the
engine running.
b.
Park in a lighted spot, if possible.
c.
Fully close all windows and doors.
d.
Keep items of value out of sight.
Special Features
The D4000 / D4005 / D4500 / D4505 series coaches include
several unique features as basic equipment such as: autoleveling, trailing axle unloading and front axle kneeling. Some
basic information on the proper operation and limitations of
these features is provided to ensure safe, efficient operation
of the coach.
Auto-Leveling
All coaches are fitted with special auto-leveling height control
valves at the front and rear drive axle suspension systems.
The valves automatically control the inflation and deflation of
the air spring bellows to maintain correct coach ride height.
These leveling valves are also used in conjunction with other
basic or optional features to enhance or modify the vehicle
suspension systems.
Trailing Axle Unloading
The coach has a trailing axle unloading feature allowing full
or partial unloading of the trailing axle. The basic unload
function is performed by positioning the manual unloading
valves to the exhaust (horizontal) position. Air from the
suspension bellows is then dumped through these valves.
When unloaded, the trailing axle air springs are sufficiently
exhausted to allow the axle to be lifted and secured, if
necessary.
The manual operated unloading valve systems work in
conjunction with the basic leveling valve system. The manual
valves are located inside the RH rear side service door.
The manual unloading valves can be used to
completely exhaust air from the trailing axle
suspension bellows. This unloading feature is
protected by a separate low air switch and alarm
circuit. Such protection is necessary, as continued
operation with the air unloaded from the
suspension bellows may cause frame damage.
Reduce coach speed when the tag axle air springs
are unloaded.
August 2016
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8
7
8
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5
6
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Figure 4. Reference photo of Drivers area. Rocker switch console configuration.
1. Instrument Panel
•
Multi Function Display
•
Tell-tale Cluster
•
System Gauges
•
HVAC Dash Controller
•
Wiper controls
•
Wheelchair Lift Master Switch ( Optional )
•
Driver’s Vent
•
Decal, Warning, Low Air
2. Lower, LH Console
•
Pushbutton Shift Selector
•
Switches, Rocker
•
Switches, Toggle
•
Mirror Control
•
12 Volt Power Source
•
Anti-Slip Pad
4
3. LH Switch Panel
•
Switches
4. Steering Column
•
Steering Wheel
•
Electric Horn
•
Tilt and Telescoping Control Lever
5. LH Foot Console ( IF APPLICABLE )
•
Directional Signal Switches
•
Headlight Beam Dimmer
6. Entrance Door Override Valve
7. Parking Brake
8. Driver Vent
August 2016
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7
5
8
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Figure 5. Reference photo of Drivers area. Toggle switch console configuration.
1. Instrument Panel
•
Multi Function Display
•
Tell-tale Cluster
•
System Gauges
•
HVAC Dash Controller
•
Wiper controls
•
Wheelchair Lift Master Switch ( Optional )
•
Driver’s Vent
•
Decal, Warning, Low Air
2. Lower, LH Console
•
Switches, Toggle
•
Mirror Control
August 2016
3. LH Panel
•
Pushbutton Shift Selector
4. Steering Column
•
Steering Wheel
•
Electric Horn
•
Tilt and Telescoping Control Lever
5. LH Foot Console ( IF APPLICABLE )
•
Directional Signal Switches
•
Headlight Beam Dimmer
6. Entrance Door Override Valve
7. Parking Brake
8. Driver Vent
5
Kneeling Feature
Rear Hi-Rise Feature
All coaches are equipped with a driver actuated kneeling
feature, which lowers the coach front suspension 3 to 6
inches from normal ride height to board passengers. The
coach should lower when the switch is positioned to “KNEEL”
and then released. When this switch is repositioned to
“RISE”, high pressure supply air re-inflates the air springs
through a fast recovery circuit and then through the normal
ride height leveling system valves. A kneeling switch is
located on the Lower LH Console.
The rear suspension hi-rise feature allows the drive axle air
spring to raise the D4500 series coach approximately 3
inches above normal ride height providing additional rear
body clearance. This feature is enabled when the RAISE
REAR/LOWER REAR switch is actuated, and automatically
controlled through the trailing axle's self-steer speed switch
control.
Avoid accessing suspension components from
outside coach wheel well areas. Unintentional
actuation of the height control valves with fully
inflated air springs could result in serious injury.
Always block the coach body adequately during
any inspections and/or repairs in these areas.
Always position the switch to lower suspension
system to normal ride height before performing
any service or inspection procedures on the rear
suspension.
During emergencies the kneeling feature may be by-passed
by positioning the manual level control valve to the
“EXHAUST” position. This allows normal leveling valve circuit
supply air to flow directly to the front air springs, by-passing
the exhaust control valve. During extended periods of nonuse, the manual isolating ball valves may also be closed by
positioning them to their “OFF” (horizontal) position.
Electronic System Diagnostic Codes
This D4000 / D4005 / D4500 / D4505 series coach is
equipped with electronically controlled engine and
transmission. A working knowledge of these system codes is
necessary in order to emergency troubleshoot if a fault
develops.
6
When set to RAISE, the rear of coach automatically rises
when speed falls below 15 mph and lowers to normal ride
height when speed exceeds 20 mph. Repositioning the
switch to LOWER returns the suspension to normal ride
height.
When the coach is raised, a tell-tale will light and
an alarm will sound.
The tag axle’s override switch will also eliminate
speed switch control over the Hi-Rise system.
If it becomes necessary to disable the tag axle selfsteering function, first position the Hi-Rise switch
to LOWER and allow the coach to reach normal
ride height. The tag override switch will keep the
coach raised if it is raised when tag override is
actuated.
Always lower the coach to normal ride height
before performing service or inspection on the rear
suspension. Do not operate the coach for extended
periods in the high position.
August 2016
ELECTRONIC STABILITY CONTROL (ESC)
D series coaches are equipped with a MeritorWABCO
stability control system that features Electronic Stability
Control (ESC) combined with Roll Stability Control (RSC).
ESC is a computerized technology that can improve a
vehicle's handling by detecting and potentially preventing
skids by automatically applying brakes to help steer the
vehicle where the driver wants to go.
ESC is automatic in that these systems become active when
the system Electronic Control Unit (ECU) senses conditions
that could produce imminent roll or directional instabilities.
Rapid lane changes or cornering at excessive speed on dry
or slippery surfaces can create the potential for spin-out or
drift out, often before the operator is aware. The ESC system
uses a lateral accelerometer, a steer angle sensor in the
steering column and a yaw rate sensor to enhance the
operator's control in these conditions.
August 2016
The stability control system is designed to assist
the operator, not to replace the operator.
The operator will notice a difference in the coach
when the ESC system becomes active, but should
continue to drive as normal and provide any
additional needed corrections. In an ESC event, the
operator may first sense a decrease in engine
power as the system ECU overrides the accelerator
pedal, and may then sense additional deceleration
from an engine brake application and service
brake applications on the steer axle brakes or all
axle brakes, depending on whether the conditions
suggest the possibility of a directional control or a
rollover event.
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August 2016
2 - PRE-SERVICE PREPARATIONS AND PROCEDURES
The Federal Motor Carrier Safety Administration and MCI
recommends that the following daily checks be made in order
to keep the coach in the best condition for safety,
convenience, service and operating economy. Report
required repairs or adjustments to maintenance personnel
before operating the coach.
Interior Components Checklist
1. Check that the entrance door and emergency exits
open, close, seal and latch properly.
2. Check parcel rack restraining cords.
3. Inspect seats and floor for debris.
These recommended checks are in addition to, not instead of
any the Federal Motor Carrier Safety Administration
requirements.
4. Check that inside and stepwell lights work.
Exterior Inspection (Walk-Around)
6. Check to see that emergency equipment and contents
are in place and properly stowed.
1. Assure that all windows, mirrors and lights are clean
and unobstructed.
2. Check that the exterior of the coach is clear and clean
of debris, and that all service doors are secure.
3. Check tires for proper pressure and inspect for
damage. Check that wheel nuts are tight and inspect
wheels for any damage.
4. Make sure the remote control switch in the engine
compartment is set for “FRONT” operation.
5. Make sure the main electrical switch, located behind
battery door, is in the “ON” position.
6. Look under the coach for any fluid leaks, animals,
maintenance personnel or for obstructions. Check the
area behind the coach if you intend to back the coach.
Operational Checklist
1. Look for any lube oil or coolant leaks with the engine
running.
2. Close and secure all baggage and service doors.
5. Check that the wheelchair access door is closed and
latched.
7. Check the brake pedal and linkage for any obstruction
that may prevent the brake from being applied or
completely releasing.
Initial Start-Up
Before proceeding with the “Initial Start-Up”
procedure, be sure there is ample distance ahead
of and behind the coach in case of unexpected
movement during engine starting.
Before starting make sure the fast idle switch is off
and the park brake is applied. Do not accelerate
the engine during initial start-up.
1. Ensure that the main battery disconnect switch is in
the “ON” position.
2. Ensure that the Park Brake control knob is pulled
“UP”, in the parking brakes “APPLIED” position.
4. Check the wheelchair lift operation daily.
3. Press the Master Power / Ignition switch to the ON
(upper) position to enable all of the multiplex modules
and turn on the coach's electrical system.
5. Position inside and outside mirrors. Adjust the driver's
seat for comfort and fasten seat belt.
4. Ensure the transmission Shift Pad Indicator in
”NEUTRAL”.
6. Make sure the tilt steering column is locked in a
comfortable driving position.
5. Wait for the CHECK ENGINE and STOP ENG tell-tale
lights to extinguish.
7. Check operation of defroster, heater, windshield
wipers and washers, and horn.
6. Start engine.
3. Check that all exterior lights are operational.
8. Do not move the coach until the dual air gauge shows
at least 100 psi pressure in both the primary and
secondary circuits.
9. Position the FAST IDLE switch to the “ON” setting to
build up the air pressure.
10. Shift the transmission into “DRIVE” by first pushing
hard on the Service Brake pedal and holding down
firmly to the floor, then depressing the “D” on the
Transmission Touch pad.
August 2016
7. Check all gauges and telltale lamps for proper
function.
8. Position the FAST IDLE switch to “ON” setting to build
up the air pressure.
9. Look and listen for any indications of system or
equipment malfunction. Report any sign of trouble to
service personnel before driving the coach.
9
Sleep Mode
Driver's Seat Adjustment
If the operator does not turn the main battery disconnect
switch to the OFF position, the electrical system will go into
“sleep mode” thirty (30) minutes after stopping the engine.
The operator can “awake” the electrical system by hitting the
entrance door switch, the hazard lights switch, or by turning
on the Master Power / Ignition switch.
The basic driver's seat can be manually adjusted for height,
fore and aft positioning, setback tilt and seat cushion pitch.
After adjusting a manually operated seat, test by pushing
forward and rearward on the seat. Make sure seat does not
move, and that the adjuster mechanisms have latched.
Park Brake Release
Use the following release procedure to free service
brakes. Do not attempt to break coach free with
engine power if brakes fail to release.
1. Release the park brake. With coach air pressure at
100 psi (689.5 kPa) or more, push the Park Brake
control knob down. Then make a full service brake
application. Park Brake release should allow normal
service brake operation.
Park brakes are set with a maximum 85 psi
regulated air supply. Make a full service brake
application to ensure complete release of the park
brake locking mechanisms.
2. Move the coach slowly and bring it to a stop to assure
that the brakes stop and hold the coach. Check that
brake pedal operation feels normal. Check to see that
all gauges remain in the normal range.
3. Move the coach a short distance at low speed and
check the steering for proper movement. The steering
wheel should feel firm with positive movement,
indicating secure attachment and function of all
related steering and suspension components.
Determine that the coach is under full control and
handling properly.
10
Other adjustments are manually actuated such as seat base
forward and rearward movement, front seat cushion tilt,
setback adjustment, headrest adjustment and internal shock
absorber adjustments.
Do not attempt adjustment of driver’s seat while
coach is in motion. The seat could suddenly and
unexpectedly move causing driver to lose control
of the vehicle.
After making a seat adjustment, always test to
ensure that the adjusters have latched. Improperly
latched seat adjusting mechanisms can impair
driving capabilities and create an unsafe operating
condition. Report any seat mechanism locking
problem immediately to service personnel.
Final Adjustment Checks
After making any of the manually operated seat adjustments,
test the seat by pushing forward and rearward. Make sure it
will not move and that the seat adjusters have securely
latched. Any movement of the seat indicates that at least one
indexing pin has not engaged. An improperly latched seat
mechanism could impair driver capabilities. Report any seat
adjustment or locking mechanism problems to service
personnel immediately.
August 2016
RECARO DRIVER'S SEAT ADJUSTMENTS
( IF APPLICABLE )
Seat adjustments are pneumatically operated and manually
operated.
Pneumatic Air Suspension Switch
The pneumatic air suspension switch is located on the control
panel. The switch (E) controls the amount of air in the air
spring suspension chamber. Pushing the pneumatic air
suspension switch up inflates the air spring suspension
chamber, raising the seat. Pushing the pneumatic air
suspension switch down lowers the seat.
Seat Cushion Rake Adjustment
The seat cushion rake (tilt) adjusting handle (F) is located on
the RH front of the seat. The front part of the seat cushion
can be adjusted 0 degrees to 15 degrees, by pulling the
handle up and positioning the thigh extension up or down to
the desired angle.
Thigh Extension / Cushion Length Adjustment
Figure 6. Seat adjustment control
The front part of the seat cushion can be extended up to two
inches, by pulling the front of the thigh extension forwards or
backwards to the desired length.
Headrest Support
Pneumatic Lumbar Support Adjustment
Adjust the headrest height by pulling up or pushing down on
the top of the headrest. Position the headrest to the desired
height. Make certain the headrest locks into place after
adjusting. Adjust the headrest tilt by pulling forward or
pushing back on the top of the headrest.
Position headrest as required.
This adjustment is important to attaining and
maintaining positive lumbar back support.
Carefully make adjustments that provide the
maximum support and driving comfort for your
specific physical structure.
A control panel, located on the right hand side of the seat,
contains three rocker-type switches controlling pneumatic
lumbar adjustment. The top switch (A) adjusts the upper
lumbar pneumatic support, the middle switch (B) adjusts the
mid lumbar pneumatic support, and the bottom switch (C)
adjusts the lower lumbar pneumatic support. Pushing a
switch forward inflates and pushing a switch rearward
deflates a lumbar pneumatic support.
Backrest Inclination
Recline adjusting knobs are located at the RH and LH rear
base of the seat back. Rotate the knobs forward or rearward
to adjust the recline angle of the seat back.
Auto Actuator Button
A forward and rearward adjusting button is located on the
control panel. Adjust the seat forward or rearward by pushing
the button (D). Use body momentum to slide the seat either
forward or rearward to the desired position. Release the
button to lock the seat in position.
August 2016
11
USSC DRIVER'S SEAT ADJUSTMENTS
(IF APPLICABLE)
Backrest Recline
Seat adjustments are pneumatically operated and manually
operated.
Recline adjusting knobs are located at the rear base of the
seat cushion. Rotate the knobs forward or rearward to adjust
the recline angle of the seat back.
Seat Tilt
D
C
A
Seat tilt adjusting knobs are located at the RH and LH side of
the seat cushion. Rotate the knobs forward or rearward to
adjust the tilt of the seat. Seat tilt is independent of seat
height adjustment.
Seat Height Adjustment
B
The height adjusting knob is located on the LH front edge of
the seat cushion. Rotation increases or decreases the
amount of air in the air bag, raising or lowering the seat
accordingly. All air can be quickly released by pulling the
knob out. Pushing it back in restores air to the system.
Headrest Support
Figure 7. Seat adjustment control
Adjust the headrest height by pulling up or pushing down on
the top of the headrest. Position the headrest to the desired
height.
This adjustment is important to attaining and
maintaining positive lumbar back support.
Carefully make adjustments that provide the
maximum support and driving comfort for your
specific physical structure.
A control panel, located on the RH front edge of the seat
cushion, contains three air lumbar switches. Pushing the
switches increases or decreases the amount of lumbar
support. The first switch (A) adjusts the top lumbar pneumatic
support, the second switch (B) adjusts the middle lumbar
pneumatic support, and the third switch (C) adjusts the
bottom lumbar pneumatic support.
Adjust the seat forward or rearward by pushing the air slide
release button (D). Use body momentum to slide the seat
either forward or rearward to the desired position. Release
the button to lock the seat in position.
12
August 2016
Driver's Seat Belt Adjustment
MIRRORS
Adjust the belt as needed while seated, sitting straight and
well back into the seat. In a single motion, pull the lap belt
across your lap far enough to push the latch plate into the
buckle until it clicks. This unlocks the retractor so the belt can
be pulled out to the proper length.
Inside Rear-view Mirrors
The inside rear-view mirrors can be adjusted up, down or
sideways. Adjust to provide a clear view of the interior rear of
coach.
Exterior Mirrors
The coach is equipped with large exterior rear-view mirrors
with convex upper mirror heads for wide angle viewing, and
larger full face lower flat mirror heads.
Using the restraint system provided can lessen the
chance and/or severity of injury in an accident or
sudden maneuver. Carefully follow the
instructions in this section on using the restraint
system.
Adjust the mirrors so that the sidewall of the coach can just
be seen in the inner portion of the mirror. This will help
determine the relationship of the coach to objects seen in the
mirror.
Ensure that some portion of the mirrors can also be seen
through the wiper sweep when they are in use.
Position the belt across your lap as low on the hips as
possible. This is necessary to spread the force of the lap belt
over the stronger hip area instead of across the abdomen.
Then adjust to a snug fit by pulling the belt firmly across your
lap toward the lap belt retractor so it can take up the slack.
This reduces the risk of sliding under the belt during an
accident.
To unfasten the belt, push in the button in the center of the
buckle. The retractor is designed to rewind the belt
automatically when the buckle is unlatched. Do not let the
belt twist while it is rewinding into the retractor. The bulk of
the twisted belt may cause the retractor to jam so it will not
rewind further. At the same time, the retractor may keep the
belt from being pulled out.
If a belt should get jammed, you may be able to release it by
working the belt in and out until the belt rewinds far enough to
unlock. If the belt remains jammed or other parts of the
restraint system do not work properly, report the condition to
service personnel promptly.
Seat Belt Inspection
Every 30 days, check the belt, buckle, latch plate, retractor
and guide loops for proper operation. Also check for loose or
damaged parts that could keep the restraint system from
operating properly. Keep sharp edges and sharp objects
away from the belts and other parts of the restraint system.
Figure 8. Exterior Mirror, Reference Photo
Keep the belts clean and dry, and replace belts if the webbing
appears frayed, cut, or otherwise damaged. Belts should be
replaced if they have been involved in an accident. Have
parts replaced if there are any questions as to their condition.
Clean seat belts with mild soap and lukewarm water only,
and avoid bleaching or dying belts as this may weaken them.
August 2016
13
PRE-TRIP INSPECTION
Before the Pre-Trip Inspection function is enabled, the
following conditions must be met:
- Select NEUTRAL on the transmission pushbutton shift
selector (PBSS),
-Set the Park Brake,
Only after these conditions are met, the Pre-Trip Inspection
function is enabled.
The exterior lights and dash tell-tales automatically activate
for two (2) minutes, when the “Pre-Trip Chk” button on the
Multi Function Display screen is pressed (Figure 9.).
The message “Pre-Trip Checking” will display on the screen
for the duration of the two (2) minutes feature, unless the
screen is pressed again or the park brake is released.
Figure 9. Pre-Trip button on MFD
Figure 10. Pre-Trip Checking Display
14
August 2016
3-SWITCHES, WARNING LIGHTS AND GAUGES
2
6
3
7
8
4
5
1
Figure 11. Instrument Panel
Instrument Panel Components ( Figure 11 )
Instrument Panel Gauges
1. Speedometer w/ Alpha-Numeric Display
Speedometer
2. Tell-tale Cluster
The speedometer which features an alpha-numeric display
reads the forward speed of the coach in miles per hour.
3. Multi Function Display (MFD)
4. HVAC Dash Controller
5. Wiper Controls
6. Front Air Pressure Gauge
7. Rear Air Pressure Gauge
8. Vent
Front Air PSI Gauge
The low air warning light on the gauge illuminates when the
air pressure drops below the pre-determined level.
In the event of a low air warning, stop the coach and
determine the cause of air loss before proceeding.
Rear Air PSI Gauge
The low air warning light on the gauge illuminates when the
air pressure drops below the pre-determined level.
In the event of a low air warning, stop the coach and
determine the cause of air loss before proceeding.
Low air pressure will illuminate the LOW AIR lamp
and a buzzer will sound, indicating that the air
pressure is too low. Stop coach and determine
reason for pressure loss.
Figure 12. Multi Function Display
August 2016
DO NOT operate the coach under 100 psi air
pressure.
15
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7
8
9
10
11
12
13
14
15
16
17
18
19
21
20
23
22
24
25
27
26
Figure 13. Multi Function Display Legend
1
2
3
4
5
6
7
11
12
13
14
15
16
9
10
17
18
19
21
16
22
23
24
25
26
27
Figure 14. Multi Function Display with Fuel Gauge Legend
16
August 2016
Tell-tale Indicator Lamp Cluster
The Tell-tale indicator lamp cluster is incorporated as part of
the Multi Function Display. The tell-tale lamps illuminate to
indicate various operating or functioning conditions or to warn
of various system malfunctions or potential system hazard
conditions. Some lamps are accompanied by a buzzer or
bell.
Tell-tale indicator lamps for components not
installed or used on this D Series coach are
disabled and do not illuminate.
1. WCL Stop Request - Illuminates when a passenger
in the wheelchair area presses the stop button.
2. Stop Request - Illuminates when a passenger
presses the stop button in the parcel rack mounted
service module above the seats.
3. WCL Interlocks (Amber) - Tell-tale light illuminates
when the wheelchair lift interlock is activated.The
wheelchair interlock system, when activated, disables
the transmission shift and throttle, sets the park brake
solenoid, and begins engine fast idle.
4. Kneel (Amber) - Illuminates in kneeling mode.
5. Rear Rise (Amber) - Tell-tale will illuminate when the
coach is traveling under 17 mph and the switch is set
to RISE.
6. Low Coolant (Amber) - A low engine coolant level is
indicated by this tell-tale. Do not run engine until the
condition is corrected.
7. High Exhaust Temperature (HET) (Amber) Illuminates when the coach is moving less than 5 mph
(approx.) and the exhaust outlet temperature exceeds
the predetermined level.
8. Brake Pad Wear (Red) - Tell-tale is disabled.
9. Low Air (Red) - Tell-tale illuminates to indicate low air
pressure in the primary brake circuit, secondary brake
circuit or accessory air pressure.
11. Tag Lock (Amber) - If tall-tale illuminates and
remains illuminated, the axle is either unlocked above
20 mph, locked below 15 mph or the manual override
is engaged.
The Tag Lock tell-tale may illuminate intermittently
when the coach is turning at or above 25 mph.
There is nothing wrong with the system, as long as
the tell-tale extinguishes when the coach comes
out of the turn and onto a straight-away.
12. Tag Steer (Amber) - Illuminates when the latching
system malfunctions and axle is not castered
correctly for travel direction
13. Lavatory Emergency (Amber) - Illuminates when a
passenger presses the emergency button in the
lavatory.
14. Auxiliary Heat (Amber) - Illuminates when the
auxiliary heater has been activated.
15. Fire Alarm (Red) - Tell-tale indicates a fire in the
engine compartment.
16. Low Fuel (Amber) - Illuminates when fuel level is
below 12.50 percent (approx.) fuel left in the tank.
17. Water in Fuel (Amber) - Water in the fuel filter.
18. Aux Brake (Green) - Tell-tale illuminates when the
Engine Brake is activated.
19. Tag Unload (Amber) - Illuminates when tag axle is
unloaded.
20. Yield To Bus (Amber) - Tell-tale is disabled.
21. Wheel End (Red) - Tell-tale is disabled.
22. Diesel Exhaust Fluid (DEF) (Amber) - The DEF
gauge reads the fluid level in the tank.
10. Brake Lights (Green) - Tell-tale illuminates when the
service brake is applied using the foot pedal.
August 2016
17
23. Voltmeter (Red) - The voltmeter reads the condition
of the 24-volt electrical system. The gauge is
calibrated in volts. The needle should be from 27 to
29 volts. If below 27 volts, the batteries are
undercharging. If above 29 volts, the batteries are
overcharging. Have the system checked if over- or
undercharging. The LED lights when voltage is too
low.
24. Speedometer - The speedometer reads the forward
speed of the coach in miles per hour.
WCL Door Open (Upper/Lower) - Icon will illuminate
indicating door ajar or unlocked condition.
Baggage Door Open - Icon illuminates when the
baggage door is open.
Entry Door Open - Icon illuminates when the entrance
door is open.
Fuel Door Open - Icon is disabled.
Bike Rack Deployed - Icon is disabled.
25. Engine Tachometer - The engine tachometer reads
engine revolutions per minute.
26. Oil Pressure - The oil pressure gauge reads engine
oil pressure in pounds per square inch or kilo Pascals.
Oil pressure should be between 50-70 psi (345 - 483
kPa). The icon illuminates when oil pressure is too
low.
27. Coolant Temperature - The coolant temperature
gauge reads engine coolant temperature in degrees
Fahrenheit or Celsius. The normal operating range is
160 - 226 F (71 - 108 C). The icon illuminates when
the temperature is above normal. Obtain service as
soon as possible.
18
August 2016
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Figure 15. Tell-tale Cluster
28. LH Turn Signal (Green)
29. Wait to Start (Amber) - Tell-tale is disabled.
30. Malfunction Indicator Lamp (MIL) (Amber) - Telltale is disabled on 2016 EPA engine configuration.
31. Check Engine (Amber) - If a fault is detected, the
Electronic Control Module (ECM) illuminates the
CHECK ENGINE light and stores a malfunction code.
32. Stop Engine (Red) - Tell-tale indicates that a serious
engine condition has been detected. Tell-tale glows
steadily, along with a warning buzzer sounding, and
the engine begins a power-down sequence.
33. Cruise Enabled (Green)
36. ABS (Anti-lock Brake System) (Amber) - Tell-tale
indicates the condition of the anti-lock brake system.
When the coach is initially started, the indicator
comes on. At approx. 5-7 mph, the light goes off and
stays off if the system is functioning properly. If the
light comes on when the coach is in motion, the ABS
is not working properly.
37. Electronic Stability Control / Automatic Traction
Control (Amber) - Tell-tale indicates an Electronic
Stability Control (ESC) or an Automatic Traction
Control (ATC) event.
38. Regeneration Lamp (DPF) (Amber) - Tell-tale
illuminates when a regeneration is required.Tell-tale is
OFF during regeneration.
34. Hi-beam (Blue) - Illuminates when high beam lights
are selected.
39. Check Trans (Amber) - Tell-tale light illuminates
indicating a transmission failure.
35. RH Turn Signal (Green)
40. Stop Hybrid (Red) - Tell-tale is disabled.
41. Park Brakes (Red) - Park Brake is applied.
42. Not Gen (Red) - This tell-tale indicates that the
alternator is not charging. Stop the engine, determine
cause of malfunction and correct.
43. Seat Belt (Red)
August 2016
19
LH Switch Panel
4. Blank
5. Engine Brake - The engine brake switch controls the
engine brake feature. In the upper HI position, all
engine compression is used as a braking force when
going down steep inclines. In the middle LOW
position, partial compression is used as a braking
force.
3
2
1
5
4
6. Fast Idle Switch - Place the transmission in Neutral,
apply the parking brakes and position the switch to
HIGH to increase engine idle speed.
7. Tag Axle - Positioning the TAG AXLE switch to LOCK
manually locks the trailing axle's self-steer function in
a straight ahead mode and illuminates the TAG LOCK
tell-tale.
6
8. Rear Rise - When the coach is traveling under 17
mph and the switch is set to RAISE, the rear of the
coach rises, the REAR LIFT tell-tale lights and the
buzzer sounds. LOWER returns the coach to normal
height.
9. ATC - On extra soft surfaces such as snow, mud or
gravel, press the MUD/SNOW switch to increase
traction by slightly increasing permissible wheel spin.
Press the switch again to turn OFF MUD/SNOW
feature.
7
8
9
10
10. Master Power / Ignition Switch- Pressing this switch
to the ON (upper) position will enable all of the
multiplex modules and turn on the coach's electrical
system.
Figure 16. LH Switch Panel
1. Interior Lights - The Interior Lights switch operates
both the overhead parcel rack, window and aisle
lights. Repositioning this switch to the lower portion
operates only the overhead aisle lights. The lights can
be illuminated only when the keyed ignition or Master
Power / Ignition switch is in the “ON” position.
2. Front Entrance Lights - The Front Entrance Lights
switch illuminates the first two rows of lights when the
entrance door opens.
3. Reading Lights - The Reading Lights switch tests all
reading lamps in the service modules at one time.
Positioning the switch to “ON” enables the parcel rack
service module's reading light switches for passenger
actuation. Positioning the switch to “OFF” eliminates
the service module's reading light feature.
20
August 2016
RH Switch Panel (IF APPLICABLE)
1
2
3
4
Figure 17. RH Switch Panel / Tour Coach
1. Hazard/Warning Lights - Pressing the Hazard/
Warning lights switch to the upper section “ON”
position, flashes all front, rear and side mounted turn
signal lights and both cluster indicators
simultaneously. Pushing the switch to the lower
section “OFF” position deactivates the Hazard/
Warning lights.
The Hazard/Warning lights automatically activate when
the passenger door opens, the Wheelchair Lift Master
Key switch is in the “WCL ON” position or when reverse gear is selected. The lights extinguish when the
passenger door closes, the Wheelchair Lift Master Key
switch is in the “WCL OFF” position and the transmission is not in reverse.
2. Blank
3. Kneel Switch - This switch controls the kneeling function. Push the switch “DOWN” to kneel or “UP' to raise
the coach from the “kneeling” position.
4. Entrance Door Switch - This switch controls door
opening and closing. Push the switch forward or back
to operate the entrance door.
August 2016
21
Lower, LH Console
7
4
8
1
6
9
10
5
20
2
3
12
15
16
17
13
11
14
10
18
19
Figure 18. Lower, LH Console ( reference only, subject to coach configuration )
1. Engine Override Switch - This switch allows the
operator to override an emergency shutdown due to
an engine malfunction. Pressing the switch allows the
operator to run the engine for an additional 30
seconds so that the operator can move the coach to a
safe parking area.
The engine overrule feature is not intended to provide
a “limp home” capability. This feature should not be
utilized to extend coach driving to a garage or other
destination, as engine damage may result from overextension of the safety feature limitations.
This switch allows the operator to override an
emergency shutdown due to an engine
malfunction. Pressing the switch allows the
operator to run the engine for an additional 30
seconds so that the operator can move the coach
to a safe parking area.
In a driving situation, this switch should be utilized
only to safely move the coach to a safe parking
area.
22
2. Entrance Door Switch - This switch controls door
opening and closing. Push the switch forward or back
to operate the entrance door.
3. Kneel Switch - This switch controls the kneeling
function. Push the switch “DOWN” to kneel or “UP' to
raise the coach from the “kneeling” position.
4. Engine Start Switch - The Engine Start switch is a
momentary-on type switch. The top switch section
must be pushed and held in the “START” or “ON”
position to engage the starter. When released, the
switch will return to the normal non-power (“OFF”)
position.
5. Hazard/Warning Lights - Pressing the Hazard/
Warning lights switch to the upper section “ON”
position, flashes all front, rear and side mounted turn
signal lights and both cluster indicators
simultaneously. Pushing the switch to the lower
section “OFF” position deactivates the Hazard/
Warning lights.
The Hazard/Warning lights automatically activate
when the passenger door opens, the Wheelchair Lift
Master Key switch is in the “WCL ON” position or
when reverse gear is selected. The lights extinguish
when the passenger door closes, the Wheelchair Lift
Master Key switch is in the “WCL OFF” position and
the transmission is not in reverse.
August 2016
6. Mirror Control - Exterior front mirror adjustments are
made using the controls. “L” (left) and “R” (right)
select the specific mirror. The heater button (7.)
controls the defog/defrost mirror heater element.
7. 110 Volt Switch
8. Ext Speaker
9. Chimes Switch - The Step/Chimes switch enables
the stepwell light and passenger chime switches.
Passengers may signal the driver by chime stop
request buttons or touch-tape switches.
10. Blank
11. Mirror Heat - The heater button controls the defog/
defrost mirror heater element.
12. Panel Brightness Switch - This switch controls the
desired panel brightness. Release switch when
desired brightness is reached.
13. Driver's Light Switch - The Driver's Light switch
provides light in the driver's area.
14. Front Dome Switch - The Front Dome switch
provides light in the stepwell area.
15. Differential Lock Switch
16. Tag Axle Unload Switch - This switch transfers part
of the load from the trailing ( tag ) axle to the drive
axle.
17. Parcel Rack Ventilation Switch - The Parcel Rack
switch activates the parcel rack blowers.
18. Auxiliary Heat Switch - The Auxiliary Heat switch is
a momentary-on type switch. The top switch section
must be pushed and held in the “START” or “ON”
position to engage the heater. To cancel the pre-heat
mode, push the switch down to the “STOP” or “OFF”
position.
19. Cup Holder
20. Pushbutton Shift Selector ( PBSS ) - The PBSS is
utilized to select transmission operating ranges.
August 2016
23
SpeakEasy 2 HANDS-FREE SYSTEM
( IF APPLICABLE )
The SpeakEasy 2 system allows the operator to record and
playback route or public address announcements over the
inside and/or outside speaker systems.
A footswitch allows messages to be recorded without having
to hold a microphone. During recording and playback, the
driver's defroster blower temporarily stops.
Recording and Playback of a Message
1.
1. Select the appropriate playback speaker(s), using
the INSIDE, OUTSIDE or BOTH switch on the control
head.
2. Press and hold the footswitch, then in a normal voice
begin speaking. The indicator light will illuminate as
long as the footswitch is held.
3. At the end of the message release the footswitch. The
same message will play back over the speaker(s).
4. The message can be canceled by quickly pressing
and releasing the footswitch.
Recording an Automated Outside Messages
Close the bi-part door before recording, because the system
is designed to play messages when the door opens.
1.
1. Press and hold the RECORD button located on the
control head, then in a normal voice begin speaking.
The indicator light will illuminate as long as the button
is held.
2. At the end of the message release RECORD button.
The same message will play back over the outside
speaker each time the door is opened.
Figure 19. SPEAKEASY 2 Control Head
Muting Outside Messages
1. Press the MUTE button located on the control head to
mute the outside message at a particular stop. The
indicator light will illuminate.
2. Resume the outside message by pressing the MUTE
button prior to reaching the next stop. The indicator
light will be OFF.
Clearing Outside Messages
The outside message can be canceled by quickly pressing
and releasing the footswitch, or by shutting down the coach.
3. Repeat Steps 1 and 2 if necessary until a satisfactory
message has been recorded.
Figure 20. SPEAKEASY 2 Footswitch
24
August 2016
SmartWave TIRE PRESURE MONITOR SYSTEM
( TPMS )
The SmartWave tire monitor system provides real-time tire
status data such as pressure and high temperature alerts for
all tire positions. It features:
1. ALARM warning light to alert driver,
2. Display screen shows alert icons, tire location and
numerical unit of pressure or temperature,
3. Control buttons to scroll through display.
The SmartWave FFD displays the following alerts:
•
Pressure Deviation Alert. If a tire deviates
from it's proper inflation pressure, the operator
is alerted to the condition via the warning light.
•
Critical Low Pressure Alert. If a tire falls below
the programmed cold inflation pressure value,
the operator is alerted to the condition via the
warning light.
•
High Temperature Alert. If a tire's temperature
exceeds the pre-determined value, the
operator is alerted.
August 2016
Figure 21. SMARTWAVE TPMS Display
25
THIS PAGE INTENTIONALLY LEFT BLANK
26
August 2016
4-STEERING COLUMN & FLOOR MOUNTED CONTROLS
Figure 22. Floor mounted controls
Ensure that the direction of force is applied to the
center of the steering wheel.
In each case, release lock lever to lock column in desired
position.
Figure 23. Steering Column Control Lever
The adjustable tilt and telescoping steering column control
lever is located on the left side of column (Figure 23). Tilt
angle can be adjusted to four positions, in addition to being
adjusted up (OUT) and down (IN) as required. Before making
any adjustment, position seat properly.
Push the tilt lock lever located on the left side of the steering
column outward from the column. Hold the steering wheel
and pull or push to the desired tilt position.
To lower or raise the steering wheel, push the lock lever
toward the steering column using your left hand. Grasp the
center of the steering wheel with your right hand and raise or
lower to the desired position.
August 2016
After adjusting steering column, apply force to the
steering wheel to ensure that column is firmly
locked before driving. Do not attempt adjustment
of the steering column while coach is in motion.
The steering column could suddenly move,
causing driver to loose control.
NOTE: The coach can still be safely steered if a
power assist steering system malfunction occurs,
however, a much greater force is required when
turning.
27
Directional Signal - Foot ( IF APPLICABLE )
Horn Control - Foot ( IF APPLICABLE )
The optional directional signal switches are mounted on a
separate foot console located next to the driver's foot rest.
RH/LH signals are selected by pressing the momentary-on
foot-operated switches. (Figure 24).
The foot operated horn is located on the driver's foot rest.
Headlamp Dimmer - Foot ( IF APPLICABLE )
The hi/low headlight beam is selected by pressing the upper,
center foot-operated dimmer switch on the driver's foot rest.
Each time the switch is pressed, the headlight beam changes
from one setting to another. (Figure 24).
Figure 25. Horn Footswitch
Horn Control - Hand
The horn is actuated by pressing the MCI button in the center
of the steering wheel.
Figure 24. LH Foot Console
Headlamp Dimmer - Hand
The steering column mounted turn signal switch incorporates
the headlamp high and low beam switch. Lift switch lever UP
and release to change from one setting to another. The blue
HI-BEAM telltale illuminates on high beam.
28
August 2016
Service Brakes
Low-Traction Road Conditions
The coach is equipped with air-operated service brakes
which are applied using the foot pedal to the left of the
accelerator pedal. The amount of pressure applied to the
pedal determines the extent and force of the brake
application.
Do not “pump” or “fan” the brakes in low-traction road
conditions. Applying firm, positive pedal pressure “energizes”
or activates the ABS. The sensors and modulator valves
cause the brakes to “pulse” or “modulate” at a very rapid rate,
sensing which wheel is near lockup because of less traction
and which wheel has enough traction. Brake pressure
automatically adjusts at each wheel.
“Panic Stop” Braking Conditions
Air system pressure must be at least 100 psi (689
kPa) before brakes can develop their full
effectiveness. Observe the air pressures indicated
on the dual air gauge at frequent intervals during
coach operation.
“Fanning” or “pumping” the brake pedal is not
recommended. This practice does not increase the
effectiveness of the brake system. It wastes air and
causes unnecessary wear on brake parts.
Stop lights on the rear of the coach automatically illuminate
when the brake pedal is depressed. A tell-tale light on the
dash illuminates when stop lights are activated.
Do not “pump” or “fan” the brakes in “panic stop” braking
conditions. Applying firm, continuous, heavy pedal pressure
“energizes” or activates the ABS. The brakes then “pulse” or
“modulate” at a very rapid rate, sensing which wheel is near
lockup because of less traction and which wheel has enough
traction. Brake pressure automatically adjusts at each wheel.
In this way, traction is maintained between the road surface
and tires, increasing the potential for stable, non-skid stops.
An “ABS” indicator light in the Multi Function Display Tell-tale
cluster tells the condition of the Anti-lock Brake System.
Upon coach starting, the indicator first flashes, then steadily
illuminates. At approximately 5-7 mph, the indicator shuts off
and stays off, indicating the system is working properly. If the
indicator illuminates when the coach is moving at road speed
(above 5-7 mph), the Anti-lock Brake System is
malfunctioning. An ABS malfunction automatically reverts the
brake system to standard non-ABS operation.
ANTI-LOCK BRAKE SYSTEM (ABS)
The ABS (Anti-lock Brake System) minimizes the potential of
“brake lock-up” in low-traction road conditions or in “panic
stop” braking situations. The coach retains a greater degree
of stability and ability to steer properly.
During braking, the Anti-lock Brake System automatically
senses any impending wheel lockup due to loss of traction.
The system monitors deceleration rates during braking and
automatically adjusts brake application pressures at each
wheel.
High-Traction Road Conditions
The Anti-lock Brake system is de-energized during normal
brake applications on high-traction, dry road surfaces. During
braking, apply a firm, positive brake pedal pressure.
Use the following release procedure to free service
brakes. Do not attempt to break coach free engine
power if brakes fail to release.
Releasing Service Brakes
In the event a normal service brake application fails to
release, reduce air pressure to below 75 ± 5 psi (517 ± 34.5
kPa) by pumping brake pedal. Operate engine until dual air
gauge reads above 100 psi.
One of these procedures should free the brakes:
1. Make a normal service brake application and then
release it.
or,
2. Make a normal park brake application, release it, and
then make a service brake application.
August 2016
29
Parking and Emergency Brakes
The coach is equipped with an air-operated parking brake
control valve for parking the bus and for emergency braking
function. Operation of the system is as follows:
Normal Operation
The Park Brake is required to be manually set
whenever the driver leaves the driver seat.
1. Stop the coach by firmly applying the Service Brake
pedal. Pull up on the park brake valve knob to set the
park brakes. Brakes will remain applied and locked,
even if coach air pressure is lost. Always apply
parking brakes by pulling up on the park brake valve
knob before leaving coach.
At coach speeds less than 2 mph, the wheelchair
lift park brake interlock is set.
2. Put the transmission in neutral by firmly pushing on
the “N” button on the Transmission Touch pad.
ELECTRONIC STABILITY CONTROL (ESC)
3. Before moving the coach, the air pressure gauge
must read 100 psi (689.5 kPa) or more.
Park Brake Release
With coach air pressure at 100 psi (689.5 kPa) or more, push
the parking brake control knob down, followed by a full
service brake application. Parking brake release should allow
normal service brake operation.
Emergency Parking Brake Release
The emergency parking brake release valve is a manually
operated on-off control. It is used to manually release the
emergency park brake. The valve is spring loaded and
remains in the exhaust (button out) position constant manual
force is applied.
Fully apply the service brakes to ensure complete
release of the park brake. If the park brake fails to
release, refer to the park and service brake release
procedure on the preceding page.
The Wheelchair Lift Sidewall Access Door and the
Wheelchair Lift Access Door must be closed before
the park brake will release.
The parking brake is interlocked with, and affects the
operation of several other coach components. The
relationship between these components and the park brake
interlock is shown in the following:
KNEELING FEATURE - APPLYING the Park Brake
energizes the kneeling relay when the kneeling switch is
activated. RELEASING the Park Brake de-energizes the
kneeling relay; the coach returns to ride height if in the
kneeling mode.
WHEELCHAIR LIFT - Manually applied push/pull valve can
be in any position. Opening either the wheelchair access
door or lift door also electrically sets the park brake.
30
The stability control system is designed to assist
the operator, not to replace the operator. The
operator will notice a difference in the coach when
the ESC system becomes active, but should
continue to drive as normal and provide any
additional needed corrections.
In an ESC event, the operator may first sense a
decrease in engine power as the system ECU
overrides the accelerator pedal, and may then
sense additional deceleration from an engine brake
application and service brake applications on the
steer axle brakes or all axle brakes, depending on
whether the conditions suggest the possibility of a
directional control or a rollover event.
D series coaches are equipped with a MeritorWABCO
stability control system that features Electronic Stability
Control (ESC) combined with Roll Stability Control (RSC).
ESC is a computerized technology that can improve a
vehicle's handling by detecting and potentially preventing
skids by automatically applying brakes to help steer the
vehicle where the driver wants to go.
ESC is automatic in that these systems become active when
the system Electronic Control Unit (ECU) senses conditions
that could produce imminent roll or directional instabilities.
Rapid lane changes or cornering at excessive speed on dry
or slippery surfaces can create the potential for spin-out or
drift-out, often before the operator is aware. The ESC system
uses a lateral accelerometer, a steer angle sensor in the
steering column and a yaw rate sensor to enhance the
operator's control in these conditions.
August 2016
5-MISCELLANEOUS COMPONENTS AND CONTROLS
Windshield and Driver's Window Blinds
Sedan Entrance Door (IF APPLICABLE)
Blinds are provided for the windshield and for the driver's
window (Figure 26). The blinds easily adjust to the desired
position by pulling down on the blind handle tab to lower or by
pulling the release cord to raise to the desired position.
An air-operated sedan entrance door is installed on the
D4000 / D4005 / D4500 / D4505 series coaches (Figure 28).
The door may be opened or closed from the driver's area or
from the exterior door switch located in the curbside exterior
pocket. Operation of the coach door is explained as follows:
1. Position the switch to the OPEN or CLOSED direction
to maintain door motion.
2. The door operation can be interrupted in mid-cycle by
releasing the switch.
3. The door lock will engage when door reaches full
closed position.
4. The door will operate normally when coach air
pressure is maintained between 90 and 120 psi. The
door will begin to move slowly and lose power with air
pressure below 90 psi.
Figure 26. Window Blinds
Driver's Modesty Panel
A driver's modesty panel and black acrylic shield is located at
the back of the driver's seat. The panel provides driver
protection and closes off the driver's area during night time
operation. The panel extends from the driver's guard rail to
slightly above the top of the passenger windows (Figure 27).
Figure 27. Driver’s Modesty Panel
August 2016
Figure 28. Sedan Door
31
Bi-Parting Entrance Door (IF APPLICABLE)
Exterior Entrance Door Switch
An air-operated Bi-Parting entrance door is installed on the
D4000 / D4005 / D4500 / D4505 series coach (Figure 29).
The door may be opened or closed from the driver's area or
from the exterior door switch located in the curbside exterior
pocket. Operation of the coach door is explained as follows:
An exterior door switch is enclosed in a pocket located
directly to the left of the entrance door. A spring-loaded snap
cover encloses the switch.
1. Position the switch forward or rearward to open or
close the door.
2. The door operation can be interrupted in mid-cycle by
moving the switch in the opposite direction.
3. The door lock will engage when door reaches full
closed position.
Entrance Door Overrule Valve
The manually-actuated entrance door overrule valve provides
for the emergency dumping of air from the entrance door
actuating air cylinder, door claw and header locking devices.
After dumping air the entrance door can be pushed open.
The valve is located on the Lower RH side of the Dash Panel.
4. When the main battery disconnect is switched to
“OFF” position, the door will close automatically.
5. The door will operate normally when coach air
pressure is maintained between 90 and 120 psi. The
door will begin to move slowly and lose power with air
pressure below 90 psi.
Figure 30. Interior Air Dump Valve
The overrule valve can also be operated from the front
junction box cable knob (Figure 31).
Figure 29. Bi-Parting Doors
32
Figure 31. J-box Air Dump Valve
August 2016
Passenger Stop Request (Optional)
Driver's Compartment - Locking (Optional)
A stop request button is accessible to each passenger in the
parcel rack service module (Figure 32). When a button is
pressed, the Stop Request icon in the Multi Function Display
illuminates and the Spotter's Display in the ceiling cap panel
shows a “Stop Requested” message.
The roadside and curbside #1 Parcel Rack compartment
includes a door with a keyed-alike lock. This lock can be set
for either unlocked or locked mode. This provides privacy and
security for the driver's items and audio/video components.
Figure 32. Parcel Rack Control Module
Figure 34. Locking Compartment
Wheelchair Stop Request Tape Switch
(IF APPLICABLE)
The Wheelchair Stop Request Tape switches are mounted in
the LH/RH wheelchair parking areas, on the wheelchair lift
door and on the opposite roadside wall below the window.
Pressing the Tape Switch illuminates the WCL Stop Request
icon on the Multi Function Display.
NOTE: After making the requested stop and closing the
entrance or wcl door, the icon automatically cancels.
Parcel Rack Capacity
The maximum capacity for a single section of parcel rack is
75 lbs.
For coaches not equipped with the Optional parcel rack
doors, a daily inspection of the load restraining cords is
required to ensure they are in good condition.
Kneeling System
The driver activated kneeling feature allows the front of the
coach to be lowered 3 to 6 inches for passenger entry. After
boarding is complete, return the coach to normal travel height
by moving the “KNEEL” Switch to the “UP” position. The
system components are installed in a control box located in
the No. 1 baggage bay. Manual override valves are mounted
in the control box to bypass the kneeling feature.
System Operation
Figure 33. Tape Switch
The kneeling system can be activated only when the door
closed, the Park Brake applied, the Wheelchair Lift is OFF
and air pressure is at 95 PSI (655 kPa). The audible and
visual indicators are activated when the kneeling switch,
located in the Lower LH Console, is positioned to “DOWN” to
activate the kneeling system. The sonalert sounds and the
amber light flashes through the complete kneeling cycle. A
red “KNEEL” telltale on the Multi Function Display also
illuminates during the kneeling cycle.
Positioning the kneeling switch to “UP” raises the coach to
normal ride height, canceling the audible and visual kneeling
indicators, completing the kneeling cycle.
August 2016
33
Back-Up Alarm
Stop Request Sign (IF APPLICABLE)
An audible back-up alarm is connected to the back-up light
circuit. The single pitch alarm is mounted in the engine
compartment and is activated automatically when Reverse
gear is selected.
The Stop Request Sign is located in the front ceiling cap
above the entrance way. This unit displays programmed
messages, “Stop Requested” and other information
programmed from the fare box (Figure 36).
Back-Up Lights
Back-up lamps are located in the rear LH/RH satellite doors.
Placing the transmission in Reverse gear automatically
illuminates the back-up lamps.
Back-Up Camera (IF APPLICABLE)
On coaches equipped with a back-up camera; once the
transmission has been placed in Reverse gear, the MFD will
automatically display the rear camera feed.
This sign is energized when either the service module signal
chime buttons or the wheelchair tape switches are actuated.
A latching relay keeps the sign illuminated until the driver's
entrance door control switch is activated to open the door.
Stop Request icon illuminates on the Multi Function Display
when a passenger requests a stop. The WCL Stop Request
illuminates when the wheelchair area tape switch is pressed.
Push the CHIME switch to the “ON” position to enable the
chime service module switches. Once the switch is activated,
the stepwell light will illuminate when the entrance doors
open, and passengers may signal the driver by chime stop
request buttons or touch-tape switches.
Figure 35.
Hazard/Warning Lights
A relay automatically activates the hazard warning lights
when the passenger door opens, during wheelchair
operations or when the transmission is in reverse gear. The
hazard/warning lights extinguish when the entrance or
wheelchair door closes or the transmission reverse gear
range is not selected.
Figure 36. Stop Request Sign
Auxiliary Heater
The auxiliary heater is located in the left rear of the engine
compartment. The auxiliary heater turns on automatically to
augment the temperature of engine coolant for coach
heating.
To preheat the coolant or test the heater, turn the auxiliary
heater on with the AUXILIARY HEATER switch.
The operator can identify function and component
diagnostics by checking either the light bars or the LED
display located on the front of the control module.
34
August 2016
6 - ENGINE OPERATION, DPF REGENERATION,
FUEL AND EXHAUST
Figure 37. Reference photo of engine compartment
Starting The Engine
The controls necessary to start and stop the engine from the
operator's compartment are mounted on the instrument panel
in front of the driver. These controls and a description of their
operation and function follow:
6. Push the momentary-on “START” switch (located
beside the transmission shift pad selector) to start
engine. Release the switch when the engine starts.
1. Ensure that the main battery disconnect switch is in
the “ON” position.
2. Ensure that the Park Brake control knob is pulled
“UP”, in the parking brakes “APPLIED” position.
3. Press the Master Power / Ignition switch to the ON
(upper) position to enable all of the multiplex modules
and turn on the coach's electrical system.
4. Select NEUTRAL on the transmission shift pad
selector on the lower LH console.
Do not engage starter for longer than 15 seconds at
a time. Allow starter motor to cool before a second
attempt. Continuous use of the starter without
allowing a cooling period may damage the starter
motor.
5. Wait for the “CHECK ENGINE” and the “STOP
ENGINE” lights to extinguish. If the system is failure
free, the lights will go out within 5 seconds.
At coach start-up, operators must not apply the
accelerator pedal until the coach air pressure is
above 90 psi on the instrument panel gauges.
Do not start the engine when the engine warning
lights stay on or do not come on momentarily after
turning on the ignition. Operating the engine under
these circumstances may cause engine damage.
August 2016
Failure to wait for the coach air pressure reach 90
psi will result in initiating the CHECK ENGINE
LIGHT (CEL) and logging fault code 39 into the
ECU memory (for low vehicle air supply pressure).
35
Engine Warm-Up
Remote Engine Operation
After the initial starting and low idle engine operation, it is
necessary to activate the fast idle for three minutes to bring
engine up to temperature, or to quickly fill the air system.
Parking brakes should be kept applied during initial warm-up,
and must be on before the fast idle will operate. Observe
gauges and telltale lamps frequently during warm-up and
subsequent operation. If abnormal conditions develop, stop
engine immediately and determine cause.
This feature is primarily for maintenance purposes.
Before attempting to start engine from rear of
coach, make sure transmission is in Neutral and
parking brake applied.
Fast idle function is interlocked to the park brake.
Stopping The Engine
1. Bring coach to complete stop.
2. Apply the parking brake and place transmission in
Neutral.
3. Idle engine at low rpm for 30 seconds, then shut down
the engine.
Shutting down a turbo-charged engine directly
from a high rpm condition may cause damage to
the turbocharger. Idling at low rpm before shutting
down the engine assures that the turbine speed
has dropped.
Figure 38. Remote Junction Box
Switches for starting and stopping the engine at the rear are
mounted on the remote electrical control panel. This panel is
located at the left side in the engine compartment. To gain
access to the panel, open rear engine compartment doors.
Starting Engine - Remote
In operator's compartment, place Master Power / Ignition
switch in the “ON” position.
In the engine compartment, put engine switch in the upper
position (ENG RUN).
Move remote switch to bottom position (REAR START) and
hold until engine starts. Use the same precautions regarding
use of starter as explained under starting engine.
Stopping Engine - Remote
To stop engine at rear, place ENG RUN switch to ENG OFF
position.
If it is necessary to work on engine without engine
running, place remote control and run switches in
OFF positions. This breaks the circuit to starter
and prevents starting the engine.
36
August 2016
Electronic Engine Control System
Multiplex Bypass Circuit
This system controls the combustion process of the engine
through timing and fuel metering relative to internal/external
sensor readings. The system continually monitors information
from the electronic transmission control system to achieve
more fuel efficient shifting.
If the engine cranks but does not start because the ignition
module fails, the engine ignition bypass switch, located in the
rear junction box, provides emergency power to start the
engine.
Various gauges are provided to show engine oil pressure and
coolant temperatures, however, the electronic control
systems generally monitor conditions that could result in
damage to the engine or that are dangerous to coach
operation. If during operation the system detects a serious
condition, (such as loss of water or oil), it should alert the
driver via the telltale warning lights. Audible alarms may also
be installed to alert driver of serious engine problems.
The system can be programmed to sequentially reduce
power and shut engine down in case of serious engine
problems. An EMERGENCY OVERRIDE switch is provided to
override the automatic engine shutdown system and will
allow engine to run for an additional 30 seconds so that
coach may be moved to safe parking area. Use the switch as
often as necessary.
In this mode, the coach should be driven straight
to a service facility.
1. Open the rear junction box compartment door
(baggage bay compartment #3). Locate the
emergency engine switch in the junction box.
Figure 39. Bypass Switches
2. Lift the red self-canceling cover and position the
toggle switch ON.
3. Get service assistance as soon as possible.
August 2016
37
DIESEL PARTICULATE FILTER (DPF) REGENERATION
MCI coaches are equipped with a diesel particulate filter
(DPF) and a regeneration system which work together to
reduce particulate emissions.
On MCI coaches there are three regeneration modes:
Passive Regen - Normal engine operation provides
sufficient exhaust temperature for regen to occur with no
noticeable effects to the driver.
Active Regen - Normal engine operation does not provide
sufficient exhaust temperature for passive regen to
occur. Regeneration system raises the exhaust temp for
regen to occur.
Stationary Regen - Normal operation of the engine will not
allow for passive or active regeneration to occur. The
operator must initiate a regen with the remote switch.
To avoid serious personal injury or property
damage, ensure that no persons or objects are at
or within two feet of the exhaust outlet at any time
during a regeneration.
Ensure that exhaust and outlet are clear of any
trash, grasses, or other vegetation or debris.
Use extreme caution during a stationary
regeneration, as exhaust gas tail pipe outlet
temperatures can exceed 900 degrees F (482
degrees C). Stationary regenerations are to be
performed outdoors only.
DO NOT leave the coach unattended during a
stationary regeneration.
DO NOT perform inside a garage or maintenance
facility.
DO NOT attach an exhaust extraction hose to the
exhaust outlet.
MCI coaches are equipped with two (2) specific tell-tales for
the regeneration system:
Regeneration Tell-tale Lamp (DPF)-Tell-tale illuminates
when a regeneration is required. Tell-tale is OFF during
regeneration.
High Exhaust Temperature Tell tale Lamp (HET) This tell-tale will illuminate when the coach is moving at a
low speed and the exhaust outlet temperature exceeds
the predetermined level.
Figure 40. Regeneration Switch, located in the
curbside, rear service compartment.
Figure 41. Regeneration Tell-tales
38
August 2016
ENGINE SPECIFIC REGEN STRATEGY
Fuel System
Before a parked or stationary regen can occur, these
requirements must be met:
When servicing any of the diesel engine installations, refer to
the applicable manufacturer's Diesel Engine Service Manual.
Fuel system components which require periodic maintenance
include the engine air cleaner and fuel filters. Care must be
taken when filling the fuel tank to prevent entry of dirt and
water.
- The DPF tell-tale lamp illuminated (solid or flashing),
- Vehicle speed is 0 MPH.,
- Locate the transmission push-button shift selector. While
making a service brake application, cycle the push-button
shift selector by pressing Neutral,
- Locate the Park brake. While making a service brake
application, cycle the Park brake ON-OFF-ON. Park brake
is applied,
Do not smoke while handling fuel.
- The HVAC system is OFF,
- Engine running at idle speed (Not fast idle),
- Park brake is applied,
- Service brake released,
- the exhaust and outlet are clear of any trash, grasses or
debris.
Hold up the regen switch to the “Initiate position” for 5
seconds and release. Do not move the switch to the “Regen
Inhibit” position.
Stationary Regen Operation
DPF tell-tale lamp will illuminate for 1 sec and turn OFF for
the duration of regen, Engine RPM will rise to 950 RPM,
HET tell-tale lamp will illuminate after approximately, 3
minutes indicating high exhaust temperature during the regen
and remain on until after the exhaust is below the
predetermined temp. Duration of the regen is 20-60 minutes
depending on the level of soot in the DPF. When the regen is
completed, all telltales will be OFF, engine RPM will return to
idle.
A Stationary Regen can be disabled by:
Disabling one or more of the Stationary Regen requirements,
or, Toggle the Regen switch to “Inhibit position” for 5
seconds, or, Turning OFF the ignition switch.
Should gasoline be put into the main or auxiliary fuel tank(s)
by mistake, the tank(s) must be completely drained and
refilled with diesel fuel. Gasoline will damage the engine. If
the engine has been run with gasoline in the tank(s), then the
entire fuel system must be drained since the fuel pump will
have pulled the gasoline into the lines and filters and into the
pump and engine.
Fuel Specification
Engines must comply with EPA mandated low emission
guidelines by using ULSD (ultra low sulfur diesel) fuel. Failure
to use ULSD fuel will result in component damage.
DO NOT put anything but DEF in the DEF tank
( blue cap ).
Diesel Exhaust Fluid (DEF)
The DEF fuel tank is separate from the diesel tank, located at
the curbside, rear corner of the #3 baggage bay compartment
(Figure 42). Open the DEF fuel door to access the blue cap
on the tank.
Diesel Exhaust Fluid (DEF) Specification
DEF must meet ISO standard 22241-1.
An Active Regen can be disabled by:
The Park Brake is applied, or transmission is in Neutral or
Reverse gear.
Figure 42.
August 2016
39
Diesel Fuel Contamination
The most common form of diesel fuel contamination is water.
Water can be introduced to the fuel supply through poor
maintenance (loose or open fuel tank cap), a contaminated
fuel supply, or condensation.
NOTE: Use care in the storage and handling of diesel fuel to
prevent contamination by dirt and water.
Condensation is particularly prevalent on units which stand
idle for long periods of time. Ambient temperature changes
cause condensation in partially filled fuel tanks.
FUEL PRO FUEL FILTER
The Fuel Pro extends filter change intervals and features a
clear cover that provides visual identification of the fuel level
(Figure 43). When the fuel level reaches the change filter line
on the filter cartridge, the element should be replaced at the
next scheduled maintenance interval. Fuel filters should be
replaced as a set.
Lubricating Oil Specification
Engines must only use CJ-4 engine oil. If the
ambient temperature is above 15F (-9.5C), 15W40
oil must be used. If the ambient temperature is
below 15F (-9.5C), 5W40 must be used. Failure to
use CJ-4 engine oil will reduce component life.
All diesel engines require heavy-duty lubricating oils. Basic
requirements of such oils are lubricating quality, high heat
resistance, and control of contaminants. The reduction of
friction and wear by maintaining an oil film between moving
parts is the primary requisite of a lubricant. Film thickness
and its ability to prevent metal-to-metal contact of moving
parts is related to oil viscosity.
Oil quality is the responsibility of the oil supplier. (The term
“oil supplier” is applicable to the refiners, blenders, and re
branders of petroleum products, and does not include
distributors of such products.)
There are many brands of commercial crankcase oil
marketed today. Obviously, engine manufacturers or users
cannot completely evaluate the numerous commercial oils.
The selection of a suitable lubricant in consultation with a
reliable oil supplier, observance of his oil drain
recommendations (based on used oil sample analysis and
experience), and proper filter maintenance, will provide the
best assurance of satisfactory oil performance.
Figure 43. Fuel Pro Filter
Temperature is the most important factor in determining the
rate at which deterioration or oxidation of the lubricating oil
will occur. The oil should have adequate thermal stability at
elevated temperatures, thereby precluding formation of
harmful carbonaceous and/or ash deposits.
The piston and compression rings must ride on a film of oil to
minimize wear and prevent ring seizure. At normal rates of
consumption, oil reaches a temperature zone at the upper
part of the piston where rapid oxidation and carbonization
can occur. In addition, as oil circulates through the engine it is
continuously contaminated by soot, acids, and water
originating from combustion. Until they are exhausted,
detergent and dispersant additives aid in keeping sludge and
varnish from depositing on engine parts, but such additives in
excessive quantities can result in detrimental ash deposits. If
abnormal amounts of insolubles form, particularly on the
piston in the compression ring area, early engine failure may
result.
Oil that is carried up the cylinder liner wall is normally
consumed during engine operation. Oil and additives leave
carbonaceous and/or ash deposits when subjected to the
elevated temperatures of the combustion chamber. Deposit
amounts are influenced by the oil composition, additive
content, engine temp., and oil consumption rate.
40
August 2016
Policy On Lubricant Additives
MCI does not recommend or support the use of any
supplementary lubricant additives. These include all products
are marketed as top oils, break-in oils, graphitizers, and
friction-reducing compounds.
Do not breathe or inhale the exhaust fumes.
Exhaust gases contain carbon monoxide, a
colorless and odorless gas, which can cause
unconsciousness and in some instances may be
lethal.
If at any time you think exhaust fumes are entering
the coach, have the cause determined and
corrected as soon as possible. If you must drive
under these conditions, discharge passengers if
possible and drive with all air vents fully open.
Keep the engine exhaust system, coach body, and
coach ventilation system properly maintained to
protect against carbon monoxide entry into the
coach. Always keep the exhaust tailpipe area clear
of snow and other material to help reduce the
build-up of exhaust gases under the vehicle. It is
recommended that the exhaust system and coach
body be inspected by a competent technician
anytime the exhaust system or coach has been
damaged, whenever a change is noticed in the
sound of the exhaust system, and each time the
coach has routine maintenance performed.
Keep the air inlet grill clear of snow, leaves, dirt or
other obstructions at all times to allow for proper
air flow through the coach ventilation system.
Do not operate the engine inside confined areas
such as garages without the use of proper exhaust
removal systems. Do not operate the engine while
parked inside narrow alley ways. If the vehicle
must be parked with the engine running for an
extended period and is in an unconfined area, turn
the HVAC system on to help force outside air into
the coach.
August 2016
41
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42
August 2016
7-TRANSMISSION OPERATION
GEN V AUTOMATIC TRANSMISSION
Shift Inhibit Logic
The B500 series GEN V is an electronically-controlled
hydraulic auto-shifting six-speed transmission. This
transmission controls all aspects of the shift function once
placed into the desired drive range. Shift range selections are
made with the touch-pad module located on the Lower LH
console.
This system prevents the transmission from selecting a gear
unless there is a full brake application (60 psi), the wheelchair
lift is deactivated, and the kneeling feature is deactivated.
A two-character digital display is located at the top of
automatic transmission shift selector. The left character of the
display, SELECT, designates N, R, or the highest gear
available of the selected forward range. The right character of
the display, MONITOR, designates the actual gear which is
being commanded by the transmission control module
(TCM).
Two-character diagnostic codes can be accessed using the
touch-pad on the pushbutton shift selector.
The MODE button, can be utilizedto invoke a special function
that has been programmed into the TCM. A text indicator on
the lower portion of the two character display illuminates
when the MODE function is activated ( Figure 44 ).
The gear selector should always be in the
NEUTRAL position when the coach is parked.
Shift Selection
The following is a brief description of the symbols used for
gear range selection on the automatic transmission shift
selector:
R - REVERSE
N - NEUTRAL
D - DRIVE; the highest forward gear will appear on the
SELECT display. The transmission will shift to the starting
gear.
During normal operation with D - DRIVE selected, the
SELECT display shows the highest attainable forward range.
The MONITOR display shows the gear which has been
commanded by the TCM (actual gear in which the
transmission is currently operating).
NOTE: Even though a lower range is selected, the
transmission may not down-shift until coach speed is
reduced, thus preventing excessive engine speed in the
lower range.
The UPSHIFT and DOWNSHIFT arrow buttons are not
functional in R - REVERSE or N - NEUTRAL.
There is no “PARK” position on the pushbutton
shift selector.
ALWAYS apply the Parking Brake to hold the coach
while unattended and place the Shift Control
Selector in the “N” (NEUTRAL) position. Refer to
“SERVICE BRAKES”, “Park Brake Release”
headings for the proper Parking Brake application
and release procedure.
Figure 44. Pushbutton Shift Selector
August 2016
When shifting from Neutral to a Drive or Reverse
range, the engine should be at normal idle speed.
When the coach is parked, the transmission should
always be in the “N” (NEUTRAL) position.
43
Telltale Warning Light
Allison Diagnostic Code Retrieval
The electronic control system is programmed to alert the
driver when something is wrong by illuminating the “CHECK
TRANS” in the tell-tale cluster.
Diagnostic codes, displayed as two digit numbers, indicate a
transmission malfunction. Diagnostic codes can be accessed
through the pushbutton shift selector. These codes are
logged in the TCM / ECU with the most severe or recent code
listed first.
Illumination of the “CHECK TRANS” at any time after engine
start (system check) indicates that a problem has been
detected. When a problem condition has been detected, the
TCM / ECU will:
- illuminate the “CHECK TRANS” tell-tale lamp,
- flash the display on the pushbutton shift selector,
- restrict shifting, and
- register a diagnostic code.
Generally, while the “CHECK TRANS” lamp is illuminated,
up-shifts and down-shifts will be restricted and direction
changes will not occur. The pushbutton shift selector should
not respond to any operator shift requests while the “CHECK
TRANS” tell-tale lamp is ON.
When the “CHECK TRANS” lamp is illuminated, the
transmission will operate in the “Limp Home” mode with
reduced capabilities. The Limp Home feature will lockup the
transmission in a selected gear to enable continued coach
operation for a short time until it can be moved safely out of
traffic. Advise service personnel immediately to minimize the
potential for damage to the transmission.
A maximum of five codes, identified as d1 to d5, can be listed
at one time. As codes are added, the oldest non-active codes
are dropped from the list. If all codes are active, the code with
the lowest priority not included on the severity list is dropped.
If the displayed code is active, the red light is illuminated on
the MODE button. If the displayed code is non-active, the red
light will not illuminate on the MODE button.
Pressing the N key on the touch-pad, with the ignition turned
ON (engine can be running), will allow the user to retrieve the
transmission codes.
Observe the two digit display for codes. Press the MODE
button to view the next code.
Record all codes.
Diagnostic Code Example
Code - P0722.
Displayed as: d1, P, 07, 22.
Do not attempt shutdown of engine or shift
transmission until coach is safely parked. If shut
down and restart is attempted, the transmission
would shift into Neutral, which would discontinue
the “Limp Home” feature and leave the coach
stranded until fault is cleared.
Each item is displayed for about one second.
d1 is the diagnostic code list position.
P0722 is the diagnostic code.
Clearing a Fault Code
Record all codes prior to clearing.
44
August 2016
ALLISON Fluid Level Check
Fluid level diagnostic information, displayed as two digit
numbers, can be accessed through the pushbutton shift
selector. These checks should in no way take the place of the
manually conducted dipstick level check.
The coach must be parked on a level surface with the
transmission in Neutral and the park brake applied. The fluid
level check may be delayed until the following conditions are
met:
- the fluid temperature is above 140F (60C) and below 220F
(104C),
- the transmission is in Neutral,
- the engine is at idle,
- the transmission output shaft is stopped,
- the coach has been stationary for approximately two
minutes, allowing the fluid to settle.
The pushbutton shift selector will indicate a delayed fluid
level check by a flashing display under SELECT and a digital
countdown from 8 to 1 under MONITOR.
The Invalid Display is activated when conditions do
not allow the fluid level to be checked.
Review the following codes and their associated
conditions to assist in quickly correcting the
condition.
CODES
DESCRIPTIONS
“OL -- 0X” - Settling time too short.
“OL -- 50" - Engine speed (rpm) too low.
“OL -- 59" - Engine speed (rpm) too high.
“OL -- 65" - Neutral (N) must be selected.
“OL -- 70" - Sump oil temperature too low.
“OL -- 79" - Sump oil temperature too high.
“OL -- 89" - Output shaft rotation.
“OL -- 95" - Sensor failure.
To exit the oil level display mode with pushbutton shift
selector, press any other button on selector.
A correct fluid level is reported when an “OL” is displayed
(“OL” indicates the Oil Level Check Mode), followed by “OK”.
The “OK” display indicates that the fluid level is within the
correct fluid level zone “OL OK” indicates correct fluid level.
NOTE: The dipstick check may not agree exactly with sensor
checks because the oil level sensor compensates for fluid
temperature.
Low fluid level is reported when an “OL” is displayed,
followed by “LO” and a number. “LO” indicates a low fluid
level, and the number indicates quarts of fluid the
transmission requires “OL LO 02" indicates that two
additional quarts of fluid should bring the level to the
acceptable zone.
NOTE: Confirm an electronically obtained low fluid condition
by making a manual fluid level check.
High fluid level is reported when an “OL” is displayed,
followed by “HI” and a number. “HI” indicates a high fluid
level, and the number indicates quarts overfilled “OL HI 01"
indicates one quart past the full level.
Invalid Display conditions are reported when an “OL” is
displayed, followed by “--” and a number. The displayed
number is a code, and would indicate an improper condition
for electronic check or a system malfunction “OL -- 70" would
indicate that the oil sump temperature is too low.
August 2016
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August 2016
8 - EMERGENCY CONDITIONS
Alarm and Warning System
The coach is equipped with tell-tale lamps and buzzer signals which immediately warn of any abnormal operating conditions.
The tell-tale lamps are located above the Multi Function Display. The buzzer is located in the Front Junction Box.
Telltale Light
Buzzer
REGENERATION (PDF)
HIGH EXHAUST TEMP
MALFUNCTION INDICATOR (MIL)
LOW AIR
HOT ENG
PARK BRAKES
NOT GEN
HI-BEAM
BACK-UP LAMPS
LOW WATER
FIRE ALARM
STOP ENG
NO
NO
NO
YES
NO
NO
NO
NO
NO
NO
YES
YES
Condition
Regen is required for 2016 engine
Exhaust outlet temp exceeds level
Failure of an emission component
Air Pressure Low
Engine Overheated
Brake On
Generator Not Charging
Headlight High Beam On
Back-up Lamps On
Low Engine Coolant Level
Indicates fire in engine compartment
Serious Engine Condition
Engine Electronic System - Warning
Gauge and telltale lamps are provided so the
operator can observe the operation and condition
of various components and equipment.
If abnormal conditions are indicated, take action at
once to locate and correct the cause before serious
damage can occur. Do not ignore warnings of
abnormal operating conditions. Regularly check all
gauges and telltale lamps during operation.
Engine Oil Gauge
Normal readings at operating temperatures are 50-70 psi
(345-483 kPa) at 1800 RPM. If the oil pressure drops below a
safe level during operation, the CHECK ENGINE or STOP
ENGINE telltale lights will illuminate. This condition should
cause the coach engine to automatically shutdown.
Engine Coolant Temperature (Overheat)
The engine coolant temp. range varies between the different
engines. If possible, avoid going to full throttle until engine
temp. reaches 140F (60C). The engine will come up to
normal operating temperature shortly after driving.
If the engine becomes overheated during operation, the
CHECK ENGINE or STOP ENGINE telltale lights will
illuminate. This condition should also cause the coach engine
to automatically shutdown. If overheating occurs, check
water level of engine cooling system as directed under
Engine Cooling System and look for other possible causes.
August 2016
Each engine installation is equipped with an alarm system to
warn the operator of an abnormal oil/coolant level and/or
temperature condition. Such conditions are indicated by
telltale lights on the instrument panel. Coaches have an
automatic system to power-down and/or shutdown engine
operation if any abnormal conditions arise.
NOTE: The automatic power-down or shutdown can be
temporarily over-ridden to move the coach to a safe location.
If the engine has begun the 30 second power-down
sequence, the following procedure can be used to keep the
coach in motion.
1. Lift the guard and activate the ENGINE SHUTDOWN
OVERRIDE switch located on the Lower LH Console.
Depress the switch at approximately 15 - 20 second
intervals as often as required to delay shutdown and
move the coach to a safe stop area.
2. Continue coach travel until a safe location is found.
Operate engine at lowest RPM possible while moving
coach.
If the engine has automatically shut down, the
following procedure must be used to restart and move
the coach.
•
•
•
Momentarily turn the Ignition switch to the
“OFF” position and back to “ON” again.
Press the Engine Shutdown Override switch,
and attempt to restart engine with the Engine
Start switch.
Move coach to a safe location. Operate the
engine at lowest RPM possible while moving
coach.
47
Alternator - Warning
A tell-tale light marked NOT GEN is located within the tell-tale
cluster. This telltale will be illuminated whenever the Master
Power / Ignition switch is “ON” and engine not operating, or
when engine is running and alternator is not charging.
If the NOT GEN telltale light goes on during normal operation,
it indicates that the alternator is not charging. Turn off all
electrical accessories, except driving lights at night, to reduce
the electrical load on the batteries and obtain service
attention as soon as possible.
Power Steering System
If the power steering system goes out because the engine
has stalled or due to a hydraulic failure, the coach can still be
steered. However, much greater effort is required, especially
in sharp turns or in low speed.
Windows close with enough force to cause injury.
Ensure that hands are clear.
Emergency Escape - Side Sash
All side passenger windows can be opened from the inside
for emergency escape purposes. Sash is hinged at the top
and can be opened by pulling out and up on the release bar,
then pushing the sash out. Instruction plates are mounted
below the sash on the release bars at each seat location
(Figure 46). Inspect regularly to assure latch is secure and
serviceable.
Emergency Escape - Roof Hatch
The roof hatch may be partially propped open by
the operator for ventilation purposes when it is
safe to do so. Before doing so, the operator should
ensure that the coach will have adequate roof
clearance with the partially opened hatch
throughout the intended route of travel. The partial
opening should not be performed when the coach
is in motion.
In no event should the roof hatch be fully opened
for ventilation or any other purpose while the
coach is being operated.
The escape hatch is located in the roof for emergency exiting.
The hatch may also be used for ventilation of the passenger
compartment during emergencies. To open in case of
emergency, turn then push knob to open as shown in the
instructions on roof hatch (Figure 45).
Figure 46. Side Sash Emergency Exit
Hazard and Warning Signal System
The coach is equipped with a flashing signal system which
flashes all directional signal lights simultaneously to warn
traffic in an emergency. The hazard warning switch, located
on the Lower LH Console, is used to energize this signal
system. A HAZARD telltale light is illuminated and both turn
indicator arrows flash when the system is operating.
The Hazard/Warning lights automatically activate when the
passenger door opens, the Wheelchair Lift Master Keys witch
is in the “WCL ON” position or when reverse gear is selected.
The lights extinguish when the bi-part passenger door closes,
the Wheelchair Lift Master Keys witch is in the “WCL OFF”
position and the transmission is not in reverse.
Recommended Tire Inflation Pressures
Ride characteristics and tire wear are affected by tire
inflation. MCI recommends that the inflations shown on the
certification plate be followed for that size tire. Inflation
pressures for tires other than those shown may be found on
the chart in the “Specifications” section of this manual.
Figure 45. Roof Hatch
48
Only use approved 22.5 - 9 inch tires.
August 2016
Remote Engine Operation
Switch - Battery Disconnect
The main battery disconnect switch, located in the battery
compartment, shuts off electrical supply from the batteries to
most electrically controlled systems (Figure 48).
This feature is primarily for maintenance purposes.
Before attempting to start engine from rear of
coach, make sure transmission is in Neutral and
parking brake applied.
Both the 12V and 24V disconnects are combined on the
rotary switch. To disconnect batteries, rotate counterclockwise to “OFF” position.
All electrical circuits are protected by fuses.
Figure 47. Remote Junction box
Switches for starting and stopping the engine at the rear are
mounted on the remote electrical control panel. This panel is
located at the left side in the engine compartment. To gain
access to the panel, open rear engine compartment doors
(Figure 47).
Figure 48. Battery Compartment
If it is necessary to work on the engine without
engine running, place remote control and run
switches in “OFF” positions. This breaks the
circuit to starter and prevents starting the engine.
Starting Engine - Remote
1. In operator's compartment, place Master Power /
Ignition switch in the “ON” position.
2. In the engine compartment, put engine switch in the
upper position (ENG RUN).
3. Move remote switch to bottom position (REAR
START) and hold until engine starts. Use the same
precautions regarding use of starter as explained
under starting engine.
Stopping Engine - Remote
To stop engine at rear, place ENG RUN switch to ENG
OFF position.
August 2016
49
Emergency Starting
The coach may require the following emergency battery
boost procedures during extreme weather conditions. The
negative and positive booster battery posts and distribution
cable are inside the right-hand engine compartment.
Do not push or tow this coach to start. This may
damage the coach. If the coach has discharged
batteries, it can be “jump started” by using energy
from another battery. Ignoring the “Emergency
Starting” procedures herein outlined could result
in: Personal injury or property damage caused by
the electrolyte squirting from battery vents or
battery explosion.
Damage to the starting or charging system of the
booster or immobilized vehicle. Do not attempt to
jump start a vehicle with a frozen battery. Frozen
batteries may rupture or explode. If a frozen battery
is suspected, examine fill vents for ice. If ice can be
seen, do not attempt to start the vehicle with
jumper cables.
Both the booster battery and discharged battery
must be handled carefully while using jumper
cables. Follow the “connecting” and
“disconnecting” procedures shown. Do not permit
vehicles to touch each other as this could establish
a ground connection and counteract the benefits of
this procedure.
Connecting Booster Cables
1. Ensure that the coach is in neutral and set the park
brake. Turn off lights, heater and other loads.
2. Ensure that the battery disconnect is ON.
Always exercise caution when the battery
disconnect is ON.
3. Turn the engine run switch OFF. Wait a few seconds
to allow the multiplex system to power down.
6. Attach one end of one positive (+) cable to the
positive terminal of the booster battery (identified by a
red color, “+” or “P” on the battery case, post or
clamp). Remove the rubber boot that covers the post
on the side of the channel on the front of the A/C
compressor base. Attach the other end of the jumper
cable to this post.
7. Taking care that clamps from one cable do not touch
clamps on the cable, attach one end of the remaining
negative (-) cable to the negative terminal of the
booster battery (identified by a black color, “-” or “N”
on the battery case, post or clamp). Attach the other
end to the ground stud on the top of the A/C front
mounting rail.
8. Switch the battery disconnect ON.
9. Turn the engine run switch to RUN. Wait a few
seconds while the multiplex system does a power-on
self-test.
10. Start the coach.
11. When the coach is running, remove the booster
cables. Observe all cautions.
Disconnecting Booster Cables
1. Taking care that clamps from one jumper cable do not
inadvertently touch clamps on the other jumper cable,
disconnect jumper lead from ground stud of the
vehicle being started. Do not lean over booster
battery when disconnecting this lead.
2. Remove remaining end of negative (-) jumper cable
from the booster battery.
3. Remove one end of the remaining jumper cable from
post on the side of the front mounting rail of the A/C
compressor, then remove the other end of the same
cable from positive terminal of the booster battery.
Secure the rubber boot over the post on the A/C
compressor mounting rail.
4. Remove cloths from open vent wells of each battery.
Discard cloths as they may have corrosive acid on
them. Install vent caps on both the booster and the
discharged battery.
Color Coded Cables
Color coded battery cables are provided to minimize the
chance of battery and cable terminals being disconnected.
Color coded battery cables identify the following: Red is
(Battery +)24 volts, Blue is (Battery +)12 volts and Black is
negative (-).
4. Switch the battery disconnect OFF.
5. Remove vent caps from both the booster and the
discharged batteries. Lay a cloth over the open vent
wells of each battery.
50
August 2016
Electrical Towing Receptacle
The towing electrical receptacle is wired to the coach front
electrical junction box to provide power from the towing
vehicle to the coach lighting system. This connects the coach
stop, clearance, hazard, turn signals, clearance and ID light
system to the towing vehicle lighting system operation.
Towing
The park brake circuit and at least one service
brake circuit require full air pressure, preferably
the primary (rear service brake) circuit.
This will allow the park brake push-pull valve to be
pushed down, allowing the locks to release and
permit the park brakes to retract.
A full service brake application will be required to
ensure release.
Towing must be from the Front.
Only tow from the rear to extract the coach from
ditches or snowbanks.
The drive axle shafts must be removed when coach
is being towed to avoid possibility of damage to
transmission.
Refer to Section 3F-Towing in the D Series
Maintenance Manual for information on towing.
1. Route the tow vehicle hoses to the coach connection
points.
2. Attach the tow truck chains in the coach tow eyes and
take up all slack.
Only operators authorized to and experienced in
towing intercity coaches may tow coaches.
The towing air connections are located in the roadside, front
service compartment ( Figure 49 ).
3. Attach safety chains as applicable.
4. Observe the normal towing precautions including, but
not limited to, the ones listed below when towing the
coach:
a. Make sure the Park Brake is released
before towing by applying the service
brakes.
b. Do not allow passengers in the coach
during towing.
c.
Do not exceed a prudent, safe towing
speed. Be aware of changing conditions.
d. Avoid “tight” turning, accelerating and
decelerating.
e. After approximately two miles towing,
check and re-tighten the safety and tow
chains as necessary.
Figure 49.
August 2016
51
Air Pressure - Warning
The primary and secondary service brakes, and suspension/
accessory air systems pressure is monitored by the main air
pressure switch located in the rear junction box. When the
Master Power / Ignition switch is in the “ON” position, the
LOW AIR warning system is initialized. If, during normal
operation, a LOW AIR warning is activated, it indicates that
air pressure is too low in one of these three air circuits.
Warnings will remain on until air pressure rises above 100 psi
(689 kPa).
A low air warning light will illuminate and a buzzer
will sound when air pressure drops below 75 ± 5
psi (517 ± 34.5 kPa) in either of these air circuits. In
the event of a low air warning, stop the vehicle at
once and determine the cause of air loss before
proceeding.
The park brake may be released and reapplied
approximately three more times in order to move
and/or park the coach in a safe location, before the
park reservoir is depleted.
Parking Brakes (Emergency Operation)
The park brake reservoir is isolated from the service brake
circuits, and provides air to the park brake circuit exclusively.
If park reservoir drops below 45 ± 5 (276 ± 34.5kPa) the
parking brakes will automatically apply. Once applied, brakes
are mechanically locked and will remain so until air has been
replenished in the park reservoir, and at least one of the
service brake reservoirs.
The coach should not be operated with air
pressure below 100 psi in either circuit, as brake
effectiveness could be reduced resulting in an
increased stopping distance.
After the park brake has automatically applied in
the emergency mode, it can not be safely released
until the park brake circuit has been filled above 75
psi ± 5 psi (519 ± 34.5 kPa), and at least one service
brake air circuit is filled above 100 psi ± 5 psi (690 ±
34.5 kPa).
Service Brakes (Emergency Operation)
Emergency Parking Brake Release
This coach is equipped with a dual circuit service brake
system with separate reservoirs for primary (rear) and
secondary (front) brake circuits. If a low air condition occurs
in the primary service brake supply circuit, secondary service
brake air is routed to the emergency stand-by valve. Fully
modulated primary (rear) braking will be available through the
drive axle brake chamber's emergency portion, along with the
secondary (front) service brakes.
The emergency parking brake release valve is a manually
operated on-off control. It is used to manually release the
emergency park brake. The valve is spring loaded and
remains in the exhaust (button out) position constant manual
force is applied.
No provisions are made for secondary circuit air
loss, because the primary brakes alone are
sufficient to stop the coach.
In the unlikely event that a low pressure condition occurs in
both service brake circuits at the same time (i.e., air
compressor or supply hose failure), the service brake system
can be used to safely stop the coach after alarm sounds.
Approx. three separate service brake applications may be
made before both circuits are depleted (depending on rate of
air loss). If necessary, the park brake can also be used to
stop the coach after service brakes are depleted.
52
Emergency Fill - Park/Service Brake System
The park/service brake air system may be filled from an
external source by applying air at two (2) of the three (3)
emergency fill schrader valves located in the front LH side
service compartment. To emergency fill the park brake
system, apply air to the emergency park system's fill valve.
To emergency fill the service brake system, apply air to at
least one of the two emergency service brake fill valves.
Filling of the park brake circuit will permit the release and
reapplication of the park brake only. Filling of the front circuit
will permit a modulated primary/secondary application, while
filling of the rear circuit will permit a normal primary brake
application.
August 2016
Filling of either service brake circuits will allow for the safe
release of the park brake and coach movement. If the entire
park/service brake system's integrity is intact, it may be
completely filled by use of the rear service fill schrader valve.
The valve is located in line on the compressor discharge
sump (ping tank) drain inside the RH rear side service
compartment.
Tools and Safety Equipment
Three collapsible reflective safety triangles are securely
mounted in the battery compartment ( Figure 51 ).
Figure 51. Safety Triangles, Location
Figure 50. Emergency Fill Valves
These have a folding stand for placing at intervals on the
roadway toward oncoming traffic. Use these to warn traffic if
the coach must be parked in an emergency situation.
Fire Extinguisher
Always fill the park brake circuit first. Before
applying air in an emergency fill procedure, ensure
that the park brake valve is in the “UP” position.
When filling the park/service brake system via the
front or rear schrader valves as outlined above, the
air does not pass through the air dryer. This may
result in water entering the air system reservoirs.
After repairs are completed, manually drain all
reservoirs to relieve any moisture present.
A 5 lb. fire extinguisher is installed under the #2 curbside side
passenger seat. To remove, lift and disengage catch on the
mounting box. Lift fire extinguisher out (Figure 52 ).
Figure 52. Fire Extinguisher, Location
August 2016
53
AMEREX Fire Suppression System
The AMEREX fire suppression system is an automatic
system that continuously monitors the engine compartment
for fires. The system uses thermo-sensors connected to an
electronic circuit monitor/control panel to electrically trigger
the release of the dry chemical (ABC) extinguisher.
In the event of fire, the green System OK LED will go out and
the red FIRE LED will come on. The system will force
chemical fire suppressant through four spray nozzles located
in the engine compartment.
An audible buzzer will sound continuously during fires. This
alarm will operate until the Push to Silence button is pushed.
When the Silence button has been pushed, the Silence
Engaged LED will be illuminated.
As a safety provision, the silence feature cannot be
operated in advance of a fire or fault condition.
When the fire is extinguished and the thermo-sensor cools,
the red FIRE LED will illuminate. The red FIRE LED will
remain illuminated until the system is serviced and the
monitor is reset.
Fault Condition
Figure 53. Amerex Control Panel
If a fault occurs in the system, the Service System LED will
be illuminated and will remain so until the condition is
repaired.
Manual Operation
The Relay Reset button located on the Amerex
control panel is disabled.
Control Panel
The manual function is used when a fault exists that could
inhibit auto/electrical actuation via the control panel. During
a fire emergency, the driver must manually pull the
disarming pin that retains the actuator switch and push the
button ( Figure 54 ). The manual fire button is located
behind the Lower LH Console on the left side of the driver’s
seat.
The control panel is responsible for driver alerts and for the
automatic activation of the system during fire hazards. The
control panel has both audible and visual alarms.
Normal Operation
During normal operation, a green System OK LED is
illuminated on the front of the control panel. This indicates
that all circuits are intact and functioning.
Fire Hazard Conditions
As a safety provision, the operator can extend engine
shutdown time for an additional 15 seconds by engaging the
ENGINE OVERRULE switch, to allow moving the coach to a
safe location. This may be done as many times as necessary
to safely bring the coach to a controlled stop.
Figure 54. Manual Fire Button
54
August 2016
9-HEATING AND AIR CONDITIONING
Main A/C System / MICROMAX
The dash controller is located on the lower curbside of the
instrument panel. Before either system will operate, the
Master Power / Ignition switch must be “ON”, NOT GEN light
off, engine running and system air pressure above 95 ± 5 psi
(655 ± 34.5 kPa).
Engage the engine fast idle when it is necessary to
operate the air conditioning system while the
coach is parked.
KEY FUNCTIONS
Figure 55. HVAC Dash Controller
Driver's Fan (Defrost) Control
Controls driver's defroster fan speed from OFF, LO, MED,
HIGH.
The flow of coolant to the driver's heater system is controlled
by the “T” handled cable-operated hot water control valve.
The control handle can be adjusted to vary flow through the
valve by pulling up and turning to lock. The driver's heat
control handle is located adjacent to the fresh air control
handle mounted to the driver's foot rest assembly.
Micromate Control Panel
The Micromate Control Panel displays the set point
temperature, interior (return air) temperature and exterior
temperature. To read interior or exterior temperature, press
the TEMPERATURE display button to illuminate the indicator
light. After a short delay, the display will return to the default
set point temperature.
Set point temperature may be changed by pressing the UP or
DOWN arrow button. The UP button will increase the set
point temperature and the DOWN button will decrease the
set point temperature. The set point temperature can be
adjusted from 60F to 80F (15C to 27C).
August 2016
Driver's Ventilation And Fresh Air
The driver's area has a separate fresh air intake system. The
fresh air control handle, adjacent to the driver's heat control
handle, operates a flap on the bottom of the driver's heater
and defroster unit ( Figure 56 ). The flap partially covers the
opening through which fresh air from a vent above the
bumper enters the driver's heater defroster system.
Placing the control handle downward opens the flap allowing
more air to enter the system. Air flow can be regulated by
locking the control handle in any position between fully up
and fully down by rotating the handle 1/8 turn. When the flap
is closed as far as possible, the system operates on mainly
recirculated air.
The air flow to the windshields is continually open
to prevent the possibility of fogging.
55
A gasper under the dash on the left-hand side near the
driver's knees vents the fresh air into the driver's area. The
right-hand gasper is used for the A/C and heating distribution.
The volume of air flow from the gaspers can be regulated by
rotating the knurled flange on the front of the gasper outlet.
Rotating the gasper will also shut off or maximize the air flow.
The direction of the air flow can be adjusted by moving the
gasper outlet in its ball socket.
Parcel Rack Ventilation
An internal ventilation system is located in the mid-section of
the left and right hand parcel rack units. The system contains
individualized passenger air outlets mounted in speaker
modules attached to the underside of the parcel racks. These
are individually-controlled by twisting “off” or “on”, and by
directing the air flow directional nozzle. The blower is
controlled by the Parcel Rack System Blower Speed switch
mounted in the upper left switch panel. Interior air supply
enters the parcel rack ventilation system through an inlet grill
on the module door ( Figure 57 ).
In warm, humid conditions, the driver's fresh air
system can assist in defogging the windshields.
Figure 57. Parcel Rack Blower
Figure 56. Ventilation Control Handles
Avoid too high temperature in the driver’s area.
This tends to induce drowsiness and may affect
your ability to safely operate the coach. It may also
affect the temperature in the passenger
compartment.
When the outside temperature is very high or very
low, both the driver’s and passenger fresh air
intakes should be closed as much as possible.
This will maximize the efficiency of the HVAC
systems in very cold or hot weather conditions.
56
August 2016
10-SERVICE AND MAINTENANCE
Service & Access Doors
The exterior view on the following page identifies all service
compartments and exterior access doors for the D4000 /
D4005 / D4500 / D4505 series coaches ( Figures 58 and 59 ).
Their locations, components contained within, and methods
of opening are as follows:
Some components may be optionally located and
accessed through other compartment service
doors.
Figure 58. D4505 Exterior Components
D4505 Exterior Components ( Figure 58 )
1. Entrance Door (Sedan)
10. Air Cleaner Service Door
2. Entrance Door Exterior Switch
11. A/C Compressor Service Door
3. Fuel Compartment Door
12. Engine & Cooling Compartment Door Latches
4. Battery Compartment
13. ID Marker Light-High Mounted
5. DEF Compartment Door
14. Brake Light-High Mounted
6. Rear Side Service Compartment Door
15. Rear Tail Light Cluster
7. A/C Condenser
16. Back-up Lights
8. Electrical Panel / Front Junction Box
17. Bumper and Spare Tire Compartment
9. Radiator Compartment
18. Directional Light
August 2016
57
Figure 59. D4500 Exterior Components
D4500 Exterior Components ( Figure 59 )
1. Entrance Door (Sedan)
10. Air Cleaner Service Door
2. Entrance Door Exterior Switch
11. A/C Compressor Service Door
3. Fuel Compartment Door
12. Engine & Cooling Compartment Door Latches
4. Battery Compartment
13. ID Marker Light-High Mounted
5. DEF Compartment Door
14. Brake Light-High Mounted
6. Rear Side Service Compartment Door
15. Rear Tail Light Cluster
7. A/C Condenser
16. Back-up Lights
8. Electrical Panel / Front Junction Box
17. Bumper and Spare Tire Compartment
9. Radiator Compartment
18. Directional Light
58
August 2016
Rear Side Service Compartment Door
The LH/RH rear side service doors are located directly
behind the rear wheel housings. Access is provided to both
sides of the engine through these doors. The suspension
components are accessed from the right side door. The
auxiliary heater, B500 transmission dipstick and rear
electrical J-box is accessed by the left side door.
When securing the door in the open position
during Sliding Wheelchair Access door operation,
install the positive lock pin in the LOWER hole of
the hinge ( Figure 60 ).
The doors feature upper and lower front mounted hinges, and
are retained by top and bottom spring bolt latches. Pull the
paddle handle out to open doors. The door is held in the open
position by a prop rod retainer clip. Move door firmly off open
position to release prop rod and close door.
Condenser Compartment Door
The condenser door is located at left side of coach behind the
no. 2 baggage compartment. Access is provided to the door
mounted condenser, condenser fans and motors, receiver
tank, filter/dryer and other A/C components.
The door features a full length front mounted hinge, and is
retained by four slot-type, quarter-turn, spring clip fasteners
at rear edge. The door is held in the open position by a
hinged metal strap. The strap must be displaced from its
locked position to close the door.
Fuel Compartment Door
The fuel compartment is located on the right side of the
coach behind the #2 baggage compartment. Access is
provided to the fuel filler cap, fuel tank and associated lines
and sensors through this door.
To access the fuel tank filler cap and neck, open the small
spring return door. Complete access to the fuel tank can be
obtained by unfastening and removing the service door.
DEF Compartment Door
The Diesel Exhaust Fluid (DEF) compartment is located on
the curbside of the coach, at the rear of the #3 baggage
compartment.
Figure 60. Battery Compartment
Entrance Door
An air-operated entrance door is provided as access into the
coach. This door is opened or closed from the interior or
exterior by activating the appropriate inner or outer door
control switches.
Wheelchair Access Door (IF APPLICABLE)
A manually operated wheel chair access door is located in
the RH forward section of the coach above baggage bay no.
2. This door provides wheelchair access to the coach using
the wheel chair lift which is stowed in the lower section of
baggage bay no. 2.
Battery Compartment Door
The battery compartment is located on the right side of the
coach directly behind the fuel door. Access is provided to the
main disconnect switch, batteries, tools, and HVAC filter
compartment by this door.
This door features a full length top mounted hinge, and
retained by two bottom spring bolt latches. The door is held in
the open position by positive lock pin. To access the main
disconnect switch, open the small spring return door. To
access the other components, pull the paddle handle out and
lift door open.
August 2016
59
Lift Cassette Access Door (IF APPLICABLE)
The lift cassette access door is located on the right side of the
coach, on baggage bay no. 2. This door provides access to
the lift cassette and the pendant control switch, which
operates the lift.
To ensure the cassette door closes with the latches
fully engaged, apply sufficient force to both latch
points when closing door (refer to Figure 61 ).
Figure 62. Release Lever
Ensure that the lever is always engaged when the
engine cooling compartment doors are closed to
prevent inadvertent opening due to high internal
compartment pressures.
Baggage Compartment Door
Figure 61. Cassette Door
Rear Engine Access Door
The rear engine access doors are located at the rear of the
coach. Engine oil level, power steering fluid, A/C
compressor and drive belt, water temperature gauge and
remote control panel are accessible from here.
The doors feature upper and lower side mounted hinges, and
are retained by top and bottom spring bolt latches.
Pull the paddle handle out on the right side door to open both
doors. The door is held in the open position by a prop rod
retainer clip. Move the door firmly off the open position to
release the prop rod and close the door.
Engine Cooling Compartment Doors
The engine cooling compartment (radiator) doors are located
above the rear engine access doors.
To open the engine cooling compartment doors, open the
curbside rear engine access door and pull the lever down,
disengaging the lever from the curbside engine cooling
compartment door. Locate the door latch and pull outward
(refer to Figure 62.). Pull doors outwards until the doors are
fully open and secured.
60
The LH/RH baggage compartment doors are located along
the side of the coach between the front and rear
wheelhouses. Access to the junction box, in-station lighting
converter and breakers (no. 1 LH compartment), center
tunnel electrical components, HVAC blower, ABS control, tire
tool bar, water valve and voltage regulator is provided
through these doors.
The door mechanism incorporates spring-assisted counterbalanced vertical opening with spring clip retention, and a
four point locking arrangement. Pull up on the latch handle,
then pull out and up on the door to open.
Always use the positive locking pins to secure the
door in the open position while loading baggage.
Lift up on the door latch, push the door closed and push the
latch down until it snaps into the latched position to close the
door.
Spring clip condition and adjustment should be
inspected prior to loading and unloading baggage
compartment.
August 2016
Tire Compartment Door
The tire compartment door is incorporated into the front
bumper. Access to the spare tire and jack is provided through
this door. The door is hinged at the bottom and retained by
two top spring bolt latches. The door features spring counterbalanced opening.
To open the tire door, open the front side service door and
pull bumper release handle. The bumper is held in the open
or (down) position by an over-center angle latch on LH
counter-balance. The angle must be displaced from its locked
position to close the bumper door.
At times, fans may not be engaged. However fan
clutches can, without warning, automatically cycle.
When working in the vicinity of the engine, care
must be exercised to keep hands, loose clothing,
etc., clear of all moving objects, i.e., belts, pulleys,
fans.
Injury could result if contact were to be made.
Front Side Service Compartment Door
The front side service door is located below the front junction
box door. The door gives access to the emergency fill valves,
accessory tank, tire compartment release handle, horns,
steering components, and windshield washer reservoir.
The door is front hinged and held closed by two slot-type,
quarter-turn, spring clip fasteners. The door is held in the
open position by a prop rod retainer clip. Move door firmly off
open position to release the prop rod and close the door.
Never pour cold coolant into a hot engine. The
sudden change in temperature may crack the
cylinder head or block.The heating and engine
cooling systems cannot normally be completely
drained. Therefore, when replenishing the system,
a proper mixture of antifreeze and water must be
installed to prevent any possible damage to the
system due to freezing conditions.
Front Junction Box Access Door
Coolant Recovery System
The front junction box door is located above the front side
service door. This door provides access to the front electrical
components, including amplifiers, emergency entrance door
air release cable, and tag axle speed switch.
The basic manual or optional automatic coolant recovery
system is incorporated into the cooling system to fill or to
replenish coolant in the event of overheating. The system
includes a low coolant level warning sensor that activates a
LOW WATER tell-tale light and actuates the pump when the
water level in the surge tank reaches a predetermined low
level. There is a sight glass on the coolant recovery tank.
The door is front hinged and held closed by two quarter-turn
spring clip fasteners. The door is held in the open position by
a prop rod retainer clip. Move the door firmly off the open
position to release the prop rod and close the door.
Back-Up Lamp Access Door
Twin rear access doors are mounted at the rear of the coach
below the LH/RH main tail lamp panels. The engine air filter,
back-up lights and A/C compressor are accessed through
these doors. The doors have top and bottom front-mounted
blind hinges and are secured by two slot-type quarter-turn
spring clip fasteners at rear.
Cooling System
The engine cooling system maintains the proper operating
temperature of the coach engine and also provides a supply
of heated water for the coach heating system. The cooling
system's radiator is filled by either a manual or automatic
coolant recovery system.
This system features a 6-gallon reserve coolant reservoir
under A/C compressor mountings inside the RH rear side
service door.
Filling
The entire cooling system is filled by the recovery system
pump via the surge tank.
1. 1. Close all drain cocks and ensure that isolation and
bypass gate valves are open.
2. Turn the main battery disconnect switch “ON”. The
LOW WATER tell-tale light on the dash will come on.
If it does not illuminate, check the lamp using the bulb
test switch.
3. Fill the coolant recovery tank and continue adding
coolant to the tank until the pump and telltale light
shut off and the system is full.
4. Hold the pump switch, located on the remote control
box, in the “ON” position. The pump will begin to operate and pump coolant into the system.
August 2016
61
The pump will shut off automatically when the
recovery tank empties. On automatic systems, the
pump starts without actuating a switch.
5. Open the petcock on the water bypass tube. This will
allow air to bleed as the system fills. Close when the
coolant begins to flow out the petcock.
6. Refill the recovery tank with reserve coolant.
The angle of the coolant recovery tank will allow
the coolant to expand as it warms up without
overflowing.
Wheel Wrench and Handle
Figure 64. Wrench Location
Spare Tire Compartment
Entry is gained by releasing the bumper retaining lever inside
the front side service compartment.
The wheel nut wrench and wrench handle are necessary to
loosen the wheel nuts. The handle is stored in the left rear
baggage compartment ( Figure 63 ). The wrench is located in
the storage tray in the battery compartment ( Figure 64 ).
Run-up block must be used on fully inflated and
flat tires for sufficient jack clearance.
Figure 65. Front Bumper, Opened
Tire & Wheel Removal - Jacking & Blocking
Wheel and tire assemblies weigh more than 100
pounds. Use caution if required to handle the
wheel and tire units.
If a flat tire occurs and the wheel is to be changed, contact
Control Center to request maintenance assistance. The
following procedures are for maintenance personnel
reference. Refer to Section 3 - LIFTING & TOWING in the
Maintenance Manual for more detailed information.
Figure 63. Handle Location
Run-up block must be used on fully inflated and
flat tires for sufficient jack clearance.
62
August 2016
Hub Pilot Wheels
Front Axle
1. Turn front wheels straight in preparation for wheel and
tire removal.
2. Run the flat tire up on run-up block. Stop the coach
and apply parking brakes.
3. Place the jack under the front jack pad and raise the
coach.
4. Before the tire is completely off the ground, partially
loosen the wheel nuts.
Figure 66. Front Axle Jacking Points
5. Raise the coach completely, remove the run-up block
and proceed to remove the wheel nuts.
Drive Axle
1. If the inner dual is to be changed, partially loosen the
wheel nuts before running onto the run-up block.
2. Run the inflated tire up on the run-up block. Stop the
coach and apply the parking brakes.
3. Place jack under the rear jack pad and raise the
coach.
4. Before the tire is completely off the ground, completely remove wheel nuts.
5. Raise the coach completely and remove the run-up
block.
Figure 67. Drive Axle Jacking Points
Run-up block must be used on fully inflated and
flat tires for sufficient jack clearance.
Trailing Axle
1. Partially loosen wheel nuts before tire is lifted off the
ground.
2. Place the tag axle tire on the run-up block. Stop the
coach and apply the parking brakes.
3. Place the jack under the rear pipe strut jack pad and
raise coach.
Figure 68. Fixed Tag Axle Jacking Points
August 2016
63
Fueling
The following emergency procedure applies to the
D4000 series coaches only.
In case the spare is already in use or trailing wheel and tire is
needed for replacement, the following procedure can be
followed as an emergency measure to reach a service
facility.
The engine fuel tank is accessible through a small access
panel on the fuel door, on the curbside of the coach
( Figure 70 ). Use only clean diesel fuel of the correct grade.
Close fuel tank filler and tighten securely after filling.
1. Turn the trailing axle air control valve “OFF”, jack the
trailing axle and remove the wheel per changing
procedure.
2. Install the holdup chain on the trailing wheel axle. The
chain is carried in the storage tray in the battery compartment.
3. Place the air release valve “ON” to re-inflate the air
springs bellows ( Figure 69 ).
Figure 70. Fuel Door
DO NOT put anything but DEF in the DEF tank
( blue cap ).
Figure 69.
The DEF fuel tank is separate from the diesel tank, located at
the curbside, rear corner of the #3 baggage bay compartment
( Figure 71 ). Open the DEF fuel door to access the blue cap
on the tank. Tighten cap securely after filling.
Reduce speed when operating the coach without a
trailing wheel. The trailing wheel tire should be
repaired and installed as soon as possible.
Trailing wheel with a flat tire must be removed if
travel distance to a service center is more than 5
miles.
Figure 71. DEF Door
64
August 2016
Lubricating Oil - Engine
Windshield Washer Reservoir
The engine oil dipstick is accessible through the rear engine
access doors.
A windshield washer reservoir with a five-gallon capacity is
mounted in a bracket on the inside of the front left side
service compartment door ( Figure 72 ).
When working in the vicinity of the engine, care
must be exercised to keep hands, loose clothing,
etc., clear of all moving objects; i.e., belts, pulleys,
fans.
It is important to note that the fan clutches may
allow the fans to be stationary, but fans may cycle
on without any prior warning. Injury could result if
contact were to be made.
The washer fluid level should be checked
frequently during inclement weather. Use a fluid
formulated for cold weather to help prevent
freezing damage. Warm windshields with the
defroster before using the washers in cold weather
to help prevent icing.
Lubricating Oil - Automatic Transmission
The transmission fluid used to apply the clutches and
lubricate and cool the components must be maintained at the
proper level. If the fluid level is too low, the clutches will not
receive adequate fluid supply and performance will be
affected. If the fluid level is too high, overheating may result
from the fluid being churned and aerated.
Lubricating Oil Power Steering Reservoir & Pump
A vented filler cap is installed on the reservoir cover. A sight
glass is installed on the housing side to visually check oil
level. Correct level is seen at the center of the viewing glass.
This level corresponds to the “FULL” level reading on the
dipstick. Check levels periodically and add fluid as required.
Figure 72. Windshield Washer Reservoir
The filter element is changed by loosening and removing the
cover retaining nut and washer. Remove the filter element
retaining spring and lift the element out of the reservoir
housing. Reverse this procedure to install the new filter
element. Do not overtightened the cover retaining nut.
Power Steering Pump
The Power Steering Pump connects to the reservoir and
steering box through hose lines and fittings.
August 2016
65
THIS PAGE INTENTIONALLY LEFT BLANK
66
August 2016
11 - WHEELCHAIR LIFT ( OPTIONAL )
RICON WHEELCHAIR LIFT ASSEMBLY
Figure 73. Ricon lift assembly
The Ricon wheelchair lift provides safe on-loading and offloading of wheelchair passengers with easy ground level
access. A pendant control switch, located on the inside of the
lift cassette access door, operates the lift. An electrohydraulic power system with emergency manual back-up
powers the lift system.
RICON F9TF LIFT OPERATING CONTROLS
The Control Pendant Switch Unit is located in the lift cassette
access door (when the door is opened). The WCL Control
Pendant contains a POWER ENABLE switch and four
buttons (Figure 74).
The wheelchair lift access door has keyed access,
incorporating a safety interlock switch along with a keyed
power switch to prevent accidental deployment. The electric
pump, emergency hand pump and fluid reservoir are located
inside the control box mounted to the rear of the No.1 RH
(curbside) baggage compartment.
5
The lift is housed in a cassette type module, mounted in the
No.2 RH (curbside) baggage bay.
Wheelchair parking space is available next to and across
from the lift platform. Special folding seats on tracks slide
away providing wheelchair parking area.
1
2
3
4
Figure 74. Ricon control pendant
1. Deploy Button
2. Up Button
3. Stow Button
4. Down Button
5. Power Enable Switch
August 2016
67
Turning ON the POWER ENABLE switch provides power to
the pendant and illuminates the DEPLOY, STOW, UP and
DOWN buttons. To operate a button, press and hold until the
function completes.
Movement of the platform can be halted at any time by
releasing the button.
Wheelchair Lift Toggle Switch
A self canceling toggle switch, located on the wheelchair lift
frame, must be switched “ON” to energize the push button
pendant switch assembly (Figure 76).
The Power Indicator should illuminate only when
the lift is operational. If the indicator does not
illuminate DURING lift operation, or remains
illuminated when the lift is NOT operating,
servicing is required.
At this point, DO NOT ATTEMPT TO OPERATE THE
LIFT. An authorized RICON dealer must be
contacted.
Wheelchair Lift Master Switch
A master ON/OFF switch (key switch or toggle switch)
located on the upper LH instrument panel (Figure 75)
energizes coach safety interlock circuits and enables the
wheelchair lift compartment toggle switch when in the “ON”
position.
Figure 76. Switch
The Wheelchair Lift toggle switch is automatically moved to
the “OFF” position when the operator closes the flip cover.
Figure 75. Master switch on instrument panel
68
August 2016
RICON F9TF LIFT OPERATION
Deploying The Lift
The wheelchair lift can be operated in either the normal mode
(electrically) or in emergency situations by the manual mode
(hand-operated pump).
Before the lift control pendant switch is enabled, these
functions must occur:
Figure 77. Emergency hydraulic hand pump
A minimum of 60 inches of clear area in front of the
lift is required during operation.
This lift is designed for use by wheelchair and
standee occupants only. Improper use of the lift
can result in personal injury.
Do not exceed rated load capacity of 660 pounds
(300 Kg).
Prior to use, inspect wheelchair lift for proper
function, required maintenance or damage. If a
problem exists, do not use lift.
•
The engine must be running,
•
Select “NEUTRAL” on the transmission Shift Pad,
•
Set the Park Brake,
•
urn the Wheelchair Lift Master Key Switch (located
on the dash) to the “ON” position,
•
Ensure the WCL Interlocks dash telltale
illuminates,
•
Fold and position passenger sliding seats to
provide wheelchair parking area (Refer to
Passenger Seats section for details),
•
Open the Lift Cassette Access Door,
•
Push the self canceling toggle switch (located on
the wheelchair lift frame) to the “ON” position.
Only after these conditions are met, the wheelchair lift system
is energized and can be operated using the Lift Control
Pendant Switch.
•
Press and hold the DEPLOY button, on the Control
Pendant switch, until the lift unit extends
completely out of the cassette enclosure.
NOTE: The lift must completely extend out of the
cassette before the lift can be raised or lowered. When
the lift extends, the bridge plate assembly automatically
flips up, acting as a rear barrier.
•
Unfasten the safety restraint belt. Raise the
handrails until the slam lock engages. Fasten the
safety restraint belt.
NOTE: The electronically interlocked safety restraint belt
must be buckled to raise or lower the lift. Power is
interrupted to the Lift Control Pendant Switch if the belt
is unbuckled.
Do not deploy lift if coach is not on level surface.
A sloping condition could cause wheelchair to roll
off platform.
All personnel charged with wheelchair lift
operations must be trained, and know all the
procedures for the wheelchair lift’s normal and
emergency operation before opening the lift with
passengers aboard.
August 2016
69
Raising The Lift
•
Stowing The Lift
Position wheelchair, facing outward if possible, in
the center of the platform and lock wheelchair
brakes,
•
Lower the handrails to platform,
•
•
Pull occupant restraint belt from retractor on
handrail and fasten to other handrail,
Position the platform anywhere above the stow
level,
•
•
Press and hold the UP button, on the Control
Pendant switch,
Press and hold the STOW button. The lift will align
to the stowing level and retract into the lift
enclosure cassette,
•
Raise the wheelchair lift to the closed wheelchair
lift sliding door, until the lift automatically stops
prior to the sliding door (limit switches from the
wheelchair lift will stop the lifting operation),
NOTE: The lift will stop approximately 12 inches below
coach floor level.
•
Grab the wheelchair door handle and pull door
open,
•
Press and hold the UP button until the lift stops at
coach floor level,
NOTE: When the lift is raised, the rolls-top automatically
flips up as a barrier. At coach floor level, the bridge plate
assembly automatically deploys across coach threshold
gap as a ramp.
•
Release occupant restraint belt, and carefully
unload and secure passenger (Refer to the
Wheelchair Restraints section for details),
Lowering The Lift
•
Position wheelchair, facing outward if possible, in
the center of the platform and lock wheelchair
brakes,
•
Pull occupant restraint belt from retractor on
handrail and fasten to other handrail,
•
Press and hold the DOWN button, on the Control
Pendant switch,
The limit switches will only allow the wheelchair lift to be
stowed when the door has been pulled back manually the last
3.0"-5.0”, or latched closed.
NOTE: When retracted, the bridge plate assembly will
automatically fold over onto the platform.
•
Turn OFF the POWER ENABLE switch on the
Control Pendant switch and stow pendant on
provided clip,
•
Push the self canceling toggle switch (located on
the wheelchair lift frame) to the “OFF” position.
Close the Lift Cassette Access Door,
NOTE: To ensure the cassette door closes with the
latches fully engaged, apply sufficient force to both latch
points when closing door.
•
Turn the Wheelchair Lift Master Switch (located on
the dash) to the “OFF” position.
•
Apply a full service brake application to ensure
complete release of the wheelchair interlock.
For more detailed operating information, refer to
the RICON Service/Owner Manual.
NOTE: The bridge plate assembly automatically flips up
when the lift is lowered from coach floor level.
•
Lower the wheelchair lift until the lift automatically
stops (limit switches from the wheel chair lift will
stop the lowering operation),
NOTE: The lift will stop approximately 12 inches below
coach floor level.
•
Grab the wheelchair door handle and manually
close the door,
•
Power will be sent back to the wheelchair lift to
allow the lift to be lowered,
•
Press and hold the DOWN button, until the
platform reaches ground level and the rolls-top
opens completely,
•
Release occupant restraint belt, and carefully
unload passenger.
70
August 2016
Threshold Warning System
The threshold warning system is located above the
wheelchair parking (threshold) area (Figure 78). The module
status indicator light illuminates when the wheelchair lift is
powered, indicating that the module is activated. Two
acoustic sensors monitor the doorway threshold area.
If the acoustic sensors detect a passenger in the threshold
area; when the lift is below coach floor height and the sliding
wheelchair access door is open, an audible buzzer and
flashing light are actuated.
Figure 78.
August 2016
71
BRAUN NUVL WHEELCHAIR LIFT ASSEMBLY
Figure 79. Braun lift assembly
The BRAUN wheelchair lift provides safe on-loading and offloading of wheelchair passengers with easy ground level
access. A pendant control switch, located on the inside of the
lift cassette access door, operates the lift.
The electric pump, emergency hand pump and fluid
reservoir are located inside the control box mounted to the
rear of the No.1 RH (curbside) baggage compartment.
BRAUN NUVL LIFT OPERATING CONTROLS
Control Pendant Switch Assembly
The Pendant Control Switch Unit is located in the lift
cassette access door. The Pendant Control contains four
buttons ( Figure 80 ).
The lift is housed in a cassette type module, mounted in the
No.2 RH (curbside) baggage bay.
Wheelchair parking space is available next to and across
from the lift platform. Special folding seats on tracks slide
away providing wheelchair parking area.
2
1
3
4
5
Figure 80. Braun control pendant
1. Up Button
2. Stow Button
3. Down Button
4. Power Enable Switch
5. Power Indicator Light
72
August 2016
Turning ON the POWER ENABLE switch provides power to
the pendant and illuminates the STOW, UP and DOWN
buttons. To operate a button, press and hold until the function
completes.
Movement of the platform can be halted at any time by
releasing the button.
Wheelchair Lift Toggle Switch
A toggle switch, located on the wheelchair lift frame, must be
switched “ON” to energize the push button pendant control
switch assembly. The green power light indicator illuminates
to signal power to the lift, when toggle switch is positioned to
the ON position.
The Power Indicator should illuminate only when
the lift is operational. If the indicator does not
illuminate DURING lift operation, or remains
illuminated when the lift is NOT operating,
servicing is required.
At this point, DO NOT ATTEMPT TO OPERATE THE
LIFT.
Wheelchair Lift Master Switch
A master ON/OFF switch (toggle switch) located on the
Instrument Panel energizes coach safety interlock circuits
and enables the wheelchair lift compartment toggle switch
when in the “ON” position.
Figure 82. Switch
Figure 81. Master switch on instrument panel
August 2016
73
BRAUN NUVL LIFT OPERATION
Deploying The Lift
The wheelchair lift can be operated in either the normal mode
(electrically) or in emergency situations by the manual mode
(hand-operated pump).
Before the lift control pendant switch is enabled, these
functions must occur:
•
The engine must be running,
•
Select “NEUTRAL” on the transmission Shift Pad,
•
Set the Park Brake,
•
Set the Wheelchair Lift Master Switch (located on
the dash) to the “ON” position,
•
Ensure the WCL Interlocks dash telltale
illuminates,
•
Fold and position passenger sliding seats to
provide wheelchair parking area (Refer to
Passenger Seats section for details),
•
Open the Lift Cassette Access Door,
•
Push the toggle switch (located on the wheelchair
lift frame) to the “ON” position.
Only after these conditions are met, the wheelchair lift system
is energized and can be operated using the Lift Control
Pendant Switch.
Figure 83. Emergency hydraulic hand pump
A minimum of 60 inches of clear area in front of the
lift is required during operation.
This lift is designed for use by wheelchair and
standee occupants only. Improper use of the lift
can result in personal injury.
Do not exceed rated load capacity of 660 pounds
(300 Kg).
Prior to use, inspect wheelchair lift for proper
function, required maintenance or damage. If a
problem exists, do not use lift.
•
Stand clear. Press the UP or DOWN switch until
the platform extends fully. Release switch.
•
Lift handrail latch handles, deploy (lift) handrails:
up to vertical position and lower handrail latch
handles fully.
•
Lift outer barrier to vertical position.
•
Latch handrail belt.
The electronically interlocked safety restraint belt must be
buckled to raise or lower the lift. Power is interrupted to the
Lift Pendant Control Switch if the belt is unbuckled.
•
Press the UP switch until the platform stops (raises
to floor level) and inner roll stop unfolds to floor
level.
•
Release switch.
Do not deploy lift if coach is not on level surface. A
sloping condition could cause wheelchair to roll
off platform.
All personnel charged with wheelchair lift
operations must be trained, and know all the
procedures for the wheelchair lift’s normal and
emergency operation before opening the lift with
passengers aboard.
74
August 2016
Raising The Lift
•
Load passenger onto platform. Lock wheelchair
brakes and latch handrail belt.
Stowing The Lift
•
Latch handrail belt.
•
Press STOW switch until platform identifies stow
level (platform performs a pair of movements
indicating stow level). Release switch, to avoid
handrails contacting coach.
•
Unlatch handrail belt.
•
Fold outer barrier down to platform (horizontal)
position.
•
Lift handrail latch handles, stow (fold) handrails
down to platform (horizontal) position and lower
handrail latch handles fully ( Figures 84 and 85 ).
Outer barrier must be fully unfolded (ramp position) until the
entire wheelchair has crossed the outer barrier.
Passenger must be positioned fully inside yellow boundaries.
•
Press UP switch to fold outer barrier UP fully
(vertical), raise the platform.
•
Raise the platform to the closed wheelchair lift
sliding door, until the lift automatically stops prior to
the sliding door (intermediate position achieved)
(limit switches from the wheelchair lift will stop the
lifting operation),
The lift will stop approximately 12 inches below coach floor
level.
•
Grab the wheelchair door handle and pull door
open,
•
Press UP switch until the lift stops at coach floor
level and unfold inner roll stop to floor level.
Release switch.
•
Unlock wheelchair brakes and carefully unload
passenger. Secure passenger (Refer to the
Wheelchair Restraints section for details).
Figure 84.
Lowering The Lift
•
Position wheelchair in the center of the platform
and lock wheelchair brakes,
Passenger must be positioned fully inside yellow boundaries.
The outer barrier must be UP and handrail belt must be
latched.
•
Press DOWN switch.
•
Lower the platform until the lift automatically stops
(intermediate position achieved) (limit switches
from the wheelchair lift will stop the lowering
operation),
The lift will stop approximately 12 inches below coach floor
level.
•
Grab the wheelchair door handle and manually
close the door,
•
Power will be sent back to the wheelchair lift to
allow the lift to be lowered,
•
Press DOWN switch until the entire platform
reaches ground level and the outer barrier unfolds
fully (ramp position). Release switch.
•
Unlock wheelchair brakes and carefully unload
passenger.
August 2016
Figure 85.
•
Latch handrail belt.
•
Press STOW switch until platform stops (retracts
fully). Release switch.
•
Push the toggle switch (located on the wheelchair
lift frame) to the “OFF” position. Close the Lift
Cassette Access Door.
75
To ensure the cassette door closes with the latches fully
engaged, apply sufficient force to both latch points when
closing door.
•
Turn the Wheelchair Lift Master Switch (located on
the dash) to the “OFF” position.
•
Apply a full service brake application to ensure
complete release of the wheelchair interlock.
Threshold Warning System
The threshold warning system is located above the
wheelchair parking (threshold) area ( Figure 86 ). The module
status indicator light illuminates when the wheelchair lift is
powered, indicating that the module is activated.
If the sensor detects a passenger in the threshold area; when
the lift is below coach floor height and the sliding wheelchair
access door is open, an audible buzzer, mounted in the light
bar, and flashing light are actuated.
For more detailed operating information, refer to
the BRAUN Service/Owner Manual.
Figure 86.
76
August 2016
Wheelchair Restraints
Passenger Seats
The passenger seats in the wheelchair parking area have
seat bottoms that fold upward, and dual pedestal bases that
slide in dual mounting tracks.
This design provides wheelchair parking space in the
designated RH curbside and LH roadside areas. One area is
immediately inside the wheelchair passenger area access
door, and the second area is directly across the aisle on the
LH roadside of the coach.
Mobility Device Securement Instructions are
located underneath the fixed (flip-up) seat.
Pedestal mounted belts, with retractors, are provided front
and rear of tie-down positions, on both the curb and road
sides, with integral end retaining buckles for each. A
wheelchair occupant shoulder restraint, with retractor, is
provided on the coach sidewall outboard of each wheelchair
tie-down position. End retaining buckles are provided on
pedestals of the fixed folding seats, rearward of each
wheelchair tie down position.
Refer to the placard affixed to the bottom of the folding seats
to identify the sliding seat instructions.
Figure 89.
Figure 87.
Figure 90.
Figure 88.
August 2016
77
Emergency Hydraulic Hand Pump
Wheelchair Door Overrule Valve
In emergency situations a manual mode is used for lowering
passengers and stowing operation. When the wheelchair lift
is manually operated, the hand pump provides hydraulic
pressure to the lift cylinder. A manual pressure release
lowers the lift. The lift must be stowed or deployed manually
by pushing back into or pulling out of the cassette.
The manually-actuated wheelchair door overrule valve
(Figure 92) provides for the emergency dumping of air from
the wheelchair door.
The manual mode should never be used for
boarding of passenger, only for the emergency
lowering of passengers and stowing of lift.
The electrically controlled power unit pump and valves, and
the manually operated hydraulic hand pump and release
valve are contained within the wheelchair lift control box
located in the front right-hand (curbside) baggage
compartment (Figure 91). All hydraulic hoses and electrical
control harnesses are routed through the baggage
compartment wall and into the lift cassette.
Figure 92.
Figure 91.
78
August 2016
12-BASIC SPECIFICATIONS
D SERIES VEHICLE HEIGHT (MAX) 137 Inches (3479.8 mm)
(From Top Of Roof Hatches)
D SERIES VEHICLE WIDTH (MAX)
102 Inches (2590 mm)
(Excludes Fenders, Mirrors And Side Turn Lights)
Figure 93.
FUEL TYPE: ULSD only
DEF TYPE: ISO standard 22241-1
ENGINE OIL: CJ-4
August 2016
79
TIRE SPECIFICATIONS
The tires listed below meet GHG regulations as LRR tires.
It is the owner's responsibility for tire maintenance.
Replacement Tires
Always replace the tires with the same rating, size and the
same or better rolling resistance coefficient (CRR). Contact
the tire manufacturer for tires' CRR rating.
TIRE CHART (9.00" RIM WIDTH)
Make and Type
Size
Axle
Load Range
Goodyear G409MBA
315/80R22.5
All Axles
J
Goodyear Metro Miler
G652 RTB
B315/80R22.5
All Axles
L
Goodyear Intercity Cruiser
315/80R22.5
All Axles
J
Michelin XZA2 Energy
315/80R22.5
All Axles
L
Firestone FS400
315/80R22.5
All Axles
L
Firestone HP 3000
315/80R22.5
All Axles
J
Bridgestone R294
315/80R22.5
All Axles
J
Bridgestone R249
315/80R22.5
All Axles
L
TIRE INFLATION CHART
Front Axle Minimum
Pressure
120 psi (827 kPa)
Front Axle Minimum
Pressure
120 psi (827 kPa)
Front Axle Minimum
Pressure
120 psi (827 kPa)
80
Drive Axle Minimum
Pressure
100 psi (690 kPa)
Drive Axle Minimum
Pressure
100 psi (690 kPa)
Drive Axle Minimum
Pressure
100 psi (690 kPa)
Tag Axle Minimum Pressure
D4500 at 50,000 GVWR
100 psi (690 kPa)
Tag Axle Minimum Pressure
D40’ Series at 46,000 GVWR
85 psi (585 kPa)
Tag Axle Minimum Pressure
D45’ Series at 48,000 GVWR
85 psi (585 kPa)
August 2016
13 - DIAGNOSTIC CODES
ALLISON B500 GEN V DIAGNOSTIC CODES
DTC
August 2016
ALLISON DIAGNOSTIC CODES Description
C1312
Retarder Request Sensor Failed Low
C1313
Retarder Request Sensor Failed High
P0122
Pedal Position Sensor Low Voltage
P0123
Pedal Position Sensor High Voltage
P0218
Transmission Fluid Over Temperature
P0561
System Voltage Performance
P0562
System Voltage Low
P0563
System Voltage High
P0602
TCM Not Programmed
P0610
TCM Vehicle Options (Trans ID) Error
P0613
TCM Processor
P0614
Torque Control Data Mismatch-ECM/TCM
P0634
TCM Internal Temperature Too High
P063E
Auto Configuration Throttle Input Not Present
P063F
Auto Configuration Engine Coolant Temp Input Not Present
P0658
Actuator Supply Voltage 1 (HSD1) Low
P0659
Actuator Supply Voltage 1 (HSD1) High
P0667
TCM Internal Temperature Sensor Circuit Range/Performance
P0668
TCM Internal Temperature Sensor Circuit Low
P0669
TCM Internal Temperature Sensor Circuit High
P0701
Transmission Control System Performance
P0702
Transmission Control System Electrical (Trans ID)
P0703
Brake Switch Circuit Malfunction
P0708
Transmission Range Sensor Circuit High Input
P070C
Transmission Fluid Level Sensor Circuit-Low Input
P070D
Transmission Fluid Level Sensor Circuit High Input
P0711
Transmission Fluid Temperature Sensor Circuit Performance
P0712
Transmission Fluid Temperature Sensor Circuit Low Input
P0713
Transmission Fluid Temperature Sensor Circuit Low Input
P0716
Turbine Speed Sensor Circuit Performance
P0717
Turbine Speed Sensor Circuit No Signal
P0719
Brake Switch ABS Input Low
P071A
RELS Input Failed On
P071D
General Purpose Input Fault
P0720
Output Speed Sensor Circuit
P0721
Output Speed Sensor Circuit Performance
P0722
Output Speed Sensor Circuit No Signal
P0726
Engine Speed Sensor Circuit Performance
P0727
Engine Speed Sensor Circuit No Signal
P0729
Incorrect 6th Gear Ratio
81
DTC
82
ALLISON DIAGNOSTIC CODES Description
P0730
Incorrect Neutral Gear Ratio
P0731
Incorrect 1st Gear Ratio
P0732
Incorrect 2nd Gear Ratio
P0733
Incorrect 3rd Gear Ratio
P0734
Incorrect 4th Gear Ratio
P0735
Incorrect 5th Gear Ratio
P0736
Incorrect Reverse Gear Ratio
P0741
Torque Converter Clutch System Stuck Off
P0776
Pressure Control Solenoid 2 Stuck Off
P0777
Pressure Control Solenoid 2 Stuck On
P0796
Pressure Control Solenoid 3 Stuck Off
P0797
Pressure Control Solenoid 3 Stuck On
P0842
Transmission Pressure Switch 1 Circuit Low
P0843
Transmission Pressure Switch 1 Circuit High
P0880
TCM Power Input Signal
P0881
TCM Power Input Signal Performance
P0882
TCM Power Input Signal Low
P0883
TCM Power Input Signal High
P0894
Transmission Component Slipping
P0960
Pressure Control Solenoid Main Mod Control Circuit Open
P0961
Pressure Control Solenoid (PCS) Main Mod System Performance
P0962
Pressure Control Solenoid Main Mod Control Circuit Low
P0963
Pressure Control Solenoid Main Mod Control Circuit High
P0964
Pressure Control Solenoid 2 (PCS2) Control Circuit Open
P0965
Pressure Control Solenoid (PCS) 2 System Performance
P0966
Pressure Control Solenoid 2 (PCS2) Control Circuit Low
P0967
Pressure Control Solenoid 2 (PCS2) Control Circuit High
P0968
Pressure Control Solenoid 3 (PCS3) Control Circuit Open
P0969
Pressure Control Solenoid (PCS) 3 System Performance
P0970
Pressure Control Solenoid 3 (PCS3) Control Circuit Low
P0971
Pressure Control Solenoid 3 (PCS3) Control Circuit High
P0973
Shift Solenoid 1 (SS1) Control Circuit Low
P0974
Shift Solenoid 1 (SS1) Control Circuit High
P0975
Shift Solenoid 2 (SS2) Control Circuit Open
P0976
Shift Solenoid 2 (SS2) Control Circuit Low
P0977
Shift Solenoid 2 (SS2) Control Circuit High
P0989
Retarder Pressure Failed Low
P0990
Retarder Pressure Failed High
P1739
Incorrect Low Gear Ratio
P1891
Throttle Position Sensor PWM Signal Low Input
P1892
Throttle Position Sensor PWM Signal High Input
P2184
Engine Coolant Temperature Sensor Circuit Low Input
P2185
Engine Coolant Temperature Sensor Circuit High Input
P2637
Torque Management Feedback Signal (SEM)
P2641
Torque Management Feedback Signal (LRTP)
August 2016
DTC
August 2016
ALLISON DIAGNOSTIC CODES Description
P2670
Actuator Supply Voltage 2 (HSD2) Low
P2671
Actuator Supply Voltage 2 (HSD2) High
P2685
Actuator Supply Voltage 3 (HSD3) Low
P2686
Actuator Supply Voltage 3 (HSD3) High
P2714
Pressure Control Solenoid 4 (PCS4) Stuck Off
P2715
Pressure Control Solenoid 4 (PCS4) Stuck On
P2718
Pressure Control Solenoid 4 (PCS4) Control Circuit Open
P2719
Pressure Control Solenoid (PCS) 4 System Performance
P2720
Pressure Control Solenoid 4 (PCS4) Control Circuit Low
P2721
Pressure Control Solenoid 4 (PCS4) Control Circuit High
P2723
Pressure Control Solenoid 1 (PCS1) Stuck Off
P2724
Pressure Control Solenoid 1 (PCS1) Stuck On
P2727
Pressure Control Solenoid 1 (PCS1) Control Circuit Open
P2728
Pressure Control Solenoid (PCS) 1 System Performance
P2720
Pressure Control Solenoid 1 (PCS1) Control Circuit Low
P2730
Pressure Control Solenoid 1 PCS1) Control Circuit High
P2736
Pressure Control Solenoid 5 (PCS5) Control Circuit Open
P2737
Pressure Control Solenoid (PCS) 5 System Performance
P2738
Pressure Control Solenoid 5 (PCS5) Control Circuit Low
P2739
Pressure Control Solenoid 5 (PCS5) Control Circuit High
P2740
Retarder Oil Temperature Hot
P2742
Retarder Oil Temperature Sensor Circuit-Low Input
P2743
Retarder Oil Temperature Sensor Circuit-High Input
P2761
TCC PCS Control Circuit Open
P2762
TCC PCS Control Circuit Range/Performance
P2763
TCC PCS Control Circuit High
P2764
TCC PCS Control Circuit Low
P2772
Four Wheel Drive Low Switch Circuit Performance
P278A
Kickdown Input Failed ON
P2793
Gear Shift Direction Circuit
P2808
Pressure Control Solenoid 6 (PCS6) Stuck Off
P2809
Pressure Control Solenoid 6 (PCS6) Stuck On
P2812
Pressure Control Solenoid 6 (PCS6) Control Circuit Open
P2813
Pressure Control Solenoid (PCS) 6 System Performance
P2814
Pressure Control Solenoid 6 (PCS6) Control Circuit Low
P2815
Pressure Control Solenoid 6 (PCS6) Control Circuit High
U0001
Hi Speed CAN Bus Reset Counter Overrun (IESCAN)
U0010
CAN BUS Reset Counter Overrun
U0100
Lost Communications with ECM/PCM (J1587)
U0103
Lost Communication With Gear Shift Module (Shift Selector) 1
U0115
Lost Communication With ECM
U0291
Lost Communication With Gear Shift Module (Shift Selector) 2
U0304
Incompatible Gear Shift Module 1 (Shift Selector) ID
U0333
Incompatible Gear Shift Module 2 (Shift Selector) ID
83
DTC
84
ALLISON DIAGNOSTIC CODES Description
U0404
Invalid Data Received From Gear Shift Module (Shift Selector) 1
U0592
Invalid Data Received From Gear Shift Module (Shift Selector) 2
August 2016
DIAGNOSTIC CODES/HVAC
HVAC PARAMETERS CODES
Parameter Codes
Code
Name
Description
P1
Return Air Temperature
This value is the temperature measured by the return air
sensor. If the sensor is shorted, it will display CL. If it is
open circuited, it will display OP.
P2
Coil Temperature
Not used.
P3
Ambient Temperature
This value is the outside temperature measured by the
ambient temperature sensor. If the sensor is shorted, it will
display CL. If it is open circuited, it will display OP.
P4
Suction line temperature
Not used.
P5
Suction pressure
This value is the suction pressure measured by the
suction pressure transducer. If the sensor is shorted, it will
display CL. If it is open circuited, it will display OP.
P6
Discharge pressure
This value is the discharge pressure measured by the
discharge pressure transducer. If the sensor is shorted, it
will display CL. If it is open circuited, it will display OP.
P7
Superheat
Not used.
P8
Analog Set Point Temperature
Not used.
P9
A/C Control Window #1
This is the number of °F above setpoint at which the
unloaders will both be energized. This value can be
modified between 0 and 10°F (0 and -12°C). The default
value is 2°F (-17°C).
P10
A/C Control Window #2
This is the number of °F above AC control window 1 at
which the first unloader will be energized. This value can
be modified between 0 and 10°F (0 and -12°C. The default
value is 2°F
(-17°C).
P11
A/C Control Window #3
This is the number of °F above AC control window 2 at
which the evaporator fan speed will be set to low. This
value can be modified between 0 and 10°F (0 and -12°C.
The default value is 1°F (-17°C).
P12
Heat Control Window
This is the number of °F below setpoint before the EHV is
energized. This value can be modified between 0 and
10°F. The default value is 2°F for heat and 4°F (-16°C) for
reheat.
P13
Compressor Safety Off Delay
This number is the minimum time in minutes that the
compressor must be off after a high or low pressure alarm
before it can be restarted. This value can be modified
between 1 and 5 minutes. The default value is 1 minute.
P14
Fan Delay
This number is the minimum time (in seconds) that the
fans must run at a particular speed before changing to
another speed. This value can be modified between 1 and
60 seconds. The default value is 2 seconds.
P15
Reheat Valve Delay
This number is the minimum time (in seconds) that the
reheat valve must be in a particular state (open/closed)
before changing to another state. This value can be
modified between 1 and 60 seconds. The default value is
2 seconds.
August 2016
85
Parameter Codes
86
(Continued)
P16
Compressor High Pressure
Switch
This is the current state of the compressor high pressure
switch input. If the switch is closed, it will display CL. If it is
open, it will display OP.
P17
Condenser Fan Speed Switch
Not used.
P18
Maximum Set Point
This is the maximum value that the operator will be
allowed to set the setpoint temperature. The value can be
modified in degrees with the up and down keys to a value
between 60–80°F
(16–27°C).
P19
Minimum Set Point
This is the minimum value that the operator will be allowed
to set the setpoint temperature. The value can be modified
in degrees with the up and down keys to a value between
60–80°F
(16–27°C).
P20
Compressor Hours High
This is the number of hours of operation that the
compressor has run with the clutch energized, shown in
thousands.
P21
Compressor Hours Low
This is the number of hours of operation that the
compressor has run with the clutch energized, shown in
hundreds, tens, and ones.
P22
Evaporator Hours High
This is the number of hours (in thousands) of operation
with the evaporator fans energized.
P23
Evaporator Hours Low
This is the number of hours (in hundreds, tens, ones) of
operation with the evaporator fans energized.
P24
Maintenance 1 Hour High
This is the value of Compressor Hours High (P20) at
which maintenance alarm #1 will be activated. This value
can be modified by the up and down arrow keys. If both
high and low values are zero, the alarm is disabled.
P25
Maintenance 1 Hour Low
This is the value of Compressor Hours Low (P21) at which
maintenance alarm #1 will be activated. This value can be
modified by the up and down arrow keys. If both high and
low values are zero, the alarm is disabled.
P26
Maintenance 2 Hours High
This is the value of Evaporator Fan Hours High (P22) at
which maintenance alarm #2 will be activated. This value
can be modified by the up and down arrow keys. If both
high and low values are zero, the alarm is disabled.
P27
Maintenance 2 Hours Low
This is the value of Evaporator Fan Hours Low (P23) at
which maintenance alarm #2 will be activated. This value
can be modified by the up and down arrow keys. If both
high and low values are zero, the alarm is disabled.
P28
Freeze Alarm Setting
This is the value at which the freeze alarm will be
activated. The default value is 32°F (0°C). This value can
be modified between 20–40°F (-7–4°C) in one degree
increments by using the arrow keys.
P29
Relay Module Voltage
This value is the voltage being supplied to the relay
module.
P30
Main Board Software Version
This is the software version of the main controller logic
board.
P31
Display Software Version
This is the software version of the driver’s display module.
P32
Ki
Not used.
P33
Kp
Not used.
August 2016
Parameter Codes
(Continued)
P34
Heat Set Point Offset
This value is the offset that can be used to change the
points at which the unit switches between heat and vent in
the heat mode. A positive value will raise the critical
temperatures (winter use) and a negative value will
decrease the critical temperatures (summer use).
P35
Default Display Temperature
This value determines what temperature value the driver’s
display will show as a default. When the value is OFF, setpoint temperature is displayed. When the value is ON,
return air temperature is displayed. This option is only
available in logic module software revisions 1.9 and
newer, and driver’s display software revision 1.3 and
newer. Otherwise, P35 will not be active and set-point
temperature will only be displayed as default.
P40
Enable Hidden Alarm
This value determines if alarms A33 and A34 are
displayed. When the value is OFF, alarms A33 and A34
will not be displayed. When the value is ON, alarms A33
and A34 will be displayed.
P41
Fresh Air Damper
Not used.
P42
Defrost Operation
This value determines if the default switch will override the
Micromate controller. If the parameter is ON, the defrost
switch will initiate unit defrost whenever it senses a need
for defrosting (the Micromate display will shut off in
defrost). If the parameter is OFF, the Micromate display
will continue to operate and override the defrost switch.
August 2016
87
DIAGNOSTIC CODES/HVAC
HVAC ALARM CODES
Alarm Code List
Code
88
Condition
Possible Cause
Correction
Controller Response
A11
Coil Freeze
Coil temperature is
Check causes of coil
less than 32°F and the freezing.
compressor is
operating.
An alarm will be generated and the
system will shutdown. The
evaporator fans will remain running
while the compressor is off.
A12
High Voltage
The battery voltage is
greater than 32 volts.
Check, repair or replace
alternator.
The system is shut down until the
voltage returns to normal levels.
A13
Low Voltage
The battery voltage is
less than 17 volts.
Check, repair or replace
wiring or alternator.
The system is shut down until the
voltage returns to normal levels.
A14
Return Air
Return air temperature Ensure all connectors are All outputs except the evaporator
Probe Failure sensor failure or wiring plugged in. Check sensor fans will be de-energized.
defective.
resistance or wiring.
A15
Suction
Pressure
Transducer
Failure
Suction pressure
transducer failure or
wiring defective.
Ensure all connectors are Both unloaders are energized.
plugged in. Check sensor
voltage or wiring.
Replace sensor or repair
wiring.
A16
Discharge
Pressure
Transducer
Failure
Discharge pressure
transducer failure or
wiring defective.
Ensure all connectors are One unloader is energized.
plugged in. Check sensor Condenser fans will run on high
voltage or wiring.
speed.
Replace sensor or repair
wiring.
A17
Low Pressure Low suction pressure
Shutdown
switch open or wiring
defective.
Check cause of low
suction pressure.
The clutch is de-energized for the
minimum off time. The evaporator
fans will remain running during this
period. After the compressor
cycles off three times in 30 minutes
all outputs will be de-energized
(except for the evaporator fans and
heat) and the system is locked out
until the power is cycled or the
alarm is reset.
A21
High
Discharge
Pressure
High discharge
pressure switch open
or wiring defective.
Check discharge
pressure transducer
reading, wiring or cause
of high discharge
pressure.
The clutch is de-energized for the
minimum off time. The condenser
and evaporator fans will remain
running during this period. After the
compressor cycles off three times
in 30 minutes all outputs will be deenergized (except for the
evaporator fans and heat) and the
system is locked out until the
power is cycled or the alarm is
reset.
A22
Breaker Trip/
Blown Fuse
Alarm
A breaker/fuse on the
relay board has tripped
or a fan relay has
failed.
Check breakers/fuse for
tripped device. Repair
short and reset/ replace
breaker/fuse.
Alarm will be generated.
August 2016
Alarm Code List (Continued)
Code
Condition
Possible Cause
Correction
Controller Response
A23
Evaporator
Evaporator fan
Fan Overload overload jumper is
open.
Ensure connector is
plugged in or repair
wiring.
Alarm will be generated.
A24
Condenser
Condenser fan
Fan Overload overload jumper is
open.
Ensure connector is
plugged in or repair
wiring.
Alarm will be generated.
A25
Not Used
A26
Not Used
A31
Maintenance
Alarm 1
The compressor hour
meter is greater than
the value in
Maintenance Hour
Meter 1.
Reset the maintenance
hour meter.
Alarm will be generated.
A32
Maintenance
Alarm 2
The evaporator hour
meter is greater than
the value in
Maintenance Hour
Meter 2.
Reset the maintenance
hour meter.
Alarm will be generated.
A33
Low Pressure Suction pressure low
Warning
enough to energize
UV2.
Check cause of low
suction pressure.
Alarm will be generated.
A34
High
Pressure
Warning
Check cause of high
discharge pressure.
Alarm will be generated.
A99
Alarm Queue All locations of the
Full
alarm queue are
currently full and no
more alarms can be
saved.
Record and clear alarm
queue.
Alarm will be generated
August 2016
Discharge pressure
high enough to
energize UV2.
89
DIAGNOSTIC CODES/ABS
WABCO ABS DIAGNOSTIC CODES
ABS Codes - The ABS Diagnostic switch, located in the rear
junction box, allows the user to access ABS fault codes. The
flashing red light indicates diagnostic codes. Each ABS code
is a 2 digit number. The first set of flashes is the first digit, and
after a slight pause the second set of flashes is the second
digit. Record all codes.
Figure 94. ABS Diagnostic Switch
Wheel Sensor Roadside Front
90
August 2016
Wheel Sensor Curbside Front
August 2016
91
Wheel Sensor Roadside Drive
92
August 2016
Wheel Sensor Curbside Drive
August 2016
93
Wheel Sensor Roadside Tag
94
August 2016
Wheel Sensor Curbside Tag
August 2016
95
Modulator Roadside Front
96
August 2016
Modulator Curbside Tag
August 2016
97
98
August 2016
DIAGNOSTIC CODES / AUXILIARY HEATER
PROHEAT Auxiliary Heater Diagnostic Codes
Auxiliary Heater Diagnostics
The operator can identify function and component diagnostics by checking either the light bars or the new LED display
located on the front of the control module. Record all Codes.
Figure 95. Proheat control module
CODE
August 2016
FAULT
01 (Function Diagnostic)
Start
02 (Function Diagnostic)
Flame Out
03 (Function Diagnostic)
Coolant Flow
04 (Function Diagnostic)
Overheat
05 (Function Diagnostic
Voltage
06 (Component Diagnostic)
Flame Sensor
07 (Component Diagnostic)
Temperature Sensor
08 (Component Diagnostic)
Fuel Pump
09 (Component Diagnostic)
Compressor
10 (Component Diagnostic)
Ignition Coil
11 (Component Diagnostic)
Coolant Pump
12 (Component Diagnostic)
Blower
14 (Component Diagnostic)
Hour Meter (Auxiliary Output)
99
DIAGNOSTIC CODES/AMEREX
AMEREX FIRE SUPPRESSION SYSTEM DIAGNOSTIC CODES
Amerex Code - Blinking LED’s on the Amerex control panel indicates diagnostic codes. Record all codes.
Figure 96. Amerex control panel
1.The blinking Service System LED indicates Service
System Blinking Codes.
2.The blinking FIRE LED indicates Blink Codes.
100
August 2016
14 - INDEX
A
B
A/C 55
Back-Up Alarm 34
Control Panel 55
Driver’s Fan 55
Fresh Air 56
Key Functions 55
Air
Air Pressure - Warning 52
Bi-Parting Door 32
Emergency Fill 52
Towing 51
Low Air 47
Overrule Valve 32
Pressure Gauge, Front 15
Pressure Gauge, Rear 15
Sedan Door 31
Service Brakes 29
Back-Up Camera 34
Back-Up Lights 34
Battery
Boosting 50
Color Coded Cables 50
Main Battery Disconnect 49
Blinds 31
Boosting 50
Brakes
ABS 29
Emergency Air Fill 52
Engine Brake 20
Park Brake Release 10
Parking and Emergency Brakes 29
Parking Brakes
Emergency 52
Service Brakes
Emergency 52
Releasing 29
Tell-tale 16
Alarm and Warning System 47
Back-up Alarm 34
Fire Alarm 17, 54
Kneeling 6
SmartWave 25
Amerex Fire Suppression System 54
Diagnostic Codes 100
Operation 54
Alternator Warning 48
Tell-tale 17
Anti-Lock Brake System (ABS) 22
Diagnostic Codes 94
Tell-tale 15
Anti-Theft Precautions 3
Automatic Transmission 43
Lubricating Oil 65
Diagnostic Codes 81
Operation 43
Auxiliary Heater 34
Diagnostic Codes 99
Tell-tale 17
C
Certification Plate 1
Check Engine
Tell-tale 16
Check Transmission
Tell-tale 16
Coach Specs
Vehicle Height 79
Vehicle Width 79
C cont’d
E
Code Retrieval
Electronic Stability Control (ESC) 6
ABS 90
Auxiliary Heater, Proheat 99
Fire Suppression System, Amerex 100
HVAC Alarm 88
HVAC Parameters 85
Transmission 44
Column, Steering
Adjustments 27
Condenser Compartment 51
Cooling System
Coolant Recovery 61
Cooling Compartment 60
Location 57
Overheat 47
Tell-tale 16
Emergency Conditions 47
Air Fill 52
Emergency Escape 48
Engine Override 22
Entrance Door Overrule Valve 32
Fire Extinguisher 53
Fire Suppression, Amerex 54
Hazard and Warning Signal 48
Lavatory 16
Multiplex Bypass Circuit 37
Parking Brakes 52
Service Brakes 52
Starting 50
Tire & Wheel Removal 62
Wheel Chair Lift 78
Emission Control Decal 1
Engine
D
Daily Inspections 9
Diagnostic Codes 71
ABS 90
Amerex 100
Auxiliary Heater 99
HVAC
Alarm 88
Parameters 85
Transmission 81
Doors, Service & Access 57, 58
Driver’s Area 4, 5
Driver’s Seat
Adjustment 10
Recaro Controls 11
Seat Belt 13
USSC Controls 12
Check Engine 16
Emergency Start 50
Engine Brake 20
Engine Compartment 35, 57
Lubricating Oil 40
Multiplex Bypass Circuit 37
Override Switch 22
Remote Operation 36
Starting 35
Stopping 36
Entrance Door
Exterior Switch 32
Interior Switch 22
Override 32
Exhaust 41
F
H
Fast Idle, Switch 20
Hazard/Warning Lights 22
Fire Extinguisher 53
Headlights 28
Flashers 48
Heating and Air Conditioning (see HVAC) 55
Fluid
Horn
DEF 39
Engine Oil 65
Fuel 39
Power Steering 65
Transmission 65
Windshield Washer 65
Foot Control 22
Hand Control 22
HVAC
Control Panel 55
Diagnostic Codes 90, 92
Driver’s Fan 55
Driver’s Ventilation 56
Key Functions 55
Parcel Rack Ventilation 56
Fuel
Filter 40
Fuel Door 57, 58
Fueling 64
Gauge 16
Specification 39
I
Initial Procedures 9
Inspections
G
Exterior Inspection 9
Interior Components Checklist 9
Operational Checklist 9
Pre-Trip 14
Seat Belt Inspection 13
Gauges
Air, Front 15
Air, Rear 15
DEF 16
Fuel 16
Instrument Panel 15
Oil Pressure 16
SmartWave TPMS 25
Speedometer 15
Tachometer 16
Voltmeter 16
Instrument Panel
Dash Panel 15
Introduction, To The Driver 1
J
Jacking 63
K
Kneeling 6, 30, 33
Switch 22
Tell-tale 16
L
O
Lavatory Emergency 16
Oil, Engine
Filter 40
Gauge 16
Specs 40
Leveling
Auto-Leveling 3
Kneeling Feature 6
Rear Hi-Rise Feature 6
Trailing Axle Unloading 3
Operational Checklist 9
Override
Lights
Back-Up Lights 34
Console Lights 22
Exterior Lights 57, 58
Front Entrance 20
Hazard/Warning Lights 34
Interior Lights 20
Reading 20
Engine Override Switch 22
Entrance Door 32
Multiplex Bypass Circuit 37
P
Power Steering 65
Pre-Trip Inspection 14
M
Public Announcements System 24
Main Battery Disconnect 49
Publication Date 1
Maintenance 7, 49
Fluids 65
Fueling 64
Tire Change 62
Mirrors
Mirror Control 22
Rear-view, Exterior 13
Rear-view, Interior 13
R
Radiator 61
Reading Lights, Switch 20
Rear Rise 6
Switch 20
Multi Function Display 16
Regeneration 38, 39
Multiplex Bypass Circuit 37
Roof Hatch 48
N
Nameplate 2
Not Generating 48
Tell-tale 16
S
T
Shift Selector, PBSS 43
Tag Axle
Tag Lock 20
Tag Unload 16
Trailing Axle Unloading 3
Sleep Mode 10
SpeakEasy 2 24
Starting the Engine 35
Emergency Start 42
Engine Warm-Up 36
Initial Start-Up 9
Remote 36
Stop Request
Button 33
Sign 34
Stopping the Engine 36
Tell-tales 16, 19
Tires
Recommended Inflation Pressure 80
SmartWave TPMS 25
Tire Specs 80
Tools and Safety Equipment 53
Towing 51
Transmission 43
Remote 36
Diagnostic Codes 81
Shift Selector 43
Switch Panel
LH Switch Panel 20
Lower LH Console 22
LH Switch Panel 21
Switches
110 Volt 22
ATC 20
Auxiliary Heat 22
Engine Brake 20
Engine Override 22
Engine Start 22
Entrance Door 22
Fast Idle 20
Kneel 22
Master Power / Ignition Switch 20
Panel Illumination 22
Parcel Rack Ventilation 22
Rear Rise 20
Tag Axle 20
Turn Signals 28
V
Vehicle Identification Number (VIN) 2
Voltmeter 16
W
Wheel Chair Lift 67
Deploying The Lift 69, 74
Lift Assembly 67, 72
Lift Operation 69, 74
Master Switch 68, 73
Operating Controls 67, 72
Threshold Warning System 71, 76
Door Overrule Valve 78
Emergency Hydraulic Hand Pump 78
Restraints 77
Wheelchair Access Door 67, 72
Wrench (Lug) 62
15 - FIGURE INDEX
A
F
ABS Diagnostic Switch 90
Fire Extinguisher 53
Air, Emergency Fill 51, 53
Floor Mounted Controls 27, 28
Amerex, Control Panel 54, 100
Fuel Pro Filter 40
Amerex, Manual Fire Button 54
B
Backup Camera 34
Baggage Door, Positive Lock Pin 59
C
Certification Plate 1
G
Gauge, Air 15
Gauge, Instrument Panel 15
Gauge, SmartWave TPMS 25
Gauge, Speedometer 15
H
HVAC Dash Controller 55
D
HVAC Dash Controller Key Functions 55
HVAC Ventilation Control Handles 56
Door, Fuel Filler, DEF 39, 64
Door, Fuel Filler, ULSD 64
Drivers Area 4, 5
I
Instrument Panel 15
E
Emergency Fill, Air 51, 53
Emergency Triangles 53
Entrance Door 31, 32
Engine Bay, ISX 35
Exterior Components 57, 58
J
Jacking Points 63
L
Lower, LH Console 22
M
S cont’d
Main Disconnect Switch ( MDS ) 49
SmartWave TPMS 25
Mirror 13
SpeakEasy 24
Modesty Panel 31
Speedometer 15
Multi Function Display ( MFD ) 16
Steering Column Control Lever 27
Mux Bypass Switch 37
Stop Request Sign 34
N
Nameplate, Coach 2
Switch Panel, LH 20
Switch Panel, RH 21
Switch, Mux Bypass 37
Switch Panel, Lower, LH Console 22
O
Override, Valve, Entrance Door 32
T
Tell-tale Cluster 19
P
Trailing Axle Control Valve 64
Tools, Wrench & Handle 62
Parcel Rack Blower 56
Threshold Warning System, Wheelchair 71, 76
Parcel Rack Control Module 32
Transmission PBSS 43
Parcel Rack Compartments 32
Triangles 53
Passenger Seats 77
PBSS, Transmission 43
Pre Trip Inspection 14
ProHeat Control Module 99
W
Washer Fluid Reservoir 65
Wheelchair Cassette Door 60
R
Regen Switch Location 38
Remote Junction Box 36, 49
Roof Hatch 48
S
Side Sash Placard 48
Seat Adjustment Control, Recaro 11
Seat Adjustment Control, USSC 12
Wheelchair Emergency Hand Pump 69, 74, 78
Wheelchair Lift Assembly 67, 72
Wheelchair Lift Control Pendant 67, 72
Wheelchair Lift Valve, Overrule 78
Wheelchair Master Switch 68, 73
Wheelchair, Threshold Warning System 71, 76
Window Blinds 31
United States Operators please notice:
The National Highway Traffic Safety Administration has requested that the following statement be provided
for your information.
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to
notifying Motor Coach Industries, Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists
in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become
involved in individual problems between you, your dealer, or Motor Coach Industries, Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in
Washington, DC, area) or write to: NHTSA, U.S. Department of Transportation, Washington, DC, 20590.
You may also obtain other information about motor vehicle safety from the Hotline.
Canadian Operators please notice:
To report or obtain information on motor vehicle safety-related defects, or manufacturers’ recalls, call
Transport Canada’s Information Centre at 1-800-333-0371, or call (613) 998---8616 if you are in the
Ottawa area.
You can email comments or questions to [email protected] or write to:
Road Safety and Motor Vehicle Regulation Directorate, Transport Canada, Tower C, Place de Ville, 330
Sparks Street, Ottawa, Ontario, K1A 0N5
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